Workshop Practical Manual

MCB1043: Manufacturing Technology
Workshop Practical Manual

May, 2011 Semester
Student Name: Actual Group Number
Student ID: Attendance (Technicians Stamp) Lab Manual Marks Work Piece Marks
Date Conventional Milling Conventional Lathe CNC Milling 1 CNC Milling 2 CNC Lathe 1 CNC Lathe 2 CNC Bridgeport Arc Welding 1 Arc Welding 2 Arc Welding 3 Metrology
Note: All lab reports must be completed by the end of each lab session. Late submissions will not be accepted.
Receive By:
Date/Time: ____________ _
SAFETY AGREEMENT
I, named as below, fully understand all the regulations pertaining to the Health, Safety and Environment in the laboratory as listed in Appendix J of this manual, and therefore shall abide and follow all the rules and instructions.
Name: IC/Passport No: Date: Signature:
1. Conventional Milling
1.1 Objective: To perform milling processes on a rectangular workpiece according to specifications given in a technical drawing. 1.2 Workshop Outcomes At the end of this workshop, students should be able to: 1. Explain the components of conventional milling machines. 2. Generate a milling process plan based on an end product. 3. Use a milling machine in the appropriate manner and according to relevant safety standards. 1.3 Machine Specifications Distance between spindle axis and table working surface: 30mm 440mm Distance between body vertical guides and table body: 218mm 469mm Table working surface: 300 mm x 1250 mm Table swivel: 45o Feed: Normal longitudinal 12.5 630 mm/min Transversal 12.5 630 mm/min Vertical 5.2 262 mm/min Main drive: 40 2000 RPM Main drive motor: 5.5 kW, 1440 RPM Feed drive motor: 1.5 kW, 920 RPM 1.4 Refer to Appendix A for procedures and machine operation details. For full operations manual, consult lab technicians and equipment manual. 1.5 Safety Instructions: Never operate the machine without wearing the correct protective
clothing, (i.e. safety shoes, safety glasses, overalls do not wear loose clothing, do not wear jewellry). Make sure the machine is suitably positioned and that the surrounding floor area is kept clean and free from scrap material, oil and grease. Always concentrate on your work careless acts can result in serious injury. Persons not involved in machine operation should be kept at a safe distance. Do not engage in the machines main drive with a loose workpiece or cutting tool. Do not attempt to adjust or remove tools when the machine is in operation. Always use protective screen when working with the vertical milling head Ensure that the cutting tools are suitable and in good working order.
Technical Drawing (label the figure)
1.6 Project Report: Conventional Milling A. Sketch the conventional milling machine, label the major components and state the functions of these components.
No 1. 2. 3. 4. 5. 6. 7. 8. 9. 10.
Component
Function
B. Sketch the tooling and workholding devices to be used and state the functions of these components.
C. Summarize the process plan for machining the part. Operation Sheet Part Name:
Op no. Operation Machine tool Cutting tool Cutting Speed Spindle Speed (RPM) Feed DOC Remarks
1.
2.
3.
4.
5.
6.
7.
8.
9.
10
Date:
D. Results
Dimensional check Dimension Nominal A B C D E Actual Technicians Verification
E. Discussion
F. Conclusion

May, 2011 Semester
Receive By:
10Date/Time: ____________ _
SAFETY AGREEMENT
11
2. Conventional Lathe
2.1 Objective: To perform lathe processes on a cylindrical workpiece according to specifications given in a technical drawing. 2.2 Workshop Outcomes At the end of this workshop, students should be able to: 1. Explain the components of a conventional lathe engine. 2. Generate a lathe process plan based on an end product. 3. Use a lathe engine in the appropriate manner and according to relevant safety standards. 2.3 Machine Specifications 2.4 Refer to Appendix B for procedures and machine operation details. For full operations manual, consult lab technicians and equipment manual. 2.5 Safety Instructions
Ensure quill cover, rapid traverse mechanism and control panel and chuck guard are closed DO NOT operate machine if there are any faults in the electrical cabinet door, quill cover or chuck guard interlocks Isolate power in advance for maintenance and repairs. The machine should be stopped at the slightest fault, the cause established and rectified. Only then should the machine be restarted DO NOT operate machine if the clearance between the guideways and the sliding surfaces of the carriage exceeds 0.03 mm. DO NOT operate the machine when the tool is not correctly fixed, when hard allowed plates with improper welding are used, or when the hard allowed replacement plates are incorrectly fixed. Ensure that you have selected a suitable mode of operation and cutting tool. Tighten the loosened tailstock if necessary. Ensure that you know how to stop a machine before starting it. Keep all guards, covers and doors in place and closed. Never lay anything on the working surface of the machine. Stop the machine immediately should anything unexpected happen.
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Technical Drawing (label the figure)
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2.6 Project Report: Conventional Lathe A. Sketch the conventional milling machine, label the major components and state the functions of these components.
No. 1. 2. 3. 4. 5. 6. 7. 8. 9. 10.
Component
Function
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B. Sketch the tooling and workholding devices to be used and state the functions of these components.
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C. Summarize the process plan for machining the part. Operation Sheet Part Name:
Op no. Operation Machine tool Cutting tool Cutting Speed Spindle Speed (RPM) Feed DOC Remarks
1.
2.
3.
4.
5.
6.
7.
8.
9.
10
Date:
16
D. Results
Dimensional check Dimension Nominal A B C D E Actual Technicians Verification
17
E. Discussion
F. Conclusion
18

