Format Laporan Mesin Milling

LABORATORIUM PERANCANGAN DAN MANUFAKTUR
WORKSHOP DTSP FTK ITS

DEPARTEMEN TEKNIK SISTEM PERKAPALAN
Kampus ITS Sukolilo Gd. WA lt.2,Surabaya 601111
FAKULTAS TEKNOLOGI KELAUTAN
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Format Laporan
Praktikum Mesin Milling
Ilmu Bahan Dan Pengerjaan Logam
Cover
Lembar Pengesahan
Abstrak (Indonesia/Inggris)
Milling machines are versatile and essential tools in the manufacturing industry, utilized for
shaping and cutting materials with precision. This abstract explores the fundamental aspects,
types, and applications of milling machines. At its core, a milling machine employs rotary
cutters to remove material from a workpiece, enabling the creation of complex shapes, slots,
holes, and flat surfaces. The evolution of milling machines has led to a diverse range of designs,
including vertical and horizontal mills, each suited to specific tasks and materials.
Daftar Isi
Daftar Gambar
Daftar Tabel
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BAB I PENDAHULUAN
1.1 Introduction
Because of the demand for high-speed and high-precision machining, machine tools with
excellent dynamic performance are being designed and manufactured. However, regenerative
chatter vibration produced by the machine tool during machining has been a problem. The
studies conducted by Tlusty and Tobias revealed that the chattering is caused by the dynamic
interaction between the cutting tool and the workpiece during the chip generation process.
They presented the basics of a dynamic cutting force model for the regenerative chatter
vibration. Various analytical stability-analysis approaches were subsequently developed by
Minis et al. and Budak and Altintas in order to quantitatively define the machining conditions for
stable milling operation (Hung Jui-Pin, 2011).
The world went through many revolutions on the manufacturing processes. It reduced the
costs of these boards to a level where it was possible to insert them into nearly all electronic
devices. One of these manufacturing processes is milling. After the Second World War the first
Computer Numerical Controlled (CNC) machines appeared. It didn’t take time to adapt them to
the many machines that existed. This is how the firsts CNC milling were developed and the
industry discovered that it was one of the best processes to manufacture many things (Basniak
Rodrigo, 2012).
CNC milling machines are usually assembled with five modular components: a machine
base, saddle, table, vertical column, and headstock with a spindle tool unit. In the spindle tool
system, the feeding mechanism of the control axis is constructed in various configurations using
linear guides, ball screws, and supporting bearings. It is well known that the ball bearing is a
primary component dominating the dynamic behavior of the rotary-shaft system, and, in
particular, of the spindle tool unit. (Hung Jui-Pin, 2011). The main material used on the milling
machine is aluminum, because of its great weight cost ratio. It’s used specially for the moving
parts, since with lower weight they will have less inertia and the motors needed to move them
will consume less power (Basniak Rodrigo, 2012).
The aim of this study was to investigate the milling machine components and evaluate
every part of it in order to understand more about milling machines. This study also has another
purpose of finishing our project as a student and making this study as a place for us to put our
works of material and metal processing evidence. This study will also discuss the relation of it
with the maritime world.
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1.2 Problem Formulation

Based on the introduction of milling machine above, the problem can be formulated as follows
1. What is a milling machine and what are the components of the milling machine?
2. How many types are there of the machine and how does it work?
3. What are the tools that can be used to help milling machine productivity?
4. What are the applications of milling machines in marine and non-marine fields?
1.3 Benefit
Based on the introduction and problem formulation of milling machine above, the benefit can
be said as follows
1. We can know what a milling machine is and the parts of it.
2. We can know the history of the milling machine.
3. We can know how the milling machine works.
4. We can know the applications of milling machines in marine and non-marine fields.
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Bab II Dasar Teori

