faculty : industrial technology total page : 23 majors

UNIVERSITAS ISLAM INDONESIA FM-UII-AA-FKU-01/R0

MANUFACTURING PROCESS TRAINING MODULE

Faculty : Industrial Technology Total Page : 23

Majors/Study Programs : Industrial Engineering Module Name : Manufacture “Iron Base”

Practicum Code : Manufacturing Process Date : September 25th, 2021

Manufacturing System Laboratory 1







TABLE OF CONTENT

I. LEARNING OBJECTIVES ....................................................................................... 3

II. MAKE A PROCESS A PART IRON BASE ............................................................ 3

2.1 Iron Base Part Design ....................................................................................... 3

2.2 Iron Base Part Material .................................................................................... 4

2.3 Iron Base Part Manufacturing Process ............................................................. 4

2.3.1 Hacksaw Machine ...................................................................................... 5

a. Basic Theory ................................................................................................ 5

b. Hacksaw Machine Chisel Bits..................................................................... 7

c. Hacksaw Machine Process on Iron Base Part ............................................. 8

d. Add- Tools of Hacksaw Machine................................................................ 9

e. Potential Hazards of Hacksaw Machine .................................................... 10

f. Personal Protective Equipment (PPE) of Hacksaw Machine .................... 11

2.3.2 Milling Machine ....................................................................................... 12

a. Basic Theory .............................................................................................. 12

b. Types of Milling Machine’s Chisels Eye .................................................. 14

c. Milling Machine Process of Iron Base ...................................................... 18

d. Add-Tools of Milling Machine ................................................................. 19

e. Potential Hazards of Milling Machine ...................................................... 21

f. Personal Protective Equipment (PPE) of Milling Machine ....................... 21

III. REFERENCE ......................................................................................................... 23







I. LEARNING OBJECTIVES

The following are the learning objectives of the Manufacturing Process practicum in Module

3:

1. The students know and understand the product made, namely iron base.

2. The students know and understand the machine used.

3. The students are able to design products using Solidwork CAM.

4. The students understand the flow of the product manufacturing process.

II. MAKE A PROCESS A PART IRON BASE

In the practicum the part base manufacturing process is one part of the key chain product

manufacturing process. Part iron base serves as a place to put other parts such as MDF base,

hangers, and ornaments. In the process of making iron base parts there are several things that

need to be considered:

2.1 Iron Base Part Design

The design is made using the appropriate size of the workpiece to be made. Measurements

on the iron base part in reality use a ruler, while in software simulations it is measured using

Solidworks using technical drawings. Technical drawing is a means by which everything

is realized by illustrating it in two-dimensional form which aims to interpret the intent of

the image maker objectively, this type of image uses internationally accepted symbols or

ISO standards. The following are the sizes contained in the technical drawing.







Figure 1 Iron Base Engineering Drawing

2.2 Iron Base Part Material

The material used in the iron base part is iron rod. Iron is a type of metal that is often used

in everyday life derived from iron ore (mine). In addition, iron is the most important metal

in the industrial world, the price of iron has a high economic value (Pakasi, 2019).

2.3 Iron Base Part Manufacturing Process

The process of making iron base parts is carried out using several machines, the first using

a hacksaw machine to cut iron rods according to the size of the iron base part, the second

using a milling machine with drill bits to make holes in the iron base part. The following is

an explanation of the hacksaw engine and milling machine.







2.3.1 Hacksaw Machine

The following is an explanation of the hacksaw machine in making iron base parts. The

chainsaw was the first machine used to cut raw materials.

a. Basic Theory

Saw machines have various constructions according to the size, shape and type of

workpiece material to be cut. The type used in the process of cutting the workpiece

or iron rod is the Hacksawing-Machine. Reciprocating Saw Machine has a

working principle by moving back and forth, the blade used in this saw has a length

between 300mm - 900mm with a thickness of 1.25mm - 3mm with HSS material

(Mohd. & et al, 2007).