May, 2011 Semester
Receive By:
19Date/Time: ____________ _
SAFETY AGREEMENT
20
3. CNC Milling 1
3.1 Objective: To perform CNC programming and operation of a CNC milling machine. 3.2 Workshop Outcomes At the end of this workshop, students should be able to: 1. Explain the components of a CNC milling machine. 2. Generate a part programme. 3. Use a CNC Milling Machine in the appropriate manner and according to relevant safety standards. 3.3 Machine Specifications: Maximum cross travel Maximum longitudinal travel Maximum head travel Working table surface Spindle speed Machine resolution
90mm 170mm 115mm 360mm x 130mm 0 4000 RPM 0.01mm
3.4 Refer to Appendix C for procedures and machine operation details. For full operations manual, consult lab technicians and equipment manual. 3.5 Safety Instructions All activities in the CNC lab must be done under supervision. Familiarize yourself with the procedure before actually
operating the equipment. If unsure, request assistance from the lab instructor. Immediately report all malfunctions or unusual occurrences to the lab instructor. Wear suitable clothing. No open-toe shoes are allowed. Slippers, bracelet, wristwatches and rings are strictly prohibited during lab. Ensure that workpiece is secured before operating the machine. Follow safety instructions by the lab instructor. Apron must be worn at all time during each practice session. Avoid foolish behaviour and concentrate on your practice. Only operate machine when the safety guards are closed. Never touch any moving parts of the machine or workpiece. Ensure that there are no loose items near the machine.
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3.6 1. 2. 3. 4. 5. 6. 7.
Tasks
Determine the appropriate machining parameters as in 3.7.B Perform all start-up and initialization procedures Set the origin at the top center of the workpiece Perform a linear interpolation along x-axis Performa a linear interpolation along y-axis Perform a linear interpolation along both x and y axes Perform a circular clockwise interpolation with an arc radius of 15 mm and arc start at 10,10. 8. Perform a circular counter-clockwise interpolation with an arc radius of 1.5 inches and arc start at -10,-10. 9. Create a square profile with a 45 mm width, using right hand radius compensation
3.7 Project Report: CNC Milling 1 A. Sketch the CNC milling machine, label the major components and state the functions of these components.
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B.
Machining parameters
Determine the appropriate (range of) machining parameters: Cutting Speed:
Feed:
Depth of cut:
Spindle speed:
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C. Part programme i) Header Part Program - Header
ii)
Part programme (body) for 3.6.3 Part Program - Body
iii)
iv)
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v)
vi)
vii)
viii)
25
D. Results
E. Discussion
F. Conclusion
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4. CNC Milling 2
4.1 Objective: To perform CNC programming and machining on a rectangular workpiece according to the given pattern and dimensions. 4.2 Workshop Outcomes At the end of this workshop, students should be able to: 1. Generate a milling process plan based on an end product. 2. Use a CNC milling machine in the appropriate manner and according to relevant safety standards. 4.3 Machine Specifications: Maximum cross travel Maximum longitudinal travel Maximum head travel Working table surface Spindle speed Machine resolution
90mm 170mm 115mm 360mm x 130mm 0 4000 RPM 0.01mm
4.4 Refer to Appendix C for procedures and machine operation details. For full operations manual, consult lab technicians and equipment manual. 4.5 Safety Instructions All activities in the CNC lab must be done under supervision. Familiarize yourself with the procedure before actually
operating the equipment. If unsure, request assistance from the lab instructor. Immediately report all malfunctions or unusual occurrences to the lab instructor. Wear suitable clothing. No open-toe shoes are allowed. Slippers, bracelet, wristwatches and rings are strictly prohibited during lab. Ensure that workpiece is secured before operating the machine. Follow safety instructions by the lab instructor. Apron must be worn at all time during each practice session. Avoid foolish behaviour and concentrate on your practice. Only operate machine when the safety guards are closed. Never touch any moving parts of the machine or workpiece. Ensure that there are no loose items near the machine.
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4.6 Project Report: CNC Milling 2 A. Pattern and dimensions for tool path
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B.
Feed:
Depth of cut:
Spindle speed:
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C. Summarize the process plan for machining the part. Operation Sheet Part Name: Op no 1. Operation Machine tool Cutting Cutting tool Speed Spindle Speed (RPM) Feed DOC Remarks
2.
3.
4.
5.
6.
7.
8.
9.
Date: 30
D. Part program.
Part Program
E. Results
31
F. Discussion
G. Conclusion
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May, 2011 Semester
Receive By:
33Date/Time: ____________ _
SAFETY AGREEMENT
34
5. CNC Lathe 1
5.1 Objective: To perform CNC programming and operation of a CNC lathe machine. 5.2 Workshop Outcomes At the end of this workshop, students should be able to: 1. Explain the components ofa CNC lathe machine. 2. Generate a part programme. 3. Use a CNC lathe machine in the appropriate manner and according to relevant safety standards. 5.3 Machine Specifications Swing over bed Swing over cross slide Distance between centers Spindle power Spindle speed Machine resolution
150mm 50mm 300mm 1 HP 0-3000 RPM 0.01 mm
5.4 Refer to Appendix D for procedures and machine operation details. For full operations manual, consult lab technicians and equipment manual. 5.5 Safety Instructions
1. All activities in the CNC lab must be done under supervision. 1. Familiarize yourself with the procedure before actually operating the equipment. If unsure, request assistance from the lab instructor. 2. Immedeately report all malfunctions or unusual occurences to the lab instructor. 3. Wear suitable clothing. No open-toe shoes are allowed. Slippers, bracelet, wristwatches and rings are strictly prohibited during lab. 4. Ensure that workpiece is secured before operating the machine. 5. Follow safety instructions by the lab instructor. 6. Apron must be worn at all time during each practice session. 7. Avoid foolish behaviour and concentrate on your practice. 8. Only operate machine when the safety guards are closed. 9. Never touch any moving parts of the machine or workpiece. Ensure that there are no loose items near the machine.
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5.6
Tasks
1. Determine the machining parameters as in 6.7.B 2. Perform all start-up and initialization procedures 3. Use rapid traverse to move the cutting tool close (within 3 mm) to the workpiece 4. Use G01 to reduce 1mm of the work piece diameter 5. Use G01 to face 1mm off the work piece 6. Perform taper process using G01 code from datum point (0,0) to (X10, Z-10).Use simulation mode to view the process. 7. Use simulation process to view G02 machining profile from datum point (0,0) to point (X10, Z-10). 8. Use G03 code to produce circular interpolation machining profile from datum point (0,0) to point (X10, Z-10)
5.7 Project Report: CNC Lathe A. Sketch the CNC lathe machine, label the major components and state the functions of these components.
36
B.
Determine the appropriate (range of) machining parameters: Cutting speed:
Feed:
Depth of cut:
Initial spindle speed:
C. Part programme i) Header Part Program - Header
37
ii)
iii)
iv)
v)
38
vi)
viii)
vii)
Part programme (end) Part Program - End
39
D. Results
G. Discussion
H. Conclusion
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6. CNC Lathe 2
6.1 Objective: To perform CNC programming and machining on a cylindrical workpiece according to the given pattern and dimensions. 6.2 Workshop Outcomes At the end of this workshop, students should be able to: 1. Generate a lathe process plan based on an end product. 2. Use a CNC lathe machine in the appropriate manner and according to relevant safety standards. 6.3 Machine Specifications: Swing over bed Swing over cross slide Distance between centers Spindle power Spindle speed Machine resolution
150mm 50mm 300mm 1 HP 0-3000 RPM 0.01 mm
6.4 Refer to Appendix D for procedures and machine operation details. For full operations manual, consult lab technicians and equipment manual. 6.5 Safety Instructions All activities in the CNC lab must be done under supervision. Familiarize yourself with the procedure before actually
operating the equipment. If unsure, request assistance from the lab instructor. Immedeately report all malfunctions or unusual occurences to the lab instructor. Wear suitable clothing. No open-toe shoes are allowed. Slippers, bracelet, wristwatches and rings are strictly prohibited during lab. Ensure that workpiece is secured before operating the machine. Follow safety instructions by the lab instructor. Apron must be worn at all time during each practice session. Avoid foolish behaviour and concentrate on your practice. Only operate machine when the safety guards are closed. Never touch any moving parts of the machine or workpiece. Ensure that there are no loose items near the machine.
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6.6 Project Report: CNC Lathe 2 A. Pattern and dimensions for tool path
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B.
Feed:
Depth of cut:
Spindle speed:
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C. Summarize the process plan for machining the part. Operation Sheet Part Name: Op no 1. Operation Machine tool Cutting Cutting tool Speed Spindle Speed (RPM) Feed DOC Remarks
2.
3.
4.
5.
6.
7.
8.
9.
Date:
44
D. Part program.
Part Program
E. Results
45
F. Discussion
G. Conclusion
46

