Manual Mill Operation

Class Outline

Objectives
Overview of Manual Mill Operations
Sample Part: Specifications
Order of Operations
Sample Part: Mill Preparation
Face Milling Principles
Sample Part: Squaring Surface #1
Sample Part: Squaring Surface #2
Sample Part: Squaring Surface #3
Sample Part: Squaring Surface #4
End Milling Principles
Sample Part: Squaring the Ends
Layout for the Mill
Sample Part: Milling the Step
Sample Part: Milling the Groove
Drilling Principles
Sample Part: Drilling
Summary

Objectives
List common manual mill operations.
Describe how a sample blueprint impacts the necessary machining
steps.
Describe the operations performed on a sample part.
Describe common setup procedures required for a mill
operation.
Describe common principles for face milling.
List the steps necessary to square the first surface onthe sample
part.
List the steps necessary to square the second surface on the
sample part.
List the steps necessary to square the third surface on the
sample part.

List the steps necessary to square the fourth surface on the

sample part. l Describe common principles for end milling.
List the steps necessary for squaring the ends of the sample
part.
Describe common layout methods used on the mill.
List the steps necessary to mill the step on the sample part.
List the steps necessary to mill the groove on the sample
part.
Describe common principles for drilling.
List the steps necessary for drilling holes in the sample part.

Figure 1. End milling uses a cylindrical

cutter to remove material from the
bottom and sides of a part.

Figure 2. The milled sample part.

Overview of Manual Mill Operations

The basic milling machine, shown in Figure 1, is capable of producing flat surfaces, as well as more
complicated features such as pockets and complex contours. The combination of these operations
on the manual mill makes it possible to produce a wide range of parts. However, most parts are
machined by following a similar series of operations.
The most common operations performed on the mill are face milling and end milling, which are
illustrated in Figure 2. Other operations include slab milling, form milling, and slotting. Milling
machines can also be used for all of the common hole making operations that are normally done
on a drill press. These operations include drilling, tapping, boring, and reaming, which are
illustrated in Figure 3.
Before performing any of these cutting operations, you must look at the blueprint and understand
the part's specifications, choose the proper cutting tools, and determine any other part
requirements. You must also understand how to properly set up the mill before machining begins
so you are prepared to make the specific part design. Once you are properly set up, you are ready
to begin machining the part. This class guides you through the machining of a common part on the
mill. You will learn how to perform common milling operations as well as understand basic principles
of each cutting operation.

Figure 1. The basic milling machine is

capable of producing flat surfaces, as
well as complex pockets and contours.

Figure 2. Face milling (A) produces

flat surfaces, while end milling
produces pockets
(B) and contours (C).

Figure 3. Hole making operations include drilling

(1), boring (2), reaming (3), and tapping (4).

Sample Part: Specifications

Imagine you are making the part in Figure 1. You must know the required finish dimensions of the
part before you can begin machining it on the mill. You must also know the type of material you are
using. The blueprint indicates that the part is made of aluminum. You can also see that the part
requires a machined "step" on the top of the part and a machined "groove" on the bottom.
As you can see in Figure 2, the blueprint also indicates all the dimensions for the part. The finish
length of the part is 4.500 in. (11.43 cm) with a width of 2.500 in. (6.35 cm). The height to the
bottom of the step is 1.375 in. (3.49 cm) and 1.875 in. (4.76 cm) to the top of the step. The depth
of the step is 0.500 in. (1.27 cm). The length from one corner of the step to the other is 1.750 in.
(4.45 cm). The length from one end of the part to the beginning of the step is 1.375 in. (4.76 cm),
as Figure 3 shows. The length of the groove is 3.000 in. (7.62 cm). The length from one end of the
part to the beginning of the groove is 0.750 in. (1.90 cm). The depth of the groove is
0.500 in. (1.27 cm). Finally, two holes are located on the centerline of the part, which is 2.250 in.
(5.72 cm) from each end of the part on the X-axis. Each hole is 0.625 in. (1.587 cm) from the front
and back of the part in the Y-axis. Both holes must have a finish diameter of 0.500 in. (1.27 cm).

Figure 1. The sample part.

Based on these print specifications, you can see that this part is symmetrical. In other words, the
part has the same dimensions on each side. Therefore, you will machine to finish dimensions on
one side of the part and do the exact same thing on the other side of the part.

