Workshop Practical Manual

MDB1043: Manufacturing Technology
Workshop Practical Manual

Sep, 2016 Semester
Student Name:
Student ID:
Date
Actual Group
Number
Attendance
(Technicians Stamp)
Lab
Manual
Marks
Conventional Milling
Conventional Lathe
CNC Milling Offline
CNC Milling 2
CNC Lathe Offline
CNC Lathe 2
Arc Welding 1
Arc Welding 2
Arc Welding 3
Metrology
Rapid Prototyping
CNC EDM Wirecut
..CUT THIS SECTION....

LAB SESSION:
NAME
MATRIX NO
SUBMISSION DATE / TIME:
AM / PM
REMARKS
STUDENT INITIAL
STAFF INITIAL:
Work
Piece
Marks
SAFETY AGREEMENT
I, named as below, fully understand all the regulations pertaining to the
Health, Safety and Environment in the laboratory as listed in Appendix J of
this manual, and therefore shall abide and follow all the rules and
instructions.
Name:
IC/Passport No:
Date:
Signature:
1. Conventional Milling
1.1 Objective: To perform milling processes on a rectangular workpiece
according to specifications given in a technical drawing.
1.2 Workshop Outcomes
At the end of this workshop, students should be able to:
1. Explain the components of conventional milling machines.
2. Generate a milling process plan based on an end product.
3. Use a milling machine in the appropriate manner and according to
relevant safety standards.
1.3 Machine Specifications
Distance between spindle axis and table working surface:
30mm 440mm
Distance between body vertical guides and table body:
218mm 469mm
Table working surface: 300 mm x 1250 mm
Table swivel: 45o
Feed: Normal longitudinal 12.5 630 mm/min
Transversal 12.5 630 mm/min
Vertical
5.2 262 mm/min
Main drive: 40 2000 RPM
Main drive motor: 5.5 kW, 1440 RPM
Feed drive motor: 1.5 kW, 920 RPM
1.4 Refer to Appendix A for procedures and machine operation details. For
full operations manual, consult lab technicians and equipment manual.
1.5 Safety Instructions:
Never operate the machine without wearing the correct protective
clothing, (i.e. safety shoes, safety glasses, overalls do not wear

loose clothing, do not wear jewellry).
Make sure the machine is suitably positioned and that the
surrounding floor area is kept clean and free from scrap material,
oil and grease.
Always concentrate on your work careless acts can result in
serious injury.
Persons not involved in machine operation should be kept at a safe
distance.
Do not engage in the machines main drive with a loose workpiece
or cutting tool.
Do not attempt to adjust or remove tools when the machine is in
operation.
Always use protective screen when working with the vertical milling
head
Ensure that the cutting tools are suitable and in good working
order.
Technical Drawing
(label the figure)
1.6 Project Report: Conventional Milling

A. Sketch the conventional milling machine, label the major components and
state the functions of these components.
No
Component
Function
1.
2.
3.
4.
5.
6.
7.
8.
9.
10.
B. Sketch the tooling and workholding devices to be used and state the
functions of these components.
C. Summarize the process plan for machining the part.

Operation Sheet
Part Name:
Op
no.
Operation
Machine
tool
Cutting
tool
Cutting
Speed
Spindle
Speed
(RPM)
Feed
DOC
Remarks
1.
2.
3.
4.
5.
6.
7.
8.
9.
10
Date:
D. Results
Dimensional check
Dimension Nominal
Actual
Technicians
Verification
A
B
C
D
E
E. Discussion
F. Conclusion

Sep, 2016 Semester
Student Name:
Student ID:
Date
Actual Group
Number
Attendance
(Technicians Stamp)
Lab
Manual
Marks
Conventional Lathe
CNC Milling Offline
CNC Milling 2
CNC Lathe Offline
CNC Lathe 2
Arc Welding 1
Arc Welding 2
Arc Welding 3
Metrology
Rapid Prototyping
CNC EDM Wirecut

LAB SESSION:
NAME
MATRIX NO
STUDENT INITIAL
STAFF INITIAL:
AM / PM
REMARKS
10
Work
Piece
Marks
2. Conventional Lathe
2.1 Objective: To perform lathe processes on a cylindrical workpiece
according to specifications given in a technical drawing.
1. Explain the components of a conventional lathe engine.
2. Generate a lathe process plan based on an end product.
3. Use a lathe engine in the appropriate manner and according to
2.4 Refer to Appendix B for procedures and machine operation details. For
2.5 Safety Instructions
Ensure quill cover, rapid traverse mechanism and control panel and
chuck guard are closed
DO NOT operate machine if there are any faults in the electrical
cabinet door, quill cover or chuck guard interlocks
Isolate power in advance for maintenance and repairs.
The machine should be stopped at the slightest fault, the cause
established and rectified. Only then should the machine be
restarted
DO NOT operate machine if the clearance between the guideways
and the sliding surfaces of the carriage exceeds 0.03 mm.
DO NOT operate the machine when the tool is not correctly fixed,
when hard allowed plates with improper welding are used, or when
the hard allowed replacement plates are incorrectly fixed.
Ensure that you have selected a suitable mode of operation and
cutting tool.
Tighten the loosened tailstock if necessary.
Ensure that you know how to stop a machine before starting it.
Keep all guards, covers and doors in place and closed.
Never lay anything on the working surface of the machine.
Stop the machine immediately should anything unexpected happen.
11
Technical Drawing
(label the figure)
12
2.6 Project Report: Conventional Lathe