May, 2011 Semester
Receive By:
47Date/Time: ____________ _
SAFETY AGREEMENT
48
7. CNC Bridgeport Milling

7.1 Objective: To perform CNC program and machining on a rectangular work piece according to the given technical drawing. 7.2 Workshop Outcomes At the end of this workshop, students should be able to: 4. Generate a milling process plan & part program based on an end product. 5. Use a CNC Bridgeport milling machine in the appropriate manner and according to relevant safety standards. 7.3 Machine Specifications: Manufacturer Model Maximum travel X Axis Y Axis Z Axis Working table surface Table load Spindle speed Bridgeport VMC 2216 560 mm 406 mm 508 mm 838mm x 356mm 341 kg 0 10,000 RPM
7.4 Refer to Appendix K for procedures and machine operation details. For full operations manual, consult lab technologists and equipment manual. 7.5 Safety Instructions All activities in the CNC lab must be done under supervision. Familiarize yourself with the procedure before actually
operating the equipment. If unsure, request assistance from the lab instructor. Immediately report all malfunctions or unusual occurrences to the lab instructor. Wear suitable clothing. No open-toe shoes are allowed. Slippers, bracelet, wristwatches and rings are strictly prohibited during lab. Ensure that work piece is secured before operating the machine. Follow safety instructions by the lab instructor. Apron must be worn at all time during each practice session. Avoid foolish behavior and concentrate on your practice. Only operate machine when the safety guards are closed. Never touch any moving parts of the machine or work piece. Ensure that there are no loose items near the machine.
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7.6 1. 2.
Tasks Generate a milling process plan and part program based on the given technical drawing. Use a CNC Bridgeport milling machine to perform the machining process.
7.7 Project Report: CNC Bridgeport Milling A. Part Program
Part Program
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B. Results
C. Discussion
D. Conclusion
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8. CNC Bridgeport Lathe

