machining 2 report

8/10/2019 Machining 2 Report

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Report the Fabrication of the Mini Precision Vise for the

BFF1811_Machining_II

Tan Jun Zhe1, Loke Chi Kin2, Khoo Bao Shen3

Department of Manufacturing Engineering, FKP University Malaysia Pahang, UMP Kampus Pekan,

26600 Pekan, Pahang Darul Makmur.

1FB14039, 2FB14050, 3FB14045

Abstract:

In general, milling is the machining process of using rotary cutters to remove material from a

workpiece advancing in a direction at an angle with the axis of the tool. Milling can be done with a

milling machine. With various attachments, milling machines can be used for boring, slotting,

circular milling dividing, and drilling. In this project, the tools like drills, end mills, and face mill are

widely use to obtain our final product, the moveable jaw and base. After finished this project,

students should understand about the types of milling operations, cutting conditions in milling,

milling machines and the machining centers and turning centers.

Introduction:

The project’s objective is to train student on how to handle a milling machine systematically to do

a project as a preparation for industrial work in the future. It also aims to train the teamwork between

students like how are they going to cooperate with team members to finish the work piece and report.

The principle parts of milling machine are base, column, knee, saddle, table, over hanging arm,

front, brace, spindle and arbour. The base of the machine is grey iron casting accurately machined on

its top and bottom surface and serves as a foundation member for all the other parts which rest upon

it. It carries the column at its one end. In some machines, the bage is hollowed and working as a

reservoir for cutting fluid. Secondly, the column is the main supporting frame mounted vertically on

the bage. The column is box shaped. Heavily ribbed inside and houses all the driving mechanisms for

the spindle and table feed. The front vertical face of the column is accurately machined and is

provided with dovetail guide ways of supporting knee. The top of the column is finished to hold an

over-arm that extends outward at the front of the machine.



Besides, the table rest on ways on the saddle and travels longitudinally. The top of the table is

accurately finished and T-slots are provided for clamping the work and other fixtures on it. A lead

screw under the table engages a nut on the saddle to move the table horizontally by hand or power.

The longitudinal travel of the table may be limited by fixing trip dogs on the side of the table. In

universal machines, the table may also be swivelled horizontally. For this purpose the table is

mounted on a circular bage which in its turn is mounted on the saddle. The circular bage is graduated

in the degree.

The knee is the rigid grey iron casting that slides up and down on the vertical way of the column

face. The adjustment of height is effected by elevating screw on the base that also supports the knee.

The knee houses the feed mechanism of the table, and in different controls to operate it. The top face

of the knee forms slid way for the saddle to provide cross travel of the table. Then, the saddle is

placed on the top of the knee, which slides on guide ways set exactly at 90° to column face. A cross

feed screw near the top of the knee engages a nut of the bottom of the saddle to move it horizontally,

by hand or power, to apply cross feed. The top of the saddle is accurately machined to provide guide

ways for the table.

After that, the table rest on ways on the saddle and travels longitudinally. The top of the table is

accurately finished and T-slots are provided for clamping the work and other fixtures on it. A lead

screw under the table engages a nut on the saddle to move the table horizontally by hand or power.

The longitudinal travel of the table may be limited by fixing trip dogs on the side of the table. In

universal machines, the table may also be swivelled horizontally. For this purpose the table is

mounted on a circular bage which in its turn is mounted on the saddle. The circular bage is graduated

in the degree.

Apart of that, the spindle of the machine is locates in the upper part of the column and receive

power from the motor through belts, gears and clutches and transmit it to the arbour the front end of

the spindle just projects from the column face and it is provided with a tapered hole into to which

various cutting tools and arbours may be inserted. The accuracy in metal machining by the cutter

depends on primarily accuracy, strength and rigidity of the spindle.

Other than that, overhanging arm is mounted on the top of column extends beyond the column face

and serve as a bearing support may be provided nearest to the cutter. More than one bearing support

may be provided for the arbour. Then, the front brace is an extra support that is fitted between the

knee and over arm to ensure further rigidity to the arbour and the knee. The front brace is slotted toallow for adjustment of the height of the knee relative to over arm.



spindle which is vertical (normal to the work table). The table can be moved in all the axes (X, Y and

Z). The spindle head which is clamped to the vertical column can be swivelled at any angle,

permitting the milling cutter mounted on the spindle to work on angular surfaces. The machines

spindle can also be adjusted up or down relative to work piece. This machine is adapted for

machining grooves, slots and flat surfaces. The end mills and face milling cutters are the usual tools

mounted on the spindle.

Milling machine is used to perform slot mill, hole-drilling, and surface mill. Surface grinder is used

to produce very fine finishes or making very light cuts, by using an abrasive wheelas the cutting

device makes the product smooth. The tools that is used is end mill, slot drill and face mill. The

diameter size of end mill used is 10mm, 12mm. The diameter of the slot drill used is 4.2mm, 8mm

and 10mm. The clamping technique used for milling machine is vise clamping. The vise can be

adjusted to any desired degree as we wanted. The clamping technique used for grinding machine is

magnetic clamp. The magnetic clamp is used because our product is a magnetic material.

