Bolt and Nut Lathe Machine

Objectives: i.

Methods of Lathe Machine and Milling Machine usage in manual

ii.

Analysis the components in the machines

iii.

The procedures of the machines usage

LATHE MACHINE Purpose : •

To rotate a part against a tool whose position it controls.

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Useful for fabricating parts and/or features that have a circular cross section. The spindle is the part of the lathe that rotates.

Workholding attachments : •

Chucks, collets, and face plate can be held in the spindle.

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The spindle is driven by an electric motor through a system of belt drives and/or gear trains.

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Spindle speed is controlled by varying the geometry of the drive train.

Tailstock : •

Can be used to support the end of the workpiece with a center, or …

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…to hold tools for drilling, reaming, threading, or cutting tapers.

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It can be adjusted in position along the ways to accommodate different length workpieces.

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PARTS OF LATHE MACHINE

• Bed : - Supports all major components of the lathe. 2

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Carriage: - Slides along the ways and consists of an assembly of the cross-slide, tool post and apron.

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Tool post: where cutting tools mounted

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Cross-slide: moves radially in and out, controlling the radial position of the cutting tool

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Apron: equipped with mechanisms for both manual & mechanized movement of the carriage and the cross-slide by means of the lead screw

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Headstock: - Fixed to the bed and is equipped with motors, pulleys and V-belts that supply power to spindle at various rotational speeds.

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Tailstock : - Can slide along the ways and be clamped at any position, supports the other end of workpiece.

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Tail center: - To hold the end of long pieces of workpiece.

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Feed rod & lead screw: - The feed rod is powered by a set of gears through the headstock. It rotates during the lathe operation and provide movement to the carriage and the cross-slide. Closing a half nut lever around the lead screw engages it with the carriage.

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Chuck: - To hold the workpiece.

WORKHOLDING DEVICES •

Workholding device is important, particularly in machine tools and machining operations

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Must hold workpiece securely

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One end of the workpiece is clamped to the spindle by the workholding device 3

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Types of workholding devices : Chuck, Collet, Face plate , Steady Rest, Follow Rest

1. Universal Chuck - 3 Jaw Chuck Use to hold a work piece which are cylinder or hexagon. For facing or center drilling the end of the work piece.

Shows 3 positions 3 jaw chuck hold a work piece. Be careful when use position (a) and (c) because the work piece can easily slip when machining at high feed rate and high depth of cut.

2.Independent chuck (4 jaw chuck) Can hold work piece more precise rather than 3 jaw chuck.

Shows 3 positions 4 jaw chuck hold a work piece. 3.Collet chuck Use to hold and machined small components

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Generally for workpiece with a maximum diameter of 25mm

Collet chuck

4. Steady rest 

Used to support a long workpiece which is 3 times its diameter. 

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To prevent workpiece from bending

5. Follow rest 

Suitable for small and long workpiece during parallel lathe machining

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To minimize flex under the pressure of the cutting tools

6. Face Plate 

Used for clamping irregularly shaped workpieces.

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The plates are round and have several slots and holes through which the workpiece is clamped.

TOOL BITS 6

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A piece of high-strength metal, usually steel, ground to make single-point cutting tools for metal-cutting operations.

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In lathe, it refers to a non-rotary cutting tool and also often referred to by the setphrase name of single-point cutting tool. The cutting edge is ground to suit a particular machining operation and may be sharpened or reshaped as needed. The ground tool bit is held rigidly by a tool holder while it is cutting.

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Cutting tools must be made of a material harder than the material which is to be cut, and the tool must be able to withstand the heat generated in the metal-cutting process.

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Standard And Various Shapes Of Tool Bit •

Facing tools are ground to provide clearance with a center.

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Roughing tools have a small side relief angle to leave more material to support the cutting edge during deep cuts.

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Finishing tools have a more rounded nose to provide a finer finish.

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Round nose tools are for lighter turning. They have no back or side rake to permit cutting in either direction.

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Left hand cutting tools are designed to cut best when traveling from left to right.

