Basic Mill Laboratory Manual

GNG2101 – Intro. to Product Dev. and Mgmt. for Engineers

Objective
The goal of the lab is to gain proficiency in the mill and understand basic subtractive milling
operations.

Background
When performing any kind of machining process where you are removing material the speed at
which you remove that material is of utmost importance. End mills, drill-bits and other cutter-
based tools are only made to withstand certain cutting conditions. As such it is critical for the life
of the tool and the efficiency of the machining process that the tools are run within their working
parameters.

Milling Machine
The milling machine is a machine that allows geometric shapes to be machined and created. They
come in two basic formats – horizontal and vertical. The workpiece is clamped or held in a work
holding device fastened to a movable table while a rotating cutter removes material from the
workpiece.

Some of the key parameters of a milling machine include its table size, table travel (X, Y, Z),
maximum distance from the quill to the table, the motor power, the speed range of the spindle, the
method of spindle speed change (Variable, belts, gear head), power requirements, feed rate range,
spindle taper, and HP. [May be better in a table]

The mills can be fitted with a variety of accessories and tools to enable them to perform a wide
range of operations. Some of these include rotary tables (to mill arcs, drill bolts circle hole patterns,
and perform indexing operations etc.), boring heads, tapping heads, Digital Readouts (DROs), drill
chucks, vises, as well as many others.

The main variables to consider when milling are:

● The tool step over – Percentage of the tool’s diameter you’re cutting with
● The type of material – For specific properties and tool selection
● The coolant selected – Specific to the type of material and tool
● Machine and work-holding – Setup rigidity
● Tool Type and Material

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Cutting Speed
Considering these factors, there is still a level of understanding that is required before the correct
values can be found. This comes with experience, however there is a simple equation that may be
used as a starting guideline for the correct rotation speed of the cutter (mill) or rotational speed of
the workpiece (lathe).

RPM =4×CS/Dia.
Examples:
Milling with a 1/2” endmill in steel Fly-cutting a surface on aluminium with a
cemented carbide tool
CS (steel) = 80 SFPM CS (aluminium) = 300 SFPM
Cutter Dia. = ½” Cutter Dia. = 3”
RPM = 4 x CS/DIA. RPM = 4 x CS/DIA
= 4 x 80/.5 = 4 x 300/3
= 640 RPM = 400 RPM

Figure 1 : Vertical Mill (found in MTC)

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 Figure 2 : Mill Head

Figure 3 : Bridgeport Style Mill (found in Brunsfield)

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 Figure 4 : Bridgeport Mill Head

Terminology
Backlash: Backlash is a term used to identify the space of no contact on a gear train when
switching from reverse to forward. As a general rule the more backlash a system the harder it is to
control the precision of the instrument and therefore is something to be avoided.

Chatter: Chatter occurs when the tool bit or the workpiece is vibrating during machining leaving
a patterned finish rather than a smooth finish and making a loud “chattering” noise. The simplest
and, usually, the most effective way to remove chatter is to make the tool clamping or piece
clamping more rigid to try and mitigate vibration. Chatter is bad because the constant vibration of
the tool will significantly decrease tool life as well as affect the overall precision of the work.

Coolant: Coolant is a liquid that is applied either as a light mist or a flow of liquid at the area of
contact between the tool bit and the piece. It performs several functions, the primary function being
to dissipate the heat generated from the cutting. Coolant also cools the workpiece and provides
lubrication during cutting to reduce tool wear. Coolant is not required on all materials and the type
of coolant varies depending on the material being machined. It can produce a better surface finish
on some materials.

Possible Milling Operations

Facing Cut: A facing cut is a cut with a small depth of cut in order to true up a face of the
workpiece that is perpendicular to the cutter axis.

Boring: Boring is an internal cut that hollows out the end of the workpiece and can be a very
precise cut.

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Drilling: Drilling is done by using a drill bit held in a drill chuck inserted into the spindle of the
mill to make a circular hole.

Side milling: This type of cut produces a flat vertical surface in the part.

Grooving: This type of cut leaves a groove in the part.

Slotting: An endmill can be used to plunge and move in any direction creating a slot into the
workpiece.

Tapping: A mill can be used to cut internal threads into a workpiece either with manual drive or
a tapping head.

Apparatus and Equipment Overview

The following equipment and materials will be used:
● 1 x mill
● 1 x mill accessories
● 1 x polycarbonate stock

Pre-Lab Preparation
Before arriving at the lab, students should review the lab manual and familiarize themselves with
the lab set up and procedures. Students need to complete a computer simulation from
https://makerepo.com/jboud030/654.fraiseuse-virtuelle-virtual-mill before the lab.

Review Questions
Name 2 operations on a mill.