(Manufacturing System Laboratory Industrial Engineering-UII)

Figure 2 Hacksaw Machine

For this reason, it takes a person's accuracy to be able to operate the saw

properly and correctly. The following is the parts of a reciprocating saw machine

(Hacksaw Machine):








Figure 3 Hacksaw Machine Parts

Table 1 Parts and Function of Hacksaw Machine

Part Name Function

Hand Wheel As a chainsaw lock lever.

Coolant Coolant is to cool the iron cylinder when operating

the saw engine.

Vise Vise (vise) is a place where the iron cylinder is

placed when it will be processed until the cutting

process is complete.







Part Name Function

Motor The driving motor is the main driver of the

chainsaw.

Extra Heavy Guide Bar For lifting and lowering the knife rest (saw frame)

and saw blade.

Cross Section Cross Section (support section) is to hold the

cylinder iron while sawing is being done.

Knife Rest As a saw blade holder.

Hacksaw Saw blade for cutting cylinder iron.

Switch On/Off The on/off button is to turn on and turn off the

chainsaw.

Handle Adjust the vise to clamp the cylinder iron.

b. Hacksaw Machine Chisel Bits

Chisel or can be called a saw blade is made of high-speed steel(HSS) or low

tungsten steel. The blade length is usually 8”, 10”, or 12”. Smooth blades have 20-

30 teeth per inch, while coarse blades have 1418 teeth per inch. Blades for general

work have 16-28 teeth per inch. In the process of making the iron base part, the

chisel used has a length of 12 "with a coarse blade type.







Figure 4 Hacksaw Machine Chisel Eye

c. Hacksaw Machine Process on Iron Base Part

Proses mesin hacksaw pada pembuatan part iron base menggunakan mata pahat

panjang 12” dengan jenis bilah kasar. Proses pada mesin hacksaw yaitu

memotong besi panjang menjadi besi dengan ukuran p x l yaitu 8 x 5 cm.

1. The long iron before the cutting process.

Figure 5 Long Iron

2. The result of the hacksaw machine.

Figure 6 Iron Base







d. Add- Tools of Hacksaw Machine

Add-tools used in the Iron base part manufacturing process:

• Vise

Vise is a tool that functions as a workpiece clamp on a milling machine,

hacksaw, or drilling machine. The vise is generally made of cast iron. Its use is

by turning the turning handle/lever to the left (counter clockwise) to open the

jaw of the vise so that the threaded rod will pull the anvil on the jaw. Likewise,

to tie a cylindrical iron, the stem is rotated to the right (clockwise) (Cahyadi,

2019).

Figure 7 Vise in Hacksaw Machine

• Coolant

Coolant is the liquid resulting mixture of ethylene or propylene glycol and water

typically has a ratio of 50/50 (Rino, 2015). Coolant is used when the machine

is working in cutting cylindrical iron, in this process, coolant is given

periodically to the surface of the workpiece that is exposed to the chisel/blade

of the machine hacksaw. The function of the coolant in the cutting process on

machine hacksaw is to clean or carry anger, reduce cutting forces, refine the

workpiece and maintain the quality of the chisel or blade, in addition to

providing liquid (Kohser, 2007).







Figure 8 Coolant

• Rasp

A rasp is a tool hand tool that serves to erode the workpiece (Pattiasina, Effendy,

& Wairatta, 2017). The use of a file to flatten and smooth the workpiece using

the workpiece is sandwiched on a vise and then smoothed by repeatedly rubbing

the file on a workpiece that has a rough surface.