A. Sketch the conventional milling machine, label the major components and
state the functions of these components.
No.
Component
Function
1.
2.
3.
4.
5.
6.
7.
8.
9.
10.
13
B. Sketch the tooling and workholding devices to be used and state the
14

Operation Sheet
Part Name:
Op
no.
Operation
Machine
tool
Cutting
tool
Cutting
Speed
Spindle
Speed
(RPM)
Feed
DOC
Remarks
1.
2.
3.
4.
5.
6.
7.
8.
9.
10
Date:
15
D. Results
Dimensional check
Dimension Nominal
Actual
Technicians
Verification
A
B
C
D
E
16
E. Discussion
F. Conclusion
17

Sep, 2016 Semester
Student Name:
Student ID:
Date
Actual Group
Number
Attendance
(Technicians Stamp)
Lab
Manual
Marks
Conventional Lathe
CNC Milling Offline
CNC Milling 2
CNC Lathe Offline
CNC Lathe 2
Arc Welding 1
Arc Welding 2
Arc Welding 3
Metrology
Rapid Prototyping
CNC EDM Wirecut

LAB SESSION:
NAME
MATRIX NO
STUDENT INITIAL
STAFF INITIAL:
AM / PM
REMARKS
18
Work
Piece
Marks
SAFETY AGREEMENT
instructions.
Name:
IC/Passport No:
Date:
Signature:
19
3. CNC Milling 1
3.1 Objective: To perform CNC programming and operation of a CNC milling
machine.
1. Explain the components of a CNC milling machine.
2. Generate a part programme.
3. Use a CNC Milling Machine in the appropriate manner and
according to relevant safety standards.
3.3 Machine Specifications:
Maximum cross travel
Maximum longitudinal travel
Maximum head travel
Working table surface
Spindle speed
Machine resolution
90mm
170mm
115mm
360mm x 130mm
0 4000 RPM
0.01mm
3.4 Refer to Appendix C for procedures and machine operation details. For
All activities in the CNC lab must be done under supervision.
Familiarize yourself with the procedure before actually
operating the equipment. If unsure, request assistance from

the lab instructor.
Immediately report all malfunctions or unusual occurrences to
the lab instructor.
Wear suitable clothing. No open-toe shoes are allowed.
Slippers, bracelet, wristwatches and rings are strictly
prohibited during lab.
Ensure that workpiece is secured before operating the
machine.
Follow safety instructions by the lab instructor.
Apron must be worn at all time during each practice session.
Avoid foolish behaviour and concentrate on your practice.
Only operate machine when the safety guards are closed.
Never touch any moving parts of the machine or workpiece.
Ensure that there are no loose items near the machine.
20
3.6
Tasks
1.
2.
3.
4.
5.
6.
7.
Determine the appropriate machining parameters as in 3.7.B

Perform all start-up and initialization procedures
Set the origin at the top center of the workpiece
Perform a linear interpolation along x-axis
Performa a linear interpolation along y-axis
Perform a linear interpolation along both x and y axes
Perform a circular clockwise interpolation with an arc radius of 15 mm
and arc start at 10,10.
8. Perform a circular counter-clockwise interpolation with an arc radius of
1.5 inches and arc start at -10,-10.
9. Create a square profile with a 45 mm width, using right hand radius
compensation
3.7 Project Report: CNC Milling 1

A. Sketch the CNC milling machine, label the major components and state the
21
B.
Machining parameters
Determine the appropriate (range of) machining parameters:

Cutting Speed:
Feed:
Depth of cut:
Spindle speed:
22
C. Part programme
i)
Header
Part Program - Header
ii)
Part programme (body) for 3.6.3

Part Program - Body
iii)

Part Program - Body
iv)

Part Program - Body
23
v)

Part Program - Body
vi)

Part Program - Body
vii)

Part Program - Body
viii)

