Table of Contents

Abstract.......................................................................................................................................................2
Introduction.................................................................................................................................................3
Universal milling machine...........................................................................................................................4
Maintenance process and procedure..........................................................................................................5
Cleaning and Lubrication.........................................................................................................................6
Parts Identification..................................................................................................................................7
Problem Identification...........................................................................................................................13
Maintain the Problem of Machine.........................................................................................................14
Trouble shooting and diagnosis of machine component maintenance...............................................14
Maintenance procedures....................................................................................................................15
Transmission System.................................................................................................................................17

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Abstract

This lab report covers the inspection and maintenance procedure work that is done during our
four weak in machine lab experiment. We maintained a universal Milling machine. Machine
code. ME-MS-MHD-03. Milling machines are widely used in the tool and die making industry
and are commonly used in the manufacturing industry for the production of a wide range of
components. Milling is a metal removal process by means of using a rotating cutter having one
or more cutting teeth. Cutting action is carried out by feeding the work piece against the rotating
cutter. The aim of the lab experiment is to learn and practice the various operations to maintain
the milling machine. We maintained the milling machine by performing different operations on
the machine. The report also includes Table to show the work that is done in the lab.

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Introduction

The objective of the lab experiment was to study and practice to maintain the milling machine
and to improve the life span of milling machine. We first made a lay out of the operations by
using the manual. We use and the order in which we use the operations on an operation manual.
Then we made an inspection and clean the machine, identify the parts of the milling machine.
Then we identify the problem that exist on the milling machine. Then finally we maintained the
machine and carried out the operations according to the layout on the operation manual and fixed
the problem occurred on milling machine.

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 Universal milling machine
Definition
Milling is a process performed with a machine in which the cutters rotate to remove the material
from the work piece present in the direction of the angle with the tool axis. With the help of the
milling machines one can perform many operations and functions starting from small objects to
large ones.
Milling machining is one of the very common manufacturing processes used in machinery
shops and industries to manufacture high precision products and parts in different shapes and
sizes.
The milling machines are also known as the multi-tasking machines (MTMs) which are multi-
purpose machines capable of milling and turning the materials as well. The milling machine has
got the cutter installed up on it which helps in removing the material from the surface of the
work piece. When the material gets cooled down then it is removed from the milling machine.   
Safety rules
For everyone using the milling machines, without exceptions!
1. Safety glasses worn at all times, by everyone in the shop!
2. No long sleeves, no gloves, no open toe shoes, and no jewelry or watches.
3. Long hair must be secured behind your head!
4. Become thoroughly familiar with the machine before operating it!
5. When in doubt, always ask a supervisor or shop manager!
6. Never use the mill (or any other equipment) when tired or rushed for time!
7. Only attempt work that you have been approved to do and are comfortable doing!
8. Get additional training, refresher courses and approval as necessary! ASK FOR HELP!
9. Never reach anywhere over, around or near any rotating cutter(s)!
10. Stop the machine every time the cutter is not cutting, not being used, or you are
changing tools/parts!
11. Only remove chips using gentle air blasts or chip brushes, be aware of cutting tools!
12. Use a chip shield to keep chips from hitting you and/or others in the area!
13. Keep ALL rags and tools away from the machine and off machine table(s) during use!
14. Be sure the holding device and workpiece are both securely clamped!
15. Always make sure that the cutting tool is sharp, at the correct height and has the
proper clearance.
16. Do not be distracted or talk to others when operating the machine.
17. Do not walk away from running machines. Turn them off every time!
18. Report ALL broken tools, cutters and/or malfunctioning equipment to a supervisor or
the shop manager!
19. Keep your work area clean (including the floor), free of chips and any oils!

