SCHOOL OF MECHANICAL ENGINEERING

UNIVERSITI TEKNOLOGI MARA

SUPERVISOR EVALUATION FORM

SUPERVISOR EVALUATION FORM

COURSE MEM460 - ENGINEERING WORKSHOP PRACTICE

LABORATORY MILLING WORKSHOP

INSTRUCTOR
MR. MOHAMAD TOLHA SUBHI
NAME

No Name Student ID Group No REMARK

MUHAMMAD AMIRUL
1 2021829696 15
HANIF BIN AHMAD

MUHAMMAD RAFIUDDIN 2021823214 15

2
BIN RAZIF

WAN MUHAMMAD 2021829586 15

3 SYAZWAN BIN WAN
SAIFPUDDIN

NUR HEZREEN NAJWA 2021600968 15

4
BINTI ABDUL MU’IZZ

AMINUDDIN BIN ABDUL 15

5 2021653034
GHANI
 Level Very Poor Poor Satisfactory Good Excellent
Guidelines
Scale 1-2 3-4 5-6 7-8 9-10

Individu
al and
Handling Technique,
Teamwo
Equipment/ Discipline &
rk
Machinery Safety
TOTA
ASSESSMENT CRITERIA Factor Factor Factor L
CO4 – (60%)
CO2 – PO5 CO3 – PO6
PO9
(Scale 1-10) (Scale 1-10)
(Scale
1-10)

MUHAMMAD
(1) AMIRUL HANIF BIN
AHMAD

MUHAMMAD
(2) RAFIUDDIN BIN
RAZIF 0
3.5 2.0 .
5
WAN MUHAMMAD
(3) SYAZWAN BIN WAN
SAIFPUDDIN

NUR HEZREEN
(4) NAJWA BINTI
ABDUL MU’IZZ

AMINUDDIN BIN
(5)
ABDUL GHANI

Note: Comments are encouraged and given directly to the individual.

Handling Equipment – CO2-PO5 (35%)
● Know- how to apply and operate
equipment
● Properly handle equipment and obey the
standard operating procedure;
● Appropriate attire suitable in conducting
lab and handling the laboratory
equipment
Individual & Teamwork - CO4-PO9 (5%)
● Function effectively as an individual, and as a member of a team; prepared and proactive.
● Effort organised and shared among members.
● Practice 5S in a workshop.
● Punctuality
Technique, Discipline & Safety CO3-PO6
(20%)
● Safety and discipline of an individual in
terms of punctuality and obey instructions
in handling the equipment and following
the safety instruction.
● Recognize the safety precaution aspects
during handling the equipment in the
workshop. (do and don’t during
experimental)
 SCHOOL OF MECHANICAL ENGINEERING
UNIVERSITI TEKNOLOGI MARA

REPORT EVALUATION FORM

REPORT EVALUATION FORM

COURSE MEM460 - ENGINEERING WORKSHOP PRACTICE

LABORATORY MILLING WORKSHOP

INSTRUCTOR
MR. MOHAMAD TOLHA SUBHI
NAME

No Name Student ID Group No REMARK

MUHAMMAD AMIRUL HANIF BIN
1 AHMAD
2021829696 15

2 MUHAMMAD RAFIUDDIN BIN RAZIF 2021823214 15

WAN MUHAMMAD SYAZWAN BIN

3 WAN SAIFPUDDIN
2021829586 15

NUR HEZREEN NAJWA BINTI ABDUL

4 MU’IZZ
2021600968 15

5 AMINUDDIN BIN ABDUL GHANI 2021653034 15

Excellen
Level Very Poor Poor Satisfactory Good
Guidelines t
Scale 1-2 3-4 5-6 7-8 9-10
Report content Weight Score (%)
SCALE
Items/ Assessment Criteria (Report) age
(1-10)
(%)
1.0 Title ● Refer to respective lab sheets /
instructions for title of experiment. - - -

2.0 Objective(s) ● State the purpose that describes the

intention of the experiment,
- - -
investigation or accomplishment.

1.0 Introduction ● Provide an understanding of the

(Theory and experiment to relate with the body of
Background) knowledge of the experiment topic 0.25
which includes necessary diagrams,
theory and equations.

3.0 Apparatus

● List of equipment, machines,

accessories, and components involved in
the experiment with the necessary
pictures/diagrams.
● May include a brief description of the 0.25
instrumentation/set-up if necessary, to
connect with the main body of
knowledge of the topic

● Describe operating procedures and

methods applied, safety and standard to
4.0 Experimental and relate with appropriate techniques using
safety procedure available modern engineering set 0.5
up/machinery and IT tools.

● Present the final product.

