MEMO

UNIVERSITY OF JEDDAH FACULTY OF ENGINEERING

TO: PROFESSOR: ABDESSALEM JARRAYA

FROM: N 80 GROUP 3

SUBJECT: MILLING MACHINE

DATE: 9TH OF MARCH 2021

Dear doctor,

with due respect, we, the student of (N 80 GROUP 3), are submitting

herewith our report as partial fulfillment of the (Basic workshop) course

requirement.

The purpose of working on this subject in this report is to introduce to the

setup, operations and adjustments of the milling machine, which includes a

discussion of the types of milling machine used to perform various types of

milling operations.

Sincerely,
 university of Jeddah
Faculty of Engineering
9th of March 2021

Team Members:
Malik Naji Ali Ahmed (2042909)
Majed Hameed Albeladi (2040289)
Loay Alghamdi (2040235)
Abdullah Mosa Al-shaikh (2040363)
Mazen Mohammed Al Beshri (2040232)
Ali Khaled Al Zahrani (2042709)
Supervised by:
PROFESSOR: ABDESSALEM JARRAYA

ABSTRAC

Milling machine is one of the important machining operations Milling machine

used for cutting & shaping metal piece with the help of rotary cutters to remove material

from a work advancing (or feeding) during a direction at an angle with the axis of the

tool. It covers a large kind of completely different operations and machines and it is

broadly classified in tow types peripheral milling and face milling.

Keywords: Milling Machine, cutters, operations, material, tool, types, peripheral, face
 Contents

1. Introduction...............................................................................................1

2. safety of milling machine.........................................................................1

3. Types of Milling machine.........................................................................3

3.1 Vertical Milling Machine.....................................................................3

3.2 Horizontal Milling Machine............................................................4

3.3 Difference Between Horizontal and Vertical Milling Machine......6

4. Parts of Milling machine...........................................................................7

5. Cutting speed............................................................................................9

6. Milling Feed............................................................................................10

7. Milling machine operation......................................................................12

8. conclusion...............................................................................................14

9. RefEREnces............................................................................................15
 1. INTRODUCTION

The milling machine is one of the important machining operations.

Milling is a machining process of removal of metal by feeding the

workpiece against rotating multipoint cutter. As the cutter rotates, each

cutting edge removes a small amount of material from the workpiece. This

process is used to generate flat surfaces or curved profile and many other

complex shapes. Milling machines are basically classified as vertical or

horizontal. The cutting tool used in the milling operation is called a milling

cutter, which consists of multiple edges called teeth. The machine can be set

to move at a faster or slower pace. Softer materials are generally milled at

higher speeds while harder materials usually require slower speeds. ln

addition, harder materials often require smaller amounts of material to be

milled off at one time.1,2

2. SAFETY OF MILLING MACHINE

 Wear appropriate CSA-certified safety glasses. Wear other personal

protective equipment as necessary (such as footwear or hearing

protection).

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 Make sure all machines have a start/stop button within easy reach of

the operator.

 Make sure that all machines have an emergency stop button (e-stop).

 Make sure that the workpiece and cutter are mounted securely before

taking a cut.

 Check that work is mounted squarely.

 Mount work in a vise that is bolted or held magnetically to the table.

Use proper hand tools to make adjustments. Refer to Hand Tools for

more information.

 Hold milling cutters with a cloth to avoid being cut when handling

them.

 Move a table as far as possible from the cutter while setting up work

to avoid injuring your hands.

 Mill the largest surface first.

 Keep hands, brushes, and rags away from the revolving milling cutter.

 Use a vacuum, brush, or rake to remove cuttings only after the cutters

have stopped moving.

 Change cutting compounds periodically.

 Keep cutters sharpened correctly and in good condition.

 Keep working surface clear of scraps, tools and materials.

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  Remove cutting tools from spindle when cleaning the machine.

 Keep floor around the milling machine free of oil and grease.10

 Use lifting equipment when appropriate to move heavy work to or

from milling machines. Refer to Materials Handling for more

information.

 Make sure the power is off before changing cutters.

 Always stay at the machine when it is in operation.

3. TYPES OF MILLING MACHINE

There are two basic types of milling operations, shown in Figures (1) and

(2).

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3.1 VERTICAL MILLING MACHINE
The most common type of milling machine. A vertical milling

machine is defined by the vertical orientation of its cutting tool. The

cutting tool is placed on a vertical spindle that can be raised or lower.

