Report the Fabrication of the Mini Precision Vise for the

BFF1811_Machining_II
Tan Jun Zhe1, Loke Chi Kin2, Khoo Bao Shen3
Department of Manufacturing Engineering, FKP University Malaysia Pahang, UMP Kampus Pekan,
26600 Pekan, Pahang Darul Makmur.
1

FB14039, 2FB14050, 3FB14045

Abstract:
In general, milling is the machining process of using rotary cutters to remove material from a
workpiece advancing in a direction at an angle with the axis of the tool. Milling can be done with a
milling machine. With various attachments, milling machines can be used for boring, slotting,
circular milling dividing, and drilling. In this project, the tools like drills, end mills, and face mill are
widely use to obtain our final product, the moveable jaw and base. After finished this project,
students should understand about the types of milling operations, cutting conditions in milling,
milling machines and the machining centers and turning centers.

Introduction:
The projects objective is to train student on how to handle a milling machine systematically to do
a project as a preparation for industrial work in the future. It also aims to train the teamwork between
students like how are they going to cooperate with team members to finish the work piece and report.
The principle parts of milling machine are base, column, knee, saddle, table, over hanging arm,
front, brace, spindle and arbour. The base of the machine is grey iron casting accurately machined on
its top and bottom surface and serves as a foundation member for all the other parts which rest upon
it. It carries the column at its one end. In some machines, the bage is hollowed and working as a
reservoir for cutting fluid. Secondly, the column is the main supporting frame mounted vertically on
the bage. The column is box shaped. Heavily ribbed inside and houses all the driving mechanisms for
the spindle and table feed. The front vertical face of the column is accurately machined and is
provided with dovetail guide ways of supporting knee. The top of the column is finished to hold an
over-arm that extends outward at the front of the machine.

Besides, the table rest on ways on the saddle and travels longitudinally. The top of the table is
accurately finished and T-slots are provided for clamping the work and other fixtures on it. A lead
screw under the table engages a nut on the saddle to move the table horizontally by hand or power.
The longitudinal travel of the table may be limited by fixing trip dogs on the side of the table. In
universal machines, the table may also be swivelled horizontally. For this purpose the table is
mounted on a circular bage which in its turn is mounted on the saddle. The circular bage is graduated
in the degree.
The knee is the rigid grey iron casting that slides up and down on the vertical way of the column
face. The adjustment of height is effected by elevating screw on the base that also supports the knee.
The knee houses the feed mechanism of the table, and in different controls to operate it. The top face
of the knee forms slid way for the saddle to provide cross travel of the table. Then, the saddle is
placed on the top of the knee, which slides on guide ways set exactly at 90 to column face. A cross
feed screw near the top of the knee engages a nut of the bottom of the saddle to move it horizontally,
by hand or power, to apply cross feed. The top of the saddle is accurately machined to provide guide
ways for the table.
After that, the table rest on ways on the saddle and travels longitudinally. The top of the table is
accurately finished and T-slots are provided for clamping the work and other fixtures on it. A lead
screw under the table engages a nut on the saddle to move the table horizontally by hand or power.
The longitudinal travel of the table may be limited by fixing trip dogs on the side of the table. In
universal machines, the table may also be swivelled horizontally. For this purpose the table is
mounted on a circular bage which in its turn is mounted on the saddle. The circular bage is graduated
in the degree.
Apart of that, the spindle of the machine is locates in the upper part of the column and receive
power from the motor through belts, gears and clutches and transmit it to the arbour the front end of
the spindle just projects from the column face and it is provided with a tapered hole into to which
various cutting tools and arbours may be inserted. The accuracy in metal machining by the cutter
depends on primarily accuracy, strength and rigidity of the spindle.
Other than that, overhanging arm is mounted on the top of column extends beyond the column face
and serve as a bearing support may be provided nearest to the cutter. More than one bearing support
may be provided for the arbour. Then, the front brace is an extra support that is fitted between the
knee and over arm to ensure further rigidity to the arbour and the knee. The front brace is slotted to
allow for adjustment of the height of the knee relative to over arm.

