Design of Mini Milling Machine

Design and Manufacturing of Mini Milling Machine
CHAPTER 1
INTRODUCTION
1.1 General:
In this century, we have seen many new developments in very advanced

manner at various fields. Many new products, machines have been innovated with
available technology and other resources. In future it may be further developed in
advance manner. Before selecting this mini milling machine as our project work, we
have dealt in several fields related to mechanical for selecting a better project work
But we hope that by doing this mini milling machine as our project work in a
successful manner it may helps us in future to carry out different works. This machine
we have manufactured is set to be the father of all machine tools. By the help of this
machine, various operations can be performed.
Various types of milling machines are available in the market but the machine
manufactured by us is highly economical in all aspects i.e. the cost of manufacturing is
less; more number of operations can be performed. It is compact in size; It occupies
only less area; It can be operated manually even by an unskilled labour; this machine
can be modified into a Semi-Automatic and Automatic milling machine by changing
and fixing some of the necessary components.
Initially it was made up of mild steel but now we have seen different types of
milling machines. The most advanced type of milling machine is NC and CNC milling
machines which are fully automatic and is numerically controlled by feeding dates and
programming is done for various operations to be performed in the Job.
A milling machine is a machine tool used for the complex shaping of metal
and other solid materials. Its basic form is that of a rotating cutter or end mill which
rotates about the spindle axis (similar to a drill), and a movable table to which the
work piece is affixed. That is to say, the cutting tool generally remains stationary
(except for its rotation) while the work piece moves to accomplish the cutting action.
Milling machines may be operated manually or under computer numerical control.
MIT Academy of Engineering Pune, B.E (Mechanical) Page 1

Milling machines can perform a vast number of complex operations, such

as slot cutting, planning, drilling, rebating, routing, etc. In our project is deals with
smaller operation using mini milling machine.
Milling can be done with a wide range of machine tools. The original class of machine
tools for milling was the milling machine (often called a mill). After the advent
of computer numerical control, milling machines evolved into machining centres
(milling machines with automatic tool changers, tool magazines or carousels, CNC
control, coolant systems, and enclosures), generally classified as vertical machining
centres (VMCs) and horizontal machining centres (HMCs). The integration of milling
into turning environments and of turning into milling environments, begun with live
tooling for lathes and the occasional use of mills for turning operations, led to a new
class of machine tools, multitasking machines (MTMs), which are purpose-built to
provide for a default machining strategy of using any combination of milling and
turning within the same work envelope.
The advantages of mini milling machine is that small components are easily
machined, operating cost is less, more number of operations are performed, production
time is less, unskilled person can also use it, simple mechanism is used, occupies less
space while the disadvantages are complex parts cannot be machined.
1.2 Milling Processes:
Fig.No.1.1 Face Milling Process (Cutter Axis is Vertical)

Milling is a cutting process that uses a milling cutter to remove material
from the surface of a workpiece. The milling cutter is a rotary cutting tool, often with
multiple cutting points. As opposed to drilling, where the tool is advanced along its

rotation axis, the cutter in milling is usually moved perpendicular to its axis so that
cutting occurs on the circumference of the cutter. As the milling cutter enters the
workpiece, the cutting edges (flutes or teeth) of the tool repeatedly cut into and exit
from the material, shaving off chips from the workpiece with each pass. The cutting
action is shear deformation; material is pushed off the workpiece in tiny clumps that
hang together to a greater or lesser extent (depending on the material) to form chips.
This makes metal cutting somewhat different (in its mechanics) from slicing softer
materials with a blade.
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.
There are two major classes of milling process:
 In face milling, the cutting action occurs primarily at the end corners of the milling
cutter. Face milling is used to cut flat surfaces (faces) into the workpiece, or to cut
flat-bottomed cavities.
 In peripheral milling, the cutting action occurs primarily along the circumference
of the cutter, so that the cross section of the milled surface ends up receiving the
shape of the cutter. In this case the blades of the cutter can be seen as scooping out
material from the work piece. Peripheral milling is well suited to the cutting of
deep slots, threads, and gear teeth.
1.3 Problem Statement:
The aim of our project is to design & manufacturing of mini-milling machine to

reduce the time required for milling small parts as well as to reduce set up time for
milling and increasing production rate.

1.4 Project Objectives:
General objective of this project is to develop a mini-milling machine up to

industrially acceptable precision and repeatability with a very limited budget (10,000
RS).This newly designed mini milling machine is used to either reduce cost or
improve performance. In addision to cost reduction this machine can be used to reduce
set up time for operations and increasing production rate. This project represents all
process for developing mini milling machine from early stage to performance stage.
To accomplish these objectives, this project work is divided into a number of tasks.
The tasks can be summarized as follows:
(1) Market analysis: Determine the current market status of small scale machine tools
and predict the market potential of the new small scale CNC machine.
(2) Machine design: Various structure designs will be compared and analyzed to come
up with an optimal structure for the machine. Critical components required such as
motor and linear guides will be carefully compared and selected.
(3) Machine fabrication: All the body parts will be machined and the components will
be purchased through various suppliers. Machine will be assembled inside the
workshop.
(4) Machine test and calibration: The finished prototype machine will be tested using
circular testing method.
(5) Total machine cost will be analyzed.
1.5 Project Scope:
(1) Design of various components of mini milling machine i.e. bed, spindle, column,
lead screw, overhanging arm.
(2) Selection of material for different components.
(3) Manufacturing of different parts as per process sheet.
(4) Assembly & testing

1.6 Methodology:
START
Literature Review
Data Collection & System Design
Selection of Material & Mechanical Design
Process planning & Material Procurement
Manufacturing & Assembly-Test &Trial
Report Preparation
END
Fig.No. 1.2 Methodology of Project
1.5.1 Literature Review:
In this phase analyse the work done by previous researchers and find out
scope for work.
1.5.2. Data Collection & System Design:
Data collection phase involves the collection of reference material for project
concept; the idea is taken from book ingenious mechanisms for designers and
inventors.

The system design comprises of development of the mechanism so that the given
concept can perform the desired operation. The system design also determines the
system components and their shape and overall dimensions, the parts are as shown in
the list.
1.5.3 Selection of Material & Mechanical Drawing:
Select the materials for different components by considering various factors,

explained in subsequent section.
The parts mentioned in list will be designed for stress and strain under the
given system of forces and appropriate dimensions will be derived. The standard parts
will be selected from PSG design data handbook.
1.5.4. Process Planning &Material Procurement:
Material is procured as per raw material specifications and part quantity. Part
process planning is done to decide the process of manufacture and appropriate
machine for the same.
1.5.5 Manufacturing & Assembly-Test & Trial:
Parts are produced as per the drawings. Assembly of device is done as per
assembly drawing and test and trial is conducted on device for evaluating
performance.
1.5.6 Report Preparation:
Report preparation of the activities carried out during the above phases is
done.
1.7 Organization of Dissertation:
The project is presented in seven chapters including introduction, literature

review process sheets, cost analysis and conclusion with further modifications. The
introduction chapter, which is chapter one, will describe the background for the idea of
mini milling machine. The project objectives and scopes have also been declared in
this chapter. This chapter also shows the methodology of the project to be completed.