8.1 Objective: To perform CNC program and machining on a cylindrical work piece according to the given technical drawing. 8.2 Workshop Outcomes At the end of this workshop, students should be able to: 1. Generate a lathe process plan & part program based on an end product. 2. Use a CNC Bridgeport lathe machine in the appropriate manner and according to relevant safety standards. 8.3 Machine Specifications Manufacturer Model Power Voltage Current Cutting Diameter Cutting Length Bore Tool Spindle Chuck size Bridgeport Romi Power Path - 15 25 KVA 230 VAC 63 A 280 mm 540 mm 51 mm 12 piece 0 - 4500 rpm 203 mm
8.4 Safety Instructions

1. All activities in the CNC lab must be done under supervision. 2. Familiarize yourself with the procedure before actually operating the equipment. If unsure, request assistance from the lab instructor. 3. Immediately report all malfunctions or unusual occurrences to the lab instructor. 4. Wear suitable clothing. No open-toe shoes are allowed. Slippers, bracelet, wristwatches and rings are strictly prohibited during lab. 5. Ensure that work piece is secured before operating the machine. 6. Follow safety instructions by the lab instructor. 7. Apron must be worn at all time during each practice session. 8. Avoid foolish behavior and concentrate on your practice. 9. Only operate machine when the safety guards are closed. 10. Never touch any moving parts of the machine or work piece. Ensure that there are no loose items near the machine.
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8.5 1. 2.
Tasks Generate a lathe process plan and part program based on the given technical drawing. Use a CNC Bridgeport lathe machine to perform the machining process.
8.6 Project Report: CNC Bridgeport Lathe H. Part Program
Part Program
53
I. Results
J. Discussion
K. Conclusion
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May, 2011 Semester
Receive By:
Date/Time: 55____________ _
SAFETY AGREEMENT
56
9. Welding 1
9.1 Objective: Familiarization with welding operations 9.2 Machine specifications Nichia Arc Welding Machine, ND-300 Stick electrode welding Input voltage: 220 V, Frequency:50/60 Hz, Rated input: 13 kW Output no-load voltage: 80 V Output range: AC 50 300 A, DC 30 250 A
9.3 Refer to Appendix E for procedures and operation details. For complete operations manual, consult lab technicians and equipment manual. 9.4 Safety Instructions:
Keep at a safe distance from the demonstrator. Exercise caution as welding fumes may be harmful to the welder. Ensure you utilize the available personal protective equipment (i.e. welding helmet/goggles, chipping goggles, leather gloves, electrode holder, welding jacket). Wear closed toe shoes, preferably boots. Discard frayed cords and wires Keep working area clean.
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9.5 Tasks 1. Familiarize yourself with the welding equipment, workpiece and welding parameters. 2. Check and modify the straightness and the squareness of the surface.
3. Place the workpiece on the table in a flat position. Using the face shield, mark/touch the electrode to the workpiece to produce an arc.
4. Move the electrode slowly while pressing the electrode until it reaches the end of the workpiece. When reaching the end of the workpiece, raise the electrode and turn it away from the workpiece. 5. With your safety goggles on, remove the slag and examine the weld by chipping with a hammer or wire brush. (USE EXTREME CARE AS THE METAL WILL BE HOT)
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6. Examine your workpiece. Consult the workshop instructor on how to improve your weld.
GOOD
POOR
POOR
7. Continue practicing bead forming until you obtain a satisfactory result. 9.6 Project Report A A. Welding equipment, workpiece and welding parameters Title: 1.
2.
3.
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4.
5.
9.7 Project Report B A. Welding equipment, workpiece and welding parameters Title: 1.
2.
3.
4.
5.
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B. Discussion
C. Conclusion
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10. Welding 2
10.1 Objective: Performing a butt joing and lap weld 10.2 Machine specifications Nichia Arc Welding Machine, ND-300 Stick electrode welding Input voltage: 220 V, Frequency:50/60 Hz, Rated input: 13 kW Output no-load voltage: 80 V Output range: AC 50 300 A, DC 30 250 A
10.5.A Butt joint 1. Check and ensure that the workpieces are straight and flat. 2. Tack weld the workpieces into a butt joint.
3. Use a face shield, mark/touch the electrode to produce an arc. When there is a spark, ensure that the angle and distance are
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correct for welding the workpiece. Move the electrode slowly while pressing the electrode until it reaches the end of the workpiece. When reaching the end of the workpiece, raise the electrode and turn it away from the workpiece
4. With your safety goggles on, remove the slag and examine the weld by chipping with a hammer or wire brush. (USE EXTREME CARE AS THE METAL WILL BE HOT) 5. Examine your workpiece. Consult the workshop instructor on how to improve your weld.
GOOD
POOR
POOR
63
11.5.B Lap weld 1. Check and ensure that the workpieces are straight and flat. 2. Tack weld the workpieces into a lap joint.
3. Use a face shield, mark/touch the electrode to produce an arc. When there is a spark, ensure that the angle and distance are correct for welding the workpiece. Move the electrode slowly while pressing the electrode until it reaches the end of the workpiece. When reaching the end of the workpiece, raise the electrode and turn it away from the workpiece
4. With your safety goggles on, remove the slag and examine the weld by chipping with a hammer or wire brush. (USE EXTREME CARE AS THE METAL WILL BE HOT)
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GOOD
10.6 Project Report A. Results
POOR
POOR
B. Discussion
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C. Conclusion
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11. Welding 3
11.1 Objective: Performing a T-joint and corner joint 11.2 Machine specifications Nichia Arc Welding Machine, ND-300 Stick electrode welding Input voltage: 220 V, Frequency:50/60 Hz, Rated input: 13 kW Output no-load voltage: 80 V Output range: AC 50 300 A, DC 30 250 A
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11.5.A T-Joint 1. Check and ensure that the workpieces are straight and flat.
2. Tack weld the workpieces into a T-shaped joint.
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4. With your safety goggles on, remove the slag and examine the weld by chipping with a hammer or wire brush. (USE EXTREME CARE AS THE METAL WILL BE HOT) 5. Examine your workpiece. Consult the workshop instructor on how to improve your weld.
GOOD
POOR
POOR
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11.5.B Corner Joint 1. Check and ensure that the workpieces are straight and flat. 2. Tack weld the workpieces into a T-shaped joint.
4. With your safety goggles on, remove the slag and examine the weld by chipping with a hammer or wire brush. (USE EXTREME CARE AS THE METAL WILL BE HOT)
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GOOD
11.6 Project Report A. Results
POOR
POOR
B. Discussion
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C. Conclusion
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May, 2011 Semester
Receive By:
73Date/Time: ____________ _
SAFETY AGREEMENT
74
12. Metrology
12.1 Objective: To familiarize with the operation of measuring gauges, instruments and equipment. Workshop objectives. By the end of this workshop, students should be able to: 1. Utilize measuring instruments in the proper manner.
12.2
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12.3 Project Report: Metrology 1. Surface Plate Function
Resolution Procedure
Results of sample measurement
Applications
Discussion
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2. V-block Function
Applications
Discussion
77
3. Vernier caliper Function
Applications
Discussion
78
4. Screw thread micrometer Function
Applications
Discussion
79
5. Outside micrometer Function
Applications
Discussion
80
6. Inside micrometer Function
Applications
Discussion
81
7. Depth micrometer Function
Applications
Discussion
82
8. Precision square Function
Applications
Discussion
83
9. Dial indicator Function
Applications
Discussion
84
10. Thickness gauge Function
Applications
Discussion
85
11. Height gauges Function
Applications
Discussion
86
12. Radius gauge Function
Applications
Discussion
87
13. Pitch gauge Function
Applications
Discussion
88
14. Telescopic gauge Function
Applications
Discussion
89
15. Bore gauge Function
Applications
Discussion
90
16. Bevel protractor Function
Applications
Discussion
91
17. Sine bar Function
Applications
Discussion
92
18. Coordinate measuring machine Function
Applications
Discussion
93
19. Laser digitizer Function
Applications
Discussion
94
20. Non-contact measuring machine Function
Applications
Discussion
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APPENDIX A -Procedures and Guidelines for Milling Project