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Maintenance process and procedure.
The machines used in the manufacturing process are subjected to a huge workload every day.
Reasonable maintenance can keep the machine efficient and reduce the probability of damage.
At the same time, it can also improve the efficiency of production, thereby bringing greater
benefits to the enterprise. The basic maintenance methods in the use of milling machines are :
Ⅰ. Cleaning of milling machine tools
1. Disassemble and clean the various oil felt pads of the milling machine tools;
2. Wipe the sliding surfaces and guide rail surfaces of the milling machine, wipe the
worktable and the horizontal, lift screw, wipe the drive transmission mechanism and the
tool holder;
3. Wipe all dead corners of the milling machine.
Ⅱ. Lubrication of milling machine tools
1. The oil holes of the milling machine are clean and unobstructed and filled with
lubricating oil;
2. Lubricating oil is added to each guideway surface and sliding surface of the milling
machine and each screw rod;
3. Check the oil tank and oil level of the transmission mechanism, and add oil to the
elevation position.
Ⅲ. Tightening of milling machine tools
1. Check and tighten the milling machine pressing plate and inserting screws;
2. Check and tighten the fixing screws of the milling machine slide block, the drive
mechanism, the hand wheel, the workbench bracket screws, and the fork top wire;
3. Check and tighten other parts to loosen the screws.
Ⅳ. Adjustment of milling machine tools
1. Check and adjust the tightness of the belt, pressure plate and trim of the milling machine;
2. Check and adjust the milling machine slide block and screw rod order.
Ⅴ. Anti-corrosion of milling machine tools
1. Remove the rust of all parts of the milling machine, protect the painted surface, and avoid
collision;
2. Out-of-service, spare equipment guide rail surface, sliding screw hand wheel and other
exposed parts that are easy to rust are coated with oil for corrosion protection.
Generally, in our lab session we have done the following activities: -
1. Cleaning and Lubrication
2. Parts Identification

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 3. Problem Identification
4. Maintain the problem of machine

Cleaning and Lubrication

Importance of Cleaning. Cleaning equipments are effective for general as well as tougher
cleaning tasks. ◦ High cleaning capability. Reduce work fatigue and increase productivity. Save
the time of hotel housekeeping staff. High maneuverability. They can reach any corner or height
of the room, which is otherwise difficult to reach. Eco-friendly, widely available, and easy to
operate. They give protection from injuries occurring while cleaning when they are handled by
using proper instructions.
We used manual equipments:- We used equipments in the cleaning process by directly using
manual energy of us with oils and kerosene. The common manual equipments are: -
1) Brooms: - Brooms consist of long bristles gathered together and inserted into a handle.
Bristles may be made of grass, corn, coconut fibers etc. Types of brooms: - -Soft Bristled
brooms- Brooms made of corn fiber, grass brooms, and used on smooth floors. -Hard bristled
Brooms- Coconut fiber brooms or yard brooms are used on rough surfaces especially
outdoors. -Wall brooms/ Tall Turks- These are used to remove cobwebs from ceilings. They
have a soft head and a long handle.
2) Brushes: - These are designed to remove dust and dirt from surfaces. Parts of brush: - a.
Stock in which bristles are inserted made of wood, metal or plastic. b. Bristles made of horse
hair, nylon, jute or coir have chisel like action which dislodges the soil c. Handle may also be
made of wood or plastic and can be detachable or non-detachable. Types of Brushes: - -Hard
Brush- Stiff bristles and well-spaced out. Removes heavy soil from rough surfaces. -Soft
brush- Softer bristles and set close together. Removes loose soil from smooth surfaces like
carpets, furniture etc. -Scrubbing Brushes- These have short, hard bristles designed for
cleaning stains and heavy soil. Also known as T brushes. Other brushes are Toilet
Brushes/Johnny Mops, Bottle Brushes, Cloth scrubbing Brush, Carpet brushes, Feather Brush
etc.
3) Cloths: - Various cloths are used in dry and wet cleaning. For efficient usage cloth can be
color coded and used by staff for different usages.
 Swabs and Wipes- These are made of loosely woven cotton cloths which are soft,
absorbent material used for wet cleaning of surface above floor level. Mainly used
for cleaning bathtubs and washbasins.
4) Containers
The staff require containers to carry, transport, and store items of use and collect waste
products. Types of containers
 Buckets- Made of plastic or galvanized iron. Used to collect water and used with mops for
cleaning.

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In Milling machine require lubrication by hand on some parts by either oil cups or hinged or
screw cup oilers. These screw cups should be filled daily or preferably at the starting of each
shift by means of oil can. The important is type of oil can for securing rapid introduction of oil.

