PROGRAMME : CEEM222

COURSE : MEM460
INSTRUCTOR : Encik Mohamad Firhan Morni

LABORATORY REPORT
LABORATORY: Milling Process

NO NAME STUDENT ID GROUP

NO
1. MUHAMMAD ANIQ ABQARI BIN
SALLEHSHAHIBBUDIN 2022464556 A(1)
2. ADAM BIN MOHD SHAHRIZAN
2022453412 A(1)
3. QURRATUL NADJWA NURAISYAH
BINTI NADZRI 2022464476 A(1)
4. ILYAS MUHAMMAD BIN EDEE
SALMAN 2022498275 A(1)
1.0 Title: Milling process

2.0 Objective

To produce a product or part from milling process. Utilizing a cutting tool, the milling
process' goal is to remove material from a workpiece. This is typically done by rotating the
cutting tool and feeding it into the workpiece, which is held in place by a fixture or a machine
vice. The material removal is achieved by the cutting edges of the tool as it makes contact
with the workpiece and removes small chips of material with each pass.

The primary objective of milling is to produce a finished part or component with precise
dimensions, surface finish, and geometry. Numerous milling techniques, such as face milling,
peripheral milling, and slot milling, among others, can be used to achieve this.

Simple flat surfaces to complex designs with close tolerances can all be produced with
milling. It is a versatile process that is commonly used in the manufacturing industry to
produce parts for various applications, including automotive, aerospace, medical devices, and
consumer products.

3.0 Introduction

The process of milling involves using a milling machine to remove or trim elements like
metal, wood, and plastic from the surface of a workpiece. It was necessary to rotate a multi-
sharp tool with a precise and determined geometry for the milling process. The material will
be removed when it comes into contact with the cutter and the cutting head needs to move
concurrently on the motorized axes [1].

The milling technique is used to create pieces, which are frequently complex and
asymmetrical. There are two main categories for milling: face milling and peripheral milling.
By developing a milling process, the method of rotational filling was developed in the past to
lessen the time and effort required for manual filling [2]. Milling are usually being used as a
secondary process either to add or refine features on parts that were
manufactured using different process. In industries and machinery shops, it was very
common to use milling process due to the function that manufacture high precision products
and parts with different size and shapes.
4.0 Experimental Procedure

4.1 Apparatus

Apparatus: Vertical milling machine, Eye piece (2 Flute End Mill and 4 Flute End Mill),
Work piece, Work lamp, spindle handle, Vice handle, Safety googles , Brush, Clamp, Vernier
Caliper, Safety boots

4.2 Apparatus setup

1. Workspace Preparation

Prepare the workspace for the milling machine setup.

2. Machine Assembly

Assemble the milling machine apparatus.

3. Workpiece Setup

Prepare the workpiece for milling.

4. Tooling Setup

Proper tool setup is essential for achieving accurate cuts and optimal results.
 Wooden Block Easy to operate due to its hardness.
Its price is also cheaper compared to
the price of metal.

End Mill Cutter It can cut in all direction. Commonly

used for countering, face milling and
profile milling.

4.2 Material Used

5.0 Experimental and safety procedure

Experimental Procedure

1. Workspace Preparation:

a. Clear the workspace of any clutter or obstacles.

b. Ensure proper lighting is available.

c. Create a level and stable surface for the milling machine.

d. Allow sufficient space around the machine for movement and material handling.

e. Post safety guidelines and emergency contact information in a visible location.

2. Machine Preparation:

a. Ensure the milling machine is properly assembled and functional.

b. Connect the machine to a stable power source following electrical safety guidelines.

c. Familiarize yourself with the machine's controls, including power switches, speed
adjustments, and feed controls.

d. Verify that all safety features are operational.

3. Workpiece Setup:

a. Select the appropriate workpiece material based on the experiment requirements.

b. Clean the workpiece to remove any dirt, debris, or contaminants.

c. Measure and mark the workpiece to indicate the desired dimensions and features.

d. Securely clamp the workpiece to the milling machine's table using clamping devices such
as a vise or clamps.

e. Align the workpiece with the milling machine's axis and adjust the table or vise position
if needed.

f. Double-check that the workpiece is securely clamped and will not move during milling.

4. Tooling Setup:
 a. Select the appropriate cutting tool based on the material, cutting operation, and desired
outcome.

b. Insert the cutting tool into the machine's spindle or tool holder.

c. Use the necessary wrenches or collets to securely fasten the tool in place.

d. Ensure the tool is aligned correctly, perpendicular to the workpiece.

e. Set the appropriate cutting speed, feed rate, and depth of cut based on the material and
tool specifications.

f. Apply cutting fluid or lubricant to reduce heat and friction during the milling process.

5. Milling Operation:

a. Power on the milling machine and ensure all safety precautions are followed.

b. Use the handwheels or control panel to position the cutting tool above the starting point
on the workpiece.

c. Lower the cutting tool to the desired depth of cut.

d. Start the milling operation, moving the cutting tool along the desired path using the
machine's feed controls.

e. Monitor the machining process closely, ensuring the tool is cutting smoothly and the
workpiece is secure.

6. Measurement and Quality Check:

a. Once the milling operation is complete, power off the machine.

b. Use measuring tools such as calipers or micrometers to measure the dimensions of the
machined features.

c. Compare the measurements with the desired specifications to assess.