(seluruh poin diberi gambar beserta penjelasannya)
2.1 Definition of Milling Machine
Picture 2.1 milling machine
Milling machine is a tool that is used to create parts by removing materials from a
workpiece with a rotary cutting tools. A milling machine is an equipment used for milling,
a subtractive type manufacturing that can be controlled manually or using a Computer
Numerical Control (CNC). There are various function that could be performed by a milling
machine by changing the type and shape of the cutting tools. Milling machine is one of
the most benefical piece in a workshop due to its versatility.
The milling machine was invented in 1818 by Eli Whitney in New Haven,
Connecticut. Before that year, to create parts workers hand files the workpiece manually
which is very time consuming. The creation of a milling hmachine helps worker with time
efficiency and without requiring a particular set of manual labor skills. These early milling
machine were used to in the process of manufacturing rife parts.
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2.2 Types and Working Mechanism of Milling Machines
2.2.1 Types of milling machine
2.2.1.1. Column & knee Type
· Hand milling machine
· Plain or horizontal milling machine
· Vertical milling machine
· Universal milling machine
· Omniversal milling machine
2.2.1.2. Fixed bed type
· Simplex milling machine
· Duplex milling machine
· Triplex milling machine
2.2.1.3. Special Type
· Rotary table milling machine
· Drum milling machine
· Profile milling machine
· Planetary milling machine
· Tracer controlled milling machine
· Pantograph milling machine
· NC/CNC Milling machine

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2.2.2 Milling machine working mechanism
before we learn on how a milling machine works, we must understand the

principle of the process. The workpiece is attached firmly to the machine’s worktable.
A rotating cutter revolves at a great speed and is attached to an arbor or spindle. The
only motion happening in this machine is rotary motion. The workpiece is advanced
and some material from the surface of the workpiece is removed by the cutting tool
that moves in a rotary motion.
Now that we have the basic understanding on the principal of how a milling
machine is working, it is easier to understand its process. Here are some of the
important steps on how a milling machine is working.
First, is the basic set up. Before we start the process of milling a workpiece,
the most crucial thing to have is a proper and correct setup. So the first step is to
have the cutting tool adjusted at the arbor. And then the arbor is connected to the
spindle. The next thing we must mount is the workpiece. We need clamping screws
for this process.
The next thing to happen is we must ensure all the controls such as saddle
position, knee position, etc. are set to zero. This will ensure exact precision I the
process. This steps are important in making sure that the measurement and the end
product are right.
Next, the actual work begins. The spindle will start to rotate which cause the
cutting tool to rotate as well. The cutting tool is moving continuously at a very high
speed. The other parts of the machine are moved slowly to move the workpiece.
Now the final part is, the workpiece being slowly moved by the controlling axis and in
this step the cutting tool is in a rotary motion and remains stationary.
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2.3 Parts of Milling Machines

(contoh pemberian nama gambar)
Picture 2.2 parts of milling machine
2.3.1. Column & base
Column and base is the main casting that supports all other parts of milling machine.
The column contains an oil reservoir and a pump which lubricates the spindle. The
column also rest on the base and the base contains coolant reservoir and a pump
which is used during the process that requires coolant.
2.3.2. Knee
The knee is a casting that supports the saddle and table. All mechanism is enclosed
within the knee. The knee is fastened to the column by dovetail ways. Its is also
supported and adjusted by a vertical positioning screw. The elevating screw is used
to adjusr the knee up and down by raising or lowering the lever.
2.3.3. Saddle and swivel table
The saddle is on the knee and supports the table. It slides on a horizontal dovetail
and is paralleled to the axis on the spindle ( on horizontal milling). The swivel table is
attached to the saddlethat can be swiveled horizontally in either directions.
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2.3.4. Power feed mechanism
It is the knee which contains the power feed mechanism. It controls the longitudinal (
left and right), transverse ( in and out) and vertical (up and down) feeds. To get the
desired rate of feed on the machine, the feed selection lever is positioned as
indicated on the feed selection plates. On some universal knee and column milling
machine, the feed is obtained by turning the speed selection handle until the desired
rate of feed is indicated on the feed dial. Most of the milling machines have a rapid
traverse lever that can be engaged when a temporary increase in the speed of the
longitudinal, transverse or vertical feeds is required. For example this lever would be
engaged when the operator is positioning or aligning the work.
2.3.5. Table
It is arectengular casting on top of the table. It is where the workpiece is being held.
It contains several T-Slots for holding the work. This table can be operated by hand
or by power.
2.3.6. Spindle
It is the shaft that is used to hold and drives the cutting tools of the milling machine.
The spindle is mounted on the bearings and supported by the column. Spindle is
driven by the electric motor through gear trains. The face of the spindle which lies
near to the table has an internal taper machined on it. The internal taper at the front
face of the spindle permits only a tapered cutter holder or arbor.
2.3.7. Over arm
Over arm is a horizontal beam at the top of the face of the column. It may be a single
casting. The overarm is used to fastened arbor support. It may consist of one or two
cylindrical bars which slide through the holes in the column.
2.3.8. Arbor support
It is a casting with bearing that supports the outer end of the arbor. It also helps in
aligning the outer end of the arbor with the spindle. It prevents the springing of outer
end of the arbor during cutting operations. The arbor support has an oil reservoir that
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lubricates the bearing surfaces. It can be clamped anywhere on the overarm. The
arbor support is used only in the horizontal types of milling machine.
2.4 Types of Cutting Tool on a Milling Machines
2.4.1. End mill
End mills are similar to drills in the sense that they can cut axially. But the
advantage for milling lies with the possibility of lateral cutting. It is sometimes
flat but sometimes it is round
2.4.2. Face mill
Face mills cannot cut axially. Instead, the cutting edges are always located onthe
sides of the cutting head. The cutting teeth are replaceable carbide inserts. This
makes the lifetime of a tool longer while maintaining a good cutting quality.
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2.4.3. Side and Face Cutter
Side-and-face cutters have teeth around the circumference as well as on one