Lastly, an arbour is considered as an extension of the machine spindle on which cutters are
securely mounted and rotated. The arbours are made with taper shanks for proper alignments with
machine spindles having taper hole on their nose. The taper shank of the arbour conforms to the
Morse taper or self-release taper whose value is 7:24. The arbour may be supported at the farthest
end from the overhanging arm or may be of cantilever type which is called stub arbour.

Methodology:
During the process cycle, steps of operations is performed onto the workpiece to yield the desired
part shape. The following operations are each defined by the types of cutter used and the path of that
cutter is used to remove steel from the workpiece. At first, we processed the work piece by using the
milling machine on mini precision vise is face milling. A face mill machine is used on the flat
surface of the workpiece in order to provide a smooth finish. The depth of the face, typically very
small, may be machined in a single pass or may be reached by machining at a smaller axial depth of
cut and making multiple passes. Follow then is by drilling. A drill is entered into the workpiece
axially and cuts a hole with a desired diameter equal to that of the drilling tool. A drilling operation
can produce a blind hole, which extends to some depth inside the workpiece, or a through hole,
which extends throughout the workpiece.

Besides that, another process that we performed is end milling. An end mill makes either slot cuts or
peripheral, determined by the step-over distance, across the workpiece in order to machine a
specified feature, such as a profile, slot, pocket, or even a complex surface contour. The depth of the
feature may be machined in a single pass or may be reached by machining at a smaller axial depth of
cut and making multiple passes. Furthermore, we also performed slot cutting. The operation of
production of key ways, grooves and slots of varying shapes and size can be performed in a milling
machine by using a mills cutter and a metal slitting saw. The last process to perform onto the work
piece is chamfer milling. A chamfer end mill makes a peripheral cut along an edge of the workpiece
or a feature to create an angled surface, known as a chamfer. This chamfer, typically with a 45
degree angle, can be machined on either the exterior or interior of a part and can follow either a
straight or curved path.

The types of machines we have used to produce our work piece are the surface grinder and the
vertical milling machine. The vertical milling machine can be recognized by the position of its

spindle which is vertical (normal to the work table). The table can be moved in all the axes (X, Y and
Z). The spindle head which is clamped to the vertical column can be swivelled at any angle,
permitting the milling cutter mounted on the spindle to work on angular surfaces. The machines
spindle can also be adjusted up or down relative to work piece. This machine is adapted for
machining grooves, slots and flat surfaces. The end mills and face milling cutters are the usual tools
mounted on the spindle.

Milling machine is used to perform slot mill, hole-drilling, and surface mill. Surface grinder is used
to produce very fine finishes or making very light cuts, by using an abrasive wheelas the cutting
device makes the product smooth. The tools that is used is end mill, slot drill and face mill. The
diameter size of end mill used is 10mm, 12mm. The diameter of the slot drill used is 4.2mm, 8mm
and 10mm. The clamping technique used for milling machine is vise clamping. The vise can be
adjusted to any desired degree as we wanted. The clamping technique used for grinding machine is
magnetic clamp. The magnetic clamp is used because our product is a magnetic material.

During the machining process, the cutting fluid used is oil-water emulsion. The coolant is used to
cool the cutting tool and also the work piece during machining process. The primary function of
cutting fluid is cooling, and at the same time, the cutting fluid acted as a lubricant. A fluid's cooling
and lubrication properties are critical in decreasing tool wear and extending tool life. Cooling and
lubrication are also important in achieving the desired size, finish and shape of the workpiece. A
secondary function of cutting fluid is to wash away chips and metal fines from the tool/workpiece
interface to prevent a finished surface from becoming marred and also to reduce the occurrence of
built-up edge (BUE).

