REPORT FOR MILLING PROJECT
MECHANICAL TECHNOLOGY LABORATORY 2
SEMESTER 2 2012/2013
COORDINATOR:
Wan Anuar bin Wan Hasssan
INSTRUCTORS:
Hazami bin Che Hussain
Asmizam bin Mokhtar
PROJECT MEMBERS:
Muhammad Amirul Azreen bin Mohd Zulkefli (MB12045)
Lee Heyy Dee (MB12101)
Muhammad Abid bin Ibrahim (MB12009)
REPORT FOR MILLING
PROJECT
MECHANICAL
TECHNOLOGY LABORATORY 2
2
milling project
Milling is the most common form of machining, a material removal process, which can create a variety of features on a part b
SEMESTER 2 2012/2013
INTRODUCTION
What is milling?
Where we can use milling?
How many process involves?
PROCEDURES
End Milling
Chamfer Milling
Face Milling
Drilling
Counterboring
Countersinking
Reaming
Tapping
CONCLUSION AND RECOMMENDATIONS
What do we get?
Important things?
INTRODUCTION
Milling is the most common form of machining, a material removal process, which can
create a variety of features on a part by cutting away the unwanted material. The milling process
requires a milling machine, work piece, fixture, and cutter. The work piece is a piece of preshaped material that is secured to the fixture, which itself is attached to a platform inside the
milling machine. The cutter is a cutting tool with sharp teeth that is also secured in the milling
machine and rotates at high speeds. By feeding the work piece into the rotating cutter, material
is cut away from this work piece in the form of small chips to create the desired shape.
Milling is typically used to produce parts that are not axially symmetric and have many
features, such as holes, slots, pockets, and even three dimensional surface contours. Parts that
are fabricated completely through milling often include components that are used in limited
quantities, perhaps for prototypes, such as custom designed fasteners or brackets. Another
application of milling is the fabrication of tooling for other processes. For example, threedimensional molds are typically milled. Milling is also commonly used as a secondary process
to add or refine features on parts that were manufactured using a different process. Due to the
high tolerances and surface finishes that milling can offer, it is ideal for adding precision
features to a part whose basic shape has already been formed.
PROCEDURES
1) Six Sides Cutting
i.
ii.
iii.
Vise is aligned and work piece is secured in the vise.
Face Mill/End Mill all four sides of the work piece to get the accurate dimension of Length
(L) and Width (W). (L = 100 mm and W = 48 mm).
Face Mill the top and the bottom of the work piece to get the desired Height (H = 24 mm).
A face mill machines a flat surface of the work piece in order to provide a
smooth finish. The depth of the face, typically very small, may be machined in a
single pass or may be reached by machining at a smaller axial depth of cut and
making multiple passes.
2) Milling A Shoulder
i.
ii.
iii.
iv.
Vise is aligned and work piece is secured in the vise.
Edge Finder is used to find the edge/side for the front side, than set the y-axis on DRO to
0.
Manually, the y-axis of the table is moved so that the 0 reading of y-axis on DRO change
to 23 mm.
Face Mill the top of the work piece to get the desired Height (H = 24 mm).
3) Chamfering 3mm x 45 and Centering The Drill Holes
A chamfer end mill makes a peripheral cut along an edge of the work piece or a
feature to create an angled surface, known as a chamfer. This chamfer, typically
with a 45 degree angle, can be machined on either the exterior or interior of a
part and can follow either a straight or curved path.
i.
ii.
iii.
Vise is aligned and work piece is secured in the vise.
Use countersunk to cut the chamfer 3mm x 45.
Make centering using center drill for all holes need to drill on the work piece.
iv.
RPM that required for center drill is calculated.
4) Holes drilling
A drill enters the work piece axially and cuts a hole with a diameter equal to that
of the tool. A drilling operation can produce a blind hole, which extends to some
depth inside the work piece, or a through hole, which extends completely through
the work piece.
i.
ii.
iii.
The holes in the work piece is drilled based on the according size in the figure.
Cutting speed that is used: 20m/min.
Coolant is used.
6) Thru holes tapping
A tap enters the work piece axially and cuts internal threads into an existing
hole. The existing hole is typically drilled by the required tap drill size that will
accommodate the desired tap. Threads may be cut to a specified depth inside
the hole (bottom tap) or the complete depth of a through hole (through tap).
i.
ii.
iii.
