MULTIVIEW DRAWING

C D I G B

A H

PROCEDURE FOR PROCESS PLAN

CUTTING
i. Measure and mark the steel block with the dimension of length width 80mm and height 48mm by height gauge. ii. iii. Put the steel block on the table of the power saw machine. Push down the adjustable brass grip and make it at least 1mm away from the marked line to have an accurate cutting. iv. v. Clamp the steel block tightly at the quince set vice. Adjust the speed of the power saw machine at 2 and switch on the power supply. vi. Allow the coolant to flow on the surface of the steel block in contact with the hacksaw. vii. viii. ix. x. Switch off the machine when the operation is done. Repeat step 2 to 7 to cut the width of 80mm and the height of 48mm. Measure with the vernier calliper. Use a metal file to file the excess part of the work piece so that the steel block have the dimension of 120mm in length, 80mm in width, and 48mm in height. 120mm,

DRILLING
xi. Measure the width of 40mm and height of 12mm of the steel block (Figure 1 Part A) with vernier calliper.

xii.

Mark the points where the holes (Figure 1 Part A and Part B) are to be drilled by using a hammer and a centre punch.

xiii. xiv. xv.

Clamp the steel block on the T-slotted table using a mechanical vice. Fix the 12mm diameter drill bit in the chuck spindle. Measure and mark 16mm long from end of the drill bit by masking tape to ensure the accuracy of the depth 16mm.

xvi.

Set the spindle speed at 420RPM (Rotate per Minute) and other machining parameters.

xvii. xviii.

Put the lubricant oil on the steel block. Switch ON the spindle motor and move the lever manually so that the steel block is fed past the drilling cutter vertically.

xix. xx. xxi.

A hole with depth 16mm is produced. Switch off the power saw machine and take out the steel block. Repeat the step 11 to 20 to produce another hole (Figure 1 Part B) on the steel block.

MILLING
Part C
xxii. Measure and mark the length 32mm and 88mm, width 24mm, and height 40mm (Figure 1 Part C) of the steel block using vernier calliper. xxiii. xxiv. xxv. xxvi. Clamp the steel block on the T-slotted table using a mechanical vice. Fix the face milling cutter (Diameter of 28mm) in the spindle. Check the zero error before beginning the milling process. Adjust the height lever to bring the cutting tool to the surface of the steel block where milling is to be done. xxvii. xxviii. xxix. Set the cutting speed at 110 FPM and other machining parameters. Allow the coolant to flow on the steel block. Switch ON the spindle motor and move the horizontal lever manually so that the steel block is fed past the milling cutter. xxx. Raise the table up by 0.2mm and make sure the milling process is performed on the surface of the steel block. xxxi. Repeat step 23 to 31 by replacing the cutter with slot drilling cutter (Diameter of 10mm) to cut out the circular end of the part C produced by face milling. xxxii. Perform milling process until the required dimension of length 56mm, width of 56mm, and the height of 8mm are cut out.

xxxiii.

Measure the length and width of the given steel block using vernier calliper to confirm the accuracy of the product.

Part D, Part I, Part H

xxxiv.

Measure and mark the length 40mm and 96mm, width 32mm, and height 32mm (Figure 1 Part D) of the steel block using vernier calliper.

xxxv. xxxvi. xxxvii. xxxviii.

Clamp the steel block on the T-slotted table using a mechanical vice. Fix the face milling cutter (Diameter of 30mm) in the spindle. Check the zero error before beginning the milling process. Adjust the height lever to bring the cutting tool to the surface of the steel block where milling is to be done.

xxxix. xl. xli.

Set the cutting speed at 110 FPM and other machining parameters. Allow the coolant to flow on the steel block. Switch ON the spindle motor and move the horizontal lever manually so that the steel block is fed past the milling cutter.

xlii.

Raise the table up by 0.2mm and make sure the milling process is performed on the surface of the steel block.

xliii.

Perform milling process until the required dimension of length 40mm, width of 40mm, and height of 8mm and end with radius of 15mm (Figure 1 Part I and Part H) are cut out.

xliv.

Measure the length and width of the given steel block using vernier calliper to confirm the accuracy of the product.