The chapter two covers the literature review on the researches currently done on the
mini milling machine. Some of the literature review shows the selection of optimum
parameters for mini milling machine and some literature review shows analysis of
structure of machine.
The chapter three covers the factor considered for designing the components,
specifications of mini milling machine, design of lead screw. It also includes selection
of different material for different components of mini milling machine and properties
of material.
The chapter four covers different operations performed on different components of

material and it also includes process sheet, which shows the sequence of operations
performed on the material and time required for different operations.
The chapter five represents the procedure for performing different operations on mini
milling machine.
The chapter six covers experimental result, analysis procedure and analysis of
different components.
The chapter seven covers total cost including cost of standard part. For manufactured
part time required for manufacturing is taken from the process sheet and cost is
calculated for each and every component. Finally total cost is summation of
manufacturing cost, cost of standard parts purchased, accessories cost and
miscellaneous cost.
Conclusion and future scope included in chapter eight and finally report ends with
chapter nine which is reference.

CHAPTER 2
LITERATURE REVIEW
In order to know the current state of art in domain of mini milling machine
literature review is undertaken. Also the literature review will be useful to identify the
gap to be bridged through this work.
2.1 A Review of Usability of Portable Milling Machine From Micro To Macro

Parts By Krishna Dave,Marnish Modi,Prof.A.N.Shyani.
From above research paper, the following points are observed:
1. With five axis micro milling machine, 2 D thin wall,3 D curved surface and a mini
impeller is machined with precision
2. With three axis milling machine micro gears up to 20 micron thin wall, and a
microelectrode machined with accuracy and precision.
3. With the hybrid five face milling machine in one set up have precisely made a work
piece with flat surfaces and free from surfaces with cavity contour milling and variable
contour milling operations.
2.2 Material Selections In Structural Design of Mini Milling Machine By S.B.

Chandgude,S.S.Patil
This research paper explains various methods to select material for different parts of
mini milling machine. As per this research paper bed is made from cast iron (Grade 35
grey) and steel grade 1080 is better material for structure of spindle column making in
mini milling machine which fulfil all the requirements of design and as per analysis of
this research paper this analysis will get a hybrid design option for structure with a
greater flexibility.

2.3 Design and Analysis of Table For Micro Milling By R.R.Honkalas, P.M.Pawar,
B.P.Ronge
This research paper explains performance parameters affecting for the table i.e.
direction of motion of sliding, shapes of guides, materials, frictional behavior,
lubrication system, construction of table.
2.4 Machining Forces and Tool Deflections In Micro Milling By Ali

Mamedov,S.Ehsan Layegh K.,Ismail Lazoglu
This paper represents, comprehensive force and deflection models for micro milling
were presented. The main focus of this paper were on prediction of cutting forces
during micro end milling and estimating the deflection amount of the micro end mill
occurred due to cutting force and deflection models were validated through the
experiments and showed good agreement.
2.5 FE Analysis of Positioning Slides of Micro Milling Machine By Sushant

Thambkar,Bhagyesh Deshmukh
This paper represents finite element analysis of slides. In this research paper analysis
done by analytical solution and finite element solution and finally the result obtained
in both analysis compared with each other. Paper also shows the step by step
procedure of finite analysis from creation of geometry to final solution.

CHAPTER 3
MECHANICAL DESIGN
3.1 Introduction:
The subject of machine design deals with the art of designing machine of
structure. A machine is a combination of resistance bodies with successfully
constrained relative motions which is used for transforming other forms of energy into
mechanical energy or transmitting and modifying available design is to create new and
better machines or structures and improving the existing ones such that it will convert
and control motions either with or without transmitting power. It is the practical
application of machinery to the design and construction of machine and structure. In
order to design simple component satisfactorily, a sound knowledge of applied science
is essential. In addition, strength and properties of materials including some
metrological are of prime importance.
Knowledge of theory of machine and other branch of applied mechanics is

also required in order to know the velocity. Acceleration and inertia force of the
various links in motion, mechanics of machinery involve the design.
3.2 Factor Considered:
Mechanical design phase is very important from the point view of designer as
whole success of the project depends on the correct design analysis of the problem.
Many preliminary alternatives are eliminated during this phase. Designer

should have adequate knowledge about physical properties of material, loads, stresses,
deformation, and failure. Theories and wear analysis, he should identify the external
and internal forces acting on the machine parts.
These forces may be classified as:
a) Dead weight forces

b) Friction forces
c) Inertia forces
d) Centrifugal forces
e) Forces generated during power transmission etc.

which will almost satisfy the functional needs. Assumptions must always be on the
safer side.
Selection of factor of safety to find working or design stress is another

important step in design of working dimensions of machine elements. The correction
in the theoretical stress values are to be made according in the kind of loads, shape of
arts& service requirements.
Selection of material should be made according to the condition of loading

shapes of products environment condition & desirable properties of material.
Provision should be made to minimize nearly adopting proper lubricating

methods.
In mechanical design the components are listed down & stored on the basis of
their procurement in two categories,
 Design parts
 Parts to be purchased
For design parts a detailed design is done &designation thus obtain are
compared to the next highest dimension which is ready available in market.
The simplification the assembly as well as post production service work. The
various tolerances on the work are specified. The processes charts are prepared &
passed on to the work are specified.
The parts to be purchased directly are selected from various catalogues

&specification so that anybody can purchase the same from retail shop with the given
specifications.

3.3 Bill of Materials:
SR.NO. PART CODE PART NAME QTY. MATERIAL

Mild Steel
1. MMM 01 Base 01
Mild Steel
2. MMM 02 Column 01
Mild Steel
3. MMM 03 Overhanging Arm 01
Phosphorus
4. MMM 04 Lead screw 03
Bronze
Mild Steel
5. MMM 05 Handle 03
Mild Steel
5. MMM 06 Bolt 03
Mild Steel
6. MMM 06 Washer 03
Mild Steel
7. MMM 07 Guide Rod 06
Standard
8. MMM 08 Square Tube -
Standard
9. MMM 09 Drill Machine 01
Table No. 3.1 Bill of Materials
3.4 Specifications of Mini Milling Machine:
Drilling Capacity 20 mm diameter

Face Mill Capacity 40 mm diameter
Speed 750 RPM
Motor Power 450 Watt
X-Travel 70 mm
Y-Travel 70 mm
Z-Travel 140 mm
Table No.3.2 Specifications of Mini Milling Machine