Figure 2. The blueprint indicates the

dimensions for the sample part.

Figure 3. The distance from the end of

the part to the beginning of the step is
1.375 in. with a depth of 0.500 inch.

Order of Operations
Refer once again to the blueprint in Figure 1. From these specifications, you can determine the best
sequence of operations for the features shown in Figure 2:
l Squaring the block requires a face milling operation with a wider face mill on each surface of
the part. A face mill is shown in Figure 3. The face milling operation removes a large portion of
material from the surfaces of the part. Squaring provides a majority cleanup to make sure
that the part's surfaces are even and parallel in the vise.
l Squaring the ends requires an end milling operation to ensure that the ends of the block
are perpendicular to the other surfaces and to the stationary vise jaw. The end mill is a
cylindrical cutter used to remove material from the surface of a part, like the one shown in
Figure 4.
l Milling the steprequires the machining of a square blockonto the topof the part. A
plunging
method is used to remove a larger portion of material from the part in a shorter time.
However, this method is not required. You can also use a face mill and conventionally mill the
surface.
l Milling the groove requires a larger portion of material to be removed from the bottom of
the part. A plunging method is also used to remove a large portion of material at a fast rate.
Again, you could also conventionally mill the surface with a face mill.
l Drilling the holes requires a drilling operation to place two holes on the centerline of the
part. The two holes must first be center drilled before they are drilled to their finish
dimensions.

Figure 1. From the blueprint, you can

determine the best sequence of
operations.

Figure 2. The features of the sample

part.

The next series of lessons will guide you through each of these operations performed on the
sample part. This part will be machined in the order of cutting operations listed above. However,
not all parts require this same order of operations.

Figure 3. A face mill removes a larger

portion of material from a part.

Figure 4. An end mill is a cylindrical

cutter used to remove material parallel
and perpendicular to the spindle's axis

Sample Part: Mill Preparation

The sample part is an aluminum part that has been saw cut to oversized dimensions, as you can
see in Figure 1. Because you are working with raw stock, you cannot assume that its dimensions
are accurate or that its surfaces are parallel. It must be machined to the finish dimensions specified
in the blueprint.
Before machining the part, you must first make sure you have completed all the necessary setup
procedures required for your particular operation. This may include aligning the mill head with the
worktable, aligning the vise properly, and making sure your workpiece is centered and aligned
with the spindle. You must also make sure you have selected the proper cutting tools for the
operation.
Before placing the part in the vise, remove all burrs and sharp corners from the part by filing or
grinding, as shown in Figure 2. Finally, determine the proper speed and feed rates and set them
accordingly. Now you are ready to begin milling your part.

Figure 1. The sample part is an

aluminum part that has been saw cut
to oversize dimensions .

Figure 2. Make sure all burrs and

sharp corners are removed from the
part by filing or grinding.

Face Milling Principles

Face milling is the process of machining a flat surface parallel to the face of the cutter, as Figure 1
shows. Face milling often uses a wider mill cutter to machine broad, flat surfaces. Smaller surfaces
are often face milled with end mills.
A face mill is used to remove large portions of material from a part. Face mills contain multiple
cutter teeth that allow faster feeds. They are available in a wide variety of diameters and number of
cutter teeth. Before beginning a face milling application, you must make sure the cutter teeth point
in the same direction as the desired rotation of the spindle. Also, most milling requires the cutter
teeth to rotate against the workpiece feed, as illustrated in Figure 2. This is known as
conventional milling.
Face milling is often used to make a heavy roughing cut before finishing the part to size. However,
it is recommended that you first make a light cut across the part to establish the size and location
of your tool.

Figure 1. Face milling often uses a

wider mill cutter to machine broad,
flat surfaces.

Figure 2. Before beginning a milling

application, make sure the cutter
teeth point in the same direction as
the desired rotation of the spindle.