side. This makes the functionality very similar to end mills but older.
2.4.4. Fly Cutter
The fly cutter have the same function as face mills. They consist of a central
body that holds either one or two tool bits (double-end fly cutters). Fly cutters
are just cheaper and the cutting bits are often made at the shop by a machinist
rather than bought from stores.
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2.4.5. Woodruff Cutter
Woodruff cutter are used to cut keyslots into parts, for example shafts. The
cutting tools have teeth perpendicular to the outside diameter to produce
suitable slots for woodruff keys.
2.4.6. Thread Mill
Thread mills are usd to producing tapped holes. Threading operations are
usually carried out on drilling equipment. Using a thread mill, though, is more
stable and has fewer limitations regarding the environment.
2.5 Types of Milling Process
2.5.1. Plain/Slab Milling
Plain milling creates a flat horizontal surface parallel to the cutter’s axis using a plain
milling cutter
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2.5.2. Face milling
Face milling produce a flat surface that is unlike the slab milling, it is perpendicular to
the cutter’s axis.
2.5.3. Bevel milling
Bevel milling have flat surface at a certain angle different from the cutter rotation
axis. Utilizing single or double angle cutters.
2.5.4. Straddle milling
Process of creating two vertical flat surfaces on both sides of the workpiece using
two side milling cutter separated by collars.
2.5.5. Gear milling
Gear milling involves shaping various gear types using form relieved cutter that
match the shape of the gear. Typically done with spaced gear teerg and universal
dividing head for indexing.
2.5.6. Saw milling
Sawmilling employs a huge sized cutter with a slender profile, designed to create
narrow slots or the division of a workpiece into two segments. To prevent undesirable
heat and stress buildup that can lead to tool and workpiece damage, the feed rate
and speeds is maintained at a lower pace compared to other milling processes.
Typically, this operation is carried out on horizontal milling machines.
2.5.7. Side milling
Side milling is the preferred choice when you need to machine a flat vertical surface
onto your workpiece. In this process, a side milling cutter is affixed to the arbour of a
horizontal milling machine, and the workpiece-holding table is elevated to the desired
depth of cut before being fed into the cutter. Additionally, the cutter is equipped with
helical flutes to facilitate chip evacuation during machining, and its diameter is
typically smaller than the width of the workpiece, similar to that of a drill bit.
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2.5.8. Thread Milling
Thread milling is a machining process used to create threads within a pre-existing

hole in a workpiece, employing specialised tools known as thread mills. This
operation is compatible with both vertical and horizontal milling machines. Unlike
tapping, thread milling is particularly well-suited for generating threads in holes larger
than the diameter of the milling tool. Thread milling entails three distinct movements:
one for rotating the thread mill, another for its axial movement into and out of the
hole, and a third for advancing the workpiece to facilitate the cutting of the desired
threads.
2.6 Tools to help with milling process