Part Program - Body
24
D. Results
E. Discussion
F. Conclusion
25
4. CNC Milling 2
4.1 Objective: To perform CNC programming and machining on a
rectangular workpiece according to the given pattern and dimensions.
1. Generate a milling process plan based on an end product.
2. Use a CNC milling machine in the appropriate manner and
according to relevant safety standards.
Maximum cross travel
Maximum longitudinal travel
Maximum head travel
Working table surface
Spindle speed
Machine resolution
90mm
170mm
115mm
360mm x 130mm
0 4000 RPM
0.01mm
4.4 Refer to Appendix C for procedures and machine operation details. For

the lab instructor.
Immediately report all malfunctions or unusual occurrences to
the lab instructor.
machine.
26
4.6 Project Report: CNC Milling 2

A.
Pattern and dimensions for tool path
27
B.

Cutting Speed:
Feed:
Depth of cut:
Spindle speed:
28

Operation Sheet
Part Name:
Op
no
Operation
Machine
tool
Cutting Cutting
tool
Speed
Spindle
Speed
(RPM)
Feed
DOC
Remarks
1.
2.
3.
4.
5.
6.
7.
8.
9.
Date:
29
D. Part program.
Part Program
E. Results
30
F. Discussion
G. Conclusion
31

Sep, 2016 Semester
Student Name:
Student ID:
Date
Actual Group
Number
Attendance
(Technicians Stamp)
Lab
Manual
Marks
Conventional Lathe
CNC Milling Offline
CNC Milling 2
CNC Lathe Offline
CNC Lathe 2
Arc Welding 1
Arc Welding 2
Arc Welding 3
Metrology
Rapid Prototyping
CNC EDM Wirecut

LAB SESSION:
NAME
MATRIX NO
STUDENT INITIAL
STAFF INITIAL:
AM / PM
REMARKS
32
Work
Piece
Marks
SAFETY AGREEMENT
instructions.
Name:
IC/Passport No:
Date:
Signature:
33
5. CNC Lathe 1
5.1 Objective: To perform CNC programming and operation of a CNC lathe
machine.
1. Explain the components ofa CNC lathe machine.
2. Generate a part programme.
3. Use a CNC lathe machine in the appropriate manner and according to
Swing over bed
Swing over cross slide
Distance between centers
Spindle power
Spindle speed
Machine resolution
150mm
50mm
300mm
1 HP
0-3000 RPM
0.01 mm
5.4 Refer to Appendix D for procedures and machine operation details. For
1. All activities in the CNC lab must be done under supervision.
1. Familiarize yourself with the procedure before actually
the lab instructor.
2. Immediately report all malfunctions or unusual occurrences
to the lab instructor.
3. Wear suitable clothing. No open-toe shoes are allowed.
4. Ensure that work piece is secured before operating the
machine.
5. Follow safety instructions by the lab instructor.
6. Apron must be worn at all time during each practice session.
7. Avoid foolish behavior and concentrate on your practice.
8. Only operate machine when the safety guards are closed.
9. Never touch any moving parts of the machine or work piece.
34
5.6
Tasks
1. Determine the machining parameters as in 6.7.B

2. Perform all start-up and initialization procedures
3. Use rapid traverse to move the cutting tool close (within 3 mm) to the
work piece
4. Use G01 to reduce 1mm of the work piece diameter
5. Use G01 to face 1mm off the work piece
6. Perform taper process using G01 code from datum point (0,0) to
(X10, Z-10).Use simulation mode to view the process.
7. Use simulation process to view G02 machining profile from datum point
(0,0) to point (X10, Z-10).
8. Use G03 code to produce circular interpolation machining profile from
datum point (0,0) to point (X10, Z-10)
5.7 Project Report: CNC Lathe

A. Sketch the CNC lathe machine, label the major components and state the
35
B.

Cutting speed:
Feed:
Depth of cut:
Initial spindle speed:
C. Part programme
i)
Header
Part Program - Header
36
ii)

Part Program - Body
iii)

Part Program - Body
iv)

Part Program - Body
v)

Part Program - Body
37
vi)

Part Program - Body
viii)

Part Program - Body
vii)
Part programme (end)

Part Program - End
38
D. Results
G. Discussion
H. Conclusion
39
6. CNC Lathe 2
6.1 Objective: To perform CNC programming and machining on a cylindrical
workpiece according to the given pattern and dimensions.
1. Generate a lathe process plan based on an end product.
2. Use a CNC lathe machine in the appropriate manner and according
to relevant safety standards.
Swing over bed
Swing over cross slide
Distance between centers
Spindle power
Spindle speed
Machine resolution
150mm
50mm
300mm
1 HP
0-3000 RPM
0.01 mm
6.4 Refer to Appendix D for procedures and machine operation details. For

the lab instructor.
Immedeately report all malfunctions or unusual occurences to
the lab instructor.
machine.
40
6.6 Project Report: CNC Lathe 2