Hand tap is used to produce thread as specified on the drawing.
Taper tap is used as a starting, followed with plug and it is finished with bottoming tap.
Coolant is used.
7) Counterboring
A counterbore tool enters the work piece axially and enlarges the top portion of
an existing hole to the diameter of the tool. Counterboring is often performed
after drilling to provide space for the head of a fastener, such as a bolt, to sit
below the surface of a part. The counterboring tool has a pilot on the end to
guide it straight into the existing hole.
i.
ii.
The right size of counterboring tool is selected to produce step hole for HCSS M10.
The pilot holes are checked to make sure there are exist before step holes are cut using
counterboring tool.
iii.
iv.
v.
RPM for counterboring process is calculated.
The counterbore is brought close to the work and it can be seen that the pilot turns freely
in the drilled hole.
The machine is started, cutting fluid then applied, and the required depth is
counterbored.
8) End milling of slots
An end mill makes either peripheral or slot cuts, determined by the step-over
distance, across the work piece in order to machine a specified feature, such as
a profile, slot, pocket, or even a complex surface contour. The depth of the
feature may be machined in a single pass or may be reached by machining at a
smaller axial depth of cut and making multiple passes. The work piece is secured
on the table of the milling machine by using the vice.
i.
ii.
iii.
iv.
v.
Slot drill is used to machine the slot as shown in the drawing.
The edge is find to set the origins or reference points.
The slot is made and the cutting speed is 15m/min.
The depth of cut should be 0.55mm - 1mm.
Depth of slot is 2mm, multiple cut might be needed.
9) Chamfering
A chamfer end mill makes a peripheral cut along an edge of the work piece or a
feature to create an angled surface, known as a chamfer. This chamfer, typically
with a 45 degree angle, can be machined on either the exterior or interior of a
part and can follow either a straight or curved path.
i.
Chamfers (1.5mm x 45) is made using chamfering tool or countersunk 45.
1
0
THE TYPE OF CUTTER MATERIAL, ITS CUTTING SPEED (CS), AND ITS SPINDLE
SPEED (RPM).
End milling
- High Speed Steel (HSS)
- 30-40 (SFM)
- 795 (RPM)
Slot Drillimg
High Speed Steel (HSS)
High Speed Steel (HSS)
30-40 (SFM)
795 (RPM)
1- 30-40 (SFM)
- 795 (RPM)
1
Chamfer milling
Face milling
-
Carbide
50-250 (SFM)
1500 (RPM)
Counterboring
-
High Speed Steel (HSS)
30-40 (SFM)
1390 (RPM)
Drilling
-
High Speed Steel (HSS)
30-40 (SFM)
1390 (RPM)
Countersinking
-
High Speed Steel (HSS)
30-40 (SFM)
1390 (RPM)
Reaming
-
High Speed Steel (HSS)
30-40 (SFM)
1390 (RPM)
Edge Finder
-
High Speed Steel (HSS)
30-40 (SFM)
100(RPM)
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Tapping
2- Using hand
CONCLUSION AND RECOMMENDATIONS
From this activity, we have learned how to organize the milling machine and understand
the operation involved. Besides that, we also know the purpose of the main parts of this
machine. From the laboratory practice also we realize that the cutter diameter should be chosen
in such a manner that it will not interfere with fixtures and other components in the setup.
Before begin the operation, we must make sure that the milling cutter that would be used was
not dull. The laboratory activities also provide us the information about the various type of
milling machines and cutters available for different milling process in the manufacturing world
process. In addition, we had gained the knowledge of understanding their usage and function
where it can produce different shapes of work piece with different types of surfaces smooth or
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and RPM. Moreover, student should are given to do their project individually. The purpose
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rough. This lab session also provide a student how to calculate and estimate a suitable FEED
behind this is to improve their skills and give more confidences once they do that. Besides that,
students also should be neat, tidy, and safely dressed, develop a responsibility for personal
safety and the safety of other students. We should never think that because we are wearing
safety goggles our eyes are safe. If the lenses are not made of approved safety shatterproof
glass, serious eye injury can occur. All safety precautions are also taken seriously with the clear
explanation from the instructor.