Enterprised-based vocational education

Advanced Lathe-Milling Module Report Batch 2

Ingga Aziz Fahmi Emang Sulaeman

1. Information a. The device we are going to make is vise for milling machine. b. The given time to make it is 3 weeks, and 1 week for assembling and evaluation. c. We are given the drawing of it. And it has 10 parts. d. In making Pos. 1 or base part, the workpiece must be machined without any loosening, so it must be clamped however we work on it. This due to the scale point will change if we loosen it since every part (drill hole, slideng tracks) of is connected to each other. e. Revision of the dimension in several parts. f. Vise handle as the additional parts that is not shown in drawing. g. To make the 450 groove, we had to change the degree of the milling machine head. h. The surface of handle support is not machined. i. The lock pin is made of round bar. 2. Planning a. Make the base b. Make the bushing c. Make the screw shaft d. Make the shaft that has inner thread or Pos 9 e. Make the handle support f. Make the handle g. Make Pos 2, 3, 4, 5, and 6 into their cubical dimension h. Drilling Pos 2, 3, 4, 5, and 6 according to the drawing i. Taping Pos 2, 3, 4, 5, and 6 according to the drawing j. Milling the 450 at the Pos 5 & 6 k. Milling Pos 3 accroding to the drawing ( for sliding groove l. Milling the oblique sides at Pos 4 m. Drilling and boring Pos 4 until 34H7 n. Making the lock pin o. Pressing the bushing into Pos 4 p. Assembling the other parts

Advance Lathe-Milling Report batch 2

3. Decision a. In making the base, firstly we make it until it reach the cubical dimension. And for most outter side we use face mill instead of end mill because it can be faster and considering that face mill is stronger and the thickness of workpiece is still in face mill ability. But for inner milling that placed inside of material we still use endmill. Beside that, in finding the center point we always use the help of thickness gauge instead of drawing the line on it with height gauge. b. In making the bushing, we always use low speed, considering the smoothness of the surface, in case it will be assembled to particular part, so we had to minimize the coarse on the surface so that it wont give any effect when it is assembled. c. The handle supprt has to be bored until particular depth. But most of drill bit can not reach that depth, so the final depth is reached by the final drill bit that is same to the diameter. So we had to be slow and carefull in boring. In making the groove for connecting to the handle, we clamp it with 3 jaw chuck, not common vise for milling machine. With this chuck, the rectangular groove can be reached. d. In milling Pos 2, 3, 4, 5, & 6, we use face mill 63 to save time. e. In finding center point for drilling Pos 2, 3, 4, 5, & 6, we always consider the scale feature on milling machine, but to recheck it, we also measure that point using vernier to make it sure that it is correct. It is not only for those parts, but for almost all parts. f. When turning Pos. 9, the tool didnt support the process of making workpiece based on the drawing. So we machined the workpiece based on the ability of the tool ( inner thread cutting tool). 4. Realization a. Problems i. Material was not available in the workshop. ii. There were 1 national holidays which shorten our time schedule. iii. For Pos. 9, the tool doesnt support the design. As the result, when it is still in progress, the tool broke, and the workpiece became damaged. iv. Drawing Pos. 6 and Pos. 3 dont have the correct dimension. So they need to be remachined. But on that day, Friday, April 13th all milling machine were being used. v. Supporting parts i.e. bolt and snap ring were out of stock. vi. The screw was not sliding easily in the inner thread. vii. The sliding groove was not sliding easily in the sliding track. viii. Face mill 63 has several blunt cutters, but it cannot be replaced because the bolt has been damaged. This cause the surface become concave. ix. The diameter of hole for bushing was too small so when it is pressed with the bushing, it doesnt get in.

Advance Lathe-Milling Report batch 2

b. Problems solving i. We forced to keep turning with that tool but we had to be more carefull. ii. We filed it until it has same dimension. iii. We re-turned the screw and filed the threa to remove the brittles and scales which make it not sliding easily. iv. We filed the sliding track because recently we found out that it is not smooth yet. v. We replaced face mill 63 with face mill 20 vi. We re-bored the hole until it reach the correct diameter and the measurement is from the side of workpiece to the inner side of the hole, not from hole diameter vii. For the handle, we make some modification, chamfer with different size between the side 5. Quality Control a. We always use scaling feature to find the center or other points, because we are sure that scale never lies. b. For several drill holes that each needs some tool or arbor replacing, we never change the center point. It means that we only drill one hole until it reach the diameter tand then we can stepped to the next hole. c. To avoid the overmilling, we used limit bolts for milling bed table. d. To make sure that the surface of the turned or milled workpiece is fine, we always use high-fineness sandpaper to re-smoothing the surface. e. For chamfering we always use file tools with high teeth numbers, in this case we used small files. f. We always give lubrication when we leave the workpiece for a long time. 6. Evaluation a. More accurate and detail design has to be iplemented. b. There are a lot of tools that dont support the working process, for example face mil cutters that can not be replaced because the bolt is broken. I think we have to be explained more about loosening small bolts and the suitable key for that because there are a lot of keys. c. We think we had to be explained more about the features in milling machine because there are a lot of parts in it that many students still dont know. For example limit bolts and how to lock and unlock the spindle for drilling and etc. Because we realize that many students may forget about it. d. Thanks first Batch lathe and mill advance, we get some knowledge in order to movable post it wasnt steady e. Hopefully the next batch have improvement from us or before batch. thanks

Advance Lathe-Milling Report batch 2