A.
Pattern and dimensions for tool path
41
B.

Cutting Speed:
Feed:
Depth of cut:
Spindle speed:
42

Operation Sheet
Part Name:
Op
no
Operation
Machine
tool
Cutting Cutting
tool
Speed
Spindle
Speed
(RPM)
Feed
DOC
Remarks
1.
2.
3.
4.
5.
6.
7.
8.
9.
Date:
43
D. Part program.
Part Program
E. Results
44
F. Discussion
G. Conclusion
45

Sep, 2016 Semester
Student Name:
Student ID:
Date
Actual Group
Number
Attendance
(Technicians Stamp)
Lab
Manual
Marks
Conventional Lathe
CNC Milling Offline
CNC Milling 2
CNC Lathe Offline
CNC Lathe 2
Arc Welding 1
Arc Welding 2
Arc Welding 3
Metrology
Rapid Prototyping
CNC EDM Wirecut

LAB SESSION:
NAME
MATRIX NO
STUDENT INITIAL
STAFF INITIAL:
AM / PM
REMARKS
46
Work
Piece
Marks
SAFETY AGREEMENT
instructions.
Name:
IC/Passport No:
Date:
Signature:
47
7. Welding 1
7.1 Objective: Familiarization with welding operations
7.2 Machine specifications
Nichia Arc Welding Machine, ND-300

Stick electrode welding
Input voltage: 220 V, Frequency:50/60 Hz, Rated input: 13 kW
Output no-load voltage: 80 V
Output range: AC 50 300 A, DC 30 250 A
7.3 Refer to Appendix E for procedures and operation details. For complete
operations manual, consult lab technicians and equipment manual.
Keep at a safe distance from the demonstrator.

Exercise caution as welding fumes may be harmful to the welder.
Ensure you utilize the available personal protective equipment (i.e.
welding helmet/goggles, chipping goggles, leather gloves, electrode
holder, welding jacket).
Wear closed toe shoes, preferably boots.
Discard frayed cords and wires
Keep working area clean.
48
7.5 Tasks
1. Familiarize yourself with the welding equipment, workpiece and
welding parameters.
2. Check and modify the straightness and the squareness of the
surface.
3. Place the workpiece on the table in a flat position. Using the face
shield, mark/touch the electrode to the workpiece to produce an arc.
4. Move the electrode slowly while pressing the electrode until it

reaches the end of the workpiece. When reaching the end of the
workpiece, raise the electrode and turn it away from the workpiece.
5. With your safety goggles on, remove the slag and examine the
weld by chipping with a hammer or wire brush. (USE EXTREME CARE
AS THE METAL WILL BE HOT)
49
6. Examine your workpiece. Consult the workshop instructor on

how to improve your weld.
GOOD
POOR
POOR
7. Continue practicing bead forming until you obtain a

satisfactory result.
7.6 Project Report A
A. Welding equipment, workpiece and welding parameters
Title:
1.
2.
3.
50
4.
5.
7.7 Project Report B

A. Welding equipment, workpiece and welding parameters
Title:
1.
2.
3.
4.
5.
51
B. Discussion
C. Conclusion
52
8. Welding 2
8.1 Objective: Performing a butt joing and lap weld


8.5.A Butt joint

1. Check and ensure that the workpieces are straight and flat.
2. Tack weld the workpieces into a butt joint.
3. Use a face shield, mark/touch the electrode to produce an arc.

When there is a spark, ensure that the angle and distance are
correct for welding the workpiece. Move the electrode slowly while
53
pressing the electrode until it reaches the end of the workpiece.

When reaching the end of the workpiece, raise the electrode and
turn it away from the workpiece
GOOD
POOR
POOR
54
8.5.B Lap weld

2. Tack weld the workpieces into a lap joint.

55

GOOD
POOR
POOR
8.6 Project Report

A. Results
B. Discussion
56
C. Conclusion
57
9. Welding 3
9.1 Objective: Performing a T-joint and corner joint


58
9.5.A T-Joint
2. Tack weld the workpieces into a T-shaped joint.