Part E
xlv. Measure and mark the length 120mm, width 76mm, and height 4mm (Figure 1 Part E) of the steel block using vernier calliper. xlvi. xlvii. xlviii. Clamp the steel block on the T-slotted table using a mechanical vice. Fix the end milling cutter (Diameter of 16mm) in the spindle. Check the zero error before beginning the milling process.

xlix.

Adjust the height lever to bring the cutting tool to the surface of the steel block where milling is to be done.

l. li. lii.

Set the cutting speed at 110 FPM and other machining parameters. Allow the coolant to flow on the steel block. Switch ON the spindle motor and move the horizontal lever manually so that the steel block is fed past the milling cutter.

liii. liv. lv.

Raise the table up by 0.2mm and make sure the milling process is performed on the surface of the steel block. Perform milling process until the required dimension of length 120mm, width of 4mm, height of 16mm are cut out. Measure the length and width of the given steel block using vernier calliper to confirm the accuracy of the product.

Part F, Part G
lvi. lvii. lviii. lix. lx. lxi. lxii. lxiii. lxiv. lxv. Measure and mark the length 16mm, width 16mm, and height 36mm (Figure 1 Part F and Part G) of the steel block using vernier calliper. Clamp the steel block on the T-slotted table using a mechanical vice. Fix the end milling cutter (Diameter of 16mm) in the spindle. Check the zero error before beginning the milling process. Adjust the height lever to bring the cutting tool to the surface of the steel block where milling is to be done. Set the cutting speed at 110 FPM and other machining parameters. Allow the coolant to flow on the steel block. Switch ON the spindle motor and move the horizontal lever manually so that the steel block is fed past the milling cutter. Raise the table up by 0.2mm and make sure the milling process is performed on the surface of the steel block. Repeat step 57 to 64 by replacing the cutter with slot drilling cutter (diameter of 10mm) to cut out the circular end of the part F and part G produced by end milling. Perform milling process until the required dimension of length 16mm, width of 64mm, and the height of 12mm are cut out. Repeat step 57 to 66 to produce part G. Measure the length and width of the given steel block using vernier calliper to confirm the accuracy of the product.

lxvi. lxvii. lxviii.

Processes
1)

Power Saw Machine Power saw machine is used to cut a metal work piece into a desire dimension. The arm of the power saw machine that with the hacksaw is moved forward and backward on the work piece to produce cutting process. Blades of the hacksaws are graded according to the material and the number of teeth per inch. High quality blades are made from High Speed Steel. Some material like carbon steel blades can also been used. The number of teeth per inch (TPI) range is generally from 14 to 24. The higher the teeth per inch, the smoother the cut. The coolant is allowed to flow on the surface of the steel bock in contact with the hacksaw to reduce the heat and to have a better

performance. The speed of the power saw machine is medium. It is because it can protect the brass grip, so that it can last longer.

2)

Drilling Process Drilling is a machining operation where a metal work piece is forced through by the drill bit with required diameter. The axis of rotation of the tool should be same as the feed direction. The tool is called the drill bit and the cutting edges are called flutes. Drilling process is used to make a hole on

the work piece. It is a continuous cutting operation. The flutes of the drill bit pierce the work piece surface during each revolution and leaving a hole through the thickness of the work piece. Lubricant oil should be added on the work piece before drilling process start to reduce the heat produced and reduce the sparks. The speed of the drilling should be controlled to ensure a precise hole is produced.

3) Milling Process Milling is a process whereby a work piece is fed past a rotating cylindrical tool with multiple cutting edges. The feed direction and the axis of rotation of the tool are perpendicular. The tool is called the milling cutter. Plane surfaces normally are created by using milling process. Milling process is operated by using the principle of rotary motion. A

milling cutter is spun about a certain axis while a work piece is advanced through it. The blades of the cutter shaves the chips of material with each pass. Milling processes are designed and the cutter makes lots of individual cuts on the material in a single run. This can be done by using a cutter with many teeth, spinning the cutter at high speed or advancing the material through the cutter slowly. Coolant is allowed to flow on the work piece to reduce heat produced and sparks. It is also to prevent the work piece overheated and burned.

Type Of Cutters

I.

Face mill: Use to produce flat surface such as facing for the top, end, edge and shallow steps of the work piece.

II.

End mill: Use to mill shoulder, angular faces, internal and external profiles, flat face or edges.

III.

Slot drill: Use to mill slots, keyways, flat seat on angular or curved surface, small counter bores or spot facing.