Parts Identification
Parts of Milling Machine
Following are the different parts of milling machine:

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 Fig.1.1 Universal milling machine
Base. The base of the machine is grey iron casting and serves as a foundation member for all
other parts which rests on it. The base carries the column at its one end. In some other machines,
the base is hollow and works as a reservoir for cutting fluid.
Colum. The column is the main supporting frame mounted on the base. It is box-shaped and
houses all the driving mechanism for the spindle and feed table. The front vertical face of the
column is precisely machined and is equipped with dovetail guideways for supporting the knee.
The top of the column is finished to hold an overarm that extends beyond the front of the
machine.

Knee. The knee is a fixed grey iron casting that slides up and down on the vertical ways of the
column face. The adjustment of height is affected by an elevating screw mounted on the base
that also supports the knee. The knee houses the feed mechanism of the table and controls to
operate it. The top face of the knee forms a slideway for the saddle that gives cross travel to the
table.
Saddle. On the top of the knee is placed the saddle, which slides on guideways set exactly at 90
degrees to the column face. A crossfeed screw near the top of the knee engages a nut on the
bottom of the saddle to move it horizontally, by hand or power, to apply cross-feed. The top of
the saddle is precisely machined to provide guideways for the table.

Table. It rests on guideways on the saddle and travels longitudinally. The top of the table is
finished accurately and T-slots are provided for clamping the work and other fixtures. A lead-
screw is provided under the table that engages with a nut on the saddle, it helps to move the table

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horizontally by hand or power. The longitudinal travel of the table possibly limited by fixing trip
dogs on the side of the table. In universal machines, the table may also be swivelled horizontally.
For this purpose, the table is mounted on a circular base, which in its turn is mounted on the
saddle. The circular base is graduated in degrees.
Overhanging arm. Overhanging arm act as a support for the arbor. It is mounted on the top of
the column extends outwards the column face and works as bearing support for the other end of
the arbor. The Overhanging arm is adjustable so that the bearing support may be provided
nearest to the cutter. More than one bearing support can be provided for the arbor.

Front brace. It is extra support, which provides rigidly to the arbor and the knee. The front base
is fitted between the knee and overarm. The front brace is slotted to allow for the adjustment of
the height of the knee relative to the overarm.
Spindle. The spindle of the machine is located in the upper part of the column and receives
power from the motor through belts, gears, and clutches and transmit it to the arbor. The front
end of the spindle just projects from the column face and is provided with a tapered hole into
which various cutting tools and arbor may be inserted. The accuracy in metal machining by the
cutter depends on the strength, accuracy and rigidity of the spindle.
Spindle Reverse Lever The position of this lever determines the spindle direction. The three
positions of the handle are; In, Middle, and Out. The middle position is the neutral position.
Never move the spindle reverse lever when the spindle is turning.
Spindle Speed Selection Lever The spindle speed selection lever is used to change the spindle
R.P.M. setting. This type of machine has a geared head so the spindle speed can only be changed
when the spindle is stopped.
Spindle Clutch Lever The spindle clutch lever engages the spindle clutch to the motor. By
manipulating the spindle clutch lever the operator can start and stop the spindle.
Arbor. Arbor is an extension of the machine spindle on which milling cutters are securely
mounted and rotated. These are made with taper shanks for proper alignment with the machine
spindles having taper holes at their nose. The taper shank of the arbor match to the Morse taper
or self-release taper whose value is 7:24. The arbor may be supported at the farthest end from the
overhanging arm or maybe of cantilever type which is called stub arbor.
Feed Rate Selection Lever The feed rate selection lever is used to change the feed rate setting.
The feed rate settings are expressed in inches per minute.
Motor Start and Stop Buttons The motor start and stop buttons control the power to the main
motor for the machine

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Problem Identification
Operator Manual: Each of our machines has its own operator manual, which has detailed
instructions for how to perform every day functions on your machine. With pictures and detailed
descriptions, your operator manual should be the first stop if you have a question about your
machine.
Parts Manual: Similar to the operator manual, every machine has a parts manual, which gives
you a detailed list of part numbers for your machine, and exploded illustrations so you can see
exactly how the parts connect and fit together.
 Depending on the manual we identified a number of problems in this milling machine.
They are: -
1. Slide lock screw poor lubrication
2. Coolant circuit breaker
3. Vertical feed engaging handle not working in full range
4. Feed change over handle does not rotate
5. Fly wheel for longitudinal traverse of table is rotate solely.
6. Handle tightening the knee to the body not rotate in full range