3.5 Power Required for Drilling:
= 2.82 × 10−6 × 𝑘 × 𝑛 × (𝐷2 − 𝑑 2 )1.5 + 7.875 ×0.02
(From PSG Design Data Book, Page No 12.1)
Where,
S= Feed/blade/revolution mm
K= Material factor
N= Rpm
Z= No. of cutting edges in contact
D= Larger dia. of hole (mm)
d = Smaller dia. of hole (mm)
h2=𝐶𝑆 × 320 ÷ 𝐷
h2= 18 × 320 ÷ 10=576
= 2.82 × 10−6 × 2.1 × 576 × 2(142 − 72 )1.5 + 7.87 × 0.02
=52.4 watt
=0.0524 kW
3.6 Power Required for Face Milling:
= 13.2 × 10−3 × 𝑘 × 𝑧 × 𝑣(1.55 × 0.02)𝛽
(From PSG Design Data Book, Page No 12.1)
= 13.2 × 10−3 × 2.1 × 2 × 20(1.55 × 0.02)0.80
=0.039KW
3.7 Selection of Motor:
Specification of motor are as follows:

[1] Power= 450 watt
[2] Speed=750 rpm
Motor torque: 𝑃 = 2 × 3.14 × 𝑁 × 𝑇/60
T= 60 × 450/2 × 3.14 × 750
T=5.72 N.m
3.8 Design of Lead Screw :
Tmotor =5.72 N.m
Torque at screw = 5.72 × 60/12
=28.6 N.m
Therefore,
(Mt) =28.6 N.m
Where,
𝑑𝑚
𝑇=( ) tan(∅ + 𝜑)
2
Initially assuming dimensions of screw which we shall check under given system of
force
Selecting material for screws:
Refer Page No. 194, Design of machine elements by V.B.Bhandari
Material Coefficient of friction(starting) Coefficient of friction(running)

Soft steel-bronze 0.10 0.08
Basic dimensions of square thread

Ref. Page No. 5.69, PSG design data
Nominal dia. Major Major dia. Minor dia. pitch Area of

dia.(bolt) (nut) core
20 20 20.5 18 2 254
Design check:
D= Nominal/outer diameter (mm) =20 mm
Dc= Core /inner diameter (mm) = 18 mm
Dm= Mean diameter =19 mm
𝑑𝑚
𝑀𝑡 = 𝑊 × ( ) tan(∅ + 𝛼)
2
Where,
W=axial load
φ =friction angle
α=helix angle
Helix angle:
𝑡𝑎𝑛 𝛼 = 𝐿/𝜋 × 𝐷𝑚
𝐴 = 𝜋𝑟 2 same as,
= 6/9 × 16
α = 1.92
Friction angle: Ref. R.S Khurmi (Table 7.5)
Coefficient of friction under different condition
Condition Coefficient of friction Coefficient of friction

Starting Running

average quality of material

& average running 0.18
condition
Coefficient of friction under different condition
µ= tan φ
0.18=tan φ
φ=10.2
𝑀𝑡 = 𝑊 × (19/2)tan(10.2 + 1.92)
𝑀𝑡 = 2.04 × 𝑊 𝑁. 𝑚𝑚
28.6 N.mm =2.04×W
W=137.53 N.mm
W=14.01 kg
This is lifting capacity of screw using motor specifications.
For screw,
Ref (Page No.59-1.12)
Tensile strength Yield strength

600 380
(a) Direct tensile or compressive stress due to axial load:
𝐹𝑐 = 𝑊 × 4/3.14 × 𝑑𝑐 2
𝐹𝑐 = 137.53 × 4/3.14 × 192
𝐹𝑐 = 21.35𝑁/𝑚𝑚2
Screw is safe in compression

(b) Torsional shear stress:
𝑀𝑡 = 3.14/(16 × 𝐹𝑐 × 𝑑𝑐 3 )
28.6 × 103 = 3.14 × 𝐹𝑐 × 𝑑𝑐𝑎𝑐𝑡 × 193 /16
𝐹𝑐𝑎𝑐𝑡 = 9.17 𝑁/𝑚𝑚2
The screw is safe in torsion
(c) Bearing pressure:
4
𝑃𝑏 = 𝑤 × 𝜋 × (𝑑𝑜2 − 𝑑𝑐 2 ) × 𝑛
Where,
Pb= Bearing pressure
N= No. of threads in contact.
Limiting values of bearing pressure
Ref. V.B Bhandari, Table No 6.4
Type of
Material Sb(N/mm2) Rubbing speed
application
High speed 15
Lead screw Bronze 1-1.5
m/min
4
𝑃𝑏 = 137.53 × 𝜋 × (202 − 182 ) × 𝑛
n = 67
Shear stress due to axial load
𝐹𝑠𝑎𝑐𝑡 = 𝑤/𝜋 × 𝑛 × 𝑑𝑐 × 𝑡
t= Thread width=P/2
t=1mm

𝐹𝑠𝑎𝑐𝑡 = 137.53/𝜋 × 67 × 19 × 1
𝐹𝑠𝑎𝑐𝑡 = 1.51 N/mm2
Screw threads are safe in shear
Stresses due to buckling of screw:
According to Rankine formula,
𝐴
𝑊𝑐𝑟 = 𝑓𝑐 × 1 + 𝑎 (𝐿𝑒/𝑘)2
Where,
Wcr = Crippling loud on screw
A= Area of c/s of root
A= Contact
Le= Equivalent unsupported length of screw decided by end condition
K= Radius of gyration=dc/4 mm
fc= Yield stress in compression
Ref. PSG design data Page No. 6.8
𝜋
4(192 ) 1
𝑊𝑐𝑟 = 300 × +( ) (127.6/194.2)
1 7500
𝑊𝑐𝑟 = 77.60 × 103 𝑁
As the critical load is high as compared to actual compressive load of 137.53 N the
screw is safe in buckling.

3.9 Selection of Material :
The proper selection of material for the different part of a machine is the main objective
in the fabrication of machine. For a design engineer it is must that he be familiar with the effect,
which the manufacturing process and heat treatment have on the properties of
materials. The Choice of material for engineering purposes depends upon the
following factors:
1. Availability of the materials.
2. Suitability of materials for the working condition in service.
3. The cost of materials.
4. Physical and chemical properties of material.
5. Mechanical properties of material.
The mechanical properties of the metals are those, which are associated with the
ability of the material to resist mechanical forces and load. We shall now discuss these
properties as follows:
1. Strength: It is the ability of a material to resist the externally applied forces.
2. Stress: Without breaking or yielding. The internal resistance offered by apart to an

externally applied force is called stress.
3. Stiffness: It is the ability of material to resist deformation under stresses. The

modules of elasticity of the measure of stiffness.
4. Elasticity: It is the property of a material to regain its original shape

after deformation when the external forces are removed. This property is desirable for
material used in tools and machines. It may be noted that steel is more elastic than
rubber.
5 Plasticity: It is the property of a material, which retain the deformation produced

under load permanently. This property of material is necessary for forging, in stamping
images on coins and in ornamental work.

