1.

0 Introduction
Milling is the process of cutting away material by feeding a workpiece past a
rotating multiple tooth cutter. The cutting action of the many teeth around the
milling cutter provides a fast method of machining. The machined surface may be
flat,angular, or curved. The surface may also be milled to any combination of
shapes. The machine for holding the workpiece, rotating the cutter, and feeding it
is known as the Milling machine.

1.1Objectives
To handle and operate the milling machine properly.
To produce the product with given dimensional correctly.

1.2 Theory
CLASSIFICATION OF MILLING:
Peripheral Milling
In peripheral (or slab) milling, the milled surface is generated by teeth located
on the periphery of the cutter body. The axis of cutter rotation is generally in a
plane parallel to the workpiece surface to be machined.
Face Milling
In face milling, the cutter is mounted on a spindle having an axis of rotation
perpendicular to the workpiece surface. The milled surface results from the action
of cutting edges located on the periphery and face of the cutter.

End Milling
The cutter in end milling generally rotates on an axis vertical
to the workpiece. It can be tilted to machine tapered surfaces.
Cutting teeth are located on both the end face of the cutter and
the periphery of the cutter body.

METHODS OF MILLING
Up Milling
Up milling is also referred to as conventional milling. The direction
of the cutter rotation opposes the feed motion. For example, if the
cutter rotates clockwise , the workpiece is fed to the right in up
milling.
Down Milling
Down milling is also referred to as climb milling. The direction of
cutter rotation is same as the feed motion. For example, if the
cutter rotates counterclockwise , the workpiece is fed to the right
in down milling. The chip formation in down milling is opposite to
the chip formation in up milling. The figure for down milling shows

that the cutter tooth is almost parallel to the top surface of the
workpiece. The cutter tooth begins to mill the full chip thickness.
Then the chip thickness gradually decreases.
Types of Milling Machines
Milling machines can be broadly classified into the following types:

Column and knee type of milling machines

Bed type
Rotary table
Tracer controlled

Milling Cutters
A milling cutter is a cutting tool that is used on a milling machine. Milling
cutters are available in many standard and special types, forms, diameters, and
widths.The teeth maybe straight (parallel to the axis of rotation) or at a helix angle.
The helix angle helps a slow engagement of the tool distributing the forces .The
cutter may be right-hand (to turn clockwise) or left-hand (to turn
counterclockwise).The figure shows a typical end milling cutter.
Features of Milling Cutters
Some of the terms used to identify the major features of a milling cutter are
given in the figure.

Cutting tools for vertical milling:

End mills (commonly used for facing,slotting and profile milling.
Rough Cut End Mills (for rapid metal moved)
Slot Drills (for producing pockets without drilling a hole before hand.
Face Milling Cutters (for heavy cutting)
2.0 Procedures
1. Prepare the material.
2. Wear the safety gear and goggle to protect your body and eye from the
flying chips.
3. The cutting tools is setup in the spindle chuck.
4. Clamp the workpiece to the machine vice.
5. Switch on the machine and do some test-run before cutting adjusting the
axes (x,y and z).
6. Move the worktable manually in horizontal direction using lever (the axes
can only be increased to 0.3mm simultaneously).
7. Start cutting by adjusting the face milling near the surface of the workpiece.
8. Start cutting beginning from the surface of the workpiece until 1mm.
9. Then,turn the workpiece to its opposite site and continue the cutting process
until obtain the correct measurement.

10.Switch off the spindle switch and pull the break whenever the workpiece
need to be measured.
11.Drill the hole with given dimensions.
12.Use the drill bit to make threads in the hole.

3.0 Observation
Below are the milling machine and the name of each component on it.

4.0 Results

5.0 Discussions and Conclusion

The time consuming to cut the material is too long and require more time to
finish the project completely.So, we need to maximize the axes to 0.3mm for each
time cutting the workpiece.The other problem is the hole that been drilled is not at
the center and difficult to drill the workpiece at the correct position.The way to
overcome the problem is mark the position of the hole to make sure the drill can be
placed correctly at its position.As the conclusion,we have learned how to organize
the milling machine and understand the operation involved.Besides,we also know
the purpose of the main parts of this machine.From the laboratory activities also
we realize that the cutter diameter should be chosen in such a manner that it will
not interfere with fixtures and other components in the setup.

5.1 References
i http://mmu.ic.polyu.edu.hk/handout/0103/0103.html#contents
ii http://www.maritime.org/doc/pdf/milling-machine.pdf
iii http://www.aps.anl.gov/APS_Engineering_Support_Division/User_ESH/
Machine_Shops_Public/20050816_pdf_files/Study_Guides/APS_Vertical_
Mill.pdf