Hereby, we attached the formula used for cutting speed:

Where,
V = Cutting speed
=
d = Diameter of cutter
n = Rotation per minute (RPM)

Process Plan:
Part 1: Base
No

Process

Size

Machine

5050105

Bench saw

Prepare raw
material

Remove burr

Squaring
base

4545100

Milling
machine

Drilling
(a) centre
drill
(b) drill

D5
(6 holes)
M5
(2 holes)

Milling
machine

Cut U-slot

8 100 4

Milling
machine

Rotate
U-slot

8 100 4

Milling
machine

Oblong slot

D10

Milling
machine

Oblong slot

D12

Milling
machine

L slot

D12

Milling
machine

10

Tapering

M5

PIC

Loke Chi Kin

Files

Tan Jun Zhe

KhooBaoShen
Tan Jun Zhe
KhooBaoShen
Loke Chi Kin

Tool

Face mill, files,

milling machine
vise, vise handle,
vernier callipers,
parallel bars, and
millets.
Drills, centre drills,
files, milling
machine vise, vise
handle, vernier
callipers, parallel
bars, and millets.
End mill, files,
milling machine
vise, vise handle,
vernier callipers,
parallel bars, and
millets.
End mill, files,
milling machine
vise, vise handle,
vernier callipers,
parallel bars, and
millets.
End mill, files,
milling machine
vise, vise handle,
vernier callipers,
parallel bars, and
millets.
End mill, files,
milling machine
vise, vise handle,
vernier callipers,
parallel bars, and
millets.
End mill, face mill,
files, milling
machine vise, vise
handle, vernier
callipers, parallel
bars, and millets.
Tap and tap holder.

Tan Jun Zhe

Loke Chi Kin

15

30

Tan Jun Zhe

KhooBaoShen

40

KhooBaoShen
Loke Chi Kin

50

Tan Jun Zhe

KhooBaoShen

60

Tan Jun Zhe

Loke Chi Kin

75

Tan Jun Zhe

KhooBaoShen
Loke Chi Kin

95

Tan Jun Zhe

KhooBaoShen
Loke Chi Kin

100

Remarks

Part 2: Movable Jaw

No.

Process

Size

Prepare raw
material

505030

Remove burr

Squaring

Machine

Tool

PIC

Bench
saw

Loke Chi Kin

Files

453024

Milling
machine

Slotting

D12

Milling
machine

V-slotting

D10

Milling
machine

Chamfering

D14

Milling
machine

Drilling

D8

Milling
machine

Boring

D14

Milling
machine

Slotting

Face mill, files,

milling machine
vise, vise handle,
vernier callipers,
parallel bars, and
millets.
End mill, files,
milling machine
vise, vise handle,
vernier callipers,
parallel bars, and
millets.
End mill, files,
universal angle
milling vise,
vernier callipers,
parallel bars, and
millets.
Face mill, files,
universal angle
milling vise,
vernier callipers,
parallel bars, and
millets.
Drill, files,
universal angle
milling vise,
vernier callipers,
parallel bars, and
millets.
Ball nose drill,
files, universal
angle milling
vise, vernier
callipers, parallel
bars, and millets.
End mill, files,
universal angle
milling vise,
vernier callipers,
parallel bars, and
millets.