During the machining process, the cutting fluid used is oil-water emulsion. The coolant is used to

cool the cutting tool and also the work piece during machining process. The primary function of

cutting fluid is cooling, and at the same time, the cutting fluid acted as a lubricant. A fluid's cooling

and lubrication properties are critical in decreasing tool wear and extending tool life. Cooling and

lubrication are also important in achieving the desired size, finish and shape of the workpiece. A

secondary function of cutting fluid is to wash away chips and metal fines from the tool/workpiece

interface to prevent a finished surface from becoming marred and also to reduce the occurrence of

built-up edge (BUE).

Hereby, we attached the formula used for cutting speed:

Where,

V = Cutting speed

π =

d = Diameter of cutter

n = Rotation per minute (RPM)

http://en.wikipedia.org/wiki/Grinding_wheel

http://www.mfg.mtu.edu/cyberman/metal_fluids/charact.html#Cooling_name

http://www.mfg.mtu.edu/cyberman/metal_fluids/charact.html#Cooling_name

http://en.wikipedia.org/wiki/Grinding_wheel



Process Plan:

Part 1: Base

No Process Size Machine Tool PIC % Remarks

1 Prepare rawmaterial 50×50×105 Bench saw - Loke Chi Kin 5

2 Remove burr Files Tan Jun Zhe

KhooBaoShen

8

3 Squaring

base

45×45×100 Milling

machine

Face mill, files,

milling machine

vise, vise handle,

vernier callipers,

parallel bars, and

millets.

Tan Jun Zhe

KhooBaoShen

Loke Chi Kin

15

4 Drilling

(a) centre

drill

(b) drill

D5

(6 holes)

M5

(2 holes)

Milling

machine

Drills, centre drills,

files, milling

machine vise, vise

handle, verniercallipers, parallel

bars, and millets.

Tan Jun Zhe

Loke Chi Kin 30

5 Cut U-slot 8 × 100 × 4 Milling

machine

End mill, files,

milling machine

vise, vise handle,

vernier callipers,

parallel bars, andmillets.

Tan Jun Zhe

KhooBaoShen

40

6 Rotate

U-slot

8 × 100 × 4 Milling

machine

End mill, files,

milling machine

vise, vise handle,

vernier callipers, parallel bars, and

millets.

KhooBaoShen

Loke Chi Kin

50

7 Oblong slot D10 Milling

machine

End mill, files,

milling machine

vise, vise handle,

vernier callipers,

parallel bars, and

millets.

Tan Jun Zhe

KhooBaoShen

60

8 Oblong slot D12 Millingmachine

End mill, files,milling machine

vise, vise handle,

vernier callipers,


Tan Jun ZheLoke Chi Kin

75

9 L slot D12 Milling

machine

End mill, face mill,

files, milling

machine vise, vise

handle, vernier

callipers, parallel

bars, and millets.

Tan Jun Zhe

KhooBaoShen

Loke Chi Kin

95

10 Tapering M5 Tap and tap holder. Tan Jun Zhe

KhooBaoShen

Loke Chi Kin

100



Part 2: Movable Jaw

No. Process Size Machine Tool PIC % Remarks

1 Prepare rawmaterial

50×50×30 Benchsaw

- Loke Chi Kin 5

2 Remove burr - Files Tan Jun ZheKhooBaoShen

8

3 Squaring 45×30×24 Millingmachine

Face mill, files,milling machinevise, vise handle,vernier callipers, parallel bars, and

millets.

Tan Jun Zhe

KhooBaoShen

Loke Chi Kin

15

4 Slotting D12 Millingmachine

End mill, files,milling machinevise, vise handle,vernier callipers, parallel bars, andmillets.

Tan Jun Zhe

KhooBaoShen

Loke Chi Kin

25

5 V-slotting D10 Millingmachine

End mill, files,universal angle

milling vise,vernier callipers,


Tan Jun Zhe

KhooBaoShen 35

6 Chamfering D14 Millingmachine

Face mill, files,universal anglemilling vise,

vernier callipers, parallel bars, andmillets.

Tan Jun ZheLoke Chi Kin

60

7 Drilling D8 Milling

machine

Drill, files,

universal anglemilling vise,vernier callipers, parallel bars, andmillets.

KhooBaoShen

Loke Chi Kin 75

8 Boring D14 Millingmachine

Ball nose drill,files, universalangle milling

vise, verniercallipers, parallel bars, and millets.

Tan Jun Zhe

Loke Chi Kin 85

9 Slotting Millingmachine

End mill, files,universal anglemilling vise,vernier callipers, parallel bars, andmillets.

