“Milling operation

On Horizontal Milling
Machine”

1. Objective:
After performing this lab session, students will be able to understand the Milling operation on
horizontal Milling Machine.

2. Problem statement:
Milling is an important material removal process used to generate flat surfaces. Flat surfaces are
normally exposed to the hazardous environment and subjected to wear and tear and due to this
challenging condition wear and tear is start therefore good flat surfaces are necessary for current
stocks making.

3. Equipment and Materials:

The equipment’s and material used in the milling machines are given below:

 Vernier calipers
 Horizontal milling machine

 Work-piece (Aluminium)

4. Theory:

4.1. Milling process:

The milling process is a type of machining that allows modeling in complex forms and trimming
bits of several materials such as metal, wood, plastic, composites etc. and meanwhile the removal
of chips and processing residues. The milling is carried out using machine such as milling
machines or machining centers.
Milling is the process of machining using rotary cutters to remove material by advancing a cutter
into a work-piece. This may be done varying direction on one or several axes, cutter head speed,
and pressure. The milling process removes material by performing many separate, small cuts.
This is accomplished by using a cutter with many teeth, spinning the cutter at high speed, or
advancing the material through the cutter slowly; most often it is some combination of these
three approaches. The speeds and feeds used are varied to suit a combination of variables. The
speed at which the piece advances through the cutter is called feed rate, or just feed; it is most
often measured in length of material per full revolution of the cutter.
4.2. Parts of Milling Machine:
The basic parts of milling machine are given below:
 Column & Base
 Knee
 Saddle and Swivel Table
 Power Feed Mechanism
 Table
 Spindle
 Over Arm / Overhanging Arm
 Arbor Support.
Over Arm

Head Stock

Arbor Assembly
Cutting Tool

Controlling
Buttons
Table

Cross Slide
Column

Water Coolers

Figure 1 Parts of Milling machine

4.3. Procedure:
The basic steps of doing this experiment are given below:

 Feed the work-piece in a direction opposite the rotation of the milling cutter
(conventional milling).
 Do not change feeds or speeds while the milling machine is in operation.
 Set the depth of cut.
 And start cutting the work-piece.
 When the cutting is done check the diameter of the surface with the help of Vernier
caliper and check its dimensional inaccuracy.

4.4. Calculations:

The calculations are observed by me is listed below in the form of table:

Serial No Cutter Thickness Internal Root Dimensional

Thickness Inaccuracy
1 14mm Above 2mm 0.98%

5. Precautions of Milling machine:

The precautions of the milling machine is listed below:

 Do not wear gloves, rings, watches or loose clothing.

 Do not attempt to mount, measure or adjust work until cutter is completely stopped.
 Do not reach over or near a revolving cutter.
 Do not use an excessively heavy cut or feed as it can cause the cutter to break.

6. Applications of Milling:
The applications of the milling machine is listed below:

 It is used to make flat surfaces, but also can produce irregular surfaces.
 They are also used to drill, bore, cut gears, and produce slots.
 The picture of the specimen is:
 Fig Milled Specimen.

7. Overall Comments:
From this experiment, we learned a lot of this from this horizontal milling machine. We
learned how to make flat surfaces and also learned the parts of the milling machine.

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