59
GOOD
POOR
POOR
60
9.5.B Corner Joint

2. Tack weld the workpieces into a T-shaped joint.

61

GOOD
POOR
POOR
9.6 Project Report

A. Results
B. Discussion
62
C. Conclusion
63

Sep, 2016 Semester
Student Name:
Student ID:
Date
Actual Group
Number
Attendance
(Technicians Stamp)
Lab
Manual
Marks
Conventional Lathe
CNC Milling Offline
CNC Milling 2
CNC Lathe Offline
CNC Lathe 2
Arc Welding 1
Arc Welding 2
Arc Welding 3
Metrology
Rapid Prototyping
CNC EDM Wirecut

LAB SESSION:
NAME
MATRIX NO
STUDENT INITIAL
STAFF INITIAL:
AM / PM
REMARKS
64
Work
Piece
Marks
SAFETY AGREEMENT
instructions.
Name:
IC/Passport No:
Date:
Signature:
65
10. Metrology
10.1
Objective: To familiarize with the operation of measuring gauges,

instruments and equipment.
10.2
Workshop objectives.
By the end of this workshop, students should be able to:
1. Utilize measuring instruments in the proper manner.
66
10.3 Project Report: Metrology

1. Surface Plate
Function
Resolution
Procedure
Results of
sample
measurement
Applications
Discussion
67
2. V-block
Function
Resolution
Procedure
Results of
sample
measurement
Applications
Discussion
68
3. Vernier caliper
Function
Resolution
Procedure
Results of
sample
measurement
Applications
Discussion
69
4. Screw thread micrometer

Function
Resolution
Procedure
Results of
sample
measurement
Applications
Discussion
70
5. Outside micrometer
Function
Resolution
Procedure
Results of
sample
measurement
Applications
Discussion
71
6. Inside micrometer
Function
Resolution
Procedure
Results of
sample
measurement
Applications
Discussion
72
7. Depth micrometer
Function
Resolution
Procedure
Results of
sample
measurement
Applications
Discussion
73
8. Precision square
Function
Resolution
Procedure
Results of
sample
measurement
Applications
Discussion
74
9. Dial indicator
Function
Resolution
Procedure
Results of
sample
measurement
Applications
Discussion
75
10. Thickness gauge

Function
Resolution
Procedure
Results of
sample
measurement
Applications
Discussion
76
11. Height gauges

Function
Resolution
Procedure
Results of
sample
measurement
Applications
Discussion
77
12. Radius gauge

Function
Resolution
Procedure
Results of
sample
measurement
Applications
Discussion
78
13. Pitch gauge

Function
Resolution
Procedure
Results of
sample
measurement
Applications
Discussion
79
14. Telescopic gauge

Function
Resolution
Procedure
Results of
sample
measurement
Applications
Discussion
80
15. Bore gauge

Function
Resolution
Procedure
Results of
sample
measurement
Applications
Discussion
81
16. Bevel protractor

Function
Resolution
Procedure
Results of
sample
measurement
Applications
Discussion
82
17. Sine bar

Function
Resolution
Procedure
Results of
sample
measurement
Applications
Discussion
83
18. Coordinate measuring machine

Function
Resolution
Procedure
Results of
sample
measurement
Applications
Discussion
84
19. Laser digitizer

Function
Resolution
Procedure
Results of
sample
measurement
Applications
Discussion
85
20. Non-contact measuring machine

Function
Resolution
Procedure
Results of
sample
measurement
Applications
Discussion
86
APPENDIX A -Procedures and Guidelines for Milling Project

Stock squaring
To create a square corner on a part, first orient an already finished edge vertically in the vise. Set
a machinist's ( L) square against the finished edge and the bottom of the vise. Lightly tap the part
with a plastic hammer to align it with the L Square. Clamp the vise down securely. Now the top
edge of the part is ready to be milled.
1.
2.
3.
4.
5.
6.
7.
8.
9.
10.
11.
12.
Setup the work piece by placing it onto the vice.

Use a parallel bar to raise the workpiece.
Secure the workpiece by tightening the vise.
Bring the face mill cutter slowly to touch the surface of the material.
Move the face mill cutter away.
Turn the quill to raise the table 0.5 mm per cut.
Mill the surface until a flat surface is achieved
Re-setup the workpiece to the next side in order to obtain a 90 angle from the first milled
side.
Ensure that you use an L square to align the workpiece before you tighten the vise.
Repeat steps 2 to 7.
Use the height gauge to mark off the remaining material.
Cut off the remaining material until the dimensions 38mm x 38mm x 25mm are achieved.
Marking
1.
2.
3.
4.
Using the center marker, punch the center of the workpiece.

Set the height gauge to the drawing and mark the workpiece.
Set the height gauge again and mark on the perpendicular side from the the previous marking.
Make a center punch on the center of the work piece.
Milling & Drilling

1.
2.
3.
4.
5.
Secure the workpiece on the milling vise again with the marking facing up.
By using the end mill cutter, mill off the marked portion.
Secure the workpiece to a drilling vise.
By using diameter 10.25mm drill bit, drill through the workpiece at the center punch mark.
Unclamp the work piece.
Tapping
1. Secure the workpiece onto the vise.
2. Tap a hole using an appropriate tap.
87
Troubleshooting Guide for Milling
88
APPENDIX B - Procedures and Guidelines for Lathe Project

1.
2.
3.
4.
5.
6.
7.
8.
9.
10.
11.
12.
13.
14.
15.
16.
Setup the raw material and tighten the chuck.