Various angle in a cutting tool have important functions in machining operation: 8

1. Rake angle: Control direction of chip flow and the strength of the tool tip. 2. Side rake angle: Control direction of chip flow. Angle typically about 5°. 3. Cutting-edge angle: Affects chip formation, tool strength, and cutting force to various degree. Angle typically about 15°. 4. Relief angle: Control interference and rubbing at the tool-work piece interface. If it too large, the tool tip may chip off, if it too small, flank wear may be excessive. Relief angle typically are 5°. 5. Nose radius: Affects surface finish and tool tip strength. The smaller the nose radius(sharp tool), the rougher the surface finish of the work piece and the lower the strength of the tool. How ever, long nose radius can lead to tool chatter.

TOOL BIT MATERIALS 1. Carbon steel •

Contain 0.9%-1.2% of carbon

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The oldest of tool material and widely use.

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Advantages: Cheap and easily shape and sharpened.

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Disadvantage: Do not have sufficient hot hardness and wear resistance for cutting at high speed when the temperature rises.

2. High-speed steel (HSS) •

Contain: Tungsten, chromium, cobalt, molybdenum.

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Use to machine at higher speed, and complex such as drilling.

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Advantage: High toughness, resistance to fracture. 9

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Disadvantage: Low hot hardness.

3. Stellite •

Contain 25%-35% chromium, 4%-25% Tungsten, 1%-3% carbon and the rest is cobalt.

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Use for roughing cuts at high feed and speed-twice the rates possible with HSS

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Advantage: high hardness, good wear resistance

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Disadvantage: not as tough as HSS and sensitive to impact forces.

4. Ceramic •

Consist of aluminium oxide.

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Moderately inexpensive

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Advantage: High hardness, high wear resistance, extremely resistant to heat, desirable in high speed applications.

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Do not need coolant during machining.

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Disadvantage: High fragility. Ceramics are considered unpredictable under unfavorable conditions. The most common ceramic materials are based on alumina (aluminium oxide), silicon nitride and silicon carbide. Used almost exclusively on turning tool bits. Hardness up to about HRC 93. Sharp cutting edges and positive rake angles are to be avoided.

5. Carbide •

2 major group of carbide (Tungsten Carbide and Titanium Carbide)

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Consist of 82% Carbide, 10% titanium and tungsten and 8% cobalt.

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Advantage: Very hard and can stand with high temperature 10

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Disadvantage: Low wear resistance

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Triple the rates possible with HSS (in term of cutting speed during machining)

6. Diamond •

Use for surface finish

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High accuracy machining(0.002-0.005 mm)

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Disadvantage: easy fracture low impact resistance.

LATHE MACHINE OPERATION •

Turning: To produce straight, conical, curve or groove work piece.

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Boring: To enlarge a hole or cylindrical cavity made by previous process or to produce circular internal grooves.

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Facing: To produce flat surface at the end of the part and perpendicular to its axis. Drilling: To produce a hole which may be followed by boring to improve its dimensional accuracy and surface finish.

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Knurling: To produce a regularly shaped roughness on cylindrical surface(making knobs)

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Tread cutting: To produce external/internal threads.

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Off-centre turning: To produce various axis symmetric shapes for functional or aesthetic purpose.

SAFE OPERATION PRACTICES To prevent risk of injury or even death, the following are some basic safety guidelines. They apply to lathes for both wood and metal, unless otherwise specified. When working on the lathe, always stand straight; never lean on the lathe or reach over the chuck when it is in operation. The area directly in front of and behind the workpiece is called the "red zone," because it is at greatest risk for projectile pieces. When turning the lathe on, try to avoid standing in the red zone, while keeping contact with the power switch in case the machine needs to be turned off. If the workpiece vibrates, this is an indication that the speed is too fast. Reduce the speed until the workpiece rotates steadily, without vibration. Threaded spindle noses should be used with caution, since rotating in the reverse direction can cause the chuck or driver plate to unscrew and detach. If working with wood, beginners should avoid material that has splits, knots, or heavy bark. Before sanding or polishing, remove the tool rest. Metal chips can be razor-sharp and should not be removed with hands. Instead, use pliers for long chips and a brush or vacuum for short chips. Compressed air should not be used to remove chips from the lathe, since it can blow the chips back into the users face. The lathe motor should always be turned off before adjusting the tool rest or any other parts, or before cleaning, lubricating, or measuring. Likewise, turn off the power and wait until the lathe comes to a full stop when mounting or removing accessories. Never leave a running lathe unattended. Power it off and wait until it has come to a full stop before leaving the work area. 12