Stock squaring To create a square corner on a part, first orient an already finished edge vertically in the vise. Set a machinist's ( L) square against the finished edge and the bottom of the vise. Lightly tap the part with a plastic hammer to align it with the L Square. Clamp the vise down securely. Now the top edge of the part is ready to be milled. 1. 2. 3. 4. 5. 6. 7. 8. 9. 10. 11. 12. Setup the work piece by placing it onto the vice. Use a parallel bar to raise the workpiece. Secure the workpiece by tightening the vise. Bring the face mill cutter slowly to touch the surface of the material. Move the face mill cutter away. Turn the quill to raise the table 0.5 mm per cut. Mill the surface until a flat surface is achieved Re-setup the workpiece to the next side in order to obtain a 90 angle from the first milled side. Ensure that you use an L square to align the workpiece before you tighten the vise. Repeat steps 2 to 7. Use the height gauge to mark off the remaining material. Cut off the remaining material until the dimensions 38mm x 38mm x 25mm are achieved.
Marking 1. Using the center marker, punch the center of the workpiece. 2. Set the height gauge to the drawing and mark the workpiece. 3. Set the height gauge again and mark on the perpendicular side from the the previous marking. 4. Make a center punch on the center of the work piece. Milling & Drilling 1. 2. 3. 4. 5. Secure the workpiece on the milling vise again with the marking facing up. By using the end mill cutter, mill off the marked portion. Secure the workpiece to a drilling vise. By using diameter 10.25mm drill bit, drill through the workpiece at the center punch mark. Unclamp the work piece.
Tapping 1. Secure the workpiece onto the vise. 2. Tap a hole using an appropriate tap.
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Troubleshooting Guide for Milling
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APPENDIX B - Procedures and Guidelines for Lathe Project

1. 2. 3. 4. 5. 6. 7. 8. 9. 10. 11. 12. 13. 14. 15. 16. Setup the raw material and tighten the chuck. Face one end first (facing process). Mark the workpiece to 90 mm and 50 mm by using a vernier height gauge. Re-clamp the raw material and ensure that the faced side is inside the chuck. Cut the material to 90 mm by using straight turning and facing processes. Center-drill a hole on both ends Use straight turning process in order to obtain 22 mm and 50 mm length. Re-set the work piece to the other side for the next process. Machine to 18 mm and 40 mm length by using straight turning process. Perform a marking process by using a vernier height gauge in order to mark 5 mm and 20 mm in length. On the 5mm length mark, perform a grooving/necking process until 8 mm is achieved. Perform a turning process to 11.8 mm and length 15 mm. Turn Compound Rest to 30 to produce a chamfer according to the project diagram. Re-clamp the raw material and perform an external threading by using a Tap & Die set M12 X 1.75. Setup raw material at the chuck again and use a live center to secure raw material. Perform taper turning to obtain 12 mm at the smaller end with angle 8.
Troubleshooting Guide for Turning
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APPENDIX C - Procedures and Guidelines for CNC Milling Project

