1. Define milling operation?

Milling is the process of machining using rotary cutters to remove material by advancing a cutter
into a workpiece. This may be done in varying directions on one or several axes, cutter head
speed, and pressure. The original class of machine tools for milling was the milling machine
(often called a mill).

2. List all types of milling operations.

i. End milling
ii. Chamfer milling
iii. Face milling
iv. Profile milling
v. Groove milling
vi. Turn milling
vii. Holes and Cavity
viii. Shoulder milling
3. List the parameters or variables that the material removal rate depends
on.
i. Depth of cut
ii. Width of cut
iii. Feed rate
4. List the types of drilling operations and what is the main difference

between them.
i. Drilling Operation
ii. Counter Boring Operation
iii. Spot-facing Operation
iv. Tapping Operation
v. Boring Operation
vi. Reaming Operation
vii. Countersinking Operation
 i. Drilling Operation

Drilling is the operation of producing a cylindrical hole by removing metal from the rotating
edge of a cutting tool called the drill.

Drilling is one of the simplest methods of producing a hole. Before drilling the centre of the hole
is located on the workpiece by drawing two lines at right angles to each other and then a centre
punch is used to produce an indentation at the center.

ii. Counter Boring Operation

Counterboring is the operation of enlarging the end of a hole cylindrically. The enlarged hole forms
a square shoulder with the original hole. This is necessary in some cases to accommodate the heads
of bolts, studs and pins.

iii. Spot-facing Operation

Spot facing is the operation of smoothing and squaring the surface around a hole for the seat for a
nut or the head of a screw. A counterbore or a special spot facing tool may be employed for this
purpose.

iv. Trapping Operation

It is the operation of cutting internal threads by means of a cutting tool called a tap. Tapping in a
drilling machine may be performed by hand or by machine.

v. Boring Operation

The cutter is held in a boring bar which has a tapered shank to fit into the spindle socket. For
perfect finishing a hole, the job is drilled slightly undersize. In precision machines, the accuracy
is as high as +0.00125mm. It is a slow process than reaming and requires several passes of the toll.

vi. Reaming operation

Reaming is an accurate way of sizing and finishing a hole which has been previously drilled. In
order to finish a hole and to bring it to the accurate size, the hole is drilled slightly undersize.
Reamer cannot originate a hole. It simply follows the path which has been previously drilled and
removes a very small amount of metal. For this reason, a reamer cannot correct a hole location.
The material removed by this process is around 0-375mm and for accurate work, this should not
exceed 0-125mm.

vii. Countersinking Operation

Countersinking is the operation of making a cone-shaped enlargement of the end of a hole to

provide a recess for a flat head screw or countersunk rivet fitted into the hole.

5. Difference Between Internal Broaching and External Broaching.

Internal broaching is a broaching method that pushes a tool completely through the workpiece,
which produces a hole that cuts the surface of the metal.

External broaching uses a cutting tool that has drafted-outward sides. This creates a precision cut
on the outside of the part. Whether you're creating gears, bolts or other components, the exact
shape and application of the broaching tool can vary.