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How many axes does the vertical mill have?

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What is the RPM you should use for a 5/8in end mill with brass?

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______________________________________________________________________________

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Coolant is used for what purpose?

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What is chatter?

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General Rules and Safety

1. Following the completion of basic training, students will be permitted to use the
Brunsfield Centre’s workshop, and only those whom have already completed basic
training will have access. Basic training will however grant limited access to the space as
students will not have access to the mill, lathe, and welding area without having
completed subsequent trainings for the respective equipment.
2. It is important to never work alone in the shop and to always have a supervisor on duty in
the space. If working alone there is no one to help in the case of an accident or injury
which makes it very dangerous.
3. Safety glasses must always be worn within the workshop. Safety glasses must be worn
even if a face shield or welding helmet is being used overtop of them. Never approach
anyone actively working the workshop without wearing safety glasses.
4. Proper footwear must be worn when working in the workshop to avoid hazardous
situations (e.g. sparks, sharp metal, hot chips from operations) where the inappropriate
footwear would cause greater levels of risk/harm. Closed-toed shoes must be worn. Not
flip flops, crocs, mesh-toed running shoes and/or similar style or type of footwear. Steel-
toed or similar footwear is recommended when working on larger, heavier projects.
5. Clothing that is long, baggy and/or loose must be rolled up. Strings on the front of a
hoodie and hanging jewelry must be tucked under a shirt or taken off. Rings must not be
worn inside of the machine shop. Long hair must also be tied back and up. These rules
are in place to avoid the danger of having machinery grab and pull you into them causing
severe harm.
6. No food or drink should be brought into the workshop. There are many chemicals,
coolants and other contaminants that can be harmful if ingested.
7. The Brunsfield centre is a serious workspace and must be treated as one. Pranks, rough-
housing, and general fooling around while within the workshop will not be tolerated. Any
behavior deemed unprofessional by a supervisor will be met with an immediate
suspension of shop privileges.

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8. All persons within the MTC and Brunsfield Centre must always be of good health both
physically and mentally as well as not being under the influence of any drugs and or
alcohol.
9. A first aid kit is located within the Brunsfield office (Room A139). Any injury severe or
small should be reported to a supervisor and an incident report should be filled. In the
case a supervisor is not present, contact the nearest designated first aider (a list of first
aiders can be found on the main door).
10. An emergency spill kit is available in the Brunsfield Centre. The spill kit can be used to
clean and or contain hazardous materials that get spilled in the shop. A supervisor must
be advised whenever the spill kit is used.
11. There are fire extinguishers and emergency stops located throughout the Brunsfield
Centre. There is one fire extinguisher located at each of the main entrance doors, and one
near the designated welding area. There are three emergency stops located at the main
entrances and in the office. Students should be familiar with the location of each fire
extinguisher. If an individual is not familiar with these locations, they should request the
information from a supervisor their first time in the workshop.
12. Students are responsible for knowing their own limited knowledge of facilities and
equipment, and to ask for assistance from a supervisor when encountering any unfamiliar
equipment or processes (i.e. if you’re not sure: Ask). Supervisors are there to help with
any matter pertaining to the workshop and would much rather take the time to explain
something many times then having someone get injured or equipment break because of
improper use of the space.
13. Before working with unfamiliar materials and chemicals, become familiar with the
product’s handling procedures. MSDS (Material Safety Data Sheets) info can be
obtained by using the Google search engine and typing “MSDS” followed by the product
name and/or asking a supervisor to see the MSDS.
14. Students as well as supervisors are entitled to a safe working environment. Safety is
everyone’s responsibility, thus anyone witnessing any unsafe behavior or working
practices must advise a supervisor immediately.
15. Any damaged equipment must be reported to a supervisor immediately to ensure shop
safety and that the issue related to the equipment is correctly addressed. A supervisor
must also be notified in the case of a broken tool to ensure that the tool was being used
properly as to avoid damage to future tools.
16. Students are responsible for keeping the workshop clean and tidy. It is required that
students clean up any work areas or machines that have been used after you have
finished. The floor must be kept free of debris and tripping hazards. All tools must be put
back in their proper places after use. Unplug all power tools while not in use.

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Procedure
1. Each group of two students will get a polycarbonate block.
2. Follow the instructor's instructions to produce the following part.
a. Start by squaring the stock.
b. Bring the stock to dimension for the length and height.
c. Drill the 2 small holes in the thinnest part of the material.
d. Drill the 2 large holes in the face of the part.

Figure 5 : Drawing of the milled part

3. Take a picture of the part for your submission.

Submission
Submit the picture by uploading it to Brightspace before the due date for your lab. All uploaded
components should be submitted as a single submission with multiple uploads, rather than separate
submissions.