Start-up and initialization procedure 1. Turn on main power switch on wall 2. Turn on Voltage Stabilizer 3. Turn on computer console 4. Turn on the controller unit 5. Release the Emergency Stop 6. Open the air valve and ensure that the pressure is at 6.9 Bar (100lbs/ft2) 7. From the MS-DOS command prompt, change directory to XLMILL. Run the Fanuc desktop tutor software by typing in FANUCMD Manual machine tool operation 1. Return the cutting tool to its home position using the control keypad by pressing [HOME], [TRVRS]. 2. Press T and enter the tool number to perform a tool change 3. Specify the spindle speed by pressing S and keying in the desired RPM. Turn on the spindle by pressing [Spindle CW]. Change the spindle speed when the spindle is still spinning by pressing S. 4. Press [JOG] to toggle between step or continous movement of the tool. Adjust the feedrate of the tool by using the up/down cursor keys. Jog the cutting tool using step as well as continuous movement to various positions. 5. Turn off the spindle 6. Return the cutting tool to its home position Numerical control operation I) Part programming and simulation 1. 2. Press [F10] to display the main menu. To start programming and simulating the NC code, press Edit & Simulate. Key in the NC program using the control keypad. Alternatively, you may quit the software ([F10], Quit) and key in the program from MS-DOS. Once you have a program saved, press [F3] from the Fanuc software to load the program. Before you can begin the simulation, set the workpiece datum, which is the (0,0) position. To set the workpiece datum, press [F9] and select Set datum. Select where you want the (0,0) position to be, relative to the workpiece. Begin the simulation by pressing [F9] and selecting Run program.
3.
4.
II) NC machining 1. Plan the operations for producing the part shown in the technical drawing (obtain the technical drawing from your lab instructor). 2. Construct a part program to machine the component and save it into a file. 3. Simulate the program to ensure that there are no errors. 4. Machine the part using the NC part program that you have developed: i. Return the cutting tool to its home position ii. Ensure that the workpiece is firmly secured iii. Jog the cutting tool to the workpiece datum iv. Commence operation by pressing [Auto], [Cycle start]
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5. Perform the shutdown procedure. 6. Clean the machine and surrounding work area. 7. Inspect the machined part for inconsistencies with the original design. Perform measurements on the machined part if and where possible. Summary of Relevant G and M Codes G00 Rapid Traverse of fast Traverse G01 Linear Interpolation G02 Clockwise Circular Interpolation G03 Counter-Clockwise Circular Interpolation G20 Imperial Units G21 Metric Units G28 Automatic Zero Return G40 Cancel cutter compensation G71 Rough out profile by turning G70 Finishing Cycle G90 Absolute Movement G91 Incremental Movement G92 Programming of the coordinate system G94 Feed rate in mm/min or in/min (G98 performs the same function in the CNC lathe) G95 Feed rate in mm/rev or in/rev M03 Start Spindle M05 Stop Spindle M06 Change Tool M30 End of Program F Feed code (F code) S Speed code (S code) T Tool code (T code)
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APPENDIX D - Procedures and Guidelines for CNC Lathe Project

