31/08/2017

MACHINING _2
BFF1811

Milling & Grinding Operation

SUBJECT SYNOPSIS
Introduce the basic concept and
operation of metal machining
processes in carrying out the
workshop practice by selecting
and applying the milling
operations and procedures.

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SUBJECT OBJECTIVES
Explain the basic features and principles of a
conventional milling machine, processes and
operations in metal machining process
Perform basic machining and quality function in
selecting and apply appropriate milling processes,
devices and operations according to the drawing,
dimensions, specifications and safety regulations

MARKS EVALUATIONS

Assignments 20%
Tests 30%
Projects + Report 40%
*Laboratory 10%

*Safety awareness, Discipline,Attitude,

Partipitation, Attendance & Ethics

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MAIN TOPICS
Milling Safety Regulations
Introduction to Milling
Types of Milling Cutter
Mounting of Cutter
Mounting of Workpiece
Milling Techniques
Speed, Feed & Machining Calculation

CHAPTER ONE
Milling Safety Regulations

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1a: Introduction
Learn to work safely as 1st thing or priority before
involve with machining
SAFE way is most correct & efficient way
SAFE working can prevent from any accident
occurred.
Accidents do not just happened, they are caused.

1b: Safe Worker Criteria

Develop a
Be neat & tidy responsibility to
always himself / herself

SAFE
WORKER

Derive satisfaction
Learn to consider
from performing
the welfare of his
work accurately &
fellow workers
safely

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1c: Categories of Safety

Machining the
Personal Grooming
Workpiece

Safety in
Securing the
Housekeeping Machine Workpiece
Shop

Safety for Precision When Operating

Equipment Milling Machine

1c a: Machining the Workpiece

Understanding all mechanisms before operate the
machine
Keep hand away from rotating tool
Stop the machine before cleaning, measuring
Without well planning, safety attires & permission,
machining is prohibited
Gloves and cloth is not allowed to use near the
rotating spindle
Dont operate the machines with more than 1 user
Any injuries should be reported & treated
immediately

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1c - b: Personal Grooming
Never wear loose clothing
Remove any watches, rings & bracelets
Long hair must be protected by hair net
Always wear the approved safety googles
Always wear a proper shoes (Safety Shoe)

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1c c: Housekeeping
Stop the machine before clean it
Always keep the machine clean
Do not place the important equipments on machine
table
Keep the floor free from oil
and grease
Sweep up the floor frequently

clean working + good order = safety

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1c d: Securing the Workpiece

Remove all burrs & sharp edges
Do not attempt to lift the heavy object which are
difficult to handle by your own
Be sure the workpiece are securely clamped on
clamping attachment
Make sure the cutter are have the safe distance from
the workpiece before it rotating

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1c e: Safety for Precision

Equipment
Do not put the measuring equipment on the machine
table
Clean the measuring equipment from coolant & chip
after being used
Dont mix-up precision equipments and cutting tool
Keep the safe distance when measuring the workpiece
to make sure it not hit with cutting tools

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1c f: When Operating a Milling

Machine
Understanding the operational and mechanism of
milling machine before operating it
Clamp al the workpieces solidly
Use the suitable arbor for selected cutting tool
Ensure all auto-feed levers are in neutral position
Dont perform cutting operation on vice or machine
table
Do not clamp the workpieces too high from vice
surfaces

Stop the machine immediately if odd noise or

vibration develops while you are operating it
Plan your work thoroughly before starting work
Return all the tools / equipments to proper storage
after being used
Stop the machine before making adjustments
Do not attempt to remove chips with your fingers
Do not talk or fooling around (horseplay) during
machining

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Safe work practices

will be observed by
force of habit

Think before acting. It cause

you nothing and may save
you from painful injury that
could result in permanent
disability

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CHAPTER TWO
Introduction to Milling

2a: Introduction
Machining process which multi-edge rotating tool is
used to remove metal
The cutter machines the w/piece while it being secured
to machine worktable
Then it brought into contact with the revolving cutter