Tools that we can use in helping the process of milling are firstly vise. Vise a
re used to clip the workpiece to make sure it stay in it place. The second tool we
need in the process is a hammer. This hammer is used to tighten the screw of the
vise. By using a hammer we can make sure that the vise is tight enough so the
workpiece stay in its place during the whole process.
To mark the workpiece we use marker or chalk as a guideline on where to
work and the outline of our work on the piece. We must mark it precisely by using
a ruler. A small mistake in the marking will cause the piece to be inconsistent or
wrong. And the last tool is a vernier calipers. The vernier calipers are used to
measure the depth of the work we done on the piece.
It works by putting the bottom part of the tool in the workpiece. Then we
make sure the bottom part sticks to the surface of the piece. If its straight and
sticks to the surface, you need to tighten the screw in the side of the calipers.
Then see the measurement in the calipers to see exactly how deep the work is
already.
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2.7 Calculations
2.7.1. Cutting speed formula
This formula is used to count the cutting speed so that we ccan precisely know the
speed to work on because if the speed is too high, it will cause overheating and if the
speed is too low it wouldn’t be efficient.
The formula is
V = cutting speed
Π = circumference constant per mm of diameter
D = diameter of the cutter
n = revolutions per minute
2.7.2. Feed rate
The feed rate is determined by three things firstly being the amount of gear in the
tool, secondly the chip load of the tool, and lastly the rotation of the milling knife. And
so, this is the formula of the feed rate
V = speed (mm/min)
n = rotation per minute (rpm)
Fz= feed rate per tooth (mm/t)
Z = number of teeth
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2.8 Application in marine and non marine

(Masing-masing 4 contoh)
(contoh penamaan tabel)
Tabel 2.1 Pengaplikasian Mesin Sekrap di Bidang Marine
no Marine Non-Marine
1
Hull machining Prototyping parts
2
Propeller repair Parts repair
3
Component fabrication Parts fabrication
4
Engine/turbine overhaul Mold making
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Bab III Tahapan Praktikum Mesin Milling
3.1 Gambar Kerja
3.2 Peralatan Praktikum (alat, pahat dan bahan)
No Name Function Image
1 Wearpack A wearpack is protective clothing

designed for industrial
environments, offering safety
against hazards like chemicals, fire,
and extreme temperatures.
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2 Milling Machine A milling machine removes

material from a work piece by
rotating a cutting tool (cutter) and
moving it into the work piece.
Milling machines, either vertical or
horizontal, are usually used to
machine flat and irregularly
shaped surfaces and can be used
to drill, bore, and cut gears,
threads, and slots.
3 Work Object Serves as an object that will be

processed on a milling machine
4 Fine File Serves as a tool for filing workpieces

so that the workpiece is not sharp
5 Coolant Fluid To cool the workpiece and the

cutting tool during cutting
operations using a machine.
6 Ruler As a tool to measure the length or

width of various surfaces.
7 Vernier Calipers to measure the thickness, inner

diameter, outer diameter, and
depth of an object.
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8 Marker to make a line or mark on an

object.
9 Sand Paper to smoothing the surface of an

object by rubbing its rough surface
against the surface of another
object.
10 Brush Paint to clean the areas of the machine

