FACULTY OF MECHANICAL ENGINEERING

In the name of God, The Most Beneficent, The Most Merciful

BMM 1821 Mechanical Laboratory

2
Prepared By
Luqman Hakim Bin Ahmad
Shah
luqmanhakim@ump.edu.my
Telephone Ext: 6234
Fakulti Kejuruteraan Mekanikal,
Universiti Malaysia Pahang
Lab Location
M30F4 (Milling Laboratory)

Lab Report Objectives

Explain about the fundamental backgrounds of milling and grinding
operation.
Discuss the result obtained from the laboratory project.

Date: ____________________

Lecturer:

_______________________

20
Student
ID

Group Members

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Section

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INTRODUCTION TO LABORATORY
1. 1 Description of the laboratory
Part of the first scheduled laboratory session will be devoted to an examination and explanation of the
laboratory and its equipment.
1.2 Safety rules and suggestions
Safety is part of every engineer's job. Safety is not only a concern of the engineer during the
conceptual development of a design, but also when a design is finally implemented and when it goes
into service. The following safety rules are in common use and are recommended for your serious
consideration. Failure to observe safe laboratory practices will be sufficient cause for immediate
dismissal from the laboratory course with an "F" grade.

Haste leads to many accidents. Work deliberately and carefully, and verify your work as you go
along.
Do not work on moving machinery, or on live electrical circuits, if possible.
When making connections, as far as it is practical, connect to the power source last; when
disconnecting, disconnect from the power source first.
Be careful to keep metallic accessories of wearing apparel or jewellery out of contact with live
electrical circuits, and keep loose articles of clothing out of contact with moving machinery.
Become safety conscious. It may save more than your grade or your job in industry; it may save your
life!

OBJECTIVE OF LABORATORY

1) To learn the milling laboratory operations as well as gain knowledges on how to operate the
milling machine.
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2) To apply the appropriate techniques when handling basic measuring equipment and instruments.
3) To complete a given workpiece by apply various basic milling operations and understand as
well.

SAFETY PROCEDURE

DO NOT use this machine unless the technician has instructed

you in its safe use and operation and has given permission.
Long and loose hair must be
contained.
Safety glasses must be worn at all
times in work areas.
CSA footwear must be worn at
all times in work areas.
Rings and jewellery must not be
worn.

Close fitting/protective clothing

must be worn.
Gloves must not be worn when
using this machine.

PRE-OPERATIONAL SAFETY CHECKS

1.
2.
3.
4.
5.
6.
7.

Ensure no slip/trip hazards are present in workspaces and walkways.

Locate and ensure you are familiar with the operation of the ON/OFF starter and E-Stop (if fitted).
Do not leave equipment on top of the machine.
Check that machine guards are in position.
Ensure cutter is in good condition and securely mounted.
Check coolant delivery system to allow for sufficient flow of coolant.
Faulty equipment must not be used. Immediately report suspect machinery.

OPERATIONAL SAFETY CHECKS

1. Keep clear of moving machine parts.
2. Never leave the machine running unattended.
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3. Follow correct clamping procedures- keep overhangs as small as possible and check work piece is
secure.
4. Set the correct speed to suit the cutter diameter, the depth of cut and the material.
5. Before making adjustments and measurements or before cleaning swarf accumulations switch off
and bring the machine to a complete standstill.

HOUSEKEEPING
1. Switch off the machine.
2. Remove milling cutters and store them safely.
3. Leave the machine and work area in a safe, clean and tidy state.

INTRODUCTION
Milling
Milling Process is a metal removal process by means of using a rotating having one or more cutting
teeth. Cutting action is carried out by feeding the workpiece against the rotating cutter. Thus, the
spindle speed, the table feed, the depth of cut, and the rotating direction of the cutter become the main
parameters of the process. Good results can be achieved with a well balance setting of these
parameters. The workpiece is fed and move in linear motion.
The advantages of milling is that it is compatible with all materials so I can be used at various stages of
the automotive manufacturing process. It is also flexible use and .it delivers short lead times, which
means that parts can be shaped and refined quickly and efficiently.
There is 2 types of milling machine which is vertical and horizontal milling machine.
Figure 1 shows the vertical milling machine and figure 2 shows the horizontal milling machine.

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Figure 1

Figure 2

There is 4 types of milling operations which is plain milling, end milling, gang milling and straddle
milling.
Milling cutter is the multi-point cutting tool. There is 3 cutting tools for horizontal milling and 4 cutting
tools for vertical milling
Horizontal Milling:
1) Slab Mills For heavy cutting of large and flat surfaces.
2) Side and Face Cutters Cutting edges on the periphery and sides of teeth for cutting shoulders
and slots.
3) Slitting Saws For cutting deep slots or for parting off.
Vertical Milling:
1)
2)
3)
4)

End Mills Used for facing, slotting and profile milling

Rough Cut End Mills For rapid metal removal.
Slot Drills For producing pockets without drilling a hole before hand.
Face Milling For heavy cutting.