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Various of Milling Operation

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Universal Milling
Machine
(Knee & Column Type)

MAKINO KE55

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Current Machine Previous Model

Spindle Speed Selector Dial

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Adjustable
Milling Table

Fixed Milling
Table

Universal Milling Machine

(Knee & Column Type)

DECKEL FP1

Mechanical
Controls

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Universal Milling
Machine
(Knee & Column
Type)

DECKEL FP1

Attachments,
Work-holding &
Indexing Fixtures

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2c: Types of Movements in

Milling
Principal Movement (Spindle Speed)
Feed Movement (Longitudinal &
Transverse)
Vertical Feed Movements

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2d: Others Machine at Milling

Workshop (1st Floor)

Deckel FP4M

Kunzmann TNC 124

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Emco FB-3

2c - a: Principal Movement
It means spindle drive system (rotary movement)
The rotation speed depends on cutting speed
Deckel FP1 = 40 rpm 2000 rpm
Deckel FP4 = 50 rpm 2500 rpm
Kunzmann = 40 rpm 2500 rpm

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2c - b: Feed Movement
Can operate manually or automatic feed
Longitudinal movement is carried out on knee (table
slide)
Transverse movement is carried out on machine
column (headstock)
Deckel FP1 feed range = 5 500 mm/minute
Longitudinal = 300 mm
Transverse = 160 mm

2c - c: Vertical Feed Movement

Can operate manually or automatic feed
Carried out by raising up the machine table to get the
correct depth
Other optional is by using vertical spindle head (drilling
process)
Vertical movement = 340 mm
Spindle head = 100 mm

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CHAPTER THREE
Types of Milling Cutter

3a: Angles on Milling Cutters

Cutter = Multi-edge cutting tool
The teeth remove chips one after another
a = clearance angle
= wedge angle
y = rake angle

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3b: Milling Cutter

Manufactured in many types & sizes
Distinguish by their form & application
Selection of cutter determines from the material to be
cut & type of cutter
Type of milling cutter: Shell-End Mill, End-Mill, Single
Lip, Two-Lipped, Angular, Side & Face, T-Slot, Circular
Saw, Ball-Nose, Formed, Face-Mill & Relieved cutter.

3b - a: Shell-End Mill Cutter

Design solidly & multiple-tooth cutter with teeth on
face & periphery & used to mill plain & stepped surface
Type N: (Normal no. of teeth) use for normal steel &
soft cast iron. Helix angle is 25o
Type H: (High no. of teeth) use for hard & tough
materials. Helix angle is 15o
Type W: (Few no. of teeth) use for soft materials. Helix
angle is 35o

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Finishing type: Spiral toothed with peripheral &

face teeth
Roughing type: designed with chip breaker shape to
allow deep cuts

3b - b: End-Mill Cutter
Similar design like shell-end mill cutter but smaller in
size
It has either straight or helical flutes
Mainly used to mill open grooves, side milling

Roughing End-Mill Finishing End-Mill

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3b - c: Single Lip Cutter

Curved edges & profile generated on the graver
grinding
Particularly used in tool & die making

3b - d: Two-Lipped Cutter
Known as Slot Cutter
Two cutting lips across the bottom
These 2 lips were different length
One lips is extending beyond the centre axis of the
cutter
Can perform plunge milling performance

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3b - e: Angular Cutter
Single angle milling cutter (dovetail cutter)
Mill guide ways
Angle available 45o, 50o, 60o
Double angle milling cutter
Mill guide ways
Angle available 45o, 50o, 60o

3b - f: Side & Face Cutter

Normally apply on horizontal milling technique
Has straight or staggered teeth
Mainly used to mill deep grooves

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3b - g: Circular (Slitting) Saw

Mainly used to mill narrow grooves or cutting-off
operations

3b - h: Ball-Nose Cutter
Use concept of centre cutting
Mill radius & difficult profiles