6. Ductility: It is the property of a material enabling it to be drawn into wire with the
application of a tensile force. A ductile material must be both strong and plastic. The
ductility is usually measured by the terms, percentage elongation and percent
reduction in area. The ductile materials commonly used in engineering practice are
mild steel, copper, aluminium, nickel, zinc, tin and lead.
7. Brittleness: It is the property of material opposite to ductile. It is the property of

breaking of a material with little permanent distortion. Brittle materials when
subjected to tensile loads snap off without giving any sensible elongation. Cast iron is
a brittle material.
8.Malleability: It is a special case of ductility, which permits material to Be rolled or

hammered into thin sheets, a malleable material should be plastic but it is not essential
to be so strong. The malleable materials commonly used in engineering practice are
lead, soft steel, wrought iron, copper and aluminium.
9. Toughness: It is the property of a material to resist the fracture due to high impact
loads like hammer blows. The toughness of the material decreases when it is heated. It is
measured by the amount of absorbed after being stressed up to the point of fracture. This
property is desirable in parts subjected to shock an impact loads.
10. Resilience: It is the property of a material to absorb energy and to resist rock and
impact loads. It is measured by amount of energy absorbed per unit volume with in
elastic limit. This property is essential for spring material.
11. Creep: When a part is subjected to a constant stress at high temperature for long
period of time, it will undergo a slow and permanent deformation called creep. This
property is considered in designing internal combustion engines, boilers and turbines.
12. Hardness: It is a very important property of the metals and has a wide verity of meanings. It
embraces many different properties such as resistance to wear scratching, deformation
and mach inability etc. It also means the ability of the metal to cut another metal. The
hardness is usually expressed in numbers, which are dependent on the method of
making the test. The hardness of a metal may be determined by the following test
a) Brinell hardness test

b) Rockwell hardness test
c) Vickers hardness (also called diamond pyramid) test
The science of the metal is a specialized and although it over flows in to real
ms of knowledge it tends to shut away from the general reader. The knowledge
of materials and their properties is of great significance for a design engineer. The
machine elements should be made of such a material which has properties suitable for
the conditions of operations. In addition to this a design engineer must be familiar with
the manufacturing processes and the heat treatment shave on the properties of the
materials. In designing the various part of the machine it is necessary to know how the
material will function in service.
For this certain characteristics or mechanical properties mostly used in

mechanical engineering practice are commonly determined from standard tensile tests.
In engineering practice, the machine parts are subjected to various forces, which may
be due to either one or more of the following.
1. Energy transmitted
2. Weight of machine
3. Frictional resistance
4. Inertia of reciprocating parts
5. Change of temperature
6. Lack of balance of moving parts
The selection of the materials depends upon the various types of stresses that
are set up during operation. The material selected should with stand it.
Another criteria for selection of metal depend upon the type of load because a
machine part resist load more easily than a live load and live load more easily than a
shock load.
Selection of the material depends upon factor of safety, which in turn depends
upon the following factors.

1. Reliabilities of properties
2. Reliability of applied load
3. The certainty as to exact mode of failure
4. The extent of simplifying assumptions
5. The extent of localized
6. The extent of initial stresses set up during manufacturing
7. The extent loss of life if failure occurs
8. The extent of loss of property if failure occurs
Materials selected in machine,
For Base, column, overhanging arm and bolt material used : Mild steel
Reasons:
1. Mild steel is readily available in market
2. It is economical to use
3. It is available in standard sizes
4. It has good mechanical properties i.e. it is easily machinable
5. It has moderate factor of safety, because factor of safety results in unnecessary

wastage of material and heavy selection. Low factor of safety results in unnecessary
risk of failure
6. It has high tensile strength
7. Low co-efficient of thermal expansion
Properties of Mild Steel:
1. Mild steel has a carbon content from 0 .15 % to 0.30%. They are easily wieldable
thus can be hardened only. They are similar to wrought iron in properties.

2. Both ultimate tensile and compressive strength of these steel increases with
increasing carbon content. They can be easily gas welded or electric or arc welded.
With increase in the carbon percentage weld ability decreases Mild steel serve the
purpose and was hence was selected because of the above purpose.

CHAPTER 4
MANUFACTURING
4.1. Parameters
In system design we mainly concentrated on the following parameters:-
4.1.1 System Selection Based on Physical Constraints:-
While selecting any machine it must be checked whether it is going to be used in

a large scale industry or a small scale industry. In our case it is to be used by a small
scale industry .So space is a major constrain. The system is to be very compact so that
it can be adjusted to corner of a room.
The mechanical design has direct norms with the system design. Hence the
foremost job is to control the physical parameters, so that the distinctions obtained
after mechanical design can be well fitted into that.
4.1.2 Arrangement of Various Components:-
Keeping into view the space restrictions the components should be laid such
that their easy removal or servicing is possible. More over every component should be
easily seen none should be hidden. Every possible space is utilized in component
arrangements.
4.1.3 Components of System:-
As already stated the system should be compact enough so that it can be

accommodated at a corner of room. All the moving parts should be well closed and
compact .A compact system design gives a high weighted structure which is desired.
4.1.4 Man Machine Interaction:-
The friendliness of a machine with the operator that is operating in an

important criteria of design. Following some of the topics included in this section.
 Design of handle
 Energy expenditure in hand operation

4.1.5 Chances of Failure:-
losses incurred by owner in case of any failure are important criteria of design.
Factor of safety while doing mechanical design is kept high so that there are less
chances of failures. Moreover periodic maintenance is required to keep unit healthy.
4.1.6 Servicing Facility:-
The layout of components should be such that easy servicing is possible.

Especially those components which require frequents servicing can be easily
disassembled.
4.1.7 Scope of Future Improvement:-
Arrangement should be provided to expand the scope of work in future. Such as

to convert the machine motor operated; the system can be easily configured to required
one.
4.1.8 Height of Machine from Ground:-
For ease and comfort of operator the height of machine should be properly
decided so that he may not get tired during operation. The machine should be slightly
higher than the ground level, also enough clearance should be provided from the
ground for cleaning purpose.
4.2 Parts of Mini Milling Machine:
4.2.1. Base:-
Base of the machine serves as a foundation member for all other parts of the machine
which rest upon it. It carries the column at its one end. In some machines, the base is
hollow and serve as a reservoir for cutting fluid. The recommended material for base is
mild steel which is mostly used in manufacturing of base of various mini milling
machine.
A hollow rectangular cross-section of mild steel with dimension 2.5 mm and length
800 mm is selected.

