KULLIYYAH OF ENGINEERING
WORKSHOP TECHNOLOGY
MME 1103
MILLING 1 & 2
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MANUFACTURING AND MATERIALS DEPARTMENT MME1103
Workshop Technology Manual
Milling
6.1 INTRODUCTION
Milling is a machining operation in which a workpart is fed past a rotating cylindrical
rotating tool with multiple cutting edges. The axis of rotation of the cutting tool is
perpendicular to the direction of feed. This orientation between the tool axis and the feed
direction is one feature that distinguishes milling from drilling. The cutting tool in milling
is called milling cutter and the edges are called teeth. The machine tool that traditionally
performs this operation is a milling machine. Figure below shows some of the application
of milling.
There are two basic cutting operations in milling which are peripheral milling and face
milling as shown in Fig. 6.2. The tool axis in peripheral milling is parallel to the surface
being machine while the axis of the cutter is perpendicular to the machined surface in
face milling.
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MANUFACTURING AND MATERIALS DEPARTMENT MME1103
Workshop Technology Manual
Milling
Several types of peripheral milling are (a) slab milling, the cutter width extend the width
of the workpiece on both sides. (b) slot milling, creating a slot in the workpiece, (c) side
milling, the cutter machine the side of the workpiece, (d) straddle milling, similar to side
milling but on both sides, (e) slit milling, the cutter separate the workpiece and (f) form,
milling, a special cutter to form the workpiece to desired shape (Fig. 6.3). In peripheral
milling there are two opposite directions of rotation that the cutter can have with respect
to the work. These cutter direction distinguish two form of milling which are up milling
and down milling as shown in Fig 6.4
Figure 6.3: Types of peripheral milling (a) slab, (b) slot, (c) side (d) straddle (e) slit and
(f) form
Operations in face milling includes (a) conventional face milling, the tool cutter is bigger
than the workpiece, (b) partial face milling, the cutter overhangs the work at one side, (c)
end millng, the cutter diameter is less than the workpiece where slots cutting can be done,
(d) profile milling, a form of end milling of which the outside periphery of the flat
surface, (e) pocket milling, another form of end milling which remove the material to
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MANUFACTURING AND MATERIALS DEPARTMENT MME1103
Workshop Technology Manual
Milling
form shallow surfaces (f) surface contouring, using ball nose cutter cutting across a
curvilinear path to create three dimensional form.
Figure 6.5: Types of face milling (a) conventional face (b) partial face (c) end (d) profile
(e) pocket and (f) surface contour.
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MANUFACTURING AND MATERIALS DEPARTMENT MME1103
Workshop Technology Manual
Milling
Figure 6.7: Important parts in (a) horizontal and (b) vertical milling machine
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MANUFACTURING AND MATERIALS DEPARTMENT MME1103
Workshop Technology Manual
Milling
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MANUFACTURING AND MATERIALS DEPARTMENT MME1103
Workshop Technology Manual
Milling
6.4 MILLING 1
Procedure
1) Prepare aluminum solid square 80mm x 50mm x 25mm workpiece. (see Fig. 6.9)
2) Machine the side surface (shaded) by 0.5mm each for a depth of 2mm as shown in
Fig. 6.10
3) Machine surface B (shaded) by 0.5mm each for a depth of 2mm. (see Fig. 6.11)
4) Machine other side of surface A by 0.5mm each until the width is 45mm. (see Fig.
6.12)
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MANUFACTURING AND MATERIALS DEPARTMENT MME1103
Workshop Technology Manual
Milling
5) Machine surface C (shaded) by 0.5mm each for a depth of 2mm. as shown in figure
below
25
6) Lastly machine the other side of surface C (shaded) surface by 0.5 each until the
length is 75mm. (see Fig. 6.15)
25
75
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MANUFACTURING AND MATERIALS DEPARTMENT MME1103
Workshop Technology Manual
Milling
6.5 MILLING 2
Procedure
1) Do the marking on the workpiece with the right equipment. The equipments are as
follows;
a. Height gauge vernier caliper
b. “L” block
c. ceramic table
2) Use “2 flute endmill cutter” of size ø 18mm to bore a blind hole with depth of 10mm.
3) Use “2 flute endmill cutter” of size ø 15mm to mill both end sides of the workpiece
with the depth of 8mm.
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MANUFACTURING AND MATERIALS DEPARTMENT MME1103
Workshop Technology Manual
Milling
Questions
1. Sketch the milling machine and label the important parts.
2. Name the tool holder and cutting tools used.
3. List 4 operations can be performed using vertical milling machine.
4. Sketch (top, front, side and isometric)of the end product referring to the
procedures.
REFERENCES
1. Groover M.P., (1996), Fundamentals of Modern Manufacturing, Materials,
Processes and Systems, International Editions, Prentice Hall.
2. Gupta J.K. (1996), Basic Workshop Practice, S. Chand & Company Ltd.
3. Kalpakian, S & Schmid, S.R. (2001), Manufacturing Engineering and
Technology – 3rd International Edition, Prentice Hall International.
4. Kalpakian, S & Schmid, S.R. (2001), Manufacturing Engineering and
Technology - 4th International Edition, Prentice Hall International.
5. Kibble R.R, Neely J.E, Meyer R.O & White W.T. (2002). Machine Tool
Practice- 7th Edition, Prentice Hall.
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