This document provides information about milling machines and various milling experiments conducted using a horizontal milling machine. It begins with an introduction to milling machines, describing their versatility and various milling processes. It then describes the different types of milling machines and cutting tools used. Several experiments are outlined demonstrating how to use a dividing head to mill different numbers of sides on a workpiece, cut spur gears, and cut spline lugs. Calculations for determining indexing ratios and selecting dividing plates are provided. The document concludes with references used.

1. 1
Workshop Report
MILLING MACHINE
Prepared by :
Khogr Kamal Ibrahim
Stage : 3rd
Mechanical Engineering

2. 2
✓ Milling Introduction
Milling machine is one of the most versatile conventional machine tools with a wide range of metal
cutting capability. Many complicated operations such as indexing, gang milling, and straddle milling etc.
can be carried out on a milling machine.
This training module is intended to give you a good appreciation on the type of milling machines and the
various types of milling processes. Emphasis is placed on its industrial applications, operations, and the
selection of appropriate cutting tools.
On completion of this module, you will
acquire some of these techniques from
the training exercises as illustrated in
figure 1. However, to gain maximum
benefit, you are strongly advised to make
yourself familiar with the following notes
before undertaking the training activities,
and to have a good interaction between
yourself and the staff in charge of your
training.
Assessment of your training will be Figure 1. Milling Products based on a combination
of your skill and attitude in getting the work done.
2. Types of Milling Machine
Most of the milling machine are constructed of ¡¥column and knee¡¦ structure and they are classified
into two main types namely Horizontal Milling Machine and Vertical Milling Machine. The name
Horizontal or Vertical is given to the machine by virtue of its spindle axis. Horizontal machines can be
further classified into Plain Horizontal and Universal Milling Machine. The main difference between the
two is that the table of an Universal Milling Machine can be set at an angle for helical milling while the
table of a Plain Horizontal Milling Machine is not.
2.1. Horizontal Milling Machine
Figure 2 shows the main features of a Plain Horizontal Milling Machine.
Figure 1.
Figure 2.

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2.2. Vertical Milling Machine
Figure 3 shows a vertical milling machine which is of similar construction to a horizontal milling
machine except that the spindle is mounted in the vertical position
a.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.
b. Ram
The ram on which the milling head is attached can be positioned forward and backward along the
slideway on the top of the column.
3. Cutting Tools
3.1. Cutting Tools for Horizontal Milling
a. Slab Mills
For heavy cutting of large and flat surfaces.
Figure 4. Slab Mill
Figure 3.

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b. Side and Face Cutters
This type of cutters has cutting edges on the periphery and sides of the teeth for cutting shoulders and slots.
Figure 5. Side and Face Cutter c
c. Slitting Saws
For cutting deep slots or for parting off.
Figure 6. Slitting Saw

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3.2. Cutting tools for Vertical Milling
a. End Mills
Commonly used for facing, slotting and profile milling
B. Rough Cut End Mills For rapid metal removal.
C. Slot Drills
For producing pockets without drilling a hole before hand.
d. Face Milling Cutters For heavy cutting.
Figure 8. Rough Cut End Mill
Figure 7. End Mills
Figure 9. Slot Drill
Figure 10. Face Milling Cutter

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✓ Industrial Applications
Milling machines are widely used in the tool and die making industry and are commonly used in the
manufacturing industry for the production of a wide range of components as shown in figure 11. Typical
examples are the milling of flat surface, indexing, gear cutting, as well as the cutting of slots and key-
ways.
✓ Milling Processes
Milling is a metal removal process by means of using a rotating cutter having one or more cutting teeth
as illustrated in figure 11.
Cutting action is carried out by feeding the workpiece against the rotating cutter. Thus, the spindle
speed, the table feed, the depth of cut, and the rotating direction of the cutter become the main
parameters of the process. Good results can only be achieved with a well balanced settings of these
parameters.
✓ Spindle Speed
Spindle speed in revolution per minute (R.P.M.) for the cutter can be calculated from the equation :-
where -- N = R.P.M. of the cutter
CS = Linear Cutting Speed of the material in m/min. ( see table 1 )
Figure 11 . Milling Process

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d = Diameter of cutter in mm
✓ Feed Rate
Feed rate (F) is defined as the rate of travel of the workpiece in mm/min. But most tool suppliers
recommend it as the movement per tooth of the cutter (f). Thus,
F = f . u . N
where -- F = table feed in mm/min f = movement per tooth of cutter in mm (
see table 1 )
u = number of teeth of cutter N =
R.P.M. of the cutter
✓ Depth of Cut
Depth of cut is directly related to the efficiency of the cutting process. The deeper the cut the faster will
be the production rate. Yet, it still depends on the strength of the cutter and the material to be cut.
For a certain type of cutter, a typical range of cut will be recommended by the supplier. Nevertheless, it
should be noted that a finer cut is usually associated with a better surface finish as well as a long tool
life. 5.4. Direction of Cutter Rotation
a. Up Cut Milling
In up cut milling, the cutter rotates in a direction opposite to the table feed as illustrated in figure 12. It
is conventionally used in most milling operations because the backlash between the leadscrew and the
nut of the machine table can be eliminated.
Figure 12. Down Cut Milling

