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MANUFACTURING PRACTICES
3.
4.
5.
6.
2.
ITEM PAGE
1. OBJECTIVES
3
2. INTRODUCTION
3
3. THEORY
3
4. SAFETY EQUIPMENT
4-5
5. TOOL USED
5-9
6. PROCEDURE
9-13
8. CONCLUSION
15
9. REFERENCES
16
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1.0 OBJECTIVES
2.0 INTRODUCTION
The goal of this lab session is to familiarize with safety procedures in the workshop,
proper handling and operation of milling machine. This laboratory activity is designed to give
practical experience for students to produce precision part conforming to the specifications on
technical drawing using a manual milling machine.
3.0 THEORY
Milling is the process of cutting away material by feeding a work piece past a rotating
multiple tooth cutter. The cutting action of the many teeth around the milling cutter provides a
fast method of machining. The machined surface may be flat, angular, or curved. The surface
may also be milled to any combination of shapes. The machine for holding the work piece,
rotating the cutter, and feeding it is known as the milling machine.
In milling, the work piece is fed in a rotating milling cutter, which is a multi-point tool,
unlike a lathe, which uses a single point cutting. The tool used in milling is called the milling
cutter.
In addition to straight milling of flat and irregularly shaped surfaces, it can perform
gear and thread cutting, drilling, boring and slotting operations, which are normally handled
on machine tools designed specifically for these specific operations. Figure 1.0 shows typical
vertical milling machine and features.
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4.0 SAFETY EQUIPMENTS
EQUIPMENTS FUNCTION
2. Jacket
- To protect the body like a piece
personal protective equipment (PPE).
3. Safety shoes
- To protects the foot from falling
objects or compression, usually
combined with a midsole plate to
protect against punctures from below.
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Goggle
Safety Jacket
Safety Boot
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2. Face mill Diameter 32-46 mm - Face mills are primarily used for
milling a face on the surface of a plate
or bar. They are predominantly used to
cut with the ends of the cutter rather
than their sides.
3. End mill Diameters 6, 10, 12 mm 2-4 - End Mills are used for making shapes
flutes
and holes in a workpiece.
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4. Center Drill size (Small) Diameter 2-3 - To fix work-piece in a certain
position (mostly central position) to
the axis of rotation.
5. Drill
- To cut a hole of circular cross-
section in solid materials.
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8. Parallel Bar - Parallels are commonly used to
support & accurately set jobs in a
vice or bolted to the machine table.
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12. Raw Material - Material that has been work on this
tasks.
6.0 PROCEDURES
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6.2 Chamfering
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6.4 Full Slot
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6.6 Half Slot
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After finish (5S)
-Always clean the workshop area. There should be no chips or fillings on the work table
or floor. Use brush,hand broom and provided cleaning solution. Place all endmills, drills
bits, wrenches, arbors, clamp,raw materials and vice grips back in the appropriate place.
7.0 RESULT
1
Width 45.00 45.00
2
Length 45.00
45.00
3 Height 40.00
40.34
4 Chamfer
Width = 6.00 Width = 5.90
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5 Pocket
Height = 4.00
Height= 4.10
6 End Mill
7 End Mill
Height= 6.00 Height= 5.90
8 Drill
Height= 30.00 Height= 30.00
7.0 DISCUSSION
From this experiment, the actual result were not accurate with the drawing result. It
maybe error occurred during this experiment. Firstly, the error that we found that was our Y-
axis at milling machine (No 7 machine) was in not good condition, the machine display at Y-
axis not showed the accurate result. So, we have problem during process in Y- axis. To avoid
this error, Y- axis of the milling machine need to be fix, so it will help the process in Y-axis
measurement of an object’s length is more or less than the true length because of your eye
being positioned at an angle to the measurement markings. For example, during this
experiment when measured the work piece by using vernier caliper or height gauge, the result
that we got was not accurate form the drawing result. So, to avoid from this error occur again,
Lastly, the tool point of end mill was in not good condition. There is a crack at the
tool point of the end mill. When the end mill been used, it effect our work piece result such as
the reading was error and it also affects the nuances of our objects. To prevent this errors
occur again, the end mill need to be change. So, it will be helpful and reduce error during the
endmill process.
8.0 CONCLUSION
As the conclusion for this project, we have learned on how to operate the milling
machine. Besides that, we also know the purpose of the main parts of this machine. When
operating the machine, we must follow the instructor to avoid any incident. The knowledge
gained in this task on milling cutters assist us in determining the type of cutter(s) to employ
for a specific operation,to include the nomenclature, selection, use and care of milling cutters
whentasked to perform milling machine operations
We must check our Personal Protective Equipment(PPE) before start the operation to
avoid any serious incident. This project also help us to familiarize the milling machine
features, handling, ang operating the milling machine. Last but not least, we were able to
produce a part using milling machine base on technical drawing.
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9.0 REFERENCES
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LAB 2: MILLING (REPORT RUBRIC)
Student 1: .Muhammad Ismanajmi Bin Rozi Matrix No.: B091810258
Correct measurement to 2
A. Product decimal places (15%)
Dimension
(20%) Work piece picture attached
(5%)
Comprehensive Discussion.
C. Discussion
Includes safety
(15%)
precautions/PPE (15%)
Student 1 Student 2
Ability to operate machine and
E. General
equipment’s (10%)
Conducts
…………………………………………… ………………………..
Name:
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