Experiment No.

05

Objective:

To perform plane milling process on aluminium work piece using slab mill
cutter

Theory:

Fig 1. Slab Mill Cutter

High Speed Steel slitting saws are used to machine a slot into material, using a milling
machine or CNC machine center. Slitting saws are round disc cutter with many teeth, to
evenly distribute the cutting force & load giving a higher feed rate than a slot drill or end
mill. Mostly slitting saws are run on an arbor with a 1” bore.

Appropriate safety equipment.

• Always wear safety goggles because the chips can be dangerous for eyes.
• Always use the correct saw for each application.
• Keep saws sharpened. A dull saw will not cut clean and tool may be broken.
• Support saw blade by using maximum diameter side collars.
• Side collars should be free of any
dirt or foreign material when assembling.
• Always be certain arbor nut is
tightened correctly.
• Larger arbor holes provide more
rigidity and least amount of deflection.
• Use proper speeds and feeds for
material being machined.
• Workpiece being cut must be
rigidly held and positioned correctly.
• Resharpen saws regularly to obtain
consistent chip removal and uniform
cutting results.
• Never stop the saw and restart
during the course of a cut.

Performance:

Fig 2. Cutter
Machine: Universal Milling machines AJUM 300

Tools: Vernier Calipers 12 inch, steel ruler, Slitting saw cutter (4’’ diameter),
Machine vise.

Material: Metal block Mild Steel (approximately 50mm x 50mm x 25mm)

Side and face milling process:
1. Before starting the machine, be sure the cutting tool is clear of the work piece. If not,
lower the work piece by lowering the knee.
2. Move the table with the x and y axis handles to position the work piece under the
cutter.
3. Lower the cutting tool or raise the table until it touches the top surface of the work
piece gently.
4. Set the micrometer dial on the knee to zero.
5. Lower the table by a suitable distance to keep the tool and workpiece apart, by turning
the knee hand wheel counter clockwise.
6. Move the table longitudinally so that the cutter is clear of the work piece at either end.
7. Turn the machine on.
8. Touch the corners of the work piece to set the origin of the work piece (the lab
instructor will demonstrate the procedure).
9. Using the side and face milling cutter on the horizontal axis spindle cut the groove or
slot of the work piece in accordance with the values found out from the data and
formulae. Always try to keep the feed and speed as accurate as possible by making the
best compromise among time, speed and feed.
10. When one turn is complete repeat the process to get the full side milling complete as
needed.

Table 1. Hand wheel scales with respect to table movement in three dimensions.
Rotation Displacement (one Scale collar (one rev)
Direction(clockwise) div)
Longitudinal Feed Right Hand 0.02mm 5mm

Cross Feed Forward( go far from 0.02mm 5mm

operator)
Vertical Feed Upward 0.01mm 1.2mm

Procedure Steps:

Because of their small cross section metal slitting saw blades are tender milling tools:

1. A too high speed of rotation leads to a premature dulling (wear) and so to a

degeneration of the surface quality of the work pieces. So calculate the proper spindle speed
using recommended charts for workpiece(50 x 50 x 25mm)

2. Find out the diameter d of the slitting saw using the Vernier calipers in mm.

3. Mount the slitting saw on the arbor using proper method under the supervision of lab
assistant. The loosing and tightening of the bolts and nuts must be carried out with much care.

4. Checking the completeness and functioning of the milling machine, of the clamping
means and auxiliaries to be applied, oil-level check and lubrication of the milling machine to
be carried out according to the lubrication schedule's cycle.

5. Chucking and fixing of the clamping means.

6. Setting-up and clamping in or on the work piece (work piece support, length feed
stop).
7. Fixing the coolant system when processing work pieces made of steel.
8. Installing of the milling protective system.

9. Clamping in the cutter arbor and clamping on the metal slitting saw blade. Do not
forget the feather key in one of the arbor rings!

10. Positioning of the milling machine table into the appropriate processing position to
the milling tool (X-Y-Z-direction) using the table adjustment hand wheels.

11. Make a groove of 1mm first and then go for 1mm again in the second cut.

While cutting keep noted the difference between climb milling and conventional milling. Use
the backlash eliminator if needed.

12. Cutting in (a small groove in the workpiece) at the rotating metal slitting saw blade.
Table feedback and make a dimensional inspection of the workpiece in the fastened
condition. If necessary, correct with manual adjustment of the head.

13. Continuation of cutting by milling using a strong jet of cooling water directed on the
place of the cutting by milling.

14. Clamping out, deburring and cleaning of the workpiece, linear measure control and
control of the angularity and surface finish.

15. If necessary, make corrections on the localization of the workpiece or the clamping
means, and on the linear or space measures to the reference face.

16. Ending up with the technique of cutting by milling you should clean the milling
machine, all tools used, auxiliaries and the whole workplace. The used metal slitting saw
blades are sent on to be sharpened again (sharpen).

Self-Assessment

• The slitting saw is made of _______________Material.

• The diameter and thickness of the slitting saw is ______________.

• The work piece is made of _________________Material.

• The feed we used to cut the material is ___________ m / Min.

• The spindle speed is kept ___________ RPM using variable speed selector levers.

• The table can move in ________________ different directions.

• What is the PPE’s necessary to work on universal milling machine?

___________________________________________________________________________

___________________________________________________________________________

___________________________________________________________________________

___________________________________________________________________________

• What is the range of feeds on the machine?

___________________________________________________________________________

___________________________________________________________________________

___________________________________________________________________________

___________________________________________________________________________

• What is the effect of diameter of cutter on the cutting of material using slitting saw?

___________________________________________________________________________

___________________________________________________________________________

___________________________________________________________________________

___________________________________________________________________________

• What is plain milling?

___________________________________________________________________________

___________________________________________________________________________

___________________________________________________________________________

___________________________________________________________________________

___________________________________________________________________________
Figure 3. Plain Milling
 Lab Rubrics scheme
Criteria Excellent (4) Good (3) Fair (2) Poor (1) score

Instruments and
Technical Instruments and Some misuse or Instruments or
tools are used
Soundness / tools are mostly inefficiency in tools are misused
appropriately and
performance used appropriately instrument usage or ineffective
effectively

Data is
Data is mostly Data is incomplete,
comprehensive,
comprehensive, Data is somewhat irrelevant, or
relevant, and
relevant, and comprehensive and inaccurately
Data Collection accurately recorded
accurately recorded relevant recorded
and Presentation - Data is effectively
- Data is mostly Data presentation is - Data presentation
presented using
effectively adequate lacks clarity or
appropriate tables,
presented coherence
graphs, and visuals

Analysis Analysis
demonstrates deep demonstrates
Analysis addresses
understanding of understanding of
some relevant Analysis lacks
the data and the data and
aspects depth or relevance
addresses all addresses most
Data Analysis - Conclusions are - Conclusions are
relevant aspects relevant aspects
somewhat illogical or not
- Conclusions - Conclusions
supported and supported by data
drawn are logical, drawn are mostly
logical
well-supported, and logical and
aligned with data supported

Scoring Guide:
• 4: Excellent - Exceeds expectations; demonstrates exceptional proficiency and
mastery.
• 3: Good - Meets expectations; demonstrates solid understanding and competency.
• 2: Fair - Partially meets expectations; some areas need improvement or refinement.
• 1: Poor - Does not meet expectations; significant deficiencies or lack of
understanding.