Start-up and initialization procedure 1. 2. 3. 4. 5. 6. Turn on main power switch on wall Turn on Voltage Stabilizer Turn on computer console Turn on the controller unit Release the Emergency Stop From the MS-DOS command prompt, change directory to XLTURN. Run the Fanuc desktop tutor software by typing in FLSTEP.
Manual machine tool operation 1. Return the cutting tool to its home position using the control keypad by pressing [HOME],[+Z] or [-Z], [+X] or [-X]. 2. Press T and enter the tool number to perform a tool change 3. Ensure that you are in the JOG mode by pressing [JOG]. 4. Specify the spindle speed by pressing S and keying in the desired RPM. Turn on the spindle by pressing [Spindle CW]. Change the spindle speed when the spindle is still spinning by pressing S. 5. Press [JOG] to toggle between step or continous movement of the tool. Adjust the feedrate of the tool by using the up/down cursor keys. Jog the cutting tool using step as well as continuous movement to various positions. 6. Turn off the spindle 7. Return the cutting tool to its home position Numerical control operation I)Part programming and simulation 1. Press [F10] to display the main menu. To start programming and simulating the NC code, press Edit & Simulate. 2. Key in the NC program using the control keypad. Alternatively, you may quit the software ([F10], Quit) and key in the program from MS-DOS. Once you have a program saved, press [F3] from the Fanuc software to load the program. 3. Press [F9] to access the simulation menu and select Set Tooling to select the approprate tool for visualization. 4. Begin the simulation by selecting Run program. 5. Explore other functions from the simulation menu: II) NC machining 1. Plan the operations for producing the part shown in the technical drawing (obtain the technical drawing from your lab instructor). 2. Construct a part program to machine the component and save it into a file. 3. Simulate the program to ensure that there are no errors. 4. Machine the part using the NC part program that you have developed 5. Return the cutting tool to its home position 6. Ensure that you have the correct tool in position 7. Ensure that the workpiece is firmly secured
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8. Check to ensure that the tool offsets are zeroed by selecting Tool Offsets. Then press cursor up/down to the tool that you have specified in your program. Press M and the corresponding axis (X or Z) to edit the tool offset. Press /#EOB to confirm and then Cancel to exit. 9. Shave a thin layer off the circumference of the workpiece and set the X offset: 10. Jog the tool to touch the circumference of the circle slightly 11. Jog the tool in the +Z direction so until the tool is about one centimeter off the face of the workpiece 12. Jog the tool in the X direction so that the tool will cut approximately 0.3mm from the circumference of the workpiece. 13. Activate the spindle to an appropriate speed 14. Jog the tool in the Z direction to start shaving a layer off the workpiece 15. Turn off the spindle 16. Measure the diameter of the workpiece 17. Key in the diameter into the X offset setting 18. Shave a thin layer off the face of the workpiece and set the Z offset: 19. Jog the tool to touch the face of the workpiece slightly. The tool should be close to the edge of the face of the workpiece 20. Jog the tool in the +X direction until the tool is about one centimeter off from the circumference of the workpiece 21. Jog the tool in the Z direction so that the tool will cut approximately 0.3mm from the face of the workpiece 22. Activate the spindle to an appropriate speed. 23. Jog the tool in the X direction to start shaving a layer off the workpiece 24. Turn off the spindle 25. Set the Z value into the Z offset setting 26. Save the tool offsets and enter an offset number 27. Load the program and commence operation by pressing [Auto], [Cycle start]. 28. Perform the shutdown procedure 29. Clean the machine and surrounding work area 30. Inspect the machined part for inconsistencies with the original design 31. Perform measurements on the machined part if and where possible Summary of Relevant G and M Codes G00 Rapid Traverse of fast Traverse G01 Linear Interpolation G02 Clockwise Circular Interpolation G03 Counter-Clockwise Circular Interpolation G20 Imperial Units G21 Metric Units G28 Automatic Zero Return G40 Cancel cutter compensation G71 Rough out profile by turning G70 Finishing Cycle G90 Absolute Movement G91 Incremental Movement G92 Programming of the coordinate system G94 Feed rate in mm/min or in/min (G98 performs the same function in the CNC lathe) G95 Feed rate in mm/rev or in/rev M03 Start Spindle M05 Stop Spindle M06 Change Tool M30 End of Program F Feed code (F code) S Speed code (S code) T Tool code (T code)
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Recommended machining parameters for CNC Lathe
Workpiece Material: Aluminium OPERATION Turning Grooving Threading SPINDLE SPEED, rpm 1000-1500 600-800 300-350 FEED, mm/min 45-55 15-25 DEPTH OF CUT, mm 0.5-1.0 0.25-0.5 0.03-0.04
Thread Parameter table NOMINAL DIA. mm M 2.5 M3 M4 M5 M6 M8 M 10 M 12 M 16 M 20 M 24 M 30 M 33 M 36 M M M M M M M M 8X1 10 X 1.25 12 X 1.25 16 X 1.5 20 X 1.5 24 X 2 30 X 2 36 X 3 PITCH mm (F) 0.45 0.5 0.7 0.8 1 1.25 1.5 1.75 2 2.5 3 3.5 3.5 4 1 1.25 1.25 1.5 1.5 2 2 3 CORE DIA. X Bolt Nut 1.948 2.013 2.387 2.459 3.141 3.242 4.019 4.134 4.773 4.918 6.466 6.647 8.160 8.376 9.853 10.106 13.546 13.835 16.933 17.294 20.320 20.752 25.706 26.211 28.706 29.211 31.903 31.67 6.773 8.466 10.466 14.16 18.16 21.546 27.546 32.32 6.918 8.647 10.767 14.376 18.376 21.835 27.835 35.752 HEIGHT OF THREAD mm (P) 0.276 0.307 0.429 0.491 0.613 0.767 0.920 1.074 1.227 1.534 1.840 2.147 2.147 2.454 0.613 0.767 0.767 0.920 0.920 1.227 1.227 1.840
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APPENDIX E Procedures for Arc Welding

Bead forming 1. Ensure that the electrodes are clamped with the positive to the arc welding machine and the negative source on the workpiece (worktable). Check the amperage of the arc welding machine. 2. Place the workpiece on the worktable. Use a face shield. Mark/touch the electrode to the workpiece to produce arc. 3. When there is a spark, ensure that the angle and the distance are right for arc welding. 4. Move the electrode slowly while pressing the electrode until it reaches the end of the workpiece. This will extinguish the flame. 5. Use a chipping hammer to remove burrs. Ensure that goggles are used as the burrs are hot and brittle. weld direction electrode
75o
electrode
3mm Bead forming Electrode angle Electrode distance
APPENDIX F - Procedures and Guidelines for CNC Bridgeport Milling Project

Machine Start Up Procedure i. ii. iii. iv. v. Turn on air compressor. Turn on main power switch on wall. Turn on machine power switch located behind the machine. Turn on control on/off switch located on the control panel. Release the Emergency Stop Button
Work Piece Datum Set Up Procedure
i.
Set up X and Y Datum Move edge finder to one of work piece side at X axis using [MPG] mode. Set X value to zero using the control keypad by pressing [POST] [REL] [OPRT] [X] [ORIGIN]
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Move edge finder to the other side of work piece at X axis. Then divide the actual X value by two, in order to get the center of work piece. Move the edge finder to the center of work piece at X axis. Set again X value to zero using the control keypad by pressing [X] [ORIGIN] Move edge finder to one of work piece side at Y axis. Set Y value to zero using the control keypad by pressing [Y] [ORIGIN] Move edge finder to the other side of work piece at Y axis. Then divide the actual Y value by two, in order to get the center of work piece. Move the edge finder to the center of work piece at Y axis. Set again Y value to zero using the control keypad by pressing [Y] [ORIGIN] Use Macros Program to setup the X and Y datum (0,0) in the system, using the control keypad by pressing [PROGRAM] [AUTO] [Type file name O3214 and press down arrow] [CYCLE START]
ii. Set up Z Datum Select the require tool. Run the tool in [MDI] mode with spindle speed 500 1000rpm. With [MPG] mode, move down the tool at Z axis until touch with the work piece surface. Use Macros Program to setup the Z datum in the system, using the control keypad by pressing [CUSTOM] [F4]
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APPENDIX G Workshop Rules and Penalties Workshop rules