Sample Part: Squaring Surface #1

At this stage, the sample part has been saw cut and all its surfaces are uneven. When you place
the rough part in the vise, make sure that the best surface of the part is against the back of the
jaw, even though this surface will eventually be machined as well. Position the part on a pair of
parallels situated in the vise. However, at this stage the parallels ensure that the workpiece sits
above the vise jaws, but they do not ensure squareness. The only surface that you know is square
is the back of the vise.
Since the first surface will be face milled, you can use a larger diameter face mill. In this example,
place a 3 in. diameter face mill in the spindle and lock the tool in place. Locking your tool in place
with the spindle lock keeps these components solid and rigid.
Because the stock is rough, you can see clearly in Figure 1 which part of the surface is the high
end. The high end is where you should touch off your tool. Use the dial on the knee to bring your
part up to touch the tool. Set the dial on the knee to zero to establish a reference point. On this
surface, you want to do a majority cleanup of the material, but you want to leave finish material to
machine it to size. Adjust the dial on the knee to roughly 0.050 in. (1.27 mm), and using the X- axis
dial, make a first pass across the part. Look at the finish and decide if you need to adjust your
speed or if you want to change how much material is removed on each pass.

Figure 1. On the rough stock, you should

touch off your tool on the high end.

Once you make a pass, take the tool off the part and go back to the start. Then, keep taking
passes until you have cleaned up the majority of the surface, as Figure 2 shows. Make sure that
you remove enough material to clean up the part, but also avoid taking off excess material past the
finish dimensions. To help visually remind you which surface you machined first, you can mark the
first machined surface with a "1," as shown in Figure 3.

Figure 2. Keep taking passes until you

have cleaned up the majority of the
surface.

Figure 3. Mark the first machined

surface with a "1" to help visually
remind you which surface you
machined first.

Sample Part: Squaring Surface #2

Before you machine the next surface, place the milled first surface against the back of the jaw.
Even though this first surface has been machined, the part still may not be sitting on the parallels
evenly because the bottom surface has yet to be machined. However, after you machine the second
surface, a machined surface will be sitting on the parallels, and you must make sure the part is
sitting securely on top of the parallels.
Like surface #1, you want to only do a majority cleanup of this surface. You do not need to
machine this surface to its finish size dimensions yet. Again, bring the part up and touch the tool
off the higher side of the part surface. Then, set the knee dial to zero to establish a reference
point. Like surface #1, set your knee dial to roughly 0.050 in. (1.27 mm) to 0.100 in (2.54 mm), and
using your X-axis dial, start making passes to ensure a majority cleanup, as Figure 1 shows. After
you set the dial on the knee, you should lock the knee to prevent any movement in this axis.
Finally, check the surface of the part to find any unmachined spots or surface irregularities. Now,
you can take the part out of the vise and mark it with a "2," as shown in Figure 2, to remind you
which surfaces have been machined.

Figure 1. Make passes in the X-axis to

ensure a majority cleanup of the
second surface.

Figure 2. After machining, mark the

second surface with a "2" to remind
you that the surface has been
machined.

Sample Part: Squaring Surface #3

Now that you have machined surface #1 and #2, position surface #2 on the parallels against the
back of the vise jaw. At this point, you now have a machined surface sitting on the parallels in the
vise. Therefore, you must remove any chips or debris that may interfere with the squareness of the
part. Also, you can use a plastic dead blow hammer to tap your part in the vise to make sure it is
secure.
Next, visually check to see if your tool is centered. The width has changed from the last surface to
this one. You must move the table in the Y-axis to center the tool. At this point, you can machine
this surface to your finish height dimension of 1.875 in. (4.76 cm).
First, bring the knee up to the tool, touch off the part, and set zero as your reference point. Before
you decide how much material to take off in the first pass, keep in mind that two surfaces have
been machined, so the part is much more square and may not require as much material to be
removed. For the first pass, you may want to take only 0.010 in. (0.0254 cm) off the part, and then
you can measure to determine how much more is required to reach the finish size.

Figure 1. You can measure the height

of the part with a caliper to determine
your starting point.

You can measure the height of the part with a micrometer or caliper to determine your starting
point. For example, let's say your caliper reads 2.056 in. (5.22 cm), like the caliper in Figure 1. You
know that you need to get to 1.875 in. (4.76 cm), so you must take 0.181 in. (0.456 cm) off the
part to machine it to finish size. You can take off this material with more than one pass. For
example, you can start by taking off 0.100 in. (0.254 cm) to rough off some material, then follow
with 0.060 in. (1.524 cm) or so, leaving yourself about 0.020 in. (0.508 cm) for a light, finish cut. You
can also use a micrometer to measure the finish height, as shown in Figure 2. When you are
finished, take the part out of the vise and mark it with a "3," as Figure 3 shows.
Figure 2. You can also use a
micrometer to measure the finish
height.