Users should avoid operating the lathe when tired or under the influence of alcohol or drugs. Alertness is vital for safe lathe operation. Special Considerations for Metalworking Lathes: Filing Filing requires special attention, since the user needs to reach over the rotating workpiece. It is recommended that the file be gripped in the left hand, which is closest to the head stock. With the right hand, balance and guide the file.

A SAFE WORK ENVIRONMENT The working environment is also a factor in safe lathe operation. The floor should be free from grease, oil, shavings, and clutter, which can cause someone to slip or trip. There should be proper air ventilation and plenty of light. Keeping the lathe and its accessories in good shape is an important safety procedure. Check regularly for any damaged parts, misalignment, and wear on moving parts. Sharpen tools regularly, and avoid working with dull or makeshift tools.

CONCLUSION Lathes have been in use for millenia, used in the crafting of metal, wood, and other solid materials. They brace the working material lengthwise and rotate it at high speeds, allowing the user to perform various operations on it. Because of the nature of the machine, the lathe can present several serious risks. Anyone using a lathe is strongly advised to exercise caution, and first-time users should be particularly fastidious about safety. Before getting started, it is essential that users have a complete understanding of the machine and its tools, as well as its safe operation. There are basic steps to take prior to turning on the machine, such as ensuring all components are securely in position and that there are no loose parts that may fly off when the gears start moving. Protective gear is necessary to safeguard against dangerous debris, while certain clothing and items should not be worn as they may get caught in the machinery. There are a number of guidelines for operating the lathe safely; they should be reviewed in detail before beginning. Finally, maintaining a safe work environment helps reduce the risk of 13

accidents. By carefully reading a lathe’s owner manual and following advice from experienced professionals, first-time lathe users can safely enjoy the fruits of craftsmanship.

MILLING MACHINES Milling is the process of machining flat, curved, or irregular surfaces by feeding the workpiece against a rotating cutter containing a number of cutting edges. The usual Mill consists basically of a motor driven spindle, which mounts and revolves the milling cutter, and a reciprocating adjustable worktable, which mounts and feeds the workpiece. Milling machines are basically classified as vertical or horizontal. These machines are also classified as knee-type, ram-type, manufacturing or bed type, and planer-type. Most milling machines have self-contained electric drive motors, coolant systems, variable spindle speeds, and power-operated table feeds

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Diagram of typical "Bridgeport style" milling machine head TYPES OF MILLING MACHINES KNEE-TYPE Knee-type mills are characterized by a vertically adjustable worktable resting on a saddle which is supported by a knee. The knee is a massive casting that rides vertically on the milling machine column and can be clamped rigidly to the column in a position where the milling head and milling machine spindle are properly adjusted vertically for operation. The plain vertical machines are characterized by a spindle located vertically, parallel to the column face, and mounted in a sliding head that can be fed up and down by hand or power. Modern vertical milling machines are designed so the entire head can also swivel to permit working on angular surfaces. 15