Tan Jun Zhe

KhooBaoShen
Tan Jun Zhe
KhooBaoShen
Loke Chi Kin

Milling
machine

%
5
8
15

Tan Jun Zhe

KhooBaoShen
Loke Chi Kin

25

Tan Jun Zhe

KhooBaoShen

35

Tan Jun Zhe

Loke Chi Kin

60

KhooBaoShen
Loke Chi Kin

75

Tan Jun Zhe

Loke Chi Kin

85

Tan Jun Zhe

KhooBaoShen

100

Remarks

Fabrication:
Many steps were carried out to produce the final shape of the work piece. Firstly, the raw materials
were prepared using bend saw. The original size of the base was 105mm 50mm 50mm while the
moveable jaw was 50mm 50mm 35mm. Before the parts were operated using the milling
machine, burr was removed using file tools. Then, the remaining processes were done by using the
milling machine.
The process was started by squaring the base with the method of face-milling. This process is done to
remove the outer park of the work piece until the required dimension, which is 100mm 35mm
45mm. The moveable jaw has undergone the process of squaring too. The required dimension was
35mm 30mm 24mm. Next, 6 holes was drilled from one side of the base on part (1) (Refer to
Appendix). Centre drill and a 4.8mm drill were used to drill through the work piece to produce the
holes. Then, centre drill was performed on part (2) followed by 10mm of drilling with a 4.1mm drill.
The process was then continued with cutting of U-slot along the base on part (3) using an 8mm end
mill and the depth is 4mm. After that, the same end mill was used to perform a rotate U-slot on part
(4) with the depth of 4mm. Afterwards, oblong slotting was performed from the bottom of work
piece. By using 10mm end mill, the oblong slot was done with the width of 16mm and 25mm deep.
Next, slotting was done around the part (5) with a 12mm end mill in order to remove the remaining
unwanted part using face mill. 65mm 35mm 25mm of metal has been removed. Lastly, two holes
of M5 were performed at part (2) with taperingusing tap and tap holder.
The moveable jaw was firstly done with U-slotting on part (6) with a 10mm end mill. Next, the same
end mill was used for the part (7), the two v-slotting. These parts are done with clamping the work
piece on the universal angel milling vise. After that, a face mill was used to chamfering at around
part (8) until the diagonal length was 16mm. Then, a 8mm drill was used to drill through the
moveable jaw diagonally at part (9), followed by an 14mm diameter ball nose with 7mm deep. Lastly,
a 10mm end mill was used for the process slotting at the part (10) which is at another surface of the
work piece.

Result and Discussion:

Part 1: Base
Part
A1
A2
A3
A4
A5
A6
A7
A8
A9
A10
B1
B2
B3
B4
B5
B6
B7
B8
B9
C1
C2
C3
C4
C5

Required Dimension, mm
45.00
8.00
19.00
8.00
10.00
12.00
37.00
45.00
10.00
8.50
25.00
11.00
25.00
12.50
M5
4.00
8.00
24.00
100.00
16.00
10.00
19.00
57.00
71.00

Actual Dimension, mm
45.10
8.20
19.00
8.10
10.00
12.00
37.20
45.00
10.00
8.50
25.10
11.00
25.00
12.50
M5
4.00
8.00
24.00
100.00
15.90
9.80
19.00
57.00
70.80

Tolerance, mm
+0.10
+0.20
0.00
+0.10
0.00
0.00
+0.20
0.00
0.00
0.00
+0.10
0.00
0.00
0.00
0.00
0.00
0.00
0.00
0.00
-0.10
-0.20
0.00
0.00
-0.20

Actual Dimension, mm
24.10
4.00
0.50
10.00
37.20
45.20
R7 depth 7
D8.20
1.82
30.20

Tolerance, mm
+0.10
0.00
0.00
0.00
+0.20
+0.20
0.00
+0.20
-0.18
+0.20

Part 2: Moveable jaw

Part
A1
A2
A3
A4
A5
A6
B1
B2
B3
C1

Required Dimension, mm
24.00
4.00
0.50
10.00
37.00
45.00
R7 depth 7
D8.00
2.00
30.00

Conclusion and recommendation:

In a nut shell, we had successfully completed this project in time with the cooperation between the
group members and guidance from lecturer. Throughout the project, we have learned about the basic
operations on the milling machine, the importance of safety in the laboratory, and some precautions
before carry out the machining work. Now we have a better understanding on various operations that
can be carry out on milling machine such as face-milling, drilling, slotting and so on.
It is recommended that to do some research and study on milling operation before carry out
machining work on it. It helps to prevent mistakes when carrying out machining job like the
selection of chuck ant the technique of clamping.

Reference:
1.

https://www.nmri.go.jp/eng/khirata/metalwork/milling/intro/index_e.html

(Retrieved 22th December 20140

2. http://www.thomasnet.com/articles/machinery-tools-supplies/how-milling-machines-work
(Retrieved 22th December 2014)
3. www.maritime.org/doc/pdf/milling-machine.pdf
(Retrieved 22th December 2014)

Appendix:

A tool named face mill which we used to

perform facing process in the milling
machine.

Slotting operation on milling machine

using end mill.

Drill chart and drill used for the drilling

process.

The work piece was clamp on the

milling machine and the operations are
performed.

Final product:
Part 1: Base

Part 2: Moveable jaw