Lab Report 1 - Milling

ETAC LABORATORY MANUAL
FACULTY OF
ENGINEERING AND TECHNOLOGY
DEPARTMENT OF MECHANICAL ENGINEERING
BGMC1513
Workshop and CNC Technologies
Name : Yoo Houng

How Man Kien
Lee Yi Heng
Haw CongTing
Kho Xuan Han
Programme : RMH – Bachelor of Mechatronics Engineering

with Honours
Year : Year 1 Semester 2
Lab A2 : Milling
Objectives:
1. To produce a workpart using a milling operation.
Theory:
Milling is a machining operation in which work is fed past a rotating tool with multiple
cutting edges. Its axis of tool rotation is perpendicular to the feed and its cutting tool is
called a milling cutter with a cutting edge called teeth. The milling machine has a
characteristic of interrupted cutting operation and the basic milling operation creates a
planar surface, while other geometries are possible. The 2 forms of milling operation are
characterised by horizontal (peripheral) and vertical (face) milling.
The milling cutter basically consists of shank and flute with the cutting edge called as
teeth. The size of the milling cutter usually is 75mm – 250mm while the diameter of it can
be 40mm – 170mm. The milling action can be controlled in three axis which are x, y, and
z. [5]
Apparatus:
1. Milling machine
2. Vernier calliper
3. Aluminium blocks
4. Metal files
Procedures:
1. Select a piece of material with the suitable dimension.
2. Set the material on the milling machine.
3. Operate the milling machine and perform the milling operation according to the
drawing dimension in Figure 1.0.
4. Guidance and supervision are provided by the laboratory technician.
5. Follow the instructions given properly when performing the milling process.
6. Inspect quality of the part after milling and perform measurement on the sample.
7. Labelled the sample by your programme and tutorial and laboratory group number.
8. Take a picture of the completed samples and submit your work sample.
Appendix :
Figure 1.0
Workflow :
1. The aluminium block is measured with vernier calliper as illustrated in Figure

2.0. Note that all the measurements are taken in millimetres.
Figure 2.0 – Initial dimension of aluminium block.
2. To standardise the board such that the dimensions are 50x50x65 (mm), the aluminium
block was prepared to be machined by a milling machine (Figure 3.0).
Figure 3.0 – Milling machine.
3. The aluminium block was held securely by the holder.
4. The handles at the side of the milling machine were turned to adjust the position of
the block such that it touches the teeth of the steel screw.
5. The z-axis was lowered by 1mm by reading the scale presented at the handle
Figure 4.0 – Reading the scale from the z-axis for better accuracy.
6. The milling machine was turned on by turning the emergency stop button
and pressing the start button.
7. The x-axis was adjusted slowly by activating the rotator, allowing the steel screw
to cut the block uniformly.
Figure 5.0 - Group member Yi Heng is adjusting the x-axis by the rotator.
8. After a clean stroke, the y-axis was adjusted to allow the steel screw to move in
a back-and-forth motion. Repeat the process until the whole surface is machined.
Figure 6.0 – Aluminium block was machined one stroke at a time.
9. The side of the machined surface was filed until smooth.
Figure 7.0 – Group member Yi Heng is filing the rough sides of the block after
machining.
10. Repeat the steps from step 3 such that all three sides were processed accordingly.
11. The aluminium block was measured with a vernier calliper to ensure its dimensions.
Figure 8.0 – Dimensions of the block after the first phase of machining.
12. The aluminium block was prepared to be machined to be as illustrated in Figure 9.0.
Figure 9.0 – The green part of the block was to be removed

13. The block was to be machined with a similar technique from steps 3 to 10.
14. To machine the centre of the block, scaling from the x-axis was to be measured
by a computer-assisted panel for 17mm.
Figure 10.0 – The x and y-axis were reset to zero and adjusted accordingly by
group member Cong Ting.
15. The final product as illustrated below.
Figure 11.0 Top view Figure 12.0 Bottom view