Figure 9 Rasp

e. Potential Hazards of Hacksaw Machine

When carrying out the process of using the machine there will be potential dangers

arising so that the following are potential hazards that can occur on a machine

hacksaw.







a. Machines that move up and down, move forward and backward, move open

and close can cause fingers, hands, or other body parts to be cut, pinched by

the machine parts resulting in scratches, cuts, fractures, amputations, and

even death.

b. Machines that use threaded workpiece clamps, if not installed properly, the

workpiece can be thrown and hit body parts causing trauma.

c. Operators who do not position themselves properly can hit the saw arm and

cause trauma.

f. Personal Protective Equipment (PPE) of Hacksaw Machine

Personal Protective Equipment (PPE) is one of the protective measures for

operators when carrying out work activities in the workplace. The function of PPE

itself is to protect a person by isolate part or all of the body from potential hazards

in the workplace (Arpian, 2018). Here are the PPEs of the hacksaw machine:

Figure 10 Hacksaw Machine PPEs







2.3.2 Milling Machine

The following is an explanation of the milling machine in the manufacture of iron base

parts. The milling machine is the second machine after the hacksaw machine process

to punch holes in the base part.

a. Basic Theory

Milling machines can work/finish the surface of a workpiece by using a knife as a

tool that is placed on a shaft called an arbor. The milling machine used in the process

of making iron base parts is a vertical milling machine.


Figure 11 Milling Machine

The parts and functions of each part on the vertical milling machine itself consist

of components or parts that are known and explained as follows (B.M. Amstead,

P.F. Oswald, & M.L. Begeman, 1992).







Figure 12 Parts of Milling Machine

Table 2 Parts and Functions of Milling Machine

Part Function

Motor Serves to drive the milling machine with electric

power, but it also regulates the speed, on/off button,

and switch on the milling machine

Feed Handle Serves to lock and lower the drill bit in the process

of “feeding”

Chuck Serves to put the milling knife and also pressing the

blade mounted on the main axis

Worktable Serves to put the hanger parts during the process

workpiece “feeding” takes place

Saddle Traverse Crank Serves to move the work table to the right and left







Part Function

Operation Control Serves to regulate the movement of the chisel,

namely reverse (the chisel rotates to the left) and

forward (the tool blade rotates to the right)

Spindle Lock Serves to lock the chucks and chisel bits so it doesn't

move

Table Traverse Crank

Handle

Serves to move the work table horizontally in front

of the “column”

Base Serves to support or as the foundation of the milling

machine and also as a coolant disposal site when the

coolant is not used anymore

Vise Serves to clamp the hanger parts firmly during the

“feeding” process

b. Types of Milling Machine’s Chisels Eye

Milling machine knives/cutters, both horizontal and vertical, have many types and

shapes. The selection of a milling knife is based on the shape of the workpiece, as well

as the ease or complexity of the workpiece to be made. Knives used in milling machines

include:

Table 3 Chisel Eye or the Knives of Milling Machine

Chisel Eye Type Figure Function

Twist Bits

(Source: www.irwin.com)

Used for drilling in various

types of wood, plastic, and

metal








Plane Frais

Mantel

(Source: travers.com)

This type of knife is used in

horizontal milling machines.

Usually used for roughing and

wide surfaces

Slot Cutter

(Source: imimg.com)

Slot Cutter serves to make

grooves on the surface of the

workpiece

Gear Cutter

(Source: travers.com)

This module knife is used to

make gears according to the

type and number of teeth

desired

Concave Radius

Blade

(Source: zps-fn.cz)

This type of knife is used to

make workpieces whose

shape has an inner radius

(concave)

Convex Radius

Blade


make workpieces whose

shape has an outer radius

(convex)








(Source: zps-fn.cz)

T-Slot Cutter

(Source: cutwel.co.uk)

This type of knife is only used

to make a "T" shaped groove

as in the milling machine

table

Angel Cutter

(Source : amazon.com)


make angular grooves whose

results are in accordance with

the angle of the knife used.

Angles range between: 30°,

45°, 50°, 60°, 70°, and 80°

Side Milling

Cutter

(Source: mimg.com)

This type of knife has a face

and a side and it can be used

for both flat and graded

milling.

Slittig Saw

(Source: amazon.com)

This type of milling knife is

used to cut or split the

workpiece. In addition, it can

also be used to make grooves

that have a small width.