When lowered, it will press into the underlying workpiece, allowing it

to remove material. When raised, the cutting tool will pull away from

the workpiece. Vertical milling machines simply have a vertically

oriented cutting tool. 3

Figure 1 Vertical Milling Machine

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3.2 HORIZONTAL MILLING MACHINE

A horizontal milling machine, on the other hand, is a type of milling

machine that has a horizontally oriented cutting tool. They work like

all other milling machines, including vertical milling machines, by

exposing a workpiece to a rotating cutting tool. While vertical milling

machines have a vertically oriented cutting tool, horizontal milling

machines have a horizontally oriented cutting tool. The cutting tool

moves horizontally across a spindle while pressing into the underlying

workpiece.4

Figure 2 Horizontal Milling Machine

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 3.3 DIFFERENCE BETWEEN HORIZONTAL AND VERTICAL
MILLING MACHINE
S.no Vertical Milling Machine Horizontal Milling Machine

In a vertical milling machine, a spindle axis Here, a spindle axis is placed in a horizontal
1 is aligned vertically. direction.

A horizontal milling machine is a little bit

2 It is cheaper. costly.

By using a horizontal milling machine, you

3 We get a poorer surface finish. will get the best surface finishing.

Vertical milling machine reduces the tool Horizontal Milling Machines help to increase
4 life. the tool life.

A horizontal milling machine requires a bit

5 This machine requires a smaller area. larger area.

In a horizontal milling
In the vertical milling machine, we don’t get machine, chips are removed and thrown away
6 the proper removal of chips. from the machine properly and easily.

It can do the work of 3 or 4 vertical milling

7 Its working capacity is low. machines easily.

This type of machine is less powerful and is It is heavier in weight and more powerful than
8 lighter in weight. vertical milling machines.

It is further divided into: It is classified as:

Bed mill Plain Horizontal milling Machine
9 Current mill Universal Horizontal Milling machine.

In short, we can say that vertical milling machines are versatile and mostly

used, while horizontal milling machine is perfect for high-cheap removal

work, high-horsepower and a heavy-duty.5

4. PARTS OF MILLING MACHINE

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 Milling Machine consists of the following Main Parts:

a) Base:
The base is the part upon which the whole machine parts are being

mounted. It is a type of foundation for the machine. The base is mostly made

up of cast iron, so it has good strength and rigidity. It also helps in the

absorption of shocks. Cutting fluid can also be stored in the base.6

b) Column:
The main supporting frame which consists of all the driving mechanisms

and the motor is called the column. The driving mechanism usually consists

of a cone pulley mechanism in which the v-belt is being used to connect it to

the motor. Further by using this driving mechanism the speed of the machine

can control as per our requirement. 7

c) Knee:
The knee shape is quite similar to that of the human body knee. The knee

is an important part of this machine which supports the other parts like the

saddle and table. The knee is attached to the column and has guideways by

which it can move up and down with the help of the elevating screw for

adjusting its height. .6

d) Saddle:

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 The saddle is present on the top of the knee which further carries the

table. Its basic function is to support the table. A saddle can slide on the

guideways which are exactly at 90 degrees to the column face. Saddle moves

crosswise(in or out) on guideways provided on the knee. 8

e) Table:
The table is present on the top of the saddle. The table consists of T-slots

or sometimes fixtures are used for holding up the workpiece on the table. A

table can travel longitudinally in a horizontal plane.6

f) Overhanging Arm:
The overhanging arm is mounted on the column and serves as bearing

support for the arbor. This arm is adjustable so that the bearing support may

be provided near to the milling cutter. There can be more than one bearing

supports to the arbor .6

g) Spindle:
The top portion of the column contains the spindle. The spindle is also an

important part of the machine as it the part where the multipoint cutter is

attached. Power required for the rotation of the spindle is obtained from the

motor through the belt, gear, and clutch assembly .6

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 h) Arbor:
Arbor It holds rotating milling cutters rigidly and mounted on the

spindle. Sometimes arbor is supported at maximum distance from support of

overhanging arm like a cantilever, it is called stub arbor. Locking provisions

are provided in the arbor assembly to ensure its reliability.9

5. CUTTING SPEED

Cutting speed is defined as the speed at which the work moves with

respect to the tool (usually measured in feet per minute). There are an

important Factors in Determining Cutting Speed in Milling machine:.11

• Type of work material

• Cutter material

• Diameter of cutter

• Surface finish required

• Depth of cut taken

• Rigidity of machine and work setup

To determine the proper cutter speed or RPM, it is necessary only to

divide the cutting speed (CS) by the circumference of the cutter.

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 Where CS = cutting speed in ft/min and D = diameter of milling cutter.

For metric calculation11

Figure 3 Recommended cutting speed

6. MILLING FEED

Feed rate is defined as the distance the tool travels during one revolution

of the part. Cutting speed and feed determines the surface finish, power

requirements, and material removal rate. The primary factor in choosing

feed and speed is the material to be cut. However, one should also consider

the material of the tool, rigidity of the workpiece, size and condition of the

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lathe, and depth of cut. There are important Factors in Determining feed rate

of the Milling machine:11

• Depth and width of cut

• Design or type of cutter

• Sharpness of cutter

• Workpiece material

• Strength and uniformity of workpiece

The ideal rate of feed may be determined as follows:

Feed = Nt CFT  RPM

Where Nt = number of teeth in the milling cutter and CFT = chip per

tooth for particular cutter and metal, RPM = revolution per minute of the

milling cutter.

