MACHINIST / MILLING
Name of Sector Production & Manufacturing Name of Module Milling
Minimum Age 18 Years Duration of Course 6 Months
ADU Code MAN703

Degree in Mechanical Engineering with one year Experience

(OR)

Diploma in Mechanical Engineering with two year Experience

(OR)

NTC/ NAC in Turner Trade with three years of Experience



TERMINAL COMPETENCY: The successful candidate would be able to:

Use safety devices.

Familiar with the necessary safety precautions required to run a milling machine Plan the sequence of operations.

Identify and know the purpose of the work-holding and driving accessories.

Identify and know the purpose of the cutting-tool-holding accessories and attachments.

Know the various types of materials, milling cutters, measuring instruments and its application.

Know the purpose of the main operational parts of horizontal and vertical milling machine.

Determine spindle speed, feed and depth of cut for different materials as roughing, finishing milling operation.

To operate the conventional Milling machine along with standard accessories.

Produce components using plain milling, angular milling, slotting and key-way cutting.

Milling six faces of a cubical block to an accuracy of ± 0.1mm

Calculate gear tooth dimensions, set up for milling a spur gear and helical gear.

Calculate and milling a square hexogen by direct indexing.

Set up and mill dovetails, V-block, & T- slot.

Identify milling fault and correction.



Practical Competencies Underpinning Knowledge (Theory)

OSH & Safety Practices: (10 hours)

  • Fire Fighting in workplace & Precautions
  • General Safety of Tools & Equipments
  • Awareness on OSH related to the job


  • Fire Extinguishers & its Types
  • Safely handling Tools & Equipments
  • Use of proper Tools & Equipments & its maintenance
  • OSH & practices to be observed as a precaution

Personnel & Material Safety: (10 hours)

  • Select, use, clean and store personal safety protective equipment.
  • Use and store of materials in a safe manner.
  • Demonstrate the use of safety devices on metal cutting machines.
  • 5S norms


  • State the safety precaution specific to turning on the lathe.
  • Safety related to handling of materials.
  • Safety devices used for safe machining.

Milling m/c & Tool specification: (40 hours)

  • Operation of milling machines
  • Tools, general cleaning and maintenance and safe storage of tools applicable to workshop tasks.
  • Identifying different types of cutter used in Horizontal milling machine.
  • Identifying different types of cutter used in Vertical milling machine
  • Identifying different parts of Horizontal milling machine and importance of each part.
  • Identifying different parts of Vertical milling machine and importance of each part


  • Introduction to milling, description, types of milling m/c - constructional features and functions.
  • Types of milling tools and their uses.
  • Classification & properties of tool materials & selection criteria. ISO specification on carbide tools.
  • Horizontal milling machine
  • Vertical milling machine
  • Horizontal milling operations- milling of flat surfaces, Gang and straddle milling, production of narrow slots, slotting and slitting of thin plates, key way cutting etc.
  • Describe vertical milling operations-milling of sunk and recessed surfaces,woodruff cutters, use of shell end mills, face mills, face slot cutters, dovetail cutters etc.

Job Holding & Centering: (40 hours)

  • Job holding devices on metal cutting machines & safety precautions.
  • Study of process planning sheet
  • Practice on leveling the job.
  • Tool holding devices and setting the same.


  • Different job holding devices in turning.
  • Describe the basic method of Work holding devices - three jaw chuck, four jaw chuck, face plate, collect chuck etc.
  • Describe the basic methods of supporting work – fixed steady, traveling steady.

Measuring job: (40 hours)

  • Measurements using Calipers & standard scale.
  • Check measurements of components/machined parts, using micrometers and verniers.
  • Check roundness of components using the dial test indicator and V-blocks.


Describe the principle of the measuring instruments: its use and care for measurement setting up and assembly operations-

Micrometer: internal, external, depth.

Vernier: Caliper, depth, height. bore dial gauge.

Dial test indicator: its measurement.

Milling operation: (120 hours)

  • Marking practice. Use of hand tools.
  • Plain milling, slab milling.
  • Work alignment, cutting as per sample and parting off.
  • Checking flatness with tri-square.
  • Checking squareness with tri-square.
  • Step milling using side and face milling cutter.
  • Milling six faces of a cubical block to an accuracy of ± 0.1mm.
  • Measure using Vernier caliper
  • Angular milling using angular milling cutter and checking with bevel protractor.
  • Slot milling using slot milling cutter / slitting saw.


  • Describe the geometry of the milling tool including tool angles and its effect on machining operation.
  • Cutting fluid types, properties & applications.
  • Selection of cutting speed, feed and depth of cut.

Advance Milling: (120 hours)

  • Centering, pilot drilling, counter drilling, and chamfering.
  • Slot milling using vertical milling machine.
  • Milling a V-block, Dovetail & T-slot
  • Use of dividing head.
  • Milling a square, hexagon on a round rod using direct indexing.


  • Describe Dividing head - types, parts,
  • Calculation of spindle speeds, feeds & depth of cut for different material for relevant milling operations such as roughing and finishing etc.
  • Calculation of direct indexing to mill a polygon.

Gear cutting: (120 hours)

  • Identify different types of gear.
  • Milling a rack, by linear indexing method.
  • Cut Spur gear on horizontal milling machine by using indexing head.
  • Gear tooth measurement using gear tooth vernier caliper.
  • Measurement of gear tooth using flange micrometer


  • Types of Gear and its use.
  • Describe universal indexing head - parts and function.
  • Describe methods of indexing and their Calculation.
  • Describe Rack - types, nomenclature
  • Nomenclature of spur gear
  • Describe methods of producing rack on
  • milling machine.
  • Describe methods of producing Spur gear on milling machine.
  • Identify and report milling machine faults