The turret and swivel head assembly is designed for making precision cuts and can be swung 360° on its base. Angular cuts to the horizontal plane may be made with precision by setting the head at any required angle within a 180° arc. The plain horizontal milling machine's column contains the drive motor and gearing and a fixed position horizontal milling machine spindle. An adjustable overhead arm containing one or more arbor supports projects forward from the top of the column. The arm and arbor supports are used to stabilize long arbors. Supports can be moved along the overhead arm to support the arbor where support is desired depending on the position of the milling cutter or cutters. The milling machine's knee rides up or down the column on a rigid track. A heavy, vertical positioning screw beneath past the milling cutter. The milling machine is excellent for forming flat surfaces, cutting dovetails and keyways, forming and fluting milling cutters and reamers, cutting gears, and so forth. Many special operations can be performed with the attachments available for milling machine use. the knee is used for raising and lowering. The saddle rests upon the knee and supports the worktable. The saddle moves in and out on a dovetail to control cross feed of the worktable. The worktable traverses to the right or left upon the saddle for feeding the workpiece past the milling cutter. The table may be manually controlled or power fed.

UNIVERSAL HORIZONTAL MILLING MACHINE The basic difference between a universal horizontal milling machine and a plain horizontal milling machine is the addition of a table swivel housing between the table and the saddle of the universal machine. This permits the table to swing up to 45° in either direction for angular and helical milling operations. The universal machine can be fitted with various attachments such as the indexing fixture, rotary table, slotting and rack cutting attachments, and various special fixtures. RAM-TYPE MILLING MACHINE The ram-type milling machine is characterized by a spindle mounted to a movable housing on the column to permit positioning the milling cutter forward or rearward in a horizontal plane. 16

Two popular ram-type milling machines are the universal milling machine and the swivel cutter head ram-type milling machine. UNIVERSAL RAM-TYPE MILLING MACHINE The universal ram-type milling machine is similar to the universal horizontal milling machine, the difference being, as its name implies, the spindle is mounted on a ram or movable housing. SWIVEL CUTTER HEAD RAM-TYPE MILLING MACHINE The cutter head containing the milling machine spindle is attached to the ram. The cutter head can be swiveled from a vertical spindle position to a horizontal spindle position or can be fixed at any desired angular position between vertical and horizontal. The saddle and knee are hand driven for vertical and cross feed adjustment while the worktable can be either hand or power driven at the operator's choice.

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Basic milling machine configurations are shown in figure 1. There are several types of milling machines. One is called a vertical milling machine as shown in Figure 1. It has high flexibility and good handling, though it has lower processing speed than another type of the milling machines. In the milling macine, a rotating tool cuts a material. As the cutting tool, a drill or an endmill is used. The table of the milling machine can be adjusted accurately at the x- (side direction), y- (vertical direction) and z- (height direction) axises with operating handles as shown inthe above figure.

GENERAL MILLING OPERATION Setup The success of any milling operation depends, Before setting up a job, be sure that the to a great extent, upon judgment in setting up the job, workpiece, the table, the taper in the spindle, selecting the proper milling cutter, and holding the cutter by the best means under the circumstances Some fundamental practices have been proved by experience to be necessary for and the arbor or cutter shank are all clean and good results on all jobs. Some of these practices are mentioned below... 

Before setting up a job, be sure that the workpiece, table, the taper in the spindle, and the arbor or cutter shank are free from chips, nicks, or burrs.

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Do not select a milling cutter of larger diameter than is necessary.

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Check the machine to see if it is in good running order and properly lubricated, and that it moves freely, but not too freely in all directions.

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Consider direction of rotation. Many cutters can be reversed on the arbor, so be sure you know whether the spindle is to rotate clockwise or counterclockwise.

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Feed the workpiece in a direction opposite the rotation of the milling cutter (conventional milling). 18

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Do not change feeds or speeds while the milling machine is in operation.

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When using clamps to secure a workpiece, be sure that they are tight and that the piece is held so it will not spring or vibrate under cut.

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Use a recommended cutting oil liberally.

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Use good judgment and common sense in planning every job, and profit from previous mistakes.

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Set up every job as close to the milling machine spindle as circumstances will permit.

MILLING OPERATIONS Milling operations may be classified under four general headings as follows: 

Face milling. Machining flat surfaces which are at right angles to the axis of the cutter.

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Plain or slab milling. Machining flat surfaces which are parallel to the axis of the cutter.

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Angular milling. Machining flat surfaces which are at an inclination to the axis of the cutter.