● Discuss the findings; make comparisons
with known information if available.
● Elaborate on possible sources of errors,
defects and sensitivity of the product
5.0 Results & Discussion and procedure applied.
0.5
● Propose any possible improvements in
the project. (set-up ideas for a future
project)
● Any recommendation to improve the
workshop in term of societal, health,
safety, legal and cultural issues
●List references to methods and related
6.0 References studies with the appropriate style of
report writing. (At least 5). 0.25
Report content Weight Score (%)
SCALE
Items/ Assessment Criteria (Report) age
(1-10)
(%)
● Able to comprehend and write effective
reports and design documentation; and
7.0 Report delivery give and receive clear instructions
(Formatting and writing skill, Language, 0.25
include Turnitin report)
● Original maximum 30%

Compulsory to include/attach this lab

report assessment form in your report
Please note: submission. NO MARK be given if
Total Marks
failure to do so.
TITTLE

Milling practice

INTRODUCTION

Milling is a machine-operated process in which the cutters rotate to remove material from the
workpiece in the direction of the tool axis.The rotational axis of the tool is parallel to the feed
direction. Based on how the main spindle is oriented, milling machines are divided into three
axes: x, y, and z. The cutting edges of the tool are called teeth, and the tool itself is called a
milling cutter. Flat surfaces are frequently made by milling. From small to large products,
milling machines can be utilized for a variety of tasks and processes. The cutter on the milling
machine helps to remove material from the surface of the workpiece. Special cutting surfaces on
the end surfaces of the milling cutters enable them to be drilled into the workpiece. A milling
cutter has tiny cutters on the end corners.

The following cutting phases or procedures are used by the milling machine: milling square,
facing to length, and milling slot. Leveling and smoothing the workpiece from all angles is the
procedure of milling square. Facing to length is the process of measuring the workpiece into the
desired measurement. The technique of creating slots on the workpiece with the desired
dimension is known as the milling slot. The spindle axis of a vertical mill is vertically positioned,
and it rotates around that axis. Additionally, the spindle can be extended, enabling drilling and
cutting operations. In contrast to the vertical mill, the horizontal mill's cutters are mounted on a
horizontal arbor. Numerous horizontal mills have rotational tables that facilitate milling at
various angles. These tables are referred to as universal tables. Aside from that, any instrument
used in a vertical mill can also be utilized in a horizontal mill.

OBJECTIVE

1. To turn the raw material into a product according to the drawing given
2. To handle the machine properly and know the function of each component of the
machine.
3.
APPARATUS

1. Vernier Caliper - Used to measure the length of the workpiece or project that has been
done.
2. End Mills 4 flute - Used for the process facing and rough cutting.
3. Milling Machine

Main Parts of Milling Machine

1. Column and base: Column and base provide support for the other parts of a
milling machine. There is an oil reservoir and pump in the column to lubricate the
spindle. The column rests on the base and also it has a coolant reservoir and a
pump to provide coolant in machining operations.
2. Knee: The gearing mechanism is enclosed within a knee. The knee is fastened to
the column by dovetail ways. It is supported and adjusted by a vertical positioning
screw also known as an elevating screw. The use of the elevating screw is to adjust
the knee up and down by raising or lowering the lever with the help of hand or
power feed.
3. Saddle and Swivel Table: The saddle is on the knee and supports the table. Saddle
slides on horizontal dovetail on the knee and dovetail are parallel to the axis of the
spindle (in horizontal milling machine). Swivel table is attached to the saddle that
swivels (revolved) horizontally in both directions.
4. Power Feed Mechanism: The power feed mechanism is in the knee. The power
feed mechanism is used to control longitudinal (left and right), transverse (in and
out), and vertical (up and down) feeds.
5. Table: A table is a rectangular casting that is presented on the top of a saddle. The
table is used to hold the work or for work holding devices. There are several
T-slots to hold work and work holding devices (jigs and fixtures). It can be
operated by hand or by power. For moving the table by hand, it engages and turns
the longitudinal hand crank. For moving it by power, it engages longitudinal
direction feeds control lever.
6. Spindle: The spindle is used to hold and drive the cutting tools of a milling
 machine. It is mounted on the bearings and has the support of the column. The
spindle is driven by an electric motor via gear trains and gear trains are on the
column. The spindle face lies near the table and has an internal taper machined on
it. There are two keys at the front face that provide a positive drive for the cutter
holder or arbor.
7. Over Arm/ Overhanging Arm: Overarm is a horizontal beam and it is on the top
face of the column. It may be a single casting and slides on the dovetail way which
is on the top face of the column.
8. Arbor Support: Arbor support is cast with a bearing that supports the outer end of
an arbor. It also helps to align the outer end of the arbor with the spindle. Arbor
support prevents the springing of the outer end of the arbor in cutting operations.
Generally, there are two types of arbor supports used in the milling machines. The
first one has a small diameter bearing hole of a maximum diameter of 1 inch. The
second one has a large diameter bearing hole of up to 23/4 inch.
9. Ram: The ram is an overhanging arm in a vertical milling machine. The one end
of the ram is mounted on the top of the column and the milling head is attached to
another.
EXPERIMENTAL AND SAFETY PROCEDURE

Experimental Procedure

A. MACHINE SET UP
1. The switch for the machine is switched on.
2. The user can easily access the control panel because it is positioned in front of the
machine.
3. In order to carefully monitor the procedure, the lamp is turned on.
4. To guarantee steady rotation, the appropriate flute end mill is placed into the
chuck and collet at the halfway point of its body.
5. The cutting end of the end mill is then inserted into the spindle and secured with a
handle. The machine's speed is set at 1400 RPM.
6. Before the milling process starts, the spindle's direction of rotation is checked.

