UNIVERSITY COLLEGE OF ENGINEERING & TECHNOLOGY MALAYSIA Faculty of Mechanical Engineering

SEMESTER 2, 2005/2006 MECHANICAL TECHNOLOGY LAB 2

Subject code : BMM1821, DMM1922, DMM 2942

Lab Sheet 1

Milling Operation.

Group Assignment : Maximum 4 persons each group. Purpose : To study the operation of milling such as face milling, end milling, chamfering, slotting, drilling, reaming, tapping, counter boring, etc. Universal milling machines. Refer to Drawing No. 102-0001 150mm vernier caliper, steel ruler, Plug gage 8H7mm, flat file, slot drill 8mm end mill 20mm (roughing & finishing), fly cutter (or face milling cutter), Machine Reamer 8H7, Center drill, Twist drill 7.6, 8.5 & 9mm, Hand taps set for M8, Counterbore for M8, countersunk 90, edge finder, deburring tool, Dial Test Indicator (DTI), slitting saw, etc. Mild Steel (Approximately 103mm x 50mm x 25mm). Machinery Handbook, Lab Manual and Handouts. 1. S. Kalpakjian, 1997 Manufacturing Processes for Engineering Materials, 3rd Ed., Addison-Wesley. 2. J. A. Schey, 1999, Introduction to Manufacturing Processes, 3rd Ed., McGraw-Hill. 3. S.F. Krar, J.W. Oswald, Technology of Machine Tools, McGraw-Hill.
Muhammad Adib bin Shaharun Mohd Fazli bin Ismail Hazami bin Che Hussain Rusli bin Ghani Asmizam bin Mokhtar Aziha bin Abdul Aziz Muhamad Rozikin bin Kamaluddin adib@kuktem.edu.my fazliismail@kuktem.edu.my hazami@kuktem.edu.my rusli@kuktem.edu.my asmizam@kuktem.edu.my aziha@kuktem.edu.my rozikin@kuktem.edu.my

Machine Project

: :

Tools/Equipments :

Material . Text books Reference Text

: : :

Coordinator Instructor

: :

FKM/0386/Mech. Tech. Lab 2/Lab sheet 1

UNIVERSITY COLLEGE OF ENGINEERING & TECHNOLOGY MALAYSIA Faculty of Mechanical Engineering

Operations: 1. Setting vise parallel 1.1. Setting vise parallel to the machine table. The dial Indicator or (DTI) assembly set is used for aligning the vise. (The lab instructor will demonstrate the procedure) 2. Secure the workpiece in the table of the milling machine using the vice. 2.1. Clean milling machine vise thoroughly. 2.2. If necessary, place parallels under the workpiece to raise the surface to be milled above the level of the vise jaws. 2.3. After the workpiece is in place, tighten the vise securely, then tap the workpiece lightly with a fort (lead) hammer to seat it. Do not tighten the vise again because this would alter the position of the workpiece and tightness of the parallels. 3. Machine Setup 3.1. Measure the diameter of the cutter with a vernier caliper. 3.2. Calculate RPM, n for cutting speed, v = 30 m/min (HSS end mill) 100m/min (carbide insert). n = v(m/min) x 1000 D(mm) 3.3. Locate the closest RPM on spindle speed chart. Check that the lever is in correct position. Follow the instructions on the panel for setting levers depending on whether you are working at the LOW or HIGH speed level (Check with the lab instructor to verify your setup before you continue). 3.4. Calculate the federate. (refer to the machinery handbook for the feed per tooth) Feedrate = feed per tooth x no. of cutter teeth x RPM Note: 1. If your machine possesses the power feed attachment, use the feed selector table near handle to select the slot to place it in. The High or Low feed rate can be set by adjusting knob in power feed mode. If power feed is not available, use handles for manual feed. 2. The direction of feed is optional on a vertical milling machine. 4. Milling a block square & parallel 4.1. In order to mill the four sides of a piece of work so that its sides are square and parallel, it is important that each side be machined in a definite order. It is very important that dirt and burrs be removed from the work, vise and parallels since they can cause inaccurate work. 4.2. The lab instructor will demonstrate the procedure to mill a block square and parallel. Note: Always use cutting lubricant when machine the workpiece.

FKM/0386/Mech. Tech. Lab 2/Lab sheet 1

UNIVERSITY COLLEGE OF ENGINEERING & TECHNOLOGY MALAYSIA Faculty of Mechanical Engineering