Face one end first (facing process).
Mark the workpiece to 90 mm and 50 mm by using a vernier height gauge.
Re-clamp the raw material and ensure that the faced side is inside the chuck.
Cut the material to 90 mm by using straight turning and facing processes.
Center-drill a hole on both ends
Use straight turning process in order to obtain 22 mm and 50 mm length.
Re-set the work piece to the other side for the next process.
Machine to 18 mm and 40 mm length by using straight turning process.
Perform a marking process by using a vernier height gauge in order to mark 5 mm and
20 mm in length.
On the 5mm length mark, perform a grooving/necking process until
8 mm is
achieved.
Perform a turning process to 11.8 mm and length 15 mm.
Turn Compound Rest to 30 to produce a chamfer according to the project diagram.
Re-clamp the raw material and perform an external threading by using a Tap & Die
set M12 X 1.75.
Setup raw material at the chuck again and use a live center to secure raw material.
Perform taper turning to obtain 12 mm at the smaller end with angle 8.
Troubleshooting Guide for Turning
89
APPENDIX C - Procedures and Guidelines for CNC Milling

Project
Start-up and initialization procedure
1. Turn on main power switch on wall
2. Turn on Voltage Stabilizer
3. Turn on computer console
4. Turn on the controller unit
5. Release the Emergency Stop
6. Open the air valve and ensure that the pressure is at 6.9 Bar (100lbs/ft2)
7. From the MS-DOS command prompt, change directory to XLMILL. Run the Fanuc desktop
tutor software by typing in FANUCMD
Manual machine tool operation
1. Return the cutting tool to its home position using the control keypad by pressing
[HOME], [TRVRS].
2. Press T and enter the tool number to perform a tool change
3. Specify the spindle speed by pressing S and keying in the desired RPM. Turn on the
spindle by pressing [Spindle CW]. Change the spindle speed when the spindle is still
spinning by pressing S.
4. Press [JOG] to toggle between step or continous movement of the tool. Adjust the
feedrate of the tool by using the up/down cursor keys. Jog the cutting tool using step as
well as continuous movement to various positions.
5. Turn off the spindle
6. Return the cutting tool to its home position
Numerical control operation
I) Part programming and simulation
1.
2.
3.
4.
Press [F10] to display the main menu. To start programming and simulating the NC
code, press Edit & Simulate.
Key in the NC program using the control keypad. Alternatively, you may quit the software
([F10], Quit) and key in the program from MS-DOS. Once you have a program saved,
press [F3] from the Fanuc software to load the program.
Before you can begin the simulation, set the workpiece datum, which is the (0,0)
position. To set the workpiece datum, press [F9] and select Set datum. Select where
you want the (0,0) position to be, relative to the workpiece.
Begin the simulation by pressing [F9] and selecting Run program.
II) NC machining
1. Plan the operations for producing the part shown in the technical drawing (obtain the
technical drawing from your lab instructor).
2. Construct a part program to machine the component and save it into a file.
3. Simulate the program to ensure that there are no errors.
4. Machine the part using the NC part program that you have developed:
i. Return the cutting tool to its home position
ii. Ensure that the workpiece is firmly secured
iii. Jog the cutting tool to the workpiece datum
90
iv.
5.
6.
7.
Commence operation by pressing [Auto], [Cycle start]

Perform the shutdown procedure.
Clean the machine and surrounding work area.
Inspect the machined part for inconsistencies with the original design.
Perform measurements on the machined part if and where possible.
Summary of Relevant G and M Codes

G00 Rapid Traverse of fast Traverse
G01 Linear Interpolation
G02 Clockwise Circular Interpolation
G03 Counter-Clockwise Circular Interpolation
G20 Imperial Units
G21 Metric Units
G28 Automatic Zero Return
G40 Cancel cutter compensation
G71 Rough out profile by turning
G70 Finishing Cycle
G90 Absolute Movement
G94 Feed rate in mm/min or in/min (G98 performs the

same function in the CNC lathe)
G95 Feed rate in mm/rev or in/rev
M03 Start Spindle
M05 Stop Spindle
M06 Change Tool
M30 End of Program
F Feed code (F code)
S Speed code (S code)
T Tool code (T code)
91
APPENDIX D - Procedures and Guidelines for CNC Lathe

Project
Start-up and initialization procedure
1.
2.
3.
4.
5.
6.
Turn on main power switch on wall

Turn on Voltage Stabilizer
Turn on computer console
Turn on the controller unit
Release the Emergency Stop
From the MS-DOS command prompt, change directory to XLTURN. Run the Fanuc
desktop tutor software by typing in FLSTEP.
Manual machine tool operation