The following is the list of operation performed to produce the base with a brief
description of each operation arranged sequentially:
1. Cutting: In this operation main target is to cut the available rectangular bar as per
required dimension. We cut the four rectangular bar of 150 mm length and two
bars of 250 mm length and two more bars of 200 mm length. These eight bars are
used to obtain base structure.
2. Surface cleaning: This process is done to make the bar burr free which are produced
due to cutting operation. End of each rectangular bar up to particular length is also
cleaned to obtain proper welding joint between two bars.
3. Welding: In this process all the rectangular bars are joined as per required
orientation to obtain the final structure of base.
4. Fig. 4.1gives constructional details about the frame.
Fig No.4.1 Base of Mini Milling Machine
4.2.2. Column:-
The column is the main supporting frame mounted vertically on the base. The front
vertical face of the column is accurately machined and is provided with guide ways for
supporting the overhanging arm .The top of the column is finished to hold an over arm
that extends outward at the front of the machine.
column is made of same material as that of frame, Mild steel with solid circular stock
of outer diameter 25 mm and length 1200 mm.
The following are the list of operation performed to produce the column, arranged
sequentially:

1. Cutting: This process is done to cut the starting stock piece into two part of length
600 mm.
2. Facing: This operation is done on lathe machine to make the surface flat of both
pieces which are cut in previous step. In this process length of each piece is reduce
to give smooth finish to both sides.
3. External turning process: This process is done to reduce the outer diameter of the
starting stock piece from 25 mm to 24 mm.
4. Welding: In this process rectangular bars are joined to the base as per required
orientation to obtain the final structure of column.
Fig. 4.2 gives constructional details about the column.
Fig.No.4.2 Column of Mini Milling Machine
4.2.3. Overhanging arm:-
The overhanging arm that is mounted on the top of the column extends beyond the
column face and serves as a bearing support for the drilling machine. The arm is
adjustable to hold different sizes of machine.
Take hollow circular rod of internal diameter 18 mm and external diameter 22 mm

with length of 200 mm & also take square tube of 2.5 with length 82 mm.

The following are the list of operation performed to produce the overhanging arm,
arranged sequentially:
5. Cutting: This process is done to cut hollow circular rod into two part of length 100
mm. and also cut the square tube in two pieces of length 40 mm
to give smooth finish to both sides.
8. Welding: In this process rectangular bars are joined to the base as per required
orientation to obtain the final structure of overhanging arm.
Fig. 4.3 gives constructional details about the overhanging arm.
Fig No.4.3 Overhanging Arm
4.2.4 Lead screw:-
The function of lead screw is to transmit the power. At the end of lead screw handle is
attached. By revolving handle motion is transmitted to the table, three lead screws
used for moment of three different axis.
Take circular rod diameter 14 mm with length of 250 mm.
The following are the list of operation performed to produce the lead screw, arranged
sequentially:

to give smooth finish to both sides. In this step length is reduced to 240 mm.
11. Threading: Threading is done on lathe machine thread is produced over the length
of rod.
Fig. 4.4 gives constructional details about the lead screw.
Fig.No.4.4 Lead screw with X axis
4.2.5 Axies:-
The mini milling machine is provided with three axis namely X,Y and Z. The purpose
of axis is to provide longitudinal, cross and vertical motions of the table.
A hollow rectangular cross-section of mild steel with dimension 2.5 mm with length
300 is selected and take circular rod of diameter 12 mm with length 600 mm and
hollow circular tube of internal diameter 12 mm and external diameter 18 mm.
The following is the list of operation performed to produce the base with a brief
description of each operation arranged sequentially:

5. Cutting: In this operation main target is to cut the available rectangular bar as per
required dimension. We cut the two rectangular bar of 300 mm length and two bars
of 150 mm length. These four bars are used to obtain base structure. Cut the
circular rod into two pieces. Cut hollow circular rod into two pieces of length 100
mm
pieces which are cut in previous step. In this process length of each piece is reduce to
give smooth finish to both sides.
starting stock.
4. Welding: In this process all the rectangular bars, circular rod and hollow (guide rod)
are joined as per required orientation to obtain the final structure of Z axis.
Fig.4.5 gives constructional details about the Z axis assembly.
Fig 4.5 X & Y Assembly
4.2.6 Handle :-
Handle is welded at the end of lead screw, handle is rotated by hand and motion is
transmitted to the table through lead screw.

Take circular rod diameter 13 mm with length of 200 mm.
The following are the list of operation performed to produce the handle, arranged
sequentially:
1. Cutting: In this process rod of circular diameter 13 mm cut into 3 pieces of length
62 mm.
pieces which are cut in previous step. In this process length of each piece is reduce to
give smooth finish to both sides. In this step length is reduced to 60 mm.
Fig. 4.6 gives constructional details about the lead screw.
Fig.No.4.6 Handle
4.2.7 Vice:-
Vices are the most common appliances for holding work on milling machine
table due to its quick loading and unloading arrangement. There are mainly three
types of vices commonly used in milling machines. They are plain vice, swivel vice,
and tool makers universal vice.
The plain vice bolted directly on the milling machine table is the most common
type of machine vice used for plain milling operations. The vice may be fastened to
the table with the jaws set either parallel or at right angles to the table T- slots. Work is

clamped between the fixed and movable jaw and for holding work pieces of irregular
shape special jaws sometimes used.
Fig.No.4.7 Vice of Mini Milling Machine
4.3 Constructional Diagram of Mini Milling Machine:
Fig.No.4.8 Constructional Diagram of Mini Milling Machine

4.4 Process Sheet:
The various tolerances on work piece are specified in the manufacturing

drawing. .The process chart are prepared and passed on to the manufacturing stage.
The parts are to be purchased directly are specified and selected from standard
catalogues
4.4.1 Process Sheet of Base:
PART CODE: MMM 01 MATERIAL SPECIFICATIONS : Mild Steel

PART NAME : Base RAW MATERIAL SIZE : □ Tube 2.5*2.5
QUANTITY : 1Nos
Sr Descripti Jigs Tools Time in Minutes
. on of & Machi Cuttin Measuri Settin Machi Total
N Operatio Fixtur ne g Tools ng g ne Time
o. n e Tools Instrum Time Time
ent
01 Take Vice _ _ _ 2 _ 2
. square
tube of
2.5*2.5m
m&
clamp
02 Cut 4 Vice _ Hacksa Scale 5 10 15
. pieces of w blade
150 mm
length
. pieces of w blade
250 mm
length
. pieces of w blade
200 mm
length
05 Welding Vice Weldin Weldin _ 5 20 25
. these g g rod
pieces as machin
per the e
drawing
Table No.4.1 Process Sheet of Base

4.4.2 Process Sheet of Handle:

PART NAME : Handle RAW MATERIAL SIZE : Ø22 *400
QUANTITY : 3 Nos
S Tools Time in Minutes
r
. Description Jigs & Measurin Setti
N of Fixtur Machi Cutting g ng
Machi
Total
o Operation e ne ne
Tools Instrume Tim Time
. Tools Time
nt e
Take circular
rod of Ø 22
and cut into Hacksa Vernier
1 Vice _ 5 15 20
3 pieces of w Blade
length 125
mm
Turn Ø 22 Three
Turning Vernier
2 to Ø 20 of jaw Lathe 5 15 20
Tool
all 3 pieces chuck
Facing B/S Three
Facing Vernier
3 of all 3 jaw Lathe 5 10 15
Tool
pieces chuck
Table No.4.2 Process Sheet of Handle

