Lab Session No: 8a

Milling Operation on Al-work piece.

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EXPERIMENT # 07:
To perform the End milling operation (slot making) on Aluminum plate, by an end
milling cutter.

PROBLEM STATEMENT:
To achieve the required dimension/slot on the work piece through end mill cutting is
important to reduce the machining time, which is done with the help of vertical milling
machine at larger depth of cuts for light materials. The objective of this experiment is to
perform the end milling operation accurately on vertical milling machine.

APPARATUS:
Vertical milling machine, End milling cutter for vertical milling machine & Al-Plates.

THEORY:
Milling Machine.
A milling machine is a machine tool that is used to cut metal with a multiple-point
cutting tool called a milling cutter. The work piece is clamped to the milling machine
table and is fed against the revolving milling cutter. The milling cutters can have cutting
teeth on the periphery or sides or both. The cutting teeth can be straight or spiral.

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Types of Milling Machine.

There are mainly two types of millings: -
Vertical milling machine.
I) Box & Column vertical Milling Machine.
II) Turret vertical Milling Machine.
III) Bed Vertical Milling Machine.
 Horizontal milling machine.
I) Plain Milling Machine.
II) Universal Milling Machine.
Both milling machines are classified on the spindle axis. In the horizontal milling, spindles
axis remains horizontal and in vertical milling, spindles axis remains vertical.
Vertical milling Machine:
A vertical milling machine which is of similar construction to a horizontal milling
machine except that the spindle is mounted in the vertical position.
Principle parts of Vertical Milling machine.
Column.
Knee.
Saddle
Ram.
Table.
Vertical milling head.
Head stock. [13]
Figure 25:

Column:
The column carries the spindle, the bearings, the gear box, the clutches, the shafts, the
pumps, and the shifting mechanisms for transmitting power from the electric motor to
the spindle at a selected speed.
Knee:
The knee mounted in front of the column. It is for supporting the table and to deliver
an up or down motion along the Z axis.

Saddle:
The saddle consists of two sideways, one on the top and one at the bottom located at
90 to each other, for providing motions in the X or Y axes by means of lead screws.

Table:
The table is mounted on top of the saddle and can be moved along the X axis. On top
of the table are some T-slots for the mounting of work piece or clamping fixtures.
Vertical milling head:
The milling head consisting the spindle, the motor, and the feed control unit is
mounted on a swivel base such that it can be set at any angle to the table.
Ram:
The ram on which the milling head is attached can be positioned forward and
backward along the sideway on the top of the column.

Head stock:
The Head stock is the main part of vertical milling which contains the gear mechanism
which are used to rotate the cutting tool of milling machine.
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Applications(Industrial) of Milling Machine.

Milling machines are widely used in the tool and die making industry.
Milling machines are commonly used in the manufacturing industry for the production
of a wide range of components as shown in figure 26. Typical examples are the milling
of flat surface, indexing, gear cutting, as well as the cutting of slots and key-ways.
Figure 26:
Cutting tools for Vertical Milling Machine.
End Mills:
Commonly used for facing, slotting and profile
milling.

End Mill.

Rough Cut End Mills:

For rapid metal removal.

Rough Cut End Mill.

Slot Drills:
For producing pockets without drilling a hole
beforehand.

Slot Drill.

Face Milling Cutter:

For heavy cutting of the material.
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Face milling cutter.

Types of collet chucks.

1). ER Collet Chuck.
The standard sizes are: ER-8, ER-11, ER-16, ER-20, ER-25, ER-32, ER-40, and ER-50.
One of ER-20 is following;
Figure 27:

2). R8 Collet Chuck.

Manufactured of hardened and ground tool steel, these collets can be recommended
for their accuracy and fine finish.
Figure 28:

3). 5C Collet Chuck.

This is a four-screw adjustment feature which allows accuracy. Adjustment to virtual
zero, eliminating any error in the collet. Used in main spindle and sub-spindle CNC chuck
applications. Accuracy guaranteed to .0002 TIR from rear and speeds up to 6000 rpm.
Figure 29:

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4). Auto lock Collet Chuck.
Figure 30:

5). Morse taper Collet Chuck.

Figure 31:

Observation for End milling operation.

The observations of end milling on Al-plate are as follows;
Work piece. ----- Aluminum plate.
Cutting Tool. ----- End milling cutting Tool.
RPM. (rev/min) L.C of cutting tool Depth of Cut. Purpose of
depth lever.(mm) (mm) experiment.
335 1/20 2.0 mm Slot making

Safety Instructions.
The Experiment will be stopped immediately if safety instructions are not properly
followed.
1. Eye protection is necessary for the students in the work area.
2. The sleeves must be folded above the elbow.
3. Lab coats are included in compulsory clothing, loose clothing especially for the female
students are not allowed.
4. Students must clean the equipment when experiment is completed with the cleaning
brush and tools must be placed back to the tool kit.
Comments:
1. All students should wear lab coats and safety goggles during their lab sessions. _____
2. All the tools should be placed at safe positions to avoid accidents. _______________
3. Before starting the end milling operation, try that your tool is not vibrating because it
can produce wear of tool and can cause an accident.