Figure 3. After machining, mark the

finished surface with a "3."

Sample Part: Squaring Surface #4

At this point, surfaces #1, #2, and #3 have been machined. The only surface left to square is
surface #4. Again, make sure that your part is sitting securely on the parallels in the vise and that the
parallels are clean and free from any chips or debris.
First, center your tool on the part. Your width has changed again, so you may need to move the Yaxis to center your tool on the part, as Figure 1 shows. You must machine this surface to the finish
width of 2.500 in. (6.35 cm). Just like the steps used with the other surfaces, you must first bring
your part up to the tool and touch off, set zero on the dial, and take a first rough pass. You can
then use a micrometer or caliper to measure the rough dimension to determine how much
material you need to remove to reach finish size. Figure 2 shows a micrometer measuring the part.
Depending on the measured dimension, you can take a few passes to reach finish size, leaving
yourself some material for a lighter, finish cut.
Always be sure that the machine is off and the cutter rotation is stopped when taking
measurements. This prevents any possible injury that could occur from the rotating tool.
centered

Figure 1. Make sure your tool is

properly in the Y-axis before making
the first cut.

Figure 2. A micrometer helps measure

the rough dimension to determine
how much material you must remove
to reach finish size.

End Milling Principles

End milling is a process that uses a cylindrical cutter to machine surfaces both parallel and
perpendicular to the spindle axis. End milling may cut with both the bottom and sides of the cutting
tool. End milling is also used to cut a variety of shapes, such as slots and contours.
As you can see in Figure 1, an end mill is a thin, cylindrical mill cutter with a concave bottom and
cutting edges that wind up the sides, which are known as flutes. End mills come in a wide variety of
sizes and flute designs. Before an end milling operation, you need to consider the number of flutes
and flute length.
The type of material you are machining determines the number of flutes you will need. The
dimensions of the part you are machining determine flute length. For example, if you are using the
side of an end mill, and the flute is too short, you will be using the wrong part of the end mill on
the surface, and you will not actually cut anything. Figure 2 shows an end mill that properly covers
the surface to be machined.
Figure 1. An end mill is a cylindrical
mill cutter with a concave bottom and
flutes that wind up the sides.

Figure 2. Make sure the flute length

covers the surface to be machined.

Sample Part: Squaring the Ends

Now that the first four surfaces are squared to each other on the sample part, you must square
the perpendicular ends of the part. You know that the two ends are parallel to each other, but
now they must be squared with the other surfaces. One way to do this is to use the sides of an
end mill.
Position the part against the back of the jaw on top of the parallels. When squaring the ends, it is
best to set your part as far down into the vise as possible so that most of the part is contained
while machining. Also, make sure the part hangs out of the vise, as you can see in Figure 1, so
there is room for the tool and a safe distance from the vise jaw.
You must first find an end mill with a flute long enough to use on the whole perpendicular surface
of the part. The height of the end is 1.875 in. (4.76 cm), so an end mill with a 2.0 in. (5.08 cm) flute
length, like the one in Figure 2, will work. For this sample part, you can use a 7/8 in. end mill in an
end mill tool holder.
Once you secure the tool into place, you must set the depth on the knee to make sure the flute
covers the surface, as shown in Figure 3. Bring the knee up to the bottom of the end mill, touch it
off, and set zero. Now, you can dial your finish dimension of 1.875 in. (4.76 cm) plus a little more to
make sure you are covering the surface. Now that you are at the correct height, bring the tool
back off the part in the X-axis. Then, come back in with the X-axis, touch the end mill on the part,
and set the X-axis as a reference point. Next, take the tool off the part with the Y-axis dial. Now
you can approach with the Y-axis and take a first pass to determine the current dimension. Keep
taking light passes until you have performed a majority cleanup.
If you are using a stop against the other side of the part, you can simply turn around your part,
secure it snugly in the vise, and perform the exact same procedure to the other side finishing the
part to the 4.500 in. (11.43 cm) length dimension.

Figure 1. Before end milling, make

sure the part hangs out of the vise so
that there is room for the tool and
there is a safe distance from the vise
jaw.