1. Return the cutting tool to its home position using the control keypad by pressing
[HOME],[+Z] or [-Z], [+X] or [-X].
2. Press T and enter the tool number to perform a tool change
3. Ensure that you are in the JOG mode by pressing [JOG].
4. Specify the spindle speed by pressing S and keying in the desired RPM. Turn on the
spindle by pressing [Spindle CW]. Change the spindle speed when the spindle is still
spinning by pressing S.
5. Press [JOG] to toggle between step or continous movement of the tool. Adjust the
feedrate of the tool by using the up/down cursor keys. Jog the cutting tool using step as
well as continuous movement to various positions.
Numerical control operation
I)Part programming and simulation
1. Press [F10] to display the main menu. To start programming and simulating the NC code,
press Edit & Simulate.
2. Key in the NC program using the control keypad. Alternatively, you may quit the software
([F10], Quit) and key in the program from MS-DOS. Once you have a program saved,
press [F3] from the Fanuc software to load the program.
3. Press [F9] to access the simulation menu and select Set Tooling to select the approprate
tool for visualization.
4. Begin the simulation by selecting Run program.
5. Explore other functions from the simulation menu:
II) NC machining
1. Plan the operations for producing the part shown in the technical drawing (obtain the
technical drawing from your lab instructor).
2. Construct a part program to machine the component and save it into a file.
3. Simulate the program to ensure that there are no errors.
4. Machine the part using the NC part program that you have developed
6. Ensure that you have the correct tool in position
7. Ensure that the workpiece is firmly secured
92
8. Check to ensure that the tool offsets are zeroed by selecting Tool Offsets. Then press
cursor up/down to the tool that you have specified in your program. Press M and the
corresponding axis (X or Z) to edit the tool offset. Press /#EOB to confirm and then
Cancel to exit.
9. Shave a thin layer off the circumference of the workpiece and set the X offset:
10. Jog the tool to touch the circumference of the circle slightly
11. Jog the tool in the +Z direction so until the tool is about one centimeter off the face of
the workpiece
12. Jog the tool in the X direction so that the tool will cut approximately 0.3mm from the
circumference of the workpiece.
13. Activate the spindle to an appropriate speed
14. Jog the tool in the Z direction to start shaving a layer off the workpiece
16. Measure the diameter of the workpiece
17. Key in the diameter into the X offset setting
18. Shave a thin layer off the face of the workpiece and set the Z offset:
19. Jog the tool to touch the face of the workpiece slightly. The tool should be close to the
edge of the face of the workpiece
20. Jog the tool in the +X direction until the tool is about one centimeter off from the
circumference of the workpiece
21. Jog the tool in the Z direction so that the tool will cut approximately 0.3mm from the
face of the workpiece
22. Activate the spindle to an appropriate speed.
23. Jog the tool in the X direction to start shaving a layer off the workpiece
25. Set the Z value into the Z offset setting
26. Save the tool offsets and enter an offset number
27. Load the program and commence operation by pressing [Auto], [Cycle start].
28. Perform the shutdown procedure
29. Clean the machine and surrounding work area
30. Inspect the machined part for inconsistencies with the original design
31. Perform measurements on the machined part if and where possible
Summary of Relevant G and M Codes
G00 Rapid Traverse of fast Traverse
G01 Linear Interpolation
G02 Clockwise Circular Interpolation
G03 Counter-Clockwise Circular Interpolation
G20 Imperial Units
G21 Metric Units
G28 Automatic Zero Return
G40 Cancel cutter compensation
G71 Rough out profile by turning
G70 Finishing Cycle
G90 Absolute Movement
G94 Feed rate in mm/min or in/min (G98 performs the

same function in the CNC lathe)
G95 Feed rate in mm/rev or in/rev
M03 Start Spindle
M05 Stop Spindle
M06 Change Tool
M30 End of Program
F Feed code (F code)
S Speed code (S code)
T Tool code (T code)
93
Recommended machining parameters for CNC Lathe
Workpiece Material: Aluminium

OPERATION
Turning
Grooving
Threading
SPINDLE SPEED,
rpm
1000-1500
600-800
300-350
FEED,
mm/min
45-55
15-25
DEPTH OF CUT,
mm
0.5-1.0
0.25-0.5
0.03-0.04
Thread Parameter table