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Maintain the Problem of Machine
Like any other machine, milling machines are subject to wear and tear. The physical wear is a
result of the use of the machines and of the abrasion caused by friction during use. Such wear
can be reduced by regular maintenance and servicing of the milling machine by the operator:

The degree of wear depends on

 Maintenance and servicing of the milling machine,

 Properties of coolants and lubricants
 Environmental conditions (dust, temperature variations, etc.) -operating conditions
(single or multi-shift operation, volume of metal removed, proper operation)

Trouble shooting and diagnosis of machine component maintenance.

Machine name. Universal milling machine. Machine code. ME-MS-MHD-03

No TROUBLE PROBABLE CASE REMEDY

.
1 Slide lock screw poor
lubrication
2 Coolant circuit breaker and
lock valve screw
3 Vertical feed engaging
handle not working in full
range
4 Feed change over handle
does not rotate
5 Fly wheel for longitudinal
traverse of table is rotate
solely.
6 Handle tightening the knee to
the body not rotate in full
range.
Over time use without
lubrication
Damage of coolant line or
circuit and lubricate the screw
Lack of lubrication in the
handle of vertical feed.
The screw of handle is stuck.
Loose connection between fly
wheel and handle, needs more
force to operate.
Poor lubrication of handle.
Add lubrication oil
Fixing and reinstalling the line of
coolant.
Add lubrication oil and try to
move it by steel rod initially.
Add lubrication oil and try to
move it by steel rod initially.
Tightening the bolt between fly
wheel and handle.
Add lubrication oil

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Maintenance procedures

Motor Removal
1. Run head to adjust to lowest speed.
2. Disconnect power.
3. Remove three screws “A” and cover “B”, Figure.
4. Using the two screws “A”, compress spring
“C”.
5. Rotate the speed changer to the highest
speed.
6. Remove the reversing switch from the belt
housing.
7. Remove the two securing screws “D”.
8. Lift the motor and rest the case on stud “E”,
Figure.
9. Ease the belt over the lower drive disc and
remove the motor.

Drive Belt Replacement

1. Remove the motor as described on Page.
2. Remove the three screws “F”, Figure,
insert into the adjacent tapped holes and
withdraw bearing housing “G”.
3. Remove the two screws and the bushings
“H”.
4. Remove four screws “I” and one screw
“J”.
5. Remove four screws securing speed
changer “K”.
6. Remove top housing “L”. Tap to clear the
dowels.
7. Replace the belt.

Timing Belt Replacement

1. Remove the motor.
2. Lower the quill to full extent.
3. Remove the two lower cap screws “M”,
Figure 3.4, from the speed changer housing.
4. Remove the four cap screws “N”.
5. Remove the top assembly “O”, and tap to
clear dowels
6. Replace the belt

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Brake Shoe Replacement
1. Remove the top section.
2. Remove the two screws “P”, Figure.
3. Remove the clutch hub assembly “Q”.
4. Replace the brake shoes “R”.
5. Remove the bearing, drive discs and
circlips from the hub assembly “Q”.
6. Replace the bearing and housing “S”.
7. Thread hub “B” through the bearing and
reassemble the discs,

Balance Spring Replacement

1. With quill in maximum up position apply quill
lock.
2. Remove screw “I”, hub “J”, and key “K”, Figure.
3. Remove screws “L”, allowing housing to rotate
slowly releasing spring tension.
4. Lift end of spring from pin on the pinion
shaft.
5. Rotate housing “M” counter-clockwise from
head casting.
6. Remove spring from housing and replace.
7. Refit spring to main housing casting. Turn
housing clockwise until spring locates on pin
in pinion shaft.