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3b - i: Formed Cutter
Incorporate the exact of the shape of the part
Suitable for production small parts
Concave, Convex & Pofiling

3b - i: Face-Mill Cutter
Mill larger surface, powerful milling operation &
economical
Carbide tipped insert in slots at cutter holder & held by
the clamping screws
Worn or broken insert can be replaced easily

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3b - i: Relieved Cutter
Used for cutting profiling shape
Examples: involutes gear cutter, twist drill groove
cutter, sprocket cutter & radius cutter

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3c: Milling Cutters Wear

Signage
Workpiece heating up rapidly
Burss forming at the edges of the cut
Unsatisfactory surface finish
Rising noise level
Dark coloured chip produced

CHAPTER FOUR
Mounting of Cutter

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4a - a: Guidelines of Cutter
Mounting
Check that the cutter runs true
Direction of spindle must be same with cutting
direction
Clean the internal taper of milling spindle
Always keep the arbor & collars clean
Mount the cutter short as possible

4a - b: Methods of Cutter
Mounting

CUTTER MOUNTING

DIRECT INDIRECT
MOUNTING MOUNTING

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Direct Mounting
The taper of cutting tool fitted directly into the taper of
the work spindle
It may have morse taper or steep taper shape

morse taper shape steep taper shape

Indirect Mounting
Cutter not inserted directly into the taper of the work
spindle
Mounted to the correct attachment

collet chuck collet end-mill

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4a - c: Mounting Attachments
1) Arbor mounting for vertical milling

Shell end arbor

Mainly use to mount shell end mill and cutter
head.

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Adapter self locking chuck

Use to reduce the internal taper in the work spindle
so that its fits on the required arbor or cutter.

Collet chuck
Design to take small cylindrical cutter to various
cutter. Widely use at industries' ER40,ER32,ER16
used with BT40 and R8 arbor

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Drill chuck
It use when there is a drilling process ,center drill,
deep drilling ,reaming ,counter bore.

Technique of milling cutter

mounting
Mounting of cutter on the vertical milling
Cutter should be clamped as near to the collet as
possible .
This is to minimize overhanging of cutter that lead
to cutter deflection.
To reduce the vibration during cutting operation
that lead to chattering at work piece

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Technique of milling cutter

mounting
Mounting cutter on horizontal milling machine.

Maximum rigidity is an essential of efficient

machining .
Arbor support permit considerable metal removal .
Cutter should be places near to headstock to
maintain the maximum rigidity of clamping and
to reduce the cutter deflection

CHAPTER FIVE
Mounting of Workpiece

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REQUIREMENT FOR
MOUNTING OF WORKPIECE
Firmly secured and withstand machining pressure.
Accessible to machining
Not deform by clamping pressure (thin wall work
piece )
Clean all surface work piece and clamping kit
before clamping.

Guidelines for mounting

Precautionary Equipment
cleaning checking

Clamping
Packing practice

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Precautionary cleaning
Clean the work table ,the vise and the
packing pieces thoroughly chip and burr)

Equipment checking
Check the dimensional accuracy and
straightness of the packing pieces
(burrs, crushing and bending)

Packing
Use tenon block bolt and shim for work
setting

Clamping practice
Grip the work piece as far down tin the
vise as possible (to avoid loosening and
chattering

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Method of clamping and type of

clamping attachment

Direct clamping
Holding pressure is provided by clamp
bolt which should be as close as possible
so it can maintain the force applied.

Vise clamping

Direct clamping

Work piece with a suitable surface can be

directly clamp on the work table, using
variety of clamp and t bolt

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Form of clamp and t-bolt

Clamping kit

Ordinary clamp

Form of clamp and t-bolt

U clamp

Gooseneck clamp

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Form of clamp and t-bolt

Edge clamping

Rules of clamping, is the hold pressure that

provide by the clamp which should be close as
possible to the work piece

Vise clamping
Machine vise .

Hydraulic vise .