End Mill Cutter

(Source: dansdiscounttools.com)

A milling knife that used to

make translucent or graded

grooves and grind flat for

relatively small areas of

width.

The chisel above that will be used in the process of making the iron base is

"Twist Bits", the chisel used to drill the surface of the iron base to form holes as hanger

part.

Figure 13 Twist Bits

Table 4 Description of Twist Bits

Name of Drill Bit Explanation

Shank

It has 2 kinds of shapes, which are cylindrical

and conical (Morse Taper). A drill that has a

small diameter cylindrical stem and it uses a

drill chuck.







While the drill with a tapered stem is placed

using a reducing sheath or directly on the

spindle of the drilling machine with a conical

hole.

Body The length is measured from the edge of the

stem to the end of the drill

Land Speed up the release of slashes. Chips are

wood chips when they are planed.

c. Milling Machine Process of Iron Base

The process to making holes with a milling machine using twist bits carried out 2 times.

1. Stage to making a hole the Iron Base (0.5 cm)

Figure 14 First making a Hole Process

2. Stage to making a hole the Iron Base (1.4 cm)

Figure 15 Second making a Hole Process







d. Add-Tools of Milling Machine

Explanation below is some add-tools that used in the process of making iron base parts

with Milling Machine:

• Vise

Vise is a tool that serves as a workpiece clamp on a milling, hacksaw, or drilling

machine. Vise is generally made of cast iron. The mechanism to use the vise is by

turning the handle to the left (counter clockwise) to open the “vise jaw” so the

threaded rod will pull the anvil not fixed on the jaw. Likewise for tying the

cylindrical iron, the stem is rotated to the right or clockwise (Cahyadi, 2019).

Figure 16 Vise

• Center Punch

A center punch is a tool for making holes in the workpiece with the tip of the pin

having an angle of 30° to 90°. The center punch is made of hardened high carbon

steel and is lined or hexagonal. In the process of making the MDF part, the center

punch is used to mark the area to be drilled before the drilling process is carried out

on the milling machine by hitting the top end of the pin with a hammer hard to

create a small hole produced from the pin







Figure 17 Center Punch

• Coolant

Coolant is a liquid mixture of ethylene or propylene glycol and water which usually

has a ratio of 50/50 (Rino, 2015). Coolant is used when the machine works in

“feeding” the hanger to make a hollow, in this process the coolant is given

periodically to the surface of the workpiece that is exposed to the chisel eye or knife

of the milling machine. The function of the coolant in the “feeding” process on the

milling machine is to clean or carry anger, reduce cutting forces, refine the

workpiece and maintain the quality of the chisel or blade, in addition to providing

liquid (Kohser, 2007).

Figure 18 Coolant







e. Potential Hazards of Milling Machine

Milling machine is a machine with the blade rotating as a main motion rotating on a

fixed axis and the workpiece moving across the cutter. The following are potential

hazards that often occur in the use of milling machines:

• Eyes hit by chips (scrap)

To avoid getting the chip in your eyes, every time you do work you must wear

glasses. Moreover, working with milling machines, where the blade rotates on a

fixed axis while the workpiece only moves across the blade.

• Hands hit by the milling knife cutter

To avoid getting your hands hit by the milling knife, if you want to take part, see,

and clean the chips that are close to the knife, it is better to turn off the shaft rotation.

• Hand hit by a chips (scrap)

This kind of danger usually occurs when we clean the scraps after working on the

milling machine. Because we know that the milling machine has more than one

cutting edge, the chips must be short and sharp. To overcome this risk then use a

brush to clean.

f. Personal Protective Equipment (PPE) of Milling Machine

Personal Protective Equipment (PPE) is one of the protective measures for operators

when carrying out work activities in the workplace, the function of PPE itself is to

protect a person with the aim of isolating part or all of the body from potential hazards

in the workplace (Arpian, 2018). The following explanation is the types of PPE that

used in the milling machine:







Figure 19 Milling Machine PPEs







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