4.4.3 Process Sheet of Guide Rod:

PART NAME : Guide rod RAW MATERIAL SIZE :ID Ø 26 *400
QUANTITY : 6 Nos
S Tools Time in Minutes
r
. Descriptio Measur Tota
Jigs & Settin
N n of Machin Cutting ing Machin l
Fixture g
o Operation e Tools Tools Instru e Time Tim
. Time
ment e
Take
circular rod
of ID Ø 26 Hacksa
Vernier
1 and cut into Vice _ w 5 15 20
6 pieces of Blade
length 50
mm
Three
Turn outer Turning Vernier
2 jaw Lathe 5 10 15
diameter Tool
chuck
Facing B/S Three
Facing Vernier
3 of all 6 jaw Lathe 5 10 15
Tool
pieces chuck
Table No.4.3 Process Sheet of Guide Rod

4.4.4 Process Sheet of Overhanging Arm:

PART NAME : Overhanging arm RAW MATERIAL SIZE : -
QUANTITY : 1 Nos
Tools Time in Minutes
Sr. Descriptio Measuri Setti
Jigs & Machi Machi
No. n of Cutting ng ng Total
Fixture ne ne
Operation Tools Instrum Tim Time
Tools Time
ent e
Take
hollow
circular Three
Vernier
01. tube of jaw Lathe _ 5 10 15
internal chuck
Ø26 &
facing B/S
Cut 2
pieces of Hacksa Scale
02. Vise _ 5 10 15
lengths 170 w blade
mm
Cut 2
pieces of
square tube Hacksa Scale
03. Vise _ 5 15 20
having w blade
length
140mm
Welding of
square
Weldi
tubes &
ng Scale
04. hollow Vise _ 5 15 20
machi
circular
ne
tube as per
drawing
Take sheet
metal of 2 Bendi
mm thick, ng Vernier
05. _ _ 5 15 20
bend in machi
circular ne
form
Weld
circular Weldi
sheet metal ng
06. Vise _ _ 5 15 20
piece Machi
between 2 ne
square

tubes
Table No.4.4 Process Sheet of Overhanging Arm
4.4.5 Process sheet of Lead Screw:
PART CODE : MMM 04 MATERIAL SPECIFICATIONS : Mild Steel

PART NAME : Lead Screw RAW MATERIAL SIZE : Ø14 *250
QUANTITY : 3 Nos
Tools Time in Minutes
Sr. Descriptio Measur Tota
Jigs & Machi Settin
No. n of Cutting ing Machin l
Fixture ne g
Operation Tools Instru e Time Tim
Tools Time
ment e
Three
Clamp
01. jaw Lathe _ _ 10 _ 10
stock
chuck
Facing both
Three
side total Facing Vernier
02. jaw Lathe 5 12 17
length 250 Tool
chuck
mm
Turn OD Ø Three
Turning Vernier
03. 14 to OD Ø jaw Lathe _ 12 12
Tool
13 chuck
Turn OD Ø Three
Turning Venier
04. 13 to OD Ø jaw Lathe _ 15 15
Tool
12 chuck
Threading Three
Threadi Vernier
05. 0.5 mm jaw Lathe 20 40 60
ng Tool
pitch chuck
Table No.4.5 Process Sheet of Lead Screw

CHAPTER 5
EXPERIMENTAL PROCEDURE
5.1 Experimental Procedure for Drilling on Mini Milling Machine:
1. Clamp the work piece properly on the vice.

2. Change the drill bit of required dimension and as per the material of work
piece.
3. Adjust the X,Y and Z axis properly.
4. Start drilling operation and slowly moves down Z axis as per depth
requirement.
5.2 Experimental Procedure for Milling on Mini Milling Machine:
1. Clamp the work piece properly on the vice.

2. Change the cutter of required dimension and as per the material of work piece.
3. Adjust the X,Y and Z axis properly.
4. Start milling operation and slowly moves down Z axis as per depth
requirement.

CHAPTER 6
RESULT & DISCUSSION
6.1 Experimental Results:
6.1.1 Test on Nylon:
6.1.1.1 Drilling operation:
Standard cutter Diameter Depth Depth

Sr.No.
diameter achieved Required achieved
01 Ø10 mm 10.1 mm 50 mm 50.2 mm
Table 6.1 Nylon Drilling Operation Result
Variation in diameter = 10.1-10 = 0.1 mm
Variation in depth = 50.2-50 = 0.2 mm
6.1.1.1 Slot milling operation:
Standard cutter Slot diameter Slot length Slot length

Sr.No.
01 Ø10 mm 10.2 mm 30 mm 30.3 mm
Table 6.2 Nylon Slot Milling Result
Variation in slot diameter = 10.2-10 = 0.2 mm
Variation in slot length = 30.3-30 = 0.3 mm
From above discussion on nylon material, variations in the dimensions are in the
acceptable range.

6.1.2 Test on Wood:
6.1.2.1 Drilling operation:
Standard cutter Diameter Depth Depth

Sr.No.
01 Ø10 mm 10.05 mm 50 mm 50.1 mm
Table 6.3 Wood Drilling Operation Result
Variation in diameter = 10.05-10 = 0.05 mm
Variation in depth = 50.1-50 = 0.1 mm
6.1.2.2 Slot milling operation:
Standard cutter Slot diameter Slot length Slot length

Sr.No.
01 Ø10 mm 10.15 mm 30 mm 30.15 mm
Table 6.2 Wood Slot Milling Result
Variation in slot diameter = 10.1-10 = 0.1 mm
Variation in slot length = 30.15-30 = 0.15 mm
From above discussion on wood, variations in the dimensions are in the acceptable
range.
6.2 Analysis Procedure:
Numerical simulations are carried out using ANSYS and the procedure incorporated in
this session
6.2.1 ANSYS Pre-Processor:
6.2.1.1 Creation of the model geometry
To begin with the analysis process, the Model generation is carried out in this
processor. A solid Model of the generated in CATIA is imported in ANSYS
6.2.1.2 Define material properties