Figure 2. Make sure that the flute

length on the end mill is long enough
to use on the whole perpendicular
surface of the part.

Figure 3. Set the depth of the knee to

make sure the flute covers the surface
to be machined.

Layout for the Mill

In machining, layout is the marking of lines, centers, or circles on metal workpieces. These
markings on the workpiece indicate the size, shape, hole locations, or other areas to be machined.
Layout provides machinists with a visual aid that helps ensure that the required specifications on a
blueprint are met. Also, layout dye is used to color metal workpieces before scribing lines, as
Figure 1 shows. Several kinds of dye are available in a variety of colors. The workpiece is first wiped
clean, then the dye is brushed or sprayed on. The layout dye allows the lines on the part to be
seen more clearly.
Machinists use a variety of common tools for measuring and layout. These include rules, squares,
and calipers to name a few. The machinist uses these tools to scribe lines, locate centers for holes,
and define the outline of parts. Figure 2 shows a machinist using calipers to scribe lines on a part.

Figure 1. Layout dye is used to color

metal before scribing lines.

Figure 2. Machinists often use

calipers to scribe lines on parts.

Sample Part: Milling the Step

Now that the entire block is squared, you are ready to machine a step into the part. The distance
from the end of the part to the beginning of the step is 1.375 in. (3.49 cm) with a depth of 0.500
in. (1.27 cm).
If you are laying out the part, brush layout fluid on the part, set your calipers to 1.375 in. (3.49
cm), and scribe the mark on the part to give you a visual reference, as Figure 1 shows. You can do
the same thing with the 0.500 in. (1.27 cm) depth. Next, place a smaller face mill in the spindle.
Move the spindle down, leaving some space for travel in the depth adjustment. Set the depth
with the adjustment nut. Then, in the Z-axis, touch off your tool, and dial just short of the desired
depth on the knee to approximately 0.480 in. (1.22 cm), and lock the knee.
Next, come over toward the part in the X-axis, but do not touch the part with the tool. You can
visually line up your tool just shy of the reference mark you made during layout. Set zero in the Xaxis as a reference point. Now, you can come in with the Y-axis and make a very slight notch to
make sure your tool is in the right location. Then, moving in about 0.25 in. (0.635 cm) to 0.50 in.
(1.27 cm) increments in the Y-axis and using the quill intermittently, you can use a plunging
method to rough out the material in a relatively short time, still staying short of the scribe marks,
and leaving room for a finish cut, as you can see in Figure 2. Keep in mind you can also
conventionally mill this surface with a face mill. The plunging method removes material at a faster
rate.
Because your part is set against the stop, and it is symmetrical, you can turn the part around and
rough out the other side. Now you can take the 7/8 in. end mill and make a light, finishing cut, as
shown in Figure 3. First, touch off the tool in the Z-axis, then back off the part and come in with
the X-axis and touch off where you roughed out the material. Then, make a light pass to determine
the current dimension, take a measurement, and determine from there how much material you
must remove. Again, because this is a symmetrical part, you can simply turn the part around and
perform the same procedure to the other side of the part. As Figure 4 shows, measure the step to
make sure it meets specifications.

Figure 1. You can scribe the part to

determine the areas to be machined.

Figure 2. Using the plunging method,

you can rough out material in a short
period of time.

Figure 3. You can use an end mill to

make a light, finishing cut on both
sides.

Figure 4. Measure the step to make sure it meets

part specifications

Sample Part: Milling the Groove

Now you are ready to turn the part over and mill the groove into the bottom of the part. The
groove is 3.00 in. (7.62 cm) in length, and the distance from the end of the part to the beginning
of the groove is 0.750 in. (1.90 cm), with a depth of 0.500 in. (1.27 cm).
First, you must select the type of mill cutter you want to use. Since you must rough out a 3.000 in.
(7.62 cm) portion of material, you may want to use a wider face mill. However, a 3 in. face mill may
be too large considering that you would already be too close to the finish size, leaving no room for
a finish cut. Therefore, you should select a face mill smaller than 3 in. (7.62 cm) in diameter. Figure 1
shows a proper-sized face mill for this procedure.
Just like when you machined the step, you can use the same plunging method to take off large
amounts of material at a faster rate. First, set the depth in the Z-axis to just shy of the 0.500 in.
(1.27 cm) dimension. Then, visually align the cutting tool just shy of the scribed reference mark
you made during layout, and set zero in the X-axis as your reference point. Now, you can start
taking plunging, rough cuts using the Y-axis and the quill until you have roughed out the part, as
Figure 2 shows. As you are making cuts, make sure that the cutter rotation is going the same
direction as the material you are cutting. If you begin to climb mill at a fast rate, you could cause
damage to the machine. Keep in mind that climb milling is not recommended for the manual mill.