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✓ Typical Milling Operations
1. Plain Milling
2. End Milling
3. Gang Milling
4. Straddle Milling
Dividing or Indexing Head.
Dividing Heads (often called indexing heads) are machine tools used to
provide controlled and repeatable rotation to a tool or workpiece, usually as an
accessory to a milling machine, grinder, or lathe. A classic and personal favorite of
in our machine shop is the Ellis Dividing Head, but you can also find a different
manufacturers dividing head that would fit your needs. What makes it work inside
the housing is a worm and worm gear transmission. Regardless of the brand they
usually come in gear ratios of 40:1 or 90:1.
Dividing heads are closely related to rotary indexers, but with a key operational
difference: Rotary indexers use a scale and show the angle of rotation (from 0 to
360 degrees), while dividing heads use pre-defined plates to rotate a fixed amount.
These plates are generally circular with multiple rows of equally-spaced holes.
Using a dividing or indexing head correctly requires you to know the number of
rotations depending on the project you're working on - you'd need to calculate how
many full rotations, and how many holes in which circular pattern to go just the
rotation you need.

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Dividing Head Formula
With a 40:1 gear ratio, you’d need to turn the crank on the dividing head 40 full turns
to rotate the workpiece once. To get 6 equal divisions, you’d need 40/6 = 6+2/3 =
6.66666 turns. The 6 turns are easy, but the remaining 0.66666 needs the holes on
the plate.
If we multiply the partial turn by the number of holes on the plate, we’ll know exactly
how far to advance the diving head: 0.66666*15 = 10 holes. Putting these together,
to divide the piece into 6 segments you would rotate the dividing head 6 turns and
10 holes.
To get 75 equal segments we’ll follow the same process: 40/75 = 0.53333 turns.
Now, there is no full rotation, but 0.53333*15 = 8 holes. So if we rotate the dividing
head forward by 8 holes each time, it will divide the workpiece into 75 equal
segments.
Brown and Sharpe type, 3 plates of 6 circles, every drilled in this way:
• Plate 1- 15, 16, 17, 18, 19, 20 holes
• Plate 2- 21, 23, 27, 29, 31, 33 holes
• Plate 3- 37, 39, 41, 43, 47, 49 holes

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Experiment No: 1
Name of Experiment : 4 side with Dividing Head
Objective:
• How to know use indexing head
• Determining and calculation side of bolt
Equipment’s:
1. horizontal milling machine
2. Vernier caliper
3. Holding Materials
4. Milling Tools and cutting tool
5. Dividing Head
Theory:
What does a dividing head do?
An indexing head, also known as a dividing head or spiral head, is a specialized tool
that allows a workpiece to be circularly indexed; that is, easily and precisely
rotated to preset angles or circular divisions.
What is a dividing plate?
Dividing plates allow you to precisely divide a circle into a
number of divisions or degrees. The indexing feature
helps prevent errors during the repetitive adjustments
required in indexing work. Dividing plates can be used to
create bolt circles, gears, polygons, and so on.

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Procedure:
a. Facing is done on sides of the work piece by milling machine
b. Find out the centre at the ends of the work piece by cutting tool .
c. Mark off centre from the main centerline and zero calibration in main screen .
d. Select a suitable cutting speed and feed.
e. Work piece is feed to the cutter automatically or manually
f. Give depth of cut by knee elevating handle according to the calculations.
g. Continue this indexing procedure for the required number of side and complete the model
Result :
DIRECT INDEXING
Indexing Ratio = 24/Z = 24/4 = 6 *3 = 18
Where Z= required number of divisions = 4
Standard Brown and Sharp Index Plates
No.1: 15, 16, 17, 18, 19, 20
No.2: 21, 23, 27, 31, 33
No.3: 37, 39, 41, 43, 47, 49
K =20 mm S= 10mm
Discussion:-
Overall, the experiment succeeded in showing that