B. FACING PROCESS

1. A vise is used to clamp the workpiece material to the milling table.

2. The x, y, and z axis handles are adjusted until the workpiece material's surface
touches the cutting tool's end.
3. The machine is turned on and the dial indication is reset to zero.
4. To make sure the surface is level, the x-axis and y-axis handles are adjusted up
and down until the end tool has completely scratched the surfaces.
5. A brush is used to clean the surface.

C. SLOT MILLING

1. A vernier caliper is used to measure the workpiece.

2. The cutting tool is positioned near the edge of the workpiece material by adjusting
the x and y-axis handles.
3. A zero value is set for the dial indication.
4. Moving the x-axis handle 47.5mm to the left will center the cutting tool on the
 workpiece. After lowering the z-axis by 2mm, the machine is turned on.
5. The slot is created by adjusting the y-axis handle.
6. Repeat steps 5 through 7 once more.
7. The cutting tool has a 16mm diameter, thus 2mm are added to the left and right
sides to create a 20mm slot.
8. The machine is shut off, and the workpiece is given a thorough brushing.

Safety Precautions

When doing the experiment, safety is the first priority. In order to reduce the possibility or
danger of harm, failure, or hazard to the operator, property, or environment, these laws
regulate the actions and practices when handling any device.

1. If you have any questions regarding machine control or how to use work
equipment properly, ask your instructor..
2. Put on proper, CSA-certified safety eyewear. To prevent risks like eye damage
from flying chips, wear personal protective equipment (PPE) as required.
3. To avoid slippage, which might present risks, keep the area around the milling
machine free of oil and grease.
4. Verify that all guards are in position and that the accessories are securely fastened.
5. After the cutters have stopped moving, vacuum or brush any extra chips.

CSA Safety eyewear Brush for cleaning the dirty

RESULT AND DISCUSSION

Drawing part Final product

The experiment's objectives were to produce a workpiece as a result of the milling

operation and to gain a better understanding of the milling process. According to the
theories behind the schemes, depending on the cutting tool, milling machines can be used
for a wide variety of tasks and tasks on tiny to large objects. The experiment started by
determining the wood block workpiece's initial width, length, and height. Next, we used
an equation to determine the cut's width, length, and height. Finally, we cut the workpiece
using the milling machine using the measurement we had established earlier. According to
principle, milling machines actually carry out a variety of tasks and duties depending on
cutting tools. Face mill and end mill were the cutting instruments used in this procedure.

The majority of milling errors are caused by inaccurate feature measurements or surface
roughness. Incorrect cutting parameters are the first possible error. For instance, the
surface of the workpiece will be rougher than desired and may have scratch marks if the
cutting parameters, such as the feed rate, spindle speed, or axial depth of cut, are too high.
Additionally, a deep cut may cause the cutter to vibrate and produce an inaccurate cut.
Additionally, using a dull cutter can lead to mistakes. For instance, a cutter's teeth will
deteriorate and become dull if it is used. Cutting with precision is more difficult with a
dull cutter. An unstable workpiece is the final error that could occur. The friction of
milling could cause the workpiece to shift and change the intended cuts if it is not tightly
fastened in the fixture. Additionally, there will be some error when the workpiece touches
the cutting equipment, whether it touches the workpiece too deeply or not at all. This error
can result in flaws. Measurement error will result from the discovery of parallax error.
The second issue comes up when we want to switch the cutting measurement, for
instance, after we finish cutting for 0.5 mm and want to switch to 1 mm. Parallax
inaccuracy is discovered while altering the measurement, and this issue can result in an
insufficient surface quality. The eyes are not the same level to the measurement on the
vernier caliper when taking the measurements. We need to do the experiment with more
caution in order to avoid this issue.
REFERENCE

1. Bergs, T., Hardt, M., & Schraknepper, D. (n.d.). STRATEGY OF MILLING CENTER
THERMAL ERROR COMPENSATION USING A TRANSFER FUNCTION MODEL
AND ITS VALIDATION OUTSIDE OF CALIBRATION RANGE. MM Science Journal.
https://www.mmscience.eu/journal/issues/november-2019/articles/strategy-of-milling-cen
ter-thermal-error-compensation-using-a-transfer-function-model-and-its-validation-outsid
e-of-calibration -range
[Accessed on 13 July 2022].

2. Milling Process, Defects, Equipment. (n.d.). CustomPartNet.

https://www.custompartnet.com/wu/milling
[Accessed on 13 July 2022].

3. Milling Machine Definition, Process and Types. Engineering Article.

https://www.engineeringarticles.org/milling-machine-definition-process-types/
[Accessed on 12 July 2022].

4. WayKen Rapid Mnufacturing. (2020, August 26). 4 Common Workpiece Defects And
Their Causes In CNC Milling.
https://waykenrm.com/blogs/cnc-milling-defects-and-solutions/
[Accessed on 12 July 2022].

5. https://www.engineeringchoice.com/milling/
[Accessed on 13 July 2022].