Figure 1. Make sure to use the proper

face mill for the amount of material to
be removed.

After you have roughed the part, you can then use the 7/8 in. end mill to finish the part to its final
dimensions, as shown in Figure 3. Also, because you are working off of a fixed stop, you can turn
the part around and perform the same procedure to the other side.

Figure 2. You can use a plunging

method to rough out the material in
the groove.

Figure 3. After roughing out the part,

you can use an end mill to finish the
part to its final dimensions.

Drilling Principles
Drilling is a process that uses a multi-point tool to penetrate the surface of a workpiece and make
a round hole. Numerous workpieces machined on the manual mill require drilling, as well as
other hole-making operations.
Before drilling, when you mount the workpiece in the vise, make sure that the holes will not be
drilled into the vise bottom or the parallels. Drills are often installed in a drill chuck in the mill's
spindle, as Figure 1 shows. When drilling holes on the mill, you must first install an edge finder in
the drill chuck so you can locate the hole center using a precise distance from the end of the
workpiece. Figure 2 shows a typical edge finder.
In most cases, you will first install a center drill in the drill chuck and drill a center hole before
using other drills, as Figure 3 shows. Center drilling prevents the longer conventional drill from
"walking" off the centerline of the hole. To maintain the spindle in the proper location, make sure
that when you change drills, raise the quill, or lower the table, you do not move the workpiece
until the hole is finished.
Figure 1. Drills are often installed in a
drill chuck in the mill's spindle.

Figure 2. An edge finder is often

installed in a drill chuck to locate hole
centers.

Figure 3. Center drilling prevents the

longer, conventional drill from
"walking" off the centerline of the
hole.

Sample Part: Drilling

The last operation you will perform on the sample part in Figure 1 is drilling two holes along the
centerline of the part. Since the length of the part is 4.500 in. (11.43 cm), the centerline is located
at 2.250 in. (5.72 cm), so both holes will be located on this line.
Your blueprint may specify the location of the datum. However, if you are unsure, you can use an
edge finder to find the exact edge of the part. Keep in mind that you have a stop set up, and the
part is positioned against the back of the vise jaw. Each hole location in this symmetrical part is
0.625 in. (1.59 cm) from the edge. So, dial 0.625 in. (1.59 cm) in the Y-axis. Then, with the X- axis,
dial to half of the 4.500 in. (11.43 cm) distance to the centerline located at 2.250 in. (5.72 cm).
The blueprint in Figure 2 shows these dimensions. Set zero as your reference point.
Once you locate the spindle properly, you are ready to center drill the hole. Because you are using a
stop and the back of the jaw, you can take your part out of the vise and turn it around. Because
the hole locations are symmetrical, your tool will already be positioned in the proper location.
Now you can center drill the next hole without having to change tools each time. Then, place a 1/2
in. diameter drill in the drill chuck, and using the quill, lower the drill into the hole, as shown in Figure
3. You can now turn the part around again and drill the second hole because the tool is already in
the proper location. Some holes may have burrs on the edges. If so, you can use a chamfer tool to
place a chamfer in each drilled hole.

Figure 1. The last operation on the

sample part requires two holes
drilled along the centerline of the
part.

Now the sample part is complete. You must make sure that you check all the dimensions of the
part with the appropriate measuring tools to ensure the part meets the specifications outlined in
the blueprint.

Figure 2. The blueprint shows the

required location of the holes in the
sample part.

Figure 3. Lower a 1/2 in. diameter drill

into the center-drilled hole.