Experimental procedure :
1) Six sides cutting
-Vise is alligned and the work piece is secured in the wise.
-This process is using face mill 6 flute.
-Remove the old surface of the work piece and get the accurate dimension of length
And Width.
- RPM= Cutting speed 1000

=90 x 1000
3.142x40
=716.197
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2)Milling a shoulder
- Vise is alligned and work piece in secured in the wise.
-Edge finder is use to find the edge/side for the front side, the set the y-axis on DRO to 0.
-Manually the y-axis of the table is moved so that the 0 reading on y-axis on DRO change
to the length based on drawing scheme.
- RPM = Cutting speed 1000

=90 x 1000
3.142x14
=2046

3)Holes drilling
-Use the edge finder to find the coordinate and mark the coordinate using central drill bit.
-Make a holes using different diameter of drill bit (8.5mm , 8.0mm and 9.2mm).
-RPM= Cutting speed 1000

=900

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4)Counterboring
-To enlarge the hole use drill bit m8 range (9.1/9.2)
-RPM use is 800.
-RPM= Cutting speed 1000

=600

5)Reaming
- Tools that used is reamer (8H7)
-8.0mm if drill bit is used
-RPM= Cutting speed 1000

=500.

6)Threading
-Hand tap is used to produce thread as specified on the drawing.
-Taper tap is used as starting followed by plug and it finish by bottom tap.
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-Coolant is used.

7)Slotting
-Slot drill is used to machine the slot as shown in the drawing.
-The edge finder is use to set the origins or reference point.
-The depth of slot is refer to the drawing scheme
-RPM= Cutting speed 1000

=900

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RESULTS
Figures below show the image of the specimen that has been fabricated.
Figure1 shows the top view, Figure 2 shows the front view and Figure 3 shows the side view.

Figure 1

Figure 2

Figure 3

Table 1 shows the comparison between actual and final dimensions for each part of the specimen.
Parts
Length
Width
Height
Height of milled shoulder

Predicted dimensions\mm
100
48
24
Right
Left
7
7

Final dimensions\mm
112
47.9
23.7
Right
Left
7
7

Width of milled shoulder

14

14

13

15

Depth of counter bore

7.12

Distance between two

counter bore
Distance between two of
reaming hole
Distance between
threading hole
Length of slot

75

75

45

45

75

75

57

56.5

Width of slot

Depth of slot

Table 1
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The dimensions for all parts of the specimen we done were almost same as the actual dimensions on the
milling project drawing scheme.With this we can get its depth dimensions same for both sides.Hence,
there is an inaccuracy of 1.0mm occurred on the width of the shoulder on the right side of the
specimen.

DISCUSSION

The work piece that we made had some defects as well. Firstly , the work piece had minor
measurement defects. During the initial process , the right side the work piece was overcut. It exceeded
a decimal of 0.50mm from the given measurement which is 24.00 mm. We overcomed it by getting a
new workpiece .The work piece also had measurement defects while drilling the counterbore.The depth
of the counterbore was less a decimal of 0.65mm from the given measurement which is 9.00mm. We
faced some problems during the progress. Some of the cutter material tool was not in a good condition.
These will damage our workpiece. To solve this problem, we need to find another tools which is in the
good condition for example make sure the tooth of the mill cutting tools must not be damaged. Even
just one slight damage also cannot use for milling operation.We had to drill it more precisely and
accurately to obtain the exact measurement. The edges of the work piece could not attain the given
angle as well. Hence ,we did it manually to attain the given angle of 45 degree .Besides , we
encountered a few problems. Initially we did not communicate well among ourselves which made it
difficult to carry out the processes. We discussed regarding this in the Whatsapp group and decided to
separate the tasks and it was a productive outcome. We also found it difficult to have group discussions
regarding the workpiece because most of us were engaged with other activities. The group discussion
was always an incomplete. We overcomed this problem by updating the absent ones about the tasks
they were assigned for through the Whatsapp group or by meeting them in person.

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CONCLUSION

In conclusion , we learned a lot from the labrotory. First and foremost , we learned the importance of
teamwork. This project would have not been a successful one if we did not work as team holding each
others back. We also learned that communication is a very vital element in every group assignment. We
always maintained a very strong bond among ourselves by communicating with each other frequently.
Furthermore , individually it was a platform for us to detect our weaknesses and strengths. Through this
, it was easier for us to separate the tasks based on our abilities. Hence , each and every process was
done precisely and on time.

REFERENCE

1. https://en.wikipedia.org/wiki/Milling_(machining)
2. https://www.youtube.com/watch?v=RYYLcsnkBBk
3. http://www-eng.lbl.gov/~als/TrashProbably/old_files_df/SD_9.x_Update_Tutorial/blending2.html
4. https://kalam.ump.edu.my/pluginfile.php/61875/mod_resource/content/1/Milling%20project
%202015.pdf

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