Tan Jun Zhe

KhooBaoShen100



Fabrication:

Many steps were carried out to produce the final shape of the work piece. Firstly, the raw materials

were prepared using bend saw. The original size of the base was 105mm × 50mm × 50mm while the

moveable jaw was 50mm × 50mm ×35mm. Before the parts were operated using the milling

machine, burr was removed using file tools. Then, the remaining processes were done by using the

milling machine.

The process was started by squaring the base with the method of face-milling. This process is done to

remove the outer park of the work piece until the required dimension, which is 100mm × 35mm ×

45mm. The moveable jaw has undergone the process of squaring too. The required dimension was

35mm × 30mm × 24mm. Next, 6 holes was drilled from one side of the base on part (1) (Refer to

Appendix). Centre drill and a 4.8mm drill were used to drill through the work piece to produce the

holes. Then, centre drill was performed on part (2) followed by 10mm of drilling with a 4.1mm drill.

The process was then continued with cutting of U-slot along the base on part (3) using an 8mm end

mill and the depth is 4mm. After that, the same end mill was used to perform a rotate U-slot on part

(4) with the depth of 4mm. Afterwards, oblong slotting was performed from the bottom of work

piece. By using 10mm end mill, the oblong slot was done with the width of 16mm and 25mm deep.

Next, slotting was done around the part (5) with a 12mm end mill in order to remove the remaining

unwanted part using face mill. 65mm × 35mm × 25mm of metal has been removed. Lastly, two holes

of M5 were performed at part (2) with taperingusing tap and tap holder.

The moveable jaw was firstly done with U-slotting on part (6) with a 10mm end mill. Next, the same

end mill was used for the part (7), the two v-slotting. These parts are done with clamping the work

piece on the universal angel milling vise. After that, a face mill was used to chamfering at around

part (8) until the diagonal length was 16mm. Then, a 8mm drill was used to drill through the

moveable jaw diagonally at part (9), followed by an 14mm diameter ball nose with 7mm deep. Lastly,a 10mm end mill was used for the process slotting at the part (10) which is at another surface of the

work piece.



Result and Discussion:

Part 1: Base

Part Required Dimension, mm Actual Dimension, mm Tolerance, mm

A1 45.00 45.10 +0.10A2 8.00 8.20 +0.20

A3 19.00 19.00 0.00

A4 8.00 8.10 +0.10

A5 10.00 10.00 0.00

A6 12.00 12.00 0.00

A7 37.00 37.20 +0.20

A8 45.00 45.00 0.00

A9 10.00 10.00 0.00

A10 8.50 8.50 0.00

B1 25.00 25.10 +0.10B2 11.00 11.00 0.00

B3 25.00 25.00 0.00

B4 12.50 12.50 0.00

B5 M5 M5 0.00

B6 4.00 4.00 0.00

B7 8.00 8.00 0.00

B8 24.00 24.00 0.00

B9 100.00 100.00 0.00

C1 16.00 15.90 -0.10

C2 10.00 9.80 -0.20

C3 19.00 19.00 0.00C4 57.00 57.00 0.00

C5 71.00 70.80 -0.20

Part 2: Moveable jaw

Part Required Dimension, mm Actual Dimension, mm Tolerance, mm

A1 24.00 24.10 +0.10

A2 4.00 4.00 0.00

A3 0.50 0.50 0.00

A4 10.00 10.00 0.00

A5 37.00 37.20 +0.20

A6 45.00 45.20 +0.20

B1 R7 depth 7 R7 depth 7 0.00

B2 D8.00 D8.20 +0.20

B3 2.00 1.82 -0.18

C1 30.00 30.20 +0.20



Conclusion and recommendation:

In a nut shell, we had successfully completed this project in time with the cooperation between the

group members and guidance from lecturer. Throughout the project, we have learned about the basic

operations on the milling machine, the importance of safety in the laboratory, and some precautions

before carry out the machining work. Now we have a better understanding on various operations that

can be carry out on milling machine such as face-milling, drilling, slotting and so on.

It is recommended that to do some research and study on milling operation before carry out

machining work on it. It helps to prevent mistakes when carrying out machining job like the

selection of chuck ant the technique of clamping.

Reference:

1. https://www.nmri.go.jp/eng/khirata/metalwork/milling/intro/index_e.html

(Retrieved 22th December 20140

2.

http://www.thomasnet.com/articles/machinery-tools-supplies/how-milling-machines-work

(Retrieved 22th December 2014)

3.

www.maritime.org/doc/pdf/milling-machine.pdf

(Retrieved 22th December 2014)



Appendix:

A tool named face mill which we used to

perform facing process in the milling

machine.

Drill chart and drill used for the drilling

process.

Slotting operation on milling machineusing end mill.

The work piece was clamp on the

milling machine and the operations are

performed.



Final product:

Part 1: Base Part 2: Moveable jaw

machining 2 report

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