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Form milling. Machining surfaces having an irregular outline.

SPECIAL OPERATIONS Explanatory names, such as sawing, slotting, gear cutting, and so forth have been given to special operations. Routing is a term applied to milling an irregular outline while controlling the workpiece movement by hand feed. Grooving reamers and taps is called fluting. Gang milling is the term applied to an operation in which two or more milling cutters are used together on one arbor. Straddle milling is the term given to an operation in which two milling cutters are used to straddle the workpiece and mill both sides at the same time. TOOLS AND EQUIPMENT: MILLING CUTTERS Classification of Milling Cutters Milling cutters are usually made of high-speed steel and are available in a great variety of shapes and sizes for various purposes. You should know the names of the most common 19

classifications of cutters, their uses, and, in a general way, the sizes best suited to the work at hand. Milling Cutter Nomenclature The figure shows two views of a common milling cutter with its parts and angles identified. These parts and angles in some form are common to all cutter types. 

The pitch refers to the angular distance between like or adjacent teeth.

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The pitch is determined by the number of teeth. The tooth face is the forward facing surface of the tooth that forms the cutting edge.

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The cutting edge is the angle on each tooth that performs the cutting.

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The land is the narrow surface behind the cutting edge on each tooth.

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The rake angle is the angle formed between the face of the tooth and the centerline of the cutter. The rake angle defines the cutting edge and provides a path for chips that are cut from the workpiece.

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The primary clearance angle is the angle of the land of each tooth measured from a line tangent to the centerline of the cutter at the cutting edge. This angle prevents each tooth from rubbing against the workpiece after it makes its cut.

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This angle defines the land of each tooth and provides additional clearance for passage of cutting oil and chips.

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The hole diameter determines the size of the arbor necessary to mount the milling cutter.

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Plain milling cutters that are more than 3/4 inch in width are usually made with spiral or helical teeth. A plain spiral-tooth milling cutter produces a better and smoother finish and requires less power to operate. A plain helical-tooth milling cutter is especially desirable when milling an uneven surface or one with holes in it.

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Types of Teeth The teeth of milling cutters may be made for right-hand or left-hand rotation, and with either right-hand or left-hand helix. Determine the hand of the cutter by looking at the face of the cutter when mounted on the spindle. A right-hand cutter must rotate counterclockwise; a lefthand cutter must rotate clockwise. The right-hand helix is shown by the flutes leading to the right; a left-hand helix is shown by the flutes leading to the left. The direction of the helix does not affect the cutting ability of the cutter, but take care to see that the direction of rotation is correct for the hand of the cutter.

LEFT AND RIGHT CUTTER

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Saw Teeth Saw teeth similar to those shown in Figure 8-3 (above) are either straight or helical in the smaller sizes of plain milling cutters, metal slitting saw milling cutters, and end milling cutters. The cutting edge is usually given about 5 degrees primary clearance. Sometimes the teeth are provided with off-set nicks which break up chips and make coarser feeds possible. Helical Milling Cutters The helical milling cutter is similar, to the plain milling cutter, but the teeth have a helix angle of 45° to 60°. The steep helix produces a shearing action that results in smooth, vibration-free cuts. They are available for arbor mounting, or with an integral shank with or without a pilot. This type of helical cutter is particularly useful for milling elongated slots and for light cuts on soft metal.

PLAIN AND HELICAL MILLING CUTTER Metal Slitting Saw Milling Cutter The metal slitting saw milling cutter is essentially a very thin plain milling cutter. It is ground slightly thinner toward the center to provide side clearance. These cutters are used for cutoff operations and for milling deep, narrow slots, and are made in widths from 1/32 to 3/16 inch. Side Milling Cutters Side milling cutters are essentially plain milling cutters with the addition of teeth on one or both sides. A plain side milling cutter has teeth on both sides and on the periphery. When teeth are added to one side only, the cutter is called a half-side milling cutter and is identified 22

as being either a right-hand or left-hand cutter. Side milling cutters are generally used for slotting and straddle milling. Interlocking tooth side milling cutters and staggered tooth side milling cutters are used for cutting relatively wide slots with accuracy. Interlocking tooth side milling cutters can be repeatedly sharpened without changing the width of the slot they will machine.