1. Download laboratory manual, print the entire document and bring to your first lab session. The lab manual must be kept at the lab and all reports must be completed during the lab session. The manual must not be taken out of the lab. 2. Bring textbook to lab as a reference. 3. Lab sessions will be assigned to you. Change of times can only be allowed for emergencies and official university functions. Change of lab times must be swapped with another student. Inform technicians 3 days before date of lab. Otherwise penalties (at instructors discretion) will be imposed. 4. Come to lab on time. Missing a lab may lead you to being barred from the final examination.
Penalties
1. Plagiarism : 50% off the mark if found texts reproduced from Laboratory Manual, senior or classmates reports, or other sources etc. 2. Safety Violations : -5 marks
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APPENDIX H - Report Writing Guidelines

The writing in the report reflects the care that went into the experimental work. Spelling and grammar are important components to be taken care of. Neatness counts. Label and name figures properly.
1. Objectives: Identify all the objectives relevant to the workshop. Objectives are important to state because these objectives are analyzed in the conclusions to determine whether the project succeeded.
5. Procedure: In you own words, Write out the actual experimental procedure followed (which might differ slightly from the standard manual). List the step-by-step summary of procedures. 2. Results: Describe the output of your project (eg: A 10.04-mm diameter hole was produced on the face of the workpiece) along with relevant sketches if necessary. Measurements of important dimensions should also be included. Observations such as chatter marks, poor surface finish or flash deposits should also be included.
3. Discussion: In this section, the results presented are analyzed and interpreted. (Explain WHY you got those results!). Also discuss how to overcome undesirable results in the future. The logic in the discussion section should support the conclusion section.
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Example: Bad:- The surface is very rough because of poor machining practice. Good:-Potential causes of the poor surface finish in this project are excessive vibration and built up edge on the cutting tool.
Vibration was mainly due to lack of stiffness in clamping of the workpiece while built up edge was due to the high depth of cut used. Surface finish therefore, can be improved by properly clamping the workpiece and reducing the depth of cut. 4. Conclusion: This section discusses the results in the context of the entire experiment; the objectives mentioned are revisited/examined to determine whether the project succeeded.
Example: Good:- A workpiece was successfully machined according to the specifications in the engineering drawing. The top surface however, exibited somewhat poor surface finish due to built up edge on the cutting tool and workpiece vibration. The operations performed included face milling, tapping and end milling. 5. References: List of reference books or website used. format e.g.: 1. Timonshenko, S., Woinowsky-Krieger, 1959. Theory of Plates and Shells. McGraw-Hill, New York. p 203 210. 2. www.plint.co.uk/at2/leaflet/te76.htm They should follow the following
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APPENDIX I Safety Precautions

Introduction Health and Safety at Work Act 1994, it is based on the self-regulation concept. It is a legal requirement that: To ensure safety and health of themselves as well as others who may be exposed to risks arising from their work activities Through effective and efficient safety management systems suited to the nature of the work activity at the workplace
Safe Practice for Engineering Trainees You should acquire and practice the safe methods of your chosen skill and by the use of intelligence; initiative and knowledge ensure the safety of the workshop and remove the risk of injury or disablement to yourself and your colleagues.
Safety Awareness Genuine safety comes from following the example set by your instructor and developing safety awareness which is the same as road sense when driving.
Major Potential Hazards The lists below are the major potential hazard in the Materials Laboratory 1. Injury through misuse applies to all equipment 2. Poisoning from toxic materials Nital, HCl, etc. 3. Injury from electric shock All equipment 4. Injury from heavy equipment All equipment 5. Injury from sharp objects or edges Brittle Fracture Testing, etc.
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General Instructions
The general instructions are given as follows: 1. Never misuse any equipment 2. Know the fire exit and locations of safety equipment 3. Avoid overcrowding at one place 4. Avoid closing to a source of heat/any high temperature component 5. Report any accident, damage or near miss to the laboratory staff.
Special Instructions 1. Wear suitable clothes (white lab coat is required) 2. Wear protective glasses, gloves or other protection equipment when required 3. Do not bring or consume foods/drinks in the laboratory. 4. Smoking is strictly prohibited. 5. Wear shoes. Sandals and slippers are not allowed. 6. Playful or prankish behavior will not be tolerated in the laboratory.
Additional Safety Instructions 1. You should be aware of the locations of the emergency switch buttons, which can be used to cut off all electric circuits in the laboratory rooms, except the lights. 2. You should be aware of the locations of fire extinguishers and fire alarms in the laboratory. 3. Any malfunctioning of laboratory equipment should be promptly reported to your instructor, as should plugged drains or other safety hazards. 4. You should be aware of the location of the first aid kit and know how to use the emergency eyewash (and shower) in the materials lab. 6. Minor cuts or bums should not be neglected. You should report them
immediately to the instructor, who will decide whether to carry out first aid procedures or to send you to the university medical centre for treatment.
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MCB1043: Manufacturing Technology