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Transmission System
A transmission is a machine in a power transmission system, which provides controlled
application of power. Often the term 5-speed transmission refers simply to the gearbox, that
uses gears and gear trains to provide speed and torque block conversions from a rotating power
source to another device.
The term transmission properly refers to the whole drivetrain, including clutch, gearbox, prop
shaft (for rear-wheel drive vehicles), differential, and final drive shafts. In the United States the
term is sometimes used in casual speech to refer more specifically to the gearbox alone, and
detailed usage differs.
The most common use is in motor vehicles, where the transmission adapts the output of
the internal combustion engine to the drive wheels. Such engines need to operate at a relatively
high rotational speed, which is inappropriate for starting, stopping, and slower travel. The
transmission reduces the higher engine speed to the slower wheel speed, increasing torque in the
process. Transmissions are also used on pedal bicycles, fixed machines, and where different
rotational speeds and torques are adapted.
Often, a transmission has multiple gear ratios (or simply "gears") with the ability to switch
between them as the speed varies. This switching may be done manually (by the operator) or
automatically (by a control unit). Directional (forward and reverse) control may also be
provided. Single-ratio transmissions also exist, which simply change the speed and torque (and
sometimes direction) of motor output.

Inside of a milling transmission

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Assembly
Some of the basic attributes for assembly of transmission system are listed below:-
1. In a milling machine having a rotatable cutter spindle, a reciprocable table and an
attachment carried thereby, the combination of transmission means for effecting
reciprocation of the table and actuation of the attachment, a power shaft, transmission
trains extending to the table and to the attachment respectively, a rate reduction unit, and
means for selectively interconnecting said unit between said power shaft 2 d either of said
trains.
2. In a milling machine having a table, a rotatable cutter, and a rotatable work holder carried
by the table for movement thereby with respect to the cutter, the combination of means for
effecting said movement including a first train coupled for actuation of the table, a second
train coupled for actuation of the work holder, a shiftable gear rate change mechanism
having an input connected to a source of power, and means to selectively connect the
output thereof to either of said trains.
3. In a milling machine having a table, a ro tatable cutter, and a rotatable work holder carried
by the table for movement thereby with respect to the cutter, the combination of means for
effecting said movement including a first train coupled for actuation of the table, a second
train coupled for actuation of the work holder, a shiftable gear rate change mechanism
having an input, means to reversibly connect said input to a source of power, and means to
selectively connect the output thereof to either of said trains.
4. In a milling machine havinga column, a cutter spindle journaled in the column, a saddle
supported by the column for adjustment in a direction parallel to the cutter spindle, a table
reciprocably mounted in the saddle for movement transversely of the cutter spindle, a
rotatable work holder carried by the table, and means for reciprocating the table and
rotating the work holder including a power shaft journaled in the saddle, a shiftable
change'gear unit carried by the saddle having an input shaft selectively connectible to said
power shaft, said mechanism also having an output rotor, and means toselectively connect
said rotor to the table or work support for several actuation by the mechanism; or both the
table and work support for simultaneous actuation.
5. In a milling machine having a column, a cutter spindle journaled in the column, a saddle
supported by the column for movement parallel to the axis of said cutter spindle, a. table
carried by the saddle, an attachment carried by the table, the combination of rotors
movable with the table for actuating the table and attachment, a power driven element
journaled in the saddle, a change gear mechanism carried by the saddle having an input
rotor and an output rotor, means to connect the output rotor severally or simultaneously to
the first-named rotors, said input rotor being connected to said element, and portions on
said element adapted to be connected to the remaining one of the first-named rotors during
several connection of the other to said output rotor.
6. In a milling machine having a saddle, a table and an attachment carried by the table, the
combination of means for actuating the table and attachment including a pair of rotatable
elements movable with the table, a pair of rotors journaled in the saddle and having a
spline connection with said elements, a power driven reversing mechanism carried by the
saddle having an output selectively connectible with said elements, and a gear reduction
unit detachably mounted on the saddle for interposition between the reversing mechanism
and one of said elements for reducing the rate of actuation thereof relative to the other.