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Vise clamping
Angular vise

Machine vise with swivel base

Other clamping attachment

Chuck clamping for round work piece

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Vise alignment technique

In setting up the vise onto machine table the
fix jaw must be parallel to the machine table .

CHAPTER SIX
Milling Technique

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Horizontal face milling (plain milling)

The axis rotation of the cutter is parallel to the
work surface.
The chip are comma shaped due to non uniform
and one side of the tooth bites in when the depth
of cuts is low.

Vertical face milling ( end Milling)

The axis of rotation of the is perpendicular to the
work surface.
The chip are uniformly thick ant the machine work
silently due to uniform load
The cuter must be perpendicular to the work piece
or it will be concave

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Method of milling
Two operating procedure that distinguished by
the direction of the cutter and the feed
direction moving.
The direction of feed can be same or opposite
of the cutter direction of rotation.
This gives the distinction between :

a) Up cut milling
b) Down cut milling

Up cut milling or conventional milling

The feed directed against the cutting motion on
the tooth
This process can b carried out on every type of
milling machine.

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Up cut milling or conventional milling

Advantages
-All type of milling machine
-the force of work piece against the revolving
cutter and compensate the machine
backlash
Disadvantages
-Slides
-Blunt

Down cut milling or climb milling

The direction of the feed and the cutting rotation

are the same
This process can be carried out on milling with
down milling attachment.

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Down cut milling or climb milling

Advantages
Milling thin work piece
Milling with deep slot, thread with deep profile
Milling twist drill
Milling with higher tensile material
Disadvantages
Casted work piece with hard surface
Forge work piece with rough and hard skin

Straddle Milling
involves the use of two side milling cutters to
machine the opposite sides of a workpiece parallel
in one cut
cutters are separated on the arbor by spacers of the
required length so that the distance between the
inside faces of the cutters is equal to the desired size

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Gang Milling
fast method of milling, used in a great deal of
production work. It is performed by using two or
more cutters on the arbor to produce the desired
shape
cutters may be a combination of plain and side
milling cutters

CHAPTER SEVEN
Speed, Feed & Machining Time
Calculation

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7a: Cutting Speed

Important factor that affected milling operation
efficiency
In order to work efficiently & economically
Its symbol is V. It is expressed in metre/min
(m/min)
Formula:
Cutting speed = diameter of cutter x x spindle speed

V=dxxn

Example cutting speed calculation:

A cutter has a diameter of 80mm. What is the

cutting speed when the spindle speed is 80 rpm?
Given : d = 80mm, n = 80rpm
Solution : V = d x x n
= 80 x 3.14 x 80
1000
= 20.1 m/min

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Exercise of cutting speed calculation:

a) d= 25 mm, n = 510 rpm, v =?

b) d= 50 mm, n = 255 rpm, v =?
c) d= 100 mm, n = 80 rpm, v =?
d) d= 14 mm, n = 1136 rpm, v =?
e) d= 10 mm, n = 637 rpm, v =?

Selection of proper cutting speed:

a) Type of material to be machined
b) Type of tool material
c) Rigidity and condition of the machine
d) Types of cutting operations
MILLING MACHINE CUTTING SPEEDS
CUTTER MAT. HIGH SPEED STEEL CUTTER CARBIDE CUTTER
RAW MAT. m/min m/min

Machine Steel 20 - 30 100 - 125

Tool Steel 18 - 20 40 - 60
Cast Iron 15 - 25 40 - 60
Bronze 20 - 35 60 - 120
Aluminium 150 - 300 150 - 300

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7b: Spindle Speed

defined as the speed at which the spindle of a
milling machine rotates per minute
Its symbol is n. It is expressed in revolution/min
(rpm)
Formula:

Spindle speed = Cutting speed

diameter of cutter x

n= v
dx

Example of spindle speed calculation:

Calculate the speed required to revolve a 75 mm

diameter of high-speed milling cutter when
selection of cutting speed is 30 m/min?
Given : d = 75mm, v = 30 m/min
Solution : n = V
dx
= 30 x 1000
75 x
= 127 rpm

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Exercise of spindle speed calculation:

a) d= 15 mm, v = 80 m/min, n =?
b) d= 40 mm, v = 15 m/min, n =?
c) d= 125 mm, v = 25 m/min, n =?
d) d= 30 mm, v = 20 m/min, n =?
e) d= 8 mm, v = 40 m/min, n =?