that are dirty
3.3 Persiapan Pengerjaan dengan Mesin Milling

a) prepare the work object
b) prepare the tools
c) mark the work object
d) check the milling machine
e) set the drill
f) place the work object on the milling machine
3.4 Proses Pengerjaan
1. Setup: The workpiece is securely mounted onto the machine's worktable or clamping fixture.
The cutting tool, known as the ram, is mounted on a vertical ram that moves up and down.
2. Feed Mechanism: The workpiece is positioned under the ram, and the feed mechanism
controls the movement of the workpiece relative to the cutting tool. This movement can be
adjusted to control the depth of cut and the length of the shape.
3. Cutting Process: Contains one or more cutting edges, typically made of high-speed steel or
carbide, arranged along its length. As the ram moves downward, the cutting edges engage
with the surface of the workpiece, removing material and creating the desired slot or shape.
4. Reciprocating Motion: The ram will rotate rapidly to cut the desired parts of the workpiece.
the motion of the ram will drill the workpiece and make a slot/shape, this motion can go right
or left to make a slot.5.Coolant and Lubrication: To dissipate heat and reduce the friction and
improve the result, cooling and lubricated liquid is used
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6. Control: Milling machines need to be controlled manually where the operator controls the
feed rate, depth of cut, and stroke length.
7. Completion: When it’s already done, the workpiece is removed and given the final touch
(deburring or polishing)
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Bab IV Penutup
(seluruh poin diberi gambar beserta penjelasannya)
4.1 Pertanyaan *(praktikan meminta grader laporan mengenai pertanyaan tambahan)
A. Jelaskan pertimbangan pemilihan jenis pahat mesin milling?
B. Jelaskan cara maintenance/ perawatan dari mesin milling
C. Apa hubungan antara RPM, kekuatan kerja, dan kedalaman hasil kerja dari
mesin?
D. Sebut dan jelaskan cara penggunaan alat-alat pengukuran yang sesuai untuk
digunakan dalam pengerjaan mesin milling
4.2 Kesimpulan *
4.3 Saran
Note:
* tiap praktikan wajib mengerjakan bab IV sendiri-sendiri.
Daftar Pustaka
(sitasi menggunakan metode Harvald baik in-text maupun untuk daftar pustaka)
Lampiran
(berisi logbook dan penugasan menggambar hasil pengukuran benda yang dilakukan
ketika asistensi ke grader laporan)
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LAMPIRAN
Lampiran 1. Logbook Praktikum
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Lampiran 2. Gambar Pengukuran Benda Kerja

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LABORATORIUM PERANCANGAN DAN MANUFAKTUR

WORKSHOP DTSP FTK ITS

1.2 Problem Formulation

Bab II Dasar Teori

Picture 2.1 milling machine

2.2 Types and Working Mechanism of Milling Machines

2.2.1 Types of milling machine

2.2.1.1. Column & knee Type

· Hand milling machine

· Plain or horizontal milling machine

· Vertical milling machine

· Universal milling machine

· Omniversal milling machine

2.2.1.2. Fixed bed type

· Simplex milling machine

· Duplex milling machine

· Triplex milling machine

2.2.1.3. Special Type

· Rotary table milling machine

· Drum milling machine

· Profile milling machine

· Planetary milling machine

· Tracer controlled milling machine

· Pantograph milling machine

· NC/CNC Milling machine

2.2.2 Milling machine working mechanism

before we learn on how a milling machine works, we must understand the

2.3 Parts of Milling Machines

Picture 2.2 parts of milling machine

2.3.1. Column & base

2.3.3. Saddle and swivel table

2.3.4. Power feed mechanism

2.3.7. Over arm

2.3.8. Arbor support

2.4 Types of Cutting Tool on a Milling Machines

2.4.1. End mill

2.4.2. Face mill

2.4.3. Side and Face Cutter

Side-and-face cutters have teeth around the circumference as well as on one

2.4.4. Fly Cutter

2.4.5. Woodruff Cutter

2.4.6. Thread Mill

2.5 Types of Milling Process

2.5.1. Plain/Slab Milling

2.5.2. Face milling

2.5.3. Bevel milling

2.5.4. Straddle milling

2.5.5. Gear milling

2.5.6. Saw milling

2.5.7. Side milling

2.5.8. Thread Milling

Thread milling is a machining process used to create threads within a pre-existing

2.6 Tools to help with milling process

2.7.1. Cutting speed formula

Π = circumference constant per mm of diameter

D = diameter of the cutter

n = revolutions per minute

2.7.2. Feed rate

n = rotation per minute (rpm)

Fz= feed rate per tooth (mm/t)

2.8 Application in marine and non marine

Bab III Tahapan Praktikum Mesin Milling

3.1 Gambar Kerja

3.2 Peralatan Praktikum (alat, pahat dan bahan)