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 7. In a knee and column type milling machine having a saddle, a table, and an attachment
superimposed one upon another, the combination of means for translating the table and
actuating the attachment including two rotors: journaled in the saddle and power actuable
at different rates, a first train extending to the table, a second train extending to
theattachment, and means to selectively connect the trains to said rotors in different
combinations whereby either train may be actuated at a fast rate and the other at a slow
rate, or both trains actuated at the same rate.
8. In a milling machine the combination with a reciprocable table. and a work rotor carried
thereby, the combination of means for actuating said parts including a first train extending
to the table, a second train extending to the rotor, a power rotatable member, individual
shiftable elements for coupling either train with said element and a rate change mechanism
adapted to be selectively interposed between either of said shifters and said element to
differentiate the rates of actuation of said trains.
9. In a milling machine having a reciprocable table and a work rotor carried thereby, the
combination of transmission means for said parts including individual rotors carried by the
table and respectively connectible to the table and tothe rotor, a power operable reversing
mechanism including a gear connected for opposite rotation thereby, and shifters
individual to said rotors for selectively connecting the table or the work rotor to said gear
for several actuation thereby, or for joint actuation thereby.
10. In a machine tool the combination with a reciprocable table and a work attachment carried
thereby, the combination of means for selectively actuating said parts individually or
simultaneously including a power train terminating in a reversing mechanism including a
clutch shiftable to a. first and second position for determining direction, and to a third or
intermediate position for interrupting the power drive, means to selectively connect the
table to said clutch mechanism for individual actuation thereby, means to selectively
connect the table and rotor to said clutch for simultaneous movement thereby, and means
trip operable by the table for shifting said clutch from either its first or second position to
its third position.
11. In a milling machine having a saddle, a table, and an attachment carried by the table, the
combination of means for driving said attachment including a power shaft journaled in the
saddle, a first rate change gearing carried by the table, means operatively connecting said
rate change gearing to the attachment, a second rate change gearing carried by the saddle,
and means to operatively connect both of said rate change gearing in series between said
power shaft and said attachment.
12. In a milling machine having a saddle, table and attachment carried thereby, the
combination of a power operable reversing mechanism mounted in the saddle, a lead
screw journaled in the table and connectible with said reverser for actuation thereby, rate
change gearing carried by the saddle, and means: to connect said attachment directly with
said reverser, or in serial relation with said rate change gearing and reverser without
disturbing said lead screw connection.
13. In a milling machine having a saddle, a table mounted thereon and an attachment carried
by the table, the combination of a power operable reversing mechanism mounted in the
saddle, rate change gearing carried by the saddle, means operatively connecting said rate
change gearing with the reversing mechanism, and means to selectively connect the table
or attachment in series with said rate change mechanism for actuation thereby in opposite
directions.

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 expanded view of the spindle milling machine transmission.

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Disassembly – The gearbox is carefully disassembled using a variety of specialized tools and
best practices.  The condition of components are reviewed and evaluated throughout the entire
disassembly process.
Component Inspection & Failure Analysis – Throughout the entire incoming and disassembly
process, information is gathered for use in the failure analysis of the gearbox.  Preventing future
failures is the primary goal of this in-depth failure analysis process.
The classification of feed gearboxes according to the type of mechanism used to change the rate
of feed is as follows:

1. Feed gearboxes with pick-off gears. Used in batch- production machine tools with
infrequent Change over from job to job, such as automatic, semiautomatic, single-
purpose, and special purpose machine tools. These gearboxes are simple in design and
are similar to those used for speed changing

2. Feed gearboxes with sliding gears. These gearboxes are widely used in general-
purpose machine tools, transmit high torques, and operate at high speeds. Figure
shows a typical gearbox that provides four different ratios. Accordingly, gears Z2, Z4,
Z6, and Z8 are keyed to the drive shaft and mesh, respectively, with gears Z1, Z3, Z5,
and Z7, which are mounted freely on the driven key shaft. The sliding key engages
any gear on the driven shaft. The engaged gear transmits the motion to the driven
shaft while the rest of the gears remain idle. The main drawbacks of

such feed boxes are the power loss and wear occurring due to the rotation of idle gears and
insufficient rigidity of the sliding key shaft. Feed boxes with sliding gears are used in small- and
medium-size drilling machines and turret lathes. Norton gearboxes. These gearboxes provide an
arithmetic series of feed steps that is suitable for cutting threads and so are widely used in engine
lathe feed gearboxes as shown in FIG

For a frame of reference, any tooth of interest on an analysis gear is usually oriented at the top of
the gear and the mating gear is located on top of the gear of interest. Standard gear diagram
showing the analysis gear below and the mating gear above it. The base plane projection of this
helical gear pair is shown above the mating gears.

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