Workshop Practice (GE102)
Reference manual for the experiment on Milling
● Experiment title: To perform milling operation like End milling (pocket
milling) and Face milling and make the part shown in the sketch from a
mild steel block on a milling for the given work piece.
● Objective(s): To familiarize working system and important parts and
functions of the milling machine. Also understand different technical
terminology and various milling operations. To Study material, geometry
of tools used in metal cutting like multi point cutting tools.
Note: All dimensions are in mm
● Introduction: A milling machine is a machine tool, which machines a
material when the work piece material is directed against a multipoint
cutter. The cutter revolves at a normal speed and the work fed slowly
past the cutter. The work can be fed in a longitudinal, vertical or cross
direction. As the work progress further, the cutter teeth remove the metal
from the work surface to produce the desired shape.
● Material and apparatus required:
(1)Milling Machine
(2)Power hacksaw
(3)Mild steel specimen 40 x 40 x40 mm.
(4)Cutting tool required (End milling and face milling cutter with tool
holding accessories etc.)
(5)Measuring device (Vernier caliper, Steel rule, try square etc.)
(6)Tool kit (Collet chuck and key, Mallet hammer, Parallel block etc.)
(7)Work holding device like machine vice and fixture.
● Method:
1. Cut the work piece from square mild steel bar (40x40x40mm) using
power hacksaw.
2. Deburring the workpiece by using hand file.
3. Hold the workpiece in the machine vice using parallel block with
sufficient height.
4. Sat the RPM (900 to 1400 clockwise rotation) and switch on the
machine.
5. Must use safety guard while operating machine.
6. Set the reference point for Z-axis and set zero on digital read out
(DRO)
7. Set depth of cut up to 0.5mm while adjusting Z-axis.
8. Perform face milling operation to moving X-axis and Y-axis using
uniform feed.
9. Change the workpiece orientation and perform same face milling
operation on all faces while checking proper dimensions
(38x38x38mm).
10. Chane the cutting tool (end mill).
11. Set the reference point according to given drawing and perform
pocket milling up to depth 5mm.
12. Mack sure cutting fluid switched on during pocket milling.
13. Un-hold the workpiece and deburring by using hand file.
14. Clean the workstation (Machine) properly.
● Precautions:
(1)Must wear proper safety shoes, goggles and apron.
(2)Follow proper safety protocol during the machining operation.
(3)Do not operate the machine without the presence of the technical staff
or TA.
(4)Make sure tool and work piece are fixed tightly.
(5)Do not touch any rotating parts of the machine.
(6)Do not touch the chips with bare hands.
(7)If hearing unusual noise, the machine should be stopped.
● Difficulties that may arise
(Write the technical difficulties that you think may arise during the
experiment)
● Conclusion
(What new knowledge(s) one can learn by doing this experiment.
How this experiment relates your daily life, write one or two sentences.)
Write about various milling operations and parameters.
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