In the present work, Mild steel is used as material for design. The young’s modulus
and the Poisson ratio is taken as 210 Gpa and 0.35 respectively.
6.2.1.3 Generating the mesh
As the material properties for the material selected are defined for the solid model.
Due care is required in meshing of a sensitive zone and comparatively insensitive
zone. Sensitive zones are hence meshed using fine mesh whereas insensitive zone is
meshed using relatively coarse mesh.
6.2.2. ANSYS Solution:
The method model is imposed with the boundary conditions and the load steps for the
detailed displacement (deformation) and stress analysis.
6.2.2.1 Define analysis type and analysis option
In the current work, one of the prime objectives is to attain the micro displacements.
Dynamic aspect is not considered as the scope of the study. Static structural analysis
module of ANSYS is considered for the analysing the different components of mini
milling machine. The static analysis focused on aspects such as force and displacement
relationships.
6.2.2.2 Specify boundary conditions
After selection of the analysis type, it is then required to impose boundary conditions
for the analysis. In this case, the model is fixed at one side and force is applied on the
top of the work piece.
6.2.2.3 Obtain Solution
This step indicates the solution process of model. The solution is carried out for
resulting deformation. The compiler processes the model and keeps the solution ready
for further processing.
6.2.3 ANSYS General Postprocessor:
One of the most important step is to view the results of an analysis in order to
understand how the applied loads affects our design. General processor is used to

review the results for static or steady state problems. Using this post processor we can
see contour displays, deformed shapes, element forces and moments, nodal
displacements, stress contour, von misses stresses, principal stresses etc. We can also
see the simulation, which indicates variation of stress, displacement at different
locations of component
6.3 Modelling & Analysis Results:
6.3.1 Modelling of Base:
Fig No 6.1 Modelling of Base
CATIA→ Part modelling→ Select the plane→ Top view→ Sketch→ Rectangle→
Drawn the rectangle as per the dimensions→ Exit workbench→ Extrude (Apply
thickness)
Select bottom view→ Sketch on the face→ Draw the square of 2.5*2.5→ Extrude the
length as per required dimension→ Rectangular pattern to create same part.

6.3.2 Analysis of Base:
Fig No 6.2 Analysis of Base
Maximum deformation occurs at the centre. Here we can see total deformation to be
very less, which is very small value and hence acceptable.
6.3.3 Modelling of Column:
Fig No 6.3 Modelling of Column
CATIA→ Part modelling→ Select the plane→ Top view→ Sketch→ Circle→ Drawn
the circle as per the dimensions→ Exit workbench→ Extrude (Apply length)

Select front view→ Sketch on the face→ Draw the rectangle→ Extrude the length as
per required dimension
6.3.4 Analysis of column:
Fig.6.4 Analysis of Column
In column, maximum deformation occurs at top portion. The maximum deformation

occurred in column is 3.0038e-11 is very less and hence acceptable.
6.3.5 Modelling of Overhanging Arm:
Fig No 6.5 Modelling of Overhanging Arm

CATIA→ Part modelling→ Select the plane→ Top view→ Sketch→ Circle→ Drawn
the circle as per the dimensions→ Exit workbench→ Extrude (Apply length)
Select face→ Sketch on the face→ Draw the square→ Extrude the length as per
required dimension
Select top view→ Sketch on the face→ Draw the circular shape (holder) → Extrude
the length as per required dimension
6.3.6 Analysis of Overhanging Arm:
Fig No .6.6 Analysis of Overhanging Arm
In overhanging arm deformation occurs in extended part of overhanging arm.

Maximum deformation is 7.77e-8 which is very less. Hence deformation is acceptable.

6.3.7 Modelling of Lead Screw:
Fig No 6.7 Modelling of Lead Screw
CATIA→ Part modelling→ Select the plane→ Front view→ Sketch→ Circle→
Drawn the circle as per the dimensions→ Exit workbench→ Extrude (Apply length)→
Select the surface→ Apply threads
6.3.8 Analysis of Lead Screw:
Fig No 6.8 Analysis of Lead Screw
In lead screw, deformation takes place at end whose connected to the handle.
Maximum deformation is 2.20e-7 which is very small. Hence lead screw is safe.

6.3.9 Modelling of Handle:
Fig No 6.9 Modelling of Handle
CATIA→ Part modelling→ Select the plane→ Front view→ Sketch→ Circle→
Drawn the circle as per the dimensions→ Exit workbench→ Extrude (Apply length)
6.3.10 Analysis of Handle:
Fig No 6.10 Analysis of Handle
Maximum stresses generated at middle portion of the handle, which is connected to

handle. Maximum stress induced within limit, Hence the design is safe.

CHAPTER 7
COST ESTIMATION
7.1 Cost Estimation of Raw Material:
7.1.1. For Base:
Material is Mild Steel,

Density of Mild Steel = 7800 Kg/m3
Volume of the stock = 𝐿 × 𝐵 × 𝐻
= 250 × 25 × 2
= 12500𝑚𝑚3
= 1250 × 10−9 𝑚3
Mass of the material = 𝜌 × 𝑣
= 7800 × 12500 × 10−9
= 0.0975𝑘𝑔 ≈ 0.10 𝑘𝑔
No. of base joints required= 8
Total mass of base = 8 × 0.10
= 0.80 𝑘𝑔 ≈ 1 𝑘𝑔
7.1.2. For Column:

Density of Mild Steel = 7800 Kg/m3
𝜋
Volume of the stock= 4 𝑑 2 × l
= 0785 × 18 × 18 × 60
= 152.68 × 103 𝑚𝑚3
= 152.68 × 10 −6 𝑚3
= 7800 × 152.68 × 10−6
= 1.16 Kg.
No. of rods required =2

Total mass of column = 2 × 1.16 𝑘𝑔
= 2.32 𝑘𝑔 ≈ 2.50 𝑘𝑔
7.1.3 For Lead Screw:
Density of Mild Steel= 7800 Kg/m3
𝜋
Volume of the stock = 4 𝑑 2 × l
𝜋
= 4 102 × 260
= 20420.35 mm3
= 20420.35 × 10−9 𝑚3
= 7800 × 20420.35 × 10−9 𝑚3
= 0.16 Kg.
No. of lead screw = 3
Total mass of lead screw = 3 × 0.16
= 0.48 𝑘𝑔 ≈ 0.50 𝑘𝑔
7.1.4. For Supporting Rod:
𝜋
Volume of the stock = 4 𝑑 2 × l
𝜋
= 4 122 × 300
= 33929.20.35 mm3

= 33929.20×10-9 m3
= 7800 × 33929.20 × 10−9
= 0.26 Kg.
No. of supporting rod = 4
Total mass of coupling = 4 × 0.26
= 1.04 Kg.
7.1.5 For Guide Rod:
𝜋
Volume of the stock= 4 (24 × 24 − 18 × 18) × 300
= 33646.45 mm3
= 33646.45 × 10−9 m3
= 7800 × 33646.45 × 10−9
= 0.26 Kg.
No. of guide rod = 6
Total mass of guide rod = 6 × 0.26
= 1.6 Kg.
Thus the summary of above calculation is depicted in tabular form given below:

Material Mass (Kg.) Cost/Kg. Total Cost
Mild steel for base 1 80 80
Mild steel for

2.50 80 200
column
Mild steel for lead
0.50 80 40
screw
Mild steel for
1.6 80 128
supporting rod
Mild steel for guide
1.04 80 84
rod
Mild steel for
1.8 80 144
supporting frame
Total Raw Material Cost (Rs.) 676
Table 7.1 Raw Material Cost
7.2 Standard Component Cost:
Cost/Unit
Sr.No. Component Qty. Total Cost
Qty
1 Vice 1 470 470
2 Drill Machine 1 1500 1500
3 Bolts 6 3 18
4 Washer 3 2 6
Total Cost (Rs.) 1994
Table 7.2 Standard Component Cost