Safety and Precautions

1. Whether the work must be securely clamped to the table or the work must be securely
clamped in a vise and tightly clamped to the table.
2. Unless otherwise instructed, do not make climb milling cuts on the shop's mills.
3. Before cutting the material, be sure the cutter is turning in the right direction.
4. To ensure that the spindle is clear for cutting, it should be manually turned before
starting the machine.
5. Make sure the power is off before replacing the cutters.
6. Always use the proper cutting fluid for the material being cut.
7. Never use the equipment at a quicker cutting speed.
8. Before collecting any measurements, make sure the equipment is completely shut off.
9. Use only well-maintained, sharp cutting tools.
10. Avoid setting anything, including tools, hammers, and wrenches, on the milling
machine table.
11. Always be nearby while the equipment is in operation.
12. Avoid cutting too deeply or feeding too quickly.
13. After using the collet tightening wrench, remove it right away.
14. To stop chips from striking other people, rig a guard or shield if it's possible to do so.
15. To stop the spindle once the power has been switched off, use the milling machine's
spindle brake.
16. To prevent injury, remove cutting instruments from the spindle before cleaning the
mill.
6.0 Results and Discussion

Figure 2

A final item or component that has been formed and dimensioned to fulfill the necessary
specifications emerges from the milling process. Depending on the type of milling process
and the materials being used, the precise results of milling can vary, but in general, milling
can produce the following effects:

Dimensional accuracy: Milling is the best method for producing parts that need to be
extremely accurate since it can produce parts with precise and consistent dimensions.

Smooth surface finish: The milling tool's cutting motion can provide the component being
machined a smooth surface finish. This is particularly crucial for components that must be
aesthetically pleasing or that will be visible.

Tight tolerances: Milling is able to create parts with tight tolerances, which means that the
part's dimensions are restricted to a very small range.

Complex geometries: Complex geometries, such as curves, angles, pockets, and contours, can
be produced using specialized milling tools and processes.

Material removal: The milling technique is ideal for producing parts from materials that are
challenging to machine using other methods because it can remove material rapidly and
effectively.

Overall, milling produces a high-quality completed item that satisfies the necessary
requirements and is prepared for usage in the application for which it was designed.
Title block
Discussion

Using rotary cutting, we learned in this experiment how a milling process, as described in [3],
takes material from a specific workpiece. In a mill, the cutter also has a number of cutting
spots and typically moves perpendicularly to an axis, cutting into the workpiece with the
knife's circumference.There are two different mill cutting point types that will be used in the
lab, a 2 flute end mill and a 4 flute end mill. Drilling, facing, and crafting can all be done
using a two-fluted end mill. But only facing and crafting are used with 4 flute end mills.

Source of Error and How to Overcome

1.Calibration

One method for overcoming error is calibration. The individual handling it made a mistake
during the calibration of the machine, which caused the calibration error.

Overcome: contrasting your experiment's findings with those of other people or with those of
a theoretical model. But which of the data sets is the exact one might not be clear. If possible,
calibration is the most effective technique to get rid of systematic mistakes. To calibrate your
experimental procedure, you run it on a reference quantity for which the correct results are
already known. If possible, calibrate all of the test's instruments and procedures using a set of
data that is the same size and shape as the unknown variable.

2. Kinematic errors

Due to manufacture errors and clearances, geometry-defining components like rotary

bearings and linear slideways may not function properly. They continue to exist regardless
of any external factors, such as forces and temperature. The alignment of the axes or the
straightness of an axis are just two examples of kinematic faults that solely depend on
position. Playing with drives, slideways, and rotating bearings causes hysteresis effects that,
depending on the direction of travel, result in different kinds of mistakes. adjustment to be
utilized significantly more frequently.

Overcome: Kinematic errors are repeatable, with calibration being relatively easy to
compensate for. Traditionally, the focus was on making mechanical improvements to devices,
for example, by grinding an axis flat, to remove these errors. Other than that, the use of
computer numerical control (CNC) now enables digital correction to be much more
commonly used. This implies that it causes an error in the z-direction if there is a calculated
high point on the x-axis

3.Possible Defects

Many defects in milling are inaccuracies in the dimensions or surface roughness

of a feature. For these defects, there are many potential reasons, including the following

1. Lack of a cutter may cause the teeth to grow dull and wear out. The ability of a dullcutter
to make precision cuts

2. An insecurely clamped workpiece will allow the friction of the milling operation, which
produces the desired cuts, to move and adapt.

3. Incorrect cutting parameters - The workpiece surface may be rougher than desired and may
have scratch marks or even burn marks if the cutting parameters, such as the feed rate, the
spindle speed, or the axial depth of the cut, are too high. Additionally, a wide cutting depth
might lead to cutter vibration and poor cut quality. Make clean cuts.

6.1 Recommendation

1. Pre-cut the workpiece to a size and shape that requires the least amount of milling.

2. The ergonomics side needs to be emphasized further.

3. To acquire the best surface of the workpiece to erase burn markings or even scratch marks,
use the necessary cutting parameters, such as the feed rate, spindle speed, and axial cutting
depth. Additionally , it may add to cutter vibration and impede increased cutting depth by
resulting in inaccurate cuts.

4. Evit lowers prices. To produce a better product and reduce human error, utilize a computer
numerical control (CNC) milling machine.
5. To avoid the collet from touching the workpiece, make sure that any element's depth is less
than the tool's length.

6. Because the teeth are less capable of performing precise cuts, avoid using a dull knife.

7.0 Conclusion

The product from milling process had been produced with exact feature from detailed
drawing by following milling square, facing to length, and milling slot processes.

8.0 References

1)Overview of CNC Milling

https://www.ardelengineering.com/cnc-milling-process
2)Milling Process
http://www.belotti.com/de-DE/milling-process.aspx
3)Milling Machine Safety Rules
https://www.lsu.edu/eng/mie/cuf/ammf/safetyrules/MillingMachines.php
4)Endmill Selection Guide https://www.redlinetools.com/resources/endmill-
information#:~:text=While%20a%20drill%20can%20only,slotting%2C%20drilling%2C
%20and%20reaming.