Discussion:
1. Overall,the aluminium block was milled into the desired shape and dimensions.
Although there were some flaws in the dimensions, the block still turned out decent.
Especially after filing the milled surfaces, the block ended up being smooth with even
cutting as observed with the naked eye.
2. Ensure that the milling machine is turned off when not operating.
3. The steel screw would keep spinning after pressing the stop button. The spindle brake
must be pressed to stop the screw from continuing to spin.(2)
4. While measuring the object at the beginning of the preparation, the scale reading is
the most crucial component of the whole measurement phase. The vernier calliper is
checked to ensure that there is no zero error so that it will give a correct reading.(3)
Figure 12.0 – The structure of a vernier calliper.(4)
Figure 13.0 – Group member Man Kien measured the object by using the vernier
calliper.
5. When the machined object is too short, there may be a risk for the steel screw to
damage the holder. To prevent that, additional support is added below the object to
increase the height. Stability must be secured while using this technique.
Figure 14.0 – Additional support added to increase the height of the aluminium
block.
6. There was a slight offset while machining the centre trough of the block. This is
because the systematic error was not accounted for.
Figure 15.0 – The centre trough is slightly off-centred.

7. Aluminium scraps would tend to pile up while machining. Sweep them periodically
with a brush for the best results.
Figure 16.0 – Aluminium scraps piling up while machining.
Figure 17.0 – A proper brush to clean up the aluminium scraps.
8. Make sure to always clean up the surroundings after finishing using the milling
machine to keep the lab room clean and tidy.
Figure 18.0 – Group member Yoo Houng was cleaning the surrounding
area.
Figure 19.0 – Group member Xuan Han was cleaning the milling machine.
Conclusion:
In conclusion from this experiment, we learned the principle of the milling machine and
the way to use a vernier calliper. We gained a better understanding of the modes of operating
the milling machine and the importance of teamwork while carrying out the experiment.
In addition, we also learned the purpose of the main parts of the machine. Besides that,
we gained the knowledge of understanding their usage and function where it can produce
different shapes and depth of the milling surface.(1) Lastly, all safety precautions should be
taken seriously with clear explanations and regulations from the instructor and lecturer while
carrying out the milling process.
Figure 20.0 – Group members are discussing the steps to carry out the milling process.
Reference:
1. Smith, S. and Tlusty, J., 1991. An overview of modeling and simulation of the milling
process.
2. Martellotti, M.E., 1941. An analysis of the milling process. Transactions of the

American Society of Mechanical Engineers, 63(8), pp.677-695.
3. Sharma, S., Thakur, S.L., Joshi, S.K. and Kulkarni, S.S., 2014. Measurement of gingival
thickness using digital vernier caliper and ultrasonographic method: a comparative
study. Journal of investigative and clinical dentistry, 5(2), pp.138-143.
4. Adda247,2020 vernier calliper. Milling process, a vernier calliper calibration.
5. 1. Cincinnati, O., Cincinnati Milling Machine Company (1922) A treatise on milling

and milling machines.

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ETAC LABORATORY MANUAL

DEPARTMENT OF MECHANICAL ENGINEERING

Name : Yoo Houng

Programme : RMH – Bachelor of Mechatronics Engineering

1. To produce a workpart using a milling operation.

1. Select a piece of material with the suitable dimension.

2. Set the material on the milling machine.

4. Guidance and supervision are provided by the laboratory technician.

1. The aluminium block is measured with vernier calliper as illustrated in Figure

Figure 2.0 – Initial dimension of aluminium block.

3. The aluminium block was held securely by the holder.

Figure 6.0 – Aluminium block was machined one stroke at a time.

9. The side of the machined surface was filed until smooth.

Figure 9.0 – The green part of the block was to be removed

15. The final product as illustrated below.

Figure 11.0 Top view Figure 12.0 Bottom view

Figure 12.0 – The structure of a vernier calliper.(4)

Figure 15.0 – The centre trough is slightly off-centred.

Figure 16.0 – Aluminium scraps piling up while machining.

Figure 17.0 – A proper brush to clean up the aluminium scraps.

2. Martellotti, M.E., 1941. An analysis of the milling process. Transactions of the

4. Adda247,2020 vernier calliper. Milling process, a vernier calliper calibration.

5. 1. Cincinnati, O., Cincinnati Milling Machine Company (1922) A treatise on milling

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