7.3 Accessories Cost:
Cost/Unit Total
Sr.No. Accessory Qty.
Qty Cost
1 Drill bit 1 100 100
2 Mill cutter 2 120 240
Total 340
Table 7.3: Accessories Cost
7.4 Machining Cost:
Sr. No. Operation Rate/Hr.(Rs) Hours Total Cost

(Rs.)
1 Cutting ------ ---- 150
2 Facing 120 3 360
3 Turning 120 5 600
4 Threading 140 6 840
6 Grinding ----- ----- 100
7 Welding ---- ----- 500
Total Machining Cost (Rs.) 2610
Table 7.4 Standard Machining Cost

7.5 Total Cost:
Element Cost (Rs.)

Raw Material Cost 676
Standard Component Cost 1994
Accessories Cost 340
Machining Cost 2610
Miscellaneous Cost 1080
Total 6700
Table 7.5 Overall Cost

CHAPTER 8
CONCLUSION AND FUTURE SCOPE
8.1 Conclusion:
With the increasing demand for small scale high precision parts in various industries,
the market for small scale machine tools has grown substantially. Using small machine
tools to fabricate small scale parts can provide both flexibility and effiency in
manufacturing approaches and reduce the capital cost, which is beneficial for small
business owners.
In this project, a small scale three axis mini milling machine is designed and analysed
under very limited budget of RS 10,000.
8.2 Future Scope:
We can make it computerised, moment of axis can be controlled by using motors. We

have to make graduations on the each axis. With the help of these graduations and the
sensors, we can find the co-ordinates on X,Y and Z axis.
With the help of these co-ordinates, we can move the spindle accordingly and the
operations performed at required location.
As this system can be made computerised, perfect accuracy will be achieved.

CHAPTER 9
REFERANCES
Reference books:
V.B.Bhandari, Design of Machine Elements-3rd edition, Mc Graw Hill Education
R.S.Khrmi, Machine Design-5th edition, S-Chand Publication
Research papers:
Manish Modi , Krishna Dave. ,The review of usability in portable milling machine
from micro to macro parts ,IJIRST –International Journal for Innovative Research in
Science & Technology| Volume 1 | Issue 6 | November 2014
S.B.Chandgude , S.S.Patil, Material selection in structural design of mini milling

machine, International Journal of Research in Advent Technology, Volume 2,Issue
1,Janurary 2014
R.R.Honkalas, P.M.Pawar, B.P.Ronge, Design and analysis of table for micro milling
,International Journal of Engineering Research and Applications, Volume 2,Issue 6,
December 2012
Ali Mamedov ,S.Ehsan Layegh K., Machining forces and tool deflections in micro
milling,14th CIRP Conference on Modelling of Machining Operations.
Sushant Thambkar,Bhagyesh Deshmukh,FE Analysis of positiong slides of micro

milling machine, International Journal of Emerging Technology and Advanced
Engineering ,Volume 3,Issue10,Octomber 2013
Handbooks:
PSG Design Data Book, Faculty of Mechanical Engineering, PSG College of

Technology, Coimbatore
N.K.Mehta,Machine Tool Design, Tata McGraw-Hill Education 2012

APPENDIX
Drawing of Machine Parts

Design of Mini Milling Machine

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Design of Mini Milling Machine

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Design and Manufacturing of Mini Milling Machine

In this century, we have seen many new developments in very advanced

MIT Academy of Engineering Pune, B.E (Mechanical) Page 1

Milling machines can perform a vast number of complex operations, such

1.2 Milling Processes:

Fig.No.1.1 Face Milling Process (Cutter Axis is Vertical)

MIT Academy of Engineering Pune, B.E (Mechanical) Page 2

The milling process removes material by performing many separate, small

There are two major classes of milling process:

The aim of our project is to design & manufacturing of mini-milling machine to

MIT Academy of Engineering Pune, B.E (Mechanical) Page 3

1.4 Project Objectives:

General objective of this project is to develop a mini-milling machine up to

(5) Total machine cost will be analyzed.

1.5 Project Scope:

MIT Academy of Engineering Pune, B.E (Mechanical) Page 4

Data Collection & System Design

Selection of Material & Mechanical Design

Process planning & Material Procurement

Manufacturing & Assembly-Test &Trial

Fig.No. 1.2 Methodology of Project

1.5.1 Literature Review:

1.5.2. Data Collection & System Design:

MIT Academy of Engineering Pune, B.E (Mechanical) Page 5

1.5.3 Selection of Material & Mechanical Drawing:

Select the materials for different components by considering various factors,

1.5.4. Process Planning &Material Procurement:

1.5.5 Manufacturing & Assembly-Test & Trial:

1.5.6 Report Preparation:

1.7 Organization of Dissertation:

The project is presented in seven chapters including introduction, literature

MIT Academy of Engineering Pune, B.E (Mechanical) Page 6

The chapter four covers different operations performed on different components of

MIT Academy of Engineering Pune, B.E (Mechanical) Page 7

2.1 A Review of Usability of Portable Milling Machine From Micro To Macro

From above research paper, the following points are observed:

2.2 Material Selections In Structural Design of Mini Milling Machine By S.B.

MIT Academy of Engineering Pune, B.E (Mechanical) Page 8

2.4 Machining Forces and Tool Deflections In Micro Milling By Ali

2.5 FE Analysis of Positioning Slides of Micro Milling Machine By Sushant

MIT Academy of Engineering Pune, B.E (Mechanical) Page 9

Knowledge of theory of machine and other branch of applied mechanics is

3.2 Factor Considered:

Many preliminary alternatives are eliminated during this phase. Designer

These forces may be classified as:

a) Dead weight forces

MIT Academy of Engineering Pune, B.E (Mechanical) Page 10

Selection of factor of safety to find working or design stress is another

Selection of material should be made according to the condition of loading

Provision should be made to minimize nearly adopting proper lubricating

The parts to be purchased directly are selected from various catalogues

MIT Academy of Engineering Pune, B.E (Mechanical) Page 11

3.3 Bill of Materials:

SR.NO. PART CODE PART NAME QTY. MATERIAL

Table No. 3.1 Bill of Materials

3.4 Specifications of Mini Milling Machine:

Drilling Capacity 20 mm diameter

Table No.3.2 Specifications of Mini Milling Machine

MIT Academy of Engineering Pune, B.E (Mechanical) Page 12

3.5 Power Required for Drilling:

= 2.82 × 10−6 × 𝑘 × 𝑛 × (𝐷2 − 𝑑 2 )1.5 + 7.875 ×0.02

(From PSG Design Data Book, Page No 12.1)