VARIOUS MILLING CUTTER After sharpening, a washer is placed between the two cutters to compensate for the ground off metal. The staggered tooth cutter is the most washer is placed between the two cutters to compensate for efficient type for milling slots where the depth exceeds the width. End Milling Cutters The end milling cutter, also called an end mill, has teeth on the end as well as the periphery. The smaller end milling cutters have shanks for chuck mounting or direct spindle mounting. End milling cutters may have straight or spiral flutes. Spiral flute end milling cutters are classified as left-hand or right-hand cutters depending on the direction of rotation of the flutes. If they are small cutters, they may have either a straight or tapered shank. The most common end milling cutter is the spiral flute cutter containing four flutes. Two-flute end milling cutters, sometimes referred to as two-lip end mill cutters, are used for milling slots and keyways where no drilled hole is provided for starting the cut. These cutters drill their own starting holes. Straight flute end milling cutters are generally used for milling both soft or tough materials, while spiral flute cutters are used mostly for cutting steel. Large end milling cutters (normally over 2 inches in diameter) (Figure 8-10) are called shell end mills and are recessed on the face to receive a screw or nut for mounting on a separate 23

shank or mounting on an arbor, like plain milling cutters. The teeth are usually helical and the cutter is used particularly for face milling operations requiring the facing of two surfaces at right angles to each other. SPEEDS FOR MILLING CUTTERS The speed of milling is the distance in FPM at which the circumference of the cutter passes over the work. The spindle RPM necessary to give a desired peripheral speed depends on the size of the milling cutter. The best speed is determined by the kind of material being cut and the size and type of cutter used, width and depth of cut, finish required, type of cutting fluid and method of application, and power and speed available are factors relating to cutter speed. FACTORS GOVERNING SPEED There are no hard and fast rules governing the speed of milling cutters; experience has shown that the following factors must be considered in regulating speed: 

A metal slitting saw milling cutter can be rotated faster than a plain milling cutter having a broad face.

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Cutters having undercut teeth (positive rake) cut more freely than those having radial teeth (without rake); hence, they may run at higher speeds.

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Angle cutters must be run at slower speeds than plain or side cutters.

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Cutters with inserted teeth generally will stand as much speed as a solid cutter.

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A sharp cutter may be operated at greater speeds than a dull one.

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A plentiful supply of cutting oil will permit the cutter to run at higher speeds than without cutting oil.

SELECTING PROPER CUTTING SPEEDS The approximate values given in Table 8-1 in Appendix A may be used as a guide for selecting the proper cutting speed. If the operator finds that the machine, the milling cutter, or the workpiece cannot be handled suitably at these speeds, immediate readjustments should be made.

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Table 8-1 lists speeds for high-speed steel milling cutters. If carbon steel cutters are used, the speed should be about one-half the recommended speed in the table. If carbide-tipped cutters are used, the speed can be doubled. If a plentiful supply of cutting oil is applied to the milling cutter and the workpiece, speeds can be increased 50 to 100 percent. For roughing cuts, a moderate speed and coarse feed often give best results; for finishing cuts, the best practice is to reverse these conditions, using a higher speed and lighter feed. SPEED COMPUTATION The formula for calculating spindle speed in revolutions per minute is as follows:

Where RPM = Spindle speed (in revolutions per minute). CS = cutting speed of milling cutter (in SFPM) D = diameter of milling cutter (in inches) For example, the spindle speed for machining a piece of steel at a speed of 35 SFPM with a cutter 2 inches in diameter is calculated as follows:

