MEB1033: Manufacturing Technology 1

Workshop Practical Manual

Year 2025

Student Name: Student ID:

Lab Work
Actual Group Attendance
Date Manual Piece
Number (Technician’s Stamp)
Marks Marks
Welding
CNC Lathe
Metrology
Conventional Lathe
Conventional Milling
EDM

……………………...CUT THIS SECTION…………………....

LAB SESSION:
STUDENT INITIAL
NAME MATRIX NO

SUBMISSION DATE / TIME: STAFF INITIAL:

AM / PM
REMARKS
 SAFETY AGREEMENT

I, named as below, fully understand all the regulations pertaining to the

Health, Safety and Environment in the laboratory as listed in Appendix of
this manual, and therefore shall abide and follow all the rules and
instructions.

Name :
IC/Passport No:
Date :
1. Conventional Milling

1.1 Objective: To perform milling processes on a rectangular work piece

according to specifications given in a technical drawing.

1.2 Workshop Outcomes

At the end of this workshop, students should be able to:
1. Explain the components of conventional milling machines.
2. Generate a milling process plan based on an end product.
3. Use a milling machine in the appropriate manner and according to
relevant safety standards.

1.3 Machine Specifications

• Distance between spindle axis and table working surface:
• 30mm – 440mm
• Distance between body vertical guides and table body:
• 218mm – 469mm
• Table working surface: 300 mm x 1250 mm
• Table swivel: 45o
• Feed: Normal – longitudinal 12.5 – 630 mm/min
Transversal 12.5 – 630 mm/min
Vertical 5.2 – 262 mm/min
• Main drive: 40 – 2000 RPM
• Main drive motor: 5.5 kW, 1440 RPM
• Feed drive motor: 1.5 kW, 920 RPM

1.4 Refer to Appendix A for procedures and machine operation details. For
full operations manual, consult lab technicians and equipment manual.

1.5 Safety Instructions:

• Never operate the machine without wearing the correct protective
clothing, (i.e. safety shoes, safety glasses, overalls – do not wear
loose clothing, do not wear jewelry).
• Make sure the machine is suitably positioned and that the
surrounding floor area is kept clean and free from scrap material,
oil and grease.
• Always concentrate on your work – careless acts can result in
serious injury.
• Persons not involved in machine operation should be kept at a safe
distance.
• Do not engage in the machine’s main drive with a loose work piece
or cutting tool.
• Do not attempt to adjust or remove tools when the machine is in
operation.
• Always use protective screen when working with the vertical milling
head
• Ensure that the cutting tools are suitable and in good working
order. 3
1.6 Milling Introduction

Milling is the process of machining flat, curved, or irregular surfaces by

feeding the work piece against a rotating cutter containing a number of
cutting edges. The usual Mill consists basically of a motor driven spindle,
which mounts and revolves in the milling cutter, and a reciprocating
adjustable worktable, which mounts and feeds the work piece.

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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1.7 Milling Process Procedure

1.7.1 Surface Milling

A) Marking ? mm
Using vernier caliper & height gauge
> Measure the initial metal block.
> Measure & mark the desired measurement.

B) Set up the workpiece ? mm ? mm

> Put workpiece on vice.
> Use parallel bar to raise the work piece.
> Secure the work piece and tighten the vise using mallet hammer.

C) Surface Milling Process

> On machine
> Move the face mill cutter slowly touch the material surface.
> Move the face mill cutter away.
> Turn the handwheel quill to raise 0.2 mm per cut.
> Mill the workpiece surface until desired measurement is achieved.
> Once finished, move away the tool from workpieces.
> Off tool
> Unclamped the workpiece.
> Remove sharp edge using filing tool.

1.7.2 Slotting

A) Marking
Using marking tool & height gauge:
> Mark the center of the work
piece (this acts as datum/center point)
> Mark the slot distance

B) Set up the workpiece

> Put workpiece on vice.
> Use parallel bar to raise the work piece.
> Secure the work piece by tightening the vise.

C) Slotting & Finish

> Move the tooling to the center datum back & forth one time.
> Increase handwheel quill to 0.2 mm per cut.
> Mill the workpiece.
> Once finished, move away the tool from workpieces.
> Off tool & unclamp the workpiece.
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 1.8 Project Report: Conventional Milling

A. Sketch the conventional milling machine, label the major components and
state the functions of these components.

No Component Function
1.
Cutting Tool To remove material from a workpiece

2.
Vise To securely hold the workpiece in place during machining operations

Table To secure and position the workpiece for machining, allowing precise movement along the
3.
x,y, and z axes
4.
Base To act as a foundation and support for all the components in the machine

X-Saddle Enables the table to move back and forth in the X-axis direction
5.

6.
Y-Saddle Enables the table to move side to side in the Y-axis direction

7.
Z-Saddle Enables the table to move up and down in the Z-axis direction

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B. Sketch all the tools used during the milling process and state
the functions.

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 C. Summarize the process plan for machining the part.

Operation Sheet
Part Name:
Spindle Feed
Op Machine Cutting Cutting Depth of
Operation Speed (Manual Remarks
no. tool tool Speed (RPM) / Auto) Cut (DOC)
1. Surface Milling Horizontal Face Mill Semi Auto 0.2mm -
Mill
125 500

2. Slotting Vertical End Mill Manual 0.2mm -

Milling
125 500

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 D. Results

Initial metal block measurements Final metal block measurements

(Sketch & Label) (Sketch & Label)

• Measurements shall be in mm

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E. Discussion
1. What is the difference between tool bit used in universal milling and
vertical turret milling and it’s used on the workpiece?
2. How does different axis benefit the product design?
3. What is the accuracy / tolerance of the machine? How does accuracy
affect the cutting process?

1. Universal milling machines can handle both horizontal and vertical milling, while
turret mills are specifically vertical, using tools like end mills and face mills for various
operations.
2. Different axis means a lot more movement in different orientations, thus providing a
flexible cutting angle for the machine to build more complex shape or design of the
product
3. From the experiment, the tolerance of the Milling Machine is 0.1-0.2 mm. The
accuracy is greatly affecting the cutting process by influencing the surface finish of
the products, efficiency of the machine and ensuring a precise dimension of the
product.

F. Conclusion
Short conclusion on the overall understanding of the laboratory done and
improvement that can be made for future to increase the students understanding on
the machine.

The laboratory session provided students with a fundamental understanding

of the milling machine, including its operation, tooling, and safety
procedures. Hands-on experience helped reinforce theoretical concepts and
develop essential machining skills

To further enhance students' comprehension, future improvements could

include a detailed explanation on how the machine is used in industry
nowadays. But overall, the session provided was perfect and well understood
by us students.

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