MANUFACTURING AND MATERIALS DEPARTMENT

MME1103 Workshop Technology Manual Milling

KULLIYYAH OF ENGINEERING

DEPARTMENT OF MANUFACTURING & MATERIALS

WORKSHOP TECHNOLOGY MME 1103

MILLING 1 & 2

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2: Types of milling (a) Peripheral and (b) Face. The cutting tool in milling is called milling cutter and the edges are called teeth. Figure 6. Figure below shows some of the application of milling.MANUFACTURING AND MATERIALS DEPARTMENT MME1103 Workshop Technology Manual Milling 6. 6. 2 .1: Parts and products machined by milling machine There are two basic cutting operations in milling which are peripheral milling and face milling as shown in Fig. The tool axis in peripheral milling is parallel to the surface being machine while the axis of the cutter is perpendicular to the machined surface in face milling. This orientation between the tool axis and the feed direction is one feature that distinguishes milling from drilling.1 INTRODUCTION Milling is a machining operation in which a workpart is fed past a rotating cylindrical rotating tool with multiple cutting edges. Figure 6. The machine tool that traditionally performs this operation is a milling machine. The axis of rotation of the cutting tool is perpendicular to the direction of feed.2.

(d) profile milling. the cutter overhangs the work at one side.3: Types of peripheral milling (a) slab. creating a slot in the workpiece. similar to side milling but on both sides. In peripheral milling there are two opposite directions of rotation that the cutter can have with respect to the work. (b) slot milling. a special cutter to form the workpiece to desired shape (Fig. (d) straddle milling. These cutter direction distinguish two form of milling which are up milling and down milling as shown in Fig 6. milling. the cutter width extend the width of the workpiece on both sides. the cutter diameter is less than the workpiece where slots cutting can be done. the tool cutter is bigger than the workpiece. (b) slot. (e) pocket milling. the cutter separate the workpiece and (f) form. (c) end millng. (e) slit milling. a form of end milling of which the outside periphery of the flat surface.MANUFACTURING AND MATERIALS DEPARTMENT MME1103 Workshop Technology Manual Milling Several types of peripheral milling are (a) slab milling. another form of end milling which remove the material to 3 . (c) side milling. 6. the cutter machine the side of the workpiece.4: Up and down milling Operations in face milling includes (a) conventional face milling.3).4 Figure 6. (b) partial face milling. (c) side (d) straddle (e) slit and (f) form Figure 6.

Figure 6. 6.MANUFACTURING AND MATERIALS DEPARTMENT MME1103 Workshop Technology Manual Milling form shallow surfaces (f) surface contouring. As shown in Fig.2 Types of milling machines Milling machines can be classified into general and production type.6 is the types of milling machines. Figure 6. In Fig.5: Types of face milling (a) conventional face (b) partial face (c) end (d) profile (e) pocket and (f) surface contour. 6.6: Category of milling machines (Dutta) 4 . In Engineering Workshop there are two types of machines available which are horizontal and vertical milling machine. 6. using ball nose cutter cutting across a curvilinear path to create three dimensional form.7 shows the important parts of a vertical and horizontal milling machines.

7: Important parts in (a) horizontal and (b) vertical milling machine 5 .MANUFACTURING AND MATERIALS DEPARTMENT MME1103 Workshop Technology Manual Milling Figure 6.

8 shows the varieties of cutting tools and it’s holders.8: Cutting holders and cutting tools 6 . Fig 6.MANUFACTURING AND MATERIALS DEPARTMENT MME1103 Workshop Technology Manual Milling 6.3 Cutting Tools and Cutter holders Several types of cutting tools and cutter holders available depends on the applications. Figure 6.

4 MILLING 1 Procedure 1) Prepare aluminum solid square 80mm x 50mm x 25mm workpiece.11: Face mill 2 mm to reduce the height from 25 to 23 mm 4) Machine other side of surface A by 0.MANUFACTURING AND MATERIALS DEPARTMENT MME1103 Workshop Technology Manual Milling 6.5mm each for a depth of 2mm.5mm each for a depth of 2mm as shown in Fig. 6. (see Fig. 6. 6. (see Fig.11) Figure 6.12) 7 .5mm each until the width is 45mm. (see Fig. 6.9: Milling workpiece 2) Machine the side surface (shaded) by 0.9) Figure 6.10: Face mill surface A to remove 2 mm of material 3) Machine surface B (shaded) by 0.10 Figure 6.

(see Fig. 6.MANUFACTURING AND MATERIALS DEPARTMENT MME1103 Workshop Technology Manual Milling Figure 6.14: Material to be removed using face milling cutter 6) Lastly machine the other side of surface C (shaded) surface by 0.15) 25 75 Figure 6.15: Last step for milling 1 8 .12: Material to be removed using face milling cutter 5) Machine surface C (shaded) by 0.5 each until the length is 75mm.5mm each for a depth of 2mm. as shown in figure below 25 Figure 6.

Height gauge vernier caliper b. 9 .MANUFACTURING AND MATERIALS DEPARTMENT MME1103 Workshop Technology Manual Milling 6. The equipments are as follows. ceramic table 2) Use “2 flute endmill cutter” of size ø 18mm to bore a blind hole with depth of 10mm.5 MILLING 2 Procedure 1) Do the marking on the workpiece with the right equipment. 3) Use “2 flute endmill cutter” of size ø 15mm to mill both end sides of the workpiece with the depth of 8mm. a. “L” block c.

R.E. 3. S. 5. Sketch (top. Kalpakian. List 4 operations can be performed using vertical milling machine. Basic Workshop Practice. S & Schmid. 2.P. Prentice Hall. 2. Kibble R. Chand & Company Ltd.. 4. Prentice Hall International. front. Manufacturing Engineering and Technology – 3rd International Edition. 3. Sketch the milling machine and label the important parts. side and isometric)of the end product referring to the procedures.7th Edition.R.MANUFACTURING AND MATERIALS DEPARTMENT MME1103 Workshop Technology Manual Milling Questions 1. (2001). Gupta J. Manufacturing Engineering and Technology . REFERENCES 1.O & White W. Processes and Systems.K. S & Schmid. Prentice Hall International. Groover M. Meyer R.R.4th International Edition. S. (2001). (1996). (1996). (2002). Fundamentals of Modern Manufacturing. 10 . Name the tool holder and cutting tools used. Neely J.T. 4. S. Prentice Hall. Kalpakian. Machine Tool Practice. International Editions. Materials.