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 Figure 4 Recommended feed rate

7. MILLING MACHINE OPERATION

Milling operations described earlier were based on major categorization

of milling. These were differentiated on the basis of the relative position of

the milling cutter and workpiece. Their detailed description is given below.

Following different operations can be performed on a milling machine:

a) Plain Milling Operation :

This is also called slab milling. This operation produces flat surfaces on

the workpiece. Feed and depth of cut are selected, the rotating milling cutter

is moved from one end of the workpiece to other ends to complete the one

pairs of the plain milling operation.7

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 b) Face Milling Operation :

This operation produces a flat surface at the face o the workpiece. This

surface is perpendicular to the surface prepared in plain milling operation.

This operation is performed by face milling cutter mounted on stub arbor of

milling machine. Depth of cut is set according to the need and crossfeed is

given to the work table. 7

c) Side Milling Operation:

This operation produces flat and vertical surfaces at the sides of the

workpiece. In this operation depth of cut is adjusted by adjusting the vertical

feed screw of the workpiece. 7

d) Straddle Milling Operation:

This is similar to the side milling operation. Two side milling cutters are

mounted on the same arbor. Distance between them is so adjusted that both

sides of the workpiece can be milled simultaneously. Hexagonal bolt can be

produced by this operation by rotating the workpiece only two times as this

operation produces two parallel faces of bolt simultaneously. 7

e) Profile Milling Operation:

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 In this operation, a template of complex shape or master die is used. A

tracer and milling cutter are synchronized together with respect to their

movements. Tracer reads the template or master die and the milling cutter

generates the same shape on the workpiece. Profile milling is an operation

used to generate the shape of a template or die. 7

f) End Milling Operation:

End milling operation produces flat vertical surfaces, flat horizontal

surfaces, and other flat surfaces making an angle from table surface using

milling cutter named as an end mill. This operation is preferably carried out

on a vertical milling machine. 7

8. CONCLUSION

The report is focused on milling machine study. Complete description

and categorization of milling machine to different categories based on its

construction is covered and a different types of milling machine. All the

main parts of the milling machine work in coordination with each other.

Cutting speed, feed rate. Different operations can be performed on the

milling machine, these operations are named on the basis of their machining

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characteristics. Depending upon the operations different milling cutters are

used to carry out these operations.

9. REFERENCES

1. Lysek, K., Gwiazda, A., and Herbus, K. “Application of CAM systems to

simulate of a milling machine work,” IOP Conference Series: Materials
Science and Engineering, V. 400, 2018, p. 042037.
2. Groover, M. P. “Fundamentals of Modern Manufacturing: Materials,
Processes, and Systems,” John Wiley & Sons, 2020, 816 pp.
3. Hung, J.-P., Lai, Y.-L., Lin, C.-Y., et al. “Modeling the machining
stability of a vertical milling machine under the influence of the preloaded
linear guide,” International Journal of Machine Tools and Manufacture,
V. 51, No. 9, 2011, pp. 731–9.
4. Hijink, J. A. W., and van der Wolf, A. C. H. “Analysis of a Milling
Machine: Computed Results Versus Experimental Data.” In:
Koenigsberger, F., Tobias, S. A., eds. Proceedings of the Fourteenth
International Machine Tool Design and Research Conference. London,
Macmillan Education UK, 1974. pp. 553–8.
5. Mishra, P. “Difference Between Horizontal and Vertical Milling
Machine.” Mechanical Booster. Available at:
https://www.mechanicalbooster.com/2018/05/difference-between-
horizontal-and-vertical-milling-machine.html. Accessed March 1, 2021.
6. “Milling Machine: Parts, Types, Operations, Milling Cutter [PDF].” The
Engineers Post. Available at: https://www.theengineerspost.com/15-
different-types-of-milling-machines/. Accessed February 28, 2021.
7. “Milling Machine: Definition, Parts, Operation, Application, [Notes &
PDF].” THEMECHANICALENGINEERING. Available at:

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 https://themechanicalengineering.com/milling-machine/. Accessed March
1, 2021.
8. Mair, G. “Introduction to manufacturing processes.” In: Mair, G., ed.
Mastering Manufacturing. London, Macmillan Education UK, 1993. pp.
89–97.
9. Adamsab, K. “Shape Optimization of Milling Arbor,” International
Journal of Engineering and Technology, 2012.
10. Government of Canada, C. C. for O. H. and S. “Metalworking
Machines - Milling Machines : OSH Answers.” Available at:
https://www.ccohs.ca/. Accessed March 1, 2021.

11. “Basic Workshop”, Chapter 6: Milling machine, Mechanical and

Materials Engineering Department University of Jeddah,2021

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