Therefore, the milling machine spindle would be set for as near 70 RPM as possible. Table 8-2 in Appendix A is provided to facilitate spindle speed computations for standard cutting speeds and standard milling cutters. FEEDS FOR MILLING The rate of feed, or the speed at which the workpiece passes the cutter, determines the time required for cutting a job. In selecting the feed. there are several factors which should be considered. Forces are exerted against the workpiece, the cutter, and their holding devices during the cutting process. The force exerted varies directly with the amount of feed and depth of cut, 25

and in turn are dependent upon the rigidity and power of the machine. Milling machines are limited by the power they can develop to turn the cutter and the amount of vibration they can resist when using coarse feeds and deep cuts. The feed and depth of the cut also depend upon the type of milling cutter being used. For example, deep cuts or coarse feeds should not be attempted when using a small diameter end milling cutter. Coarse cutters with strong cutting teeth can be fed at a faster rate because the chips may be washed out more easily by the cutting oil. Coarse feeds and deep cuts should not be used on a frail workpiece if the piece is mounted in such a way that its holding device is not able to prevent springing or bending. Experience and judgment are extremely valuable in selecting the correct milling feeds. Even though suggested rate tables are given. remember that these are suggestions only. Feeds are governed by many variable factors, such as the degree of finish required. Using a coarse feed, the metal is removed more rapidly but the appearance and accuracy of the surface produced may not reach the standard desired for the finished product. Because of this fact, finer feeds and increased speeds are used for finer, more accurate finishes, while for roughing, to use a comparatively low speed and heavy feed. More mistakes are made on overspeeding and underfeeding than on underspeeding and overfeeding. Overspeeding may be detected by the occurrence of a squeaking, scraping sound. If vibration (referred to as chattering) occurs in the milling machine during the cutting process, the speed should be reduced and the feed increased. Too much cutter clearance, a poorly supported workpiece, or a badly worn machine gear are common causes of chattering. Direction of Feed It is usually regarded as standard practice to feed the workpicce against the milling cutter. When the workpiece is fed against the milling cutter, the teeth cut under any scale on the workpiece surface and any backlash in the feed screw is taken up by the force of the cut.

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Direction of feed As an exception to this recommendation, it is advisable to feed with the milling cutter when cutting off stock or when milling comparatively deep or long slots. The direction of cutter rotation is related to the manner in which the workpiece is held. The cutter should rotate so that the piece springs away from the cutter; then there will be no tendency for the force of the cut to loosen the piece. No milling cutter should ever be rotated backward; this will break the teeth. If it is necessary to stop the machine during a finishing cut, the power feed should never be thrown out, nor should the workpiece be fed back under the cutter unless the cutter is stopped or the workpiece lowered. Never change feeds while the cutter is rotating.

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Fig.2, Handles of a Milling Machine

Fig.1, Milling Machine

ACCESSORIES OF MILLING MACHINE There are several accessories for the milling process except the cutting tools. Following accessoriess are very useful. Vise A vise is used for fixing of the material, and it is fixed to the table of the milling machine firmly. In the case of the cutting of a largesized material, the vise can be remived from the table. But when the vise is installed again, it has to be fix accurately in the x-axis. We should not remove the vise except unavoidable cases.

Fig.3, Vise

Digital Scale The table of the milling machine can be adjusted accurately at the x-, y- and z- axises. We can adjust the positions with seeing the scales on the operating handles. Moreover, if a digital scales as shown in Figure 4 is set, it is efficient that we operate with seeing the values of the digital scale. The digital scale indicates Fig.4, Digital Scale with the minimum unit of 5/1000 mm of x28

and y- axises. Point Master In order to get a high accurate processing, the zero point must be adjusted exactly. A point master as shown in Figure 5 is the convenient tool for the adjustment. LEDs of the point master light when the point touches a metal material including the vise. We can find the zero point easily with this tool.

Fig.5, Point Master

MECHANICAL PARTS MADE BY A MILLING MACHINE The parts of various form can be made from using the milling machine. Mechanical parts made by the milling machine are introduced in followings.

Fig.6, A Part of a Fish Robot

Fig.7, Backbone of a Fish Robot

This is the part used for the power unit of a

Some parts manufactured using the milling

fish robot, UPF-2001. Its complicated form

machine are put together. Almost all parts

is made using an endmill.

are the simple form near a rectangular parallelepiped.

