King Fahd University of Petroleum & Minerals

Mechanical Engineering Department

ME 407: Manufacturing Processes -Lab (211)

Instructor: Faheemuddin Patel

Lab Report Title: Milling

Lab Report Number: 4

Name: Mohammed Alsihaimi

ID #: 201616760
Section #: 2
Submission Date: 2021 \ 10\ 5

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 1. Objectives.

1.1 To review Milling Process and the process variables.

1.2 To study the effect of Milling process variables such as:

i. Cutting speed, V.

ii. The table feed velocity, v.

iii. Coolant

on

Surface Roughness

2. Tables:

Milling Process
Workpiece: Mild Steel
Cutting Tool Material : HSS
Cutting Tool Name: Helical Slab
Milling Cutter
Depth of cut,
Cutter Dia, D= 4 inch 0.03 inch
d=
No of Teeth, Width of cut,
12 2 inch
n= w=
Table1: Changing Cutting Speed (V)
Roughnes
Roughness
s
f MRR (microns)
No N (rpm) v(in/min) V(fpm) (microns)
(in/tooth) (in3/min) with
w/o
Coolant
Coolant
1 127 2.5 133.0 1.64E-03 0.15 2.66 2.11
2 173 2.5 181.2 1.20E-03 0.15 2.5 1.98
3 236 2.5 247.1 8.83E-04 0.15 2.41 1.91
4 344 2.5 360.2 6.06E-04 0.15 2.28 1.79

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 Table2: Changing Table Speed(v)
Roughness Roughness
f MRR (microns) (microns)
No N (rpm) v(in/min) V(fpm)
(in/tooth) (in3/min) w/o with
Coolant Coolant
1 236 1.8 247.1 6.36E-04 0.108 1.35 1.09
2 236 2.5 247.1 8.83E-04 0.150 1.53 1.25
3 236 3.5 247.1 1.24E-03 0.210 1.77 1.43
4 236 5 247.1 1.77E-03 0.300 2.08 1.63

3. Sample calculation

For table 1 change cutting speed:

No N (rpm) v(in/min) D (inch) d (inch) w (inch) n (tooth)

1 127 2.5 4 0.03 2 12

4
V =πDN =π × ×127=132.99 ft /min
12

v 2.5 −3
f= = =1.64∗10 ∈¿ tooth
nN 12× 127
3
MRR=wvd=2 ×2.5 × 0.03=0.15 i n /min

For table 2 change table speed:

No N (rpm) v(in/min) D (inch) d (inch) w (inch) n (tooth)

1 236 1.8 4 0.03 2 12

4
V =πDN =π × ×236=247.14 ft /min
12

v 1.8 −4
f= = =6.36∗10 ∈¿ tooth
nN 12× 236
3
MRR=wvd=2 ×1.8 × 0.03=0.108 i n /min

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4. Plot

Plot 1 Ra (no coolant) and Ra (with coolant) vs Cutting speed (V):

Roughness vs Cutting speed

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2.5
Roughness (microns)

2 f(x) = 4.60172382950517 x^-0.160409219175909

1.5

0.5

0
100 150 200 250 300 350 400
V(fpm)

Roughness (microns) w/o Coolant

Roughness (microns) with Coolant
Power (Roughness (microns) with Coolant)

Plot 2 Ra (no coolant) and Ra (with coolant) vs Table speed (v):

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 Roughness vs Table speed
2.5

2
Roughness (microns)

1.5 f(x) = 0.868094084600115 x^0.39424798612418

0.5

0
1 1.5 2 2.5 3 3.5 4 4.5 5 5.5
v(in/min)

Roughness (microns) w/o Coolant

Roughness (microns) with Coolant
Power (Roughness (microns) with Coolant)

5. Discussion of the Results

In this experiment, we found that the use of coolant will reduce the surface roughness

of the tested sample. Moreover, increase the cutting speed will reduce the surface roughness

and feed rate, but increase the table speed will increase the surface roughness and feed rate.

Furthermore, the material removal rate stays constant when changing the cutting speed but

increases when increasing the table speed.

6. Conclusion.

In conclusion, after doing the experiment we concluded that the use of coolant

is important to maintain a smooth surface roughness. Moreover, this experiment helps

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to select the appropriate cutting speed, table speed for the required surface roughness.

In this experiment, I learned how to run the milling machine with varying the cutting

speed and the table speed. Moreover, I learned how to acquire the surface roughness

reading. Furthermore, I learned the effect of changing the cutting speed and the table

speed with coolant and without in the material removal rate, surface roughness and

feed rate. Thus, the objectives of the laboratory have been achieved.