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Experiment No: 2
Name of Experiment : 6 side with Dividing Head
Objective:
• How to know use indexing head
• Determining and calculation side of bolt
Equipment’s:
1. horizontal milling machine
2. Vernier caliper
3. Holding Materials
4. Milling Tools and cutting tool
5. Dividing Head
Theory:
Procedure:
i Facing is done on sides of the work piece by milling machine
ii Find out the centre at the ends of the work piece by cutting tool .
iii Mark off centre from the main centerline and zero calibration in main screen .
iv Select a suitable cutting speed and feed.
v Work piece is feed to the cutter automatically or manually
vi Give depth of cut by knee elevating handle according to the calculations.
h. Continue this indexing procedure for the required number of side and complete the model

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Result :
DIRECT INDEXING
Indexing Ratio = 24/Z = 24/6 = 4 *4 = 16
Where Z= required number of divisions = 6
Standard Brown and Sharp Index Plates
No.1: 15, 16, 17, 18, 19, 20
No.2: 21, 23, 27, 31, 33
No.3: 37, 39, 41, 43, 47, 49
K =20 mm
Discussion:-
Overall, the experiment succeeded in showing that

14. 14
Experiment No: 3
Name : SPUR GEAR CUTTING IN MILLING MACHINE
Objective: To perform spur gear cutting using horizontal milling machine on a work piece.
Theory :
Spur gears or straight-cut gears are the simplest type of gear. They consist
of a cylinder or disk with the teeth projecting radially, and although they are
not straight-sided in form (they are usually of special form to achieve
constant drive ratio, mainly involute), the edge of each tooth is straight and
aligned parallel to the axis of rotation. These gears can be meshed together
correctly only if they are fitted to parallel shafts.
TOOLS REQUIRED
1. horizontal milling machine
2. Vernier caliper
3. Holding Materials
4. Milling Tools
5. MATERIAL USED (Aluminum )

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CALCULATION:
Z = 4.8 mm . of teeth = 30
Blank Diameter = (Z + 2) /DP
= (20 + 2)/10=2.2” or 55.88mm
DP= Diametral Pitch=10
Indexing Calculation = 40 / Z = 40 / 30 =
3
4
= 1
1
3
*
7
7
= 1
7
21
Standard Brown and Sharp Index Plates
No.1: 15, 16, 17, 18, 19, 20
No.2: 21, 23, 27, 29,31, 33
No.3: 37, 39, 41, 43, 47, 49

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Experiment No: 4
Name of Experiment: 3 side with Dividing Head
Objective:
• How to know use indexing head
• Determining and calculation side
Equipment’s:
6. horizontal milling machine
7. Vernier caliper
8. Holding Materials
9. Milling Tools and cutting tool
10.Dividing Head
Procedure:
vii Facing is done on sides of the work piece by milling machine
viii Find out the centre at the ends of the work piece by cutting tool .
ix Mark off centre from the main centerline and zero calibration in main screen .
x Select a suitable cutting speed and feed.
xi Work piece is feed to the cutter automatically or manually
xii Give depth of cut by knee elevating handle according to the calculations.
i. Continue this indexing procedure for the required number of side and complete the model

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Result :
DIRECT INDEXING
Indexing Ratio = 24/Z = 24/3 = 8 *2 = 16
Where Z= required number of divisions = 6
Standard Brown and Sharp Index Plates
No.1: 15, 16, 17, 18, 19, 20
No.2: 21, 23, 27, 31, 33
No.3: 37, 39, 41, 43, 47, 49

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Experiment No: 5
Name of Experiment: Spline Lug with Dividing Head
Objective:
• How to know use indexing head
• Determining and calculation side
Equipment’s:
11.horizontal milling machine
12.Vernier caliper
13.Holding Materials
14.Milling Tools and cutting tool
15.Dividing Head
Procedure:
xiii Facing is done on sides of the work piece by milling machine
xiv Find out the centre at the ends of the work piece by cutting tool .
xv Mark off centre from the main centerline and zero calibration in main screen .
xvi Select a suitable cutting speed and feed.
xvii Work piece is feed to the cutter automatically or manually
xviii Give depth of cut by knee elevating handle according to the calculations.
j. Continue this indexing procedure for the required number of side and complete the model

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Result :
DIRECT INDEXING
Indexing Calculation = 40 / Z = 40 / 8 =5*3=15
Standard Brown and Sharp Index Plates
No.1: 15, 16, 17, 18, 19, 20
No.2: 21, 23, 27, 29,31, 33
No.3: 37, 39, 41, 43, 47, 49

20. 20
References
1.Groover, P. M., "Fundamentals of Modern Manufacturing", WILEY Inc., 2.
International Edition, 2002.
2.DeGarmo, E. Paul, et al, “Materials and Processes in Manufacturing”, McMillan Publishing 2000
3.Tlusty, G., "Manufacturing Process and Equipment", Prentice Hall Inc., 2000.
4.Schey, John A., "Introduction to Manufacturing Processes", McGraw Hill, Second Edition, 1987.
5. internet browser (google chrome )