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(a) Connecting Rods

(b) A Drive Mechanism of a Stirling Engine

Fig.8, Connecting Rods of a Stirling Engine These are connecting rods of a 50 W Class Stirling engine, Mini-Ecoboy. Since the thickness of parts is quite thin, the fixation to the table is difficult, and it is hard to manufacture. And since it was the parts which need remarkable accuracy, we had to be careful in the processing.

SAFETY RULES FOR MILLING MACHINES Milling machines require special safety precautions while being used. These are in addition to those safety precautions as described. 

Do not make contact with the revolving cutter.

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Place a wooden pad or suitable cover over the table surface to protect it from possible damage.

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Use the buddy system when moving heavy attachments.

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Do not attempt to tighten arbor nuts using machine power.

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When installing or removing milling cutters, always hold them with a rag to prevent cutting your hands.

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While setting up work, install the cutter last to avoid being cut.

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Never adjust the workpiece or work mounting devices when the machine is operating.

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Chips should be removed from the workpiece with an appropriate rake and a brush.

NOTE Chip rake should be fabricated to the size of the T-slots. 

Shut the machine off before making any adjustments or measurements.

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When using cutting oil, prevent splashing by using appropriate splash guards. Cutting oil on the floor can cause a slippery condition that could result in operator injury

Figure: Chip Rake

CONCLUSION Milling cutters play an important role in performing milling machine operations. We can know which cutter to select and use for a specific operation or determine the overall quality of the final product. The knowledge gained in this task during the workshop practice will assist us in determining the type of cutter(s) to employ for a specific operation, to include the nomenclature, selection, use and care of milling cutters when tasked to perform milling machine operations. All extra precautions measures should be taken before and while conducting the milling machines.

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REFERENCES 1. http://www.powershow.com/view/13f25bNTMyZ/MILLING_powerpoint_ppt_presentati on/ accessed on 6 March 2015. 2. https://www.google.com.my/search? q=milling+machine+parts+and+functions+ppt&espv=2&biw=1440&bih=785&tbm=isch &tbo=u&source=univ&sa=X&ei=5LkMVdHYFI2jugT00YCwDQ&ved=0CC4QsAQ&d pr=1 accessed on 6 March 2015. 3. http://www.ebay.com/gds/Important-Safety-Tips-for-First-Time-LatheUsers-/10000000177630397/g.html accessed on 6 March 2015. 4. http://www.slideshare.net/muhammadabidibrahim/report-for-milling-project accessed on 6 March 2015. 5. http://armyordnance.tpub.com/od16448/od164480075.htm accessed on 6 March 2015.

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APPENDICES Tool life As a general rule the relationship between the tool life and cutting speed is VTn = C where; V = cutting speed in m/min T = tool life in min C = a constant For high-speed steel tools the value of C ranges from 0.14 to 0.1 and for carbide tools the value would be 0.2. Characteristics of Tool Material For efficient cutting a tool must have the following properties: Hot Hardness This means the ability to retain its hardness at high temperatures. All cutting operations generate heat, which will affect the tool¡¦s hardness and eventually its ability to cut. Strength and Resistance to Shock At the start of a cut the first bite of the tool into the work results in considerable shock loading on the tool. It must obviously be strong enough to withstand it. Low Coefficient of Friction The tool rubbing against the workpiece and the chip rubbing on the top face of the tool produce heat which must be kept to a minimum. Rake Angle Rake angle is the angle between the top face of the tool and the normal to the work surface at the cutting edge. In general, the larger the rake angle, the smaller the cutting force on the tool. A large rake angle will improve cutting action, but would lead to early tool failure, since the tool wedge angle is relatively weak. A compromise must therefore be made between adequate strength and good cutting action. Metal Being Cut

Cast Iron

Hard Steel / 33

Medium

Mild Steel

Aluminium

Top Rake Angle

0°

Brass

Carbon Steel

8°

14°

Typical value for top rake angle

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20°

40°