5. Milling a shoulder 5.1. Secure the workpiece in the table of the milling machine using the vice. 5.2. Use an edge finder (or any suitable tools/methods) to find reference point of the workpiece. (the lab. instructor will demonstrate the procedure) 5.3. Set the micrometer dial on the cross feed and/or DRO for the Y axis to zero. 5.4. Select cutter (rough cut end mill) of sufficient diameter to cut the shoulder. 5.5. Placed the tool at the right position. Check the required dimensions (depth & width) of the shoulder. 5.6. Lower the cutting tool or raise the table using the crank until it touches the top surface of the workpiece gently. 5.7. Set the micrometer dial on the vertical feed and/or DRO for the Z axis to zero. 5.8. Before starting the machine, be sure the cutting tool is clear of the workpiece. If not, lower the workpiece using crank or move the workpiece clear from the cutting tool. 5.9. Turn the machine on. 5.10. Move the table with the longitudinal feed handle to cut the workpiece. It is advisable to cut the workpiece using up cut method rather than down cut method. Raise the table 1~2mm for the depth of cut. You might need multiple cuts. Left the allowances about 0.5mm (depth & width) for the finishing cut. 5.11. Change tool for the finishing cut and repeat again step 5.3 until 5.9. 5.12. Do the finishing cut. Note: Check the dimensions of your work before you proceed to the next process. 6. Cut chamfer 3mm x 45 6.1. Use the countersunk 90 or chamfering tool to cut the chamfer required. (The lab instructor will demonstrate the procedure). 7. Centering for drill holes. 7.1. Make centering using center drill for all holes need to drill on the workpiece. 7.2. Calculate the RPM required for center drill. 8. Drill holes 8.1. Make sure you chose right size of twist drill to drill holes. The twist drill size for metrics tap is calculated using this formula: (Tap drill size = major diameter pitch) & the allowance for ream holes using machine reamer is 0.4mm. 8.2. Calculate the RPM for each size of twist drills that will be use for drilling process. Use cutting speed, cs = 20m/min. 8.3. Use coolant when drill holes. 9. Ream holes. 9.1. Use machine reamer to ream holes. 9.2. Calculate the RPM for the reaming process. RPM for the reaming process is approximately to 2/3 that used for drilling. Speed, feed and reaming allowances are the three main factors which will affect the accuracy and finish of hole and the life of the reamer. 9.3. Use oil coolant type as a cutting lubricant to improve the hole finish and prolong the life of the reamer. 9.4. Check the size of holes using plug gage.

FKM/0386/Mech. Tech. Lab 2/Lab sheet 1

UNIVERSITY COLLEGE OF ENGINEERING & TECHNOLOGY MALAYSIA Faculty of Mechanical Engineering

Note: Never, under any circumstances, turns a reamer backward, as it will dull the cutting teeth. 10. Tapping Thru holes 10.1. Use hand tap to produce thread on holes as specified on the drawing. 10.2. Always start using the taper tap, follow with plug & finish it with bottoming tap when the tapping process using hand taps. 10.3. Use oil coolant type as a cutting lubricant. Note: Always check the tap for squareness while tapping the work using hand tap. 11. Counterboring 11.1. Select the right size of counterboring tool to produce step hole for HCSS M8. 11.2. Make sure the pilot holes or thru holes are there before start to cut step holes using counterboring tool. 11.3. Calculate the RPM for the counterboring process. RPM for the 1/ of that used for drilling. counterboring process is approximately 3 11.4. Bring the counterbore close to the work and see that the pilot turns freely in the drilled hole. 11.5. Start the machine, apply cutting fluid and counterbore to the required depth. 12. End milling of slots 12.1. Secure the workpiece in the table of the milling machine using the vice. 12.2. Use two flute end mill or slot drill to machine the slot as shown on the drawing. 12.3. Edge finds the workpiece to set the origins or reference points of the workpiece. 12.4. Make a slot as shown in the drawing. The cutting speed should be 15m/min and the depth of cut when machine the work should be 0.5mm ~ 1mm for each cut. 12.5. The depth of slot should be 2mm. You might need multiple cuts. 13. Chamfering 13.1. Make chamfers as shown in the drawing using chamfering tool or countersunk 90. 14. Mill corner slot 14.1. Mount slitting saw 2mm thickness to the arbor. (the lab. instructor will demonstrate the procedure) Note: The machine spindle will be setup at a horizontal position.

FKM/0386/Mech. Tech. Lab 2/Lab sheet 1

UNIVERSITY COLLEGE OF ENGINEERING & TECHNOLOGY MALAYSIA Faculty of Mechanical Engineering

Lab Report Format

The purpose of the lab reports is to give practice in summarizing completely and accurately the assigned lab task. Lab reports must follow this outline: 1. Front Matter (5%) Title page (course No, lab title, name, date) Abstract (methods, results, and conclusion of the report in miniature, up to 100 words) Table of contents List of figures and tables List of symbols 2. Report Body (85%) (Refer to Items to be included in the report body.) Introduction (objectives, definition of the lab, main conclusion) (20%) Experimental description (tasks, procedures, equipment) (20%) Results (20%) Discussion (10%) Conclusion (10%) Recommendations (5%) 3. Appendixes (15%) References Supporting details

Items to be included in the report body. Machine, tools, equipments, material, etc which were involved or used in your lab assignment. Measured dimensions of the finished part. (all the dimensions shown on the drawing) Cutting conditions used for each feature. Calculating the RPM of cutting tools. Calculating the machining time. Calculating the rate of feed. Process planning (On your own words) The procedure for setting vise parallel to the machine table. The procedure for milling a block square & parallel. The process picking up an edge with and edge finder. Recommendation & conclusion.

FKM/0386/Mech. Tech. Lab 2/Lab sheet 1