Selection of proper cutting speed:

a) For longer cutter life, use the lower cutting speeds in
the recommended range
b) Know the hardness of the material to be machined
c) When starting a new job, use the lower range of the
cutting speed and gradually increase to the higher
range if conditions permit
d) If a fine finish is required, reduce the feed rather than
increase the cutter speed
e) The use of coolant, properly applied, will generally
produce a better finish and lengthen the life of the
cutter since it absorbs heat, acts as a lubricant and
washes chips away

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7c: Feed
defined as the distance in millimeters per minute
that the work moves into the cutter
Its symbol is f. It is expressed in mm/min
Formula:

Feed = no of teeth x rec. feed/tooth x spindle speed

f = N x f/t x n

Example of feed calculation:

Calculate the feed in millimeters per minute for 75mm
diameter and 6 tooth helical milling cutter when
machining a cast iron workpiece.
Given : v = 60m/min, feed/tooth = 0.25mm
Solution : First, calculate the rpm of the cutter.

n= V Feed= N x feed/tooth x rpm

dx = 6 x 0.25 x 255
= 60 x 1000 = 383 mm/min
75 x
= 255 rpm

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Factors on which feed rate depends on

a) The depth and width of the cut.

b) The design or type of the cutter.
c) The sharpness of the cutter.
d) The workpiece material.
e) The strength and uniformity of the
workpiece.
f) The type of finish and accuracy required.
g) The power and rigidity of the machine

Recommended Feed Per Tooth (For HSS Cutter)

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Machining Time Calculation

Formula:

I = Workpiece length to be milled

lu = Over travel
la = Advance.
L = Total Milling Length
d = Milling Cutter Diameter
n = r.p.m of the Cutter
Ts = Machining Time (min)
f = Rate of Feed (mm/min)

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Formula:

Machining Time = Travelling Distance of the Milling Table (mm)

Rate of Feed (mm/min)

ts = L
f

NOTE: The travelling distance depends on the length of the

cut to be milled, the type of cutter used and the type of
milling performed.

Example:

A mild steel block with a length of 250 mm has to be rough milled by

plain milling. Calculate the machining time required.

Given: Ia =30mm, lu = 5mm, rate of feed (f)= 100mm/min

Solution : L= I+a+u
= 250mm + 5mm + 30mm
: ts = L / f = 285
100mm/ min
= 2.85 mins

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Example:
The diagram below represents a rectangular workpiece size 100 mm x
40 mm that need to be machined and using a 25 mm diameter end-mill
cutter that has 4 teethes. Cutting speed has been set at 25 m/min. The
feed per tooth is selected at 0.15 mm/tooth. The advance distance of
the cutter from workpiece is 20 mm and over travel of the cutter is 15
mm. A 3 mm thickness of the workpiece need to be milled and the
maximum depth cut of this cutter is 2 mm.
Cutting direction

Milling cutter workpiece Milling cutter

lu la

By showing a proper calculation, calculate

a) spindle speed of the cutter

b) feed-rate of the machine table
c) machining time (10 marks)
c) f ts = L / f
One way direction
L = l + la + lu
L = 100mm + 20mm + 15mm
a) n = v / d x pi L = 135 mm
n = (25 x 1000) / (25 x 3.14) Overall direction
n = 319 rev / min OL = 135 mm x 4
OL = 540 mm
b) f = N x feed/tooth x n Machining time
f = 4 x 0.15 x 319 rev / min ts = L / f
f = 191.4 mm / min ts = 540 mm / 191.4 mm/min
ts = 2.82 minutes

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