Summary
The basic milling machine can produce flat surfaces, as well as more complicated features, such as
pockets and complex contours. The most common operations performed on the mill are face
milling and end milling. Other operations include slab milling, form milling, slotting, as well as holemaking operations such as drilling, tapping, and boring. Before performing milling operations,
make sure you understand the part's specifications, choose the proper cutting tools, and properly
set up the mill before machining begins.
The sample part in this class underwent the following milling operations: squaring the block,
squaring the ends, milling a step, milling a groove, and drilling two holes. Squaring the block
requires a face milling operation. A face mill is a wider cutter used to remove large portions of
material from a part. The first two surfaces of the sample part required a majority cleanup of the
surface with a face mill. The next two surfaces were then squared to size. Next, the ends of the
part were squared to their finish sizes. To square the ends of the part perpendicular with the
other surfaces requires the sides of an end mill. End milling uses a cylindrical cutter to machine
surfaces both parallel and perpendicular to the spindle axis.
Once the sample part is squared, you can mill the step and the groove into the part. Laying out
these dimensions on the part gives you a visual reference when milling. Both features can be milled
using a plunging method with the Y-axis and quill. However, you can also conventionally mill these
features with a face mill. The plunging method removes material at a faster rate. Keep in mind that
the part is symmetrical, so each side requires the same milling operation.

Figure 1. Drilling (1), boring (2),

reaming (3), and tapping (4) are
common hole-making operations
performed on the mill.

Finally, two holes are drilled into the part. Make sure you find the proper location of the holes with
an edge finder. Then, center drill the holes before using a 1/2 in. diameter drill to drill the holes.
Center drilling prevents the longer, conventional drill from "walking" off the centerline of the hole.

Figure 2. The features required on the

sample part.

Class Vocabulary

Boring

The process of enlarging an existing hole with a single-point tool.

Caliper

A measuring instrument with two pairs of jaws on one end and a long beam containing a marked scale of unit
divisions. One pair of jaws measures external features; the other pair measures internal features.

Center Drill
Center Drilled
Conventional Milling

Dead Blow Hammer

Drill Press

Drilling
Edge Finder
End Mill
End Milling
Face Mill
Face Milling
Flute
Form Milling
Layout

A type of drill with a wide shank and a 60-degree angle tip.

Using a center drill to make a tapered hole in the end of a part to be supported by a center.
A type of milling that feeds the cutter against the cutter rotation. Conventional milling is typically used for roughing
the part to size.
A type of hammer that gives a solid blow to different materials without damaging their surfaces.
A machining tool that uses a drill to penetrate the surface of a workpiece and make a round hole. Drill presses can
be used for a variety of hole-making operations.
The process of using a multi-point tool to penetrate the surface of a workpiece and make a round hole.
A device used on a mill to locate the exact position of a part edge along the X-axis or Y-axis.
A narrow cutting tool that can be used to machine grooves, slots, circular slots, etc. into workpieces.
A milling operation that uses a narrower mill to create pockets and contours in a workpiece.
A type of mill cutter that contains multiple cutting teeth and is often used to remove large amounts of material.
A milling operation that produces a flat surface by guiding a wider mill across the surface of the workpiece.
A groove on the periphery of a cutter that allows for chip flow away from the cut.
A milling operation that uses a mill with a unique shape to create that shape into the workpiece.
The marking of lines, centers, or circles on metal workpieces. Layout work shows size, shape, hole locations, or
areas to be machined.

Layout Dye

A fluid that is brushed on a metal workpiece before layout that allows the lines to be seen more clearly.

Micrometer

A handheld measuring device used to inspect the dimensions of parts. The typical micrometer is accurate within
0.001 in. or 0.02 mm.

Milling Machine

A machine that uses a multi-point tool to remove metal from the surface of a workpiece.

Parallels

Two metal supports that are used to position the workpiece to the desired working height in the vise.

Plunging

A process that consists of quick movements of the quill and Y-axis to remove larger amounts of material in a short
time.

Reaming

The process of using a multi-point tool to smooth the interior surface of a hole.

Slab Milling
Slotting
Squaring
Symmetrical

A milling operation that uses a cylindrical mill on an axis parallel to the worktable to create a flat surface.
A milling operation that cuts a narrow ridge into the surface of a workpiece
The process of making the sides of a part even and parallel using a rough face milling operation.
A part that can be divided by a line into two equal halves, with identical features that are equal distances from the
dividing line. Both sides appear as mirror images of each other.

Tapping

The process of cutting internal threads in a round hole with a multi-point tool.