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FAKULTI TEKNOLOGI KEJURUTERAAN

MEKANIKAL & PEMBUATAN


UNIVERSITI TEKNIKAL MALAYSIA MELAKA

MANUFACTURING PRACTICES

BMMP 1303 SEMESTER 2 SESI 2018/2019

CONVENTIONAL MILLING LAB REPORT

NAME OF GROUP 1. MUHAMMAD ISMANAJMI BIN ROZI B091810258


MEMBERS &
MATRIX NUMBER 2. LUQMAN HAQIM BIN AMIR HAMZAH B091810235

3.

4.

5.

6.

YEAR & PROGRAM 1BMMH S1/2

SUBMISSION DATE 2019

NAME OF INSTRUCTOR 1. EN. MOHD RUZI BIN HARUN

2.

EXAMINER’S COMMENT VERIFICATION STAMP

TOTAL MARKS: / 100


TABLE OF CONTENTS

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

7. RESULT & DISCUSSION


13-15

8. CONCLUSION
15

9. REFERENCES
16

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1.0 OBJECTIVES

At the end of the practical activity, will be able to:


1. Apply safety procedures while working in the workshop.
2. Familiarize the milling machine features, handling and operating milling machine.
3. Produce a part by using milling machine based on technical drawing.

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

1. Goggle - To protective eyewear that usually


enclose or protect the area surrounding
the eye in order to prevent particulates,
water or chemicals from striking
the eyes.

2. Jacket
- To protect the body like a piece
personal protective equipment (PPE).

- To protects regular clothing that are


worn underneath.

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

5.0 TOOL USED

TOOL USED FUNCTIONS

1. Vertical Milling Machine


- The vertical milling machine is a
precision tool used for shaping and
fabrication by the removal of stock
typically from metallic work pieces.

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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.

6. Vernier caliper - A Vernier caliper is a precision


instrument that measures internal
dimensions, outside dimensions, and
depth.

7. Flat File - Flat file is a tool used to remove fine


amounts of material from a
workpiece.

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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.

9. Height Gauge - A height gauge is a measuring


device used for determining
the height of objects, and for
marking of items to be worked on.

10. Copper Mallet - To used when forming sheet metal,


forcing tight-fitting parts together,
auto-body repairs, and more.

11. Technical Drawing - This drawing is helpful to carry out


this task.

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12. Raw Material - Material that has been work on this
tasks.

6.0 PROCEDURES

6.1 Six sides cutting

i. Vise is aligned and work piece is secured in the vise.


ii. Face mill/End mill all four ides of the work piece to get the accurate dimension of
length(L) and width (W).L=51mm and w = 51mm
iii. Face mill the top and the bottom of the work piece to get the desired height(40mm)

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6.2 Chamfering

i. Slot drill used to machine.


ii. The edge find to set the origins references points.
iii. The slot is made and the early cutting speed is 800rpm
iv. The height of cut should be 0.1mm-0.55mm.
v. Height of slot is 6mm, multiple cut might be needed.
vi. Last 1mm, height of cut is 0.2mm and speed is 1000rpm.

6.3 Pocket milling process

i. Slot drill used to machine.


ii. The edge is find to set the origins reference points.
iii. The slot is made and the early cutting speed is 800rpm.
iv. The height of cut should be 0.1mm-0.55mm.
v. Height of slot is 4mm, multiple cut might be needed.
vi. Last 1mm, height of cut is 0.2mm and speed is 1000rpm.

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6.4 Full Slot

i. Slot drill is used to machine.


ii. The edge is find to set the origins reference points.
iii. The slot is made and early cutting speed is 800rpm.
iv. The height of cut should be 0.1mm-0.5mm.
v. Height of slot is 6mm and the width is 12mm, mulitiple cut might be needed.
vi. Last 1mm, height of cut is 0.2mm and speed is 1000rpm

6.5 Holes drilling


i. The holes in the work piece is drilled and the size of drill is 12mm.
ii. Cutting speed that is used : 600rpm

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6.6 Half Slot

i. Slot drill is used to machine.


ii. The edge is find to set the origins reference points.
iii. The slot is made and early cutting speed is 800rpm.
iv. The height of cut should be 0.1mm-0.5mm.
v. Height of slot is 6mm, length is 15mm and the width is 12mm, mulitiple cut might be
needed.
vi. Last 1mm, height of cut is 0.2mm and speed is 1000rpm

6.6 Chamfering (45 )


i. Slot drill is used to machine.
ii. Set the work piece at 45 .
iii. The slot is made and the early cutting speed is 800rpm.
iv. The height of cut should be 4.23 mm.
v. Last 1mm and speed is 1000rpm.

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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

Dimension (mm) ±0.1


Item Details
Drawing Actual

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

Height = 6.00 Height = 6.12

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5 Pocket

Height = 4.00
Height= 4.10

6 End Mill

Height= 6.00 Height= 6.20

Width= 12.00 Width= 11.60

7 End Mill
Height= 6.00 Height= 5.90

Width= 12.00 Width= 11.60

Length= 15.00 Length= 14.80

8 Drill
Height= 30.00 Height= 30.00

Diameter= 12.00 Diameter= 11.60


9

Length= 6.00 Length= 10.00

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

become more easily and get more accurate result.


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Next, the error that we found was parallax error. Parallax error occurs when the

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,

our eyes need to be parallel during take the measurement result.

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

1.Groover, P. M., "Fundamentals of Modern Manufacturing", WILEY Inc., 2. International


Edition, 2002.

2.DeGarmo, E. Paul, et al, “Materials and Processes in Manufacturing”, McMillan Publishing


2000

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LAB 2: MILLING (REPORT RUBRIC)
Student 1: .Muhammad Ismanajmi Bin Rozi Matrix No.: B091810258

Student 2:Luqman Haqim Bin Amir Hamzah Matrix No.: B091810235

Course/ Section: 1 BMMH 1/2

Topic in report Evaluation Scores

Correct measurement to 2
A. Product decimal places (15%)
Dimension
(20%) Work piece picture attached
(5%)

Correct processes arranged in


correct manner (10%)
B. Manufacturing
Cutting Tools Use (10%)
Sheet (35%)
Sketch and Process Parameters
included (15%)

Comprehensive Discussion.
C. Discussion
Includes safety
(15%)
precautions/PPE (15%)

D. Conclusion Comprehensive conclusion


(10%) (10%)

Student 1 Student 2
Ability to operate machine and
E. General
equipment’s (10%)
Conducts

(10%) Attitude, behavior,


involvement with others (10%)

Total Score ____/ 100 ____/ 100

Overall Report Mark / 5% / 5%

Instructor Signature: Date:

…………………………………………… ………………………..

Name:

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