NOMINAL DIA.
mm
M 2.5
M3
M4
M5
M6
M8
M 10
M 12
M 16
M 20
M 24
M 30
M 33
M 36
M
M
M
M
M
M
M
M
8X1
10 X 1.25
12 X 1.25
16 X 1.5
20 X 1.5
24 X 2
30 X 2
36 X 3
PITCH mm (F)
0.45
0.5
0.7
0.8
1
1.25
1.5
1.75
2
2.5
3
3.5
3.5
4
CORE DIA. X
Bolt
Nut
1.948 2.013
2.387 2.459
3.141 3.242
4.019 4.134
4.773 4.918
6.466 6.647
8.160 8.376
9.853 10.106
13.546 13.835
16.933 17.294
20.320 20.752
25.706 26.211
28.706 29.211
31.903 31.67
1
1.25
1.25
1.5
1.5
2
2
3
6.773
8.466
10.466
14.16
18.16
21.546
27.546
32.32
6.918
8.647
10.767
14.376
18.376
21.835
27.835
35.752
HEIGHT OF
THREAD mm (P)
0.276
0.307
0.429
0.491
0.613
0.767
0.920
1.074
1.227
1.534
1.840
2.147
2.147
2.454
0.613
0.767
0.767
0.920
0.920
1.227
1.227
1.840
94
APPENDIX E Procedures for Arc Welding

Bead forming
1. Ensure that the electrodes are clamped with the positive to the arc welding machine
and the negative source on the workpiece (worktable). Check the amperage of the arc
welding machine.
2. Place the workpiece on the worktable. Use a face shield. Mark/touch the electrode to
the workpiece to produce arc.
3. When there is a spark, ensure that the angle and the distance are right for arc welding.
4. Move the electrode slowly while pressing the electrode until it reaches the end of the
workpiece. This will extinguish the flame.
5. Use a chipping hammer to remove burrs. Ensure that goggles are used as the burrs are
hot and brittle.
weld direction
electrode
75o
electrode
3mm
Bead forming
Electrode angle
Electrode distance
APPENDIX F - Procedures and Guidelines for CNC Bridgeport

Milling Project
Machine Start Up Procedure
i.
ii.
iii.
iv.
v.
Turn on air compressor.

Turn on main power switch on wall.
Turn on machine power switch located behind the machine.
Turn on control on/off switch located on the control panel.
Release the Emergency Stop Button
Work Piece Datum Set Up Procedure
i.
Set up X and Y Datum
Move edge finder to one of work piece side at X axis using [MPG] mode.
Set X value to zero using the control keypad by pressing
[POST] [REL] [OPRT] [X] [ORIGIN]
95
Move edge finder to the other side of work piece at X axis.

Then divide the actual X value by two, in order to get the center of work piece.
Move the edge finder to the center of work piece at X axis.
Set again X value to zero using the control keypad by pressing
[X] [ORIGIN]
Move edge finder to one of work piece side at Y axis.

Set Y value to zero using the control keypad by pressing
[Y] [ORIGIN]
Move edge finder to the other side of work piece at Y axis.
Then divide the actual Y value by two, in order to get the center of work piece.
Move the edge finder to the center of work piece at Y axis.
Set again Y value to zero using the control keypad by pressing
[Y] [ORIGIN]
Use Macros Program to setup the X and Y datum (0,0) in the system, using the control
keypad by pressing
[PROGRAM] [AUTO] [Type file name O3214 and press down arrow]
[CYCLE START]
ii. Set up Z Datum
Select the require tool.

Run the tool in [MDI] mode with spindle speed 500 1000rpm.
With [MPG] mode, move down the tool at Z axis until touch with the work piece surface.
Use Macros Program to setup the Z datum in the system, using the control keypad by
pressing
[CUSTOM] [F4]
96
APPENDIX G Workshop Rules and Penalties

Workshop rules
1. Download laboratory manual, print the entire document and bring to your first lab
session. The lab manual must be kept at the lab and all reports must be completed
during the lab session. The manual must not be taken out of the lab.
2. Bring textbook to lab as a reference.
3. Lab sessions will be assigned to you. Change of times can only be allowed for
emergencies and official university functions. Change of lab times must be swapped
with another student. Inform technicians 3 days before date of lab. Otherwise
penalties (at instructors discretion) will be imposed.
4. Come to lab on time.
Missing a lab may lead you to being barred from the final examination.
Penalties
1. Plagiarism
: 50% off the mark if found texts reproduced from Laboratory

Manual, senior or classmates reports, or other sources etc.
2. Safety Violations : -5 marks
97
APPENDIX H - Report Writing Guidelines

The writing in the report reflects the care that went into the experimental work.
Spelling and grammar are important components to be taken care of. Neatness
counts. Label and name figures properly.
1. Objectives:
Identify all the objectives relevant to the workshop. Objectives are important to
state because these objectives are analyzed in the conclusions to determine
whether the project succeeded.
5. Procedure:
In you own words, Write out the actual experimental procedure followed (which
might differ slightly from the standard manual). List the step-by-step summary
of procedures.
2. Results:
Describe the output of your project (eg: A 10.04-mm diameter hole was
produced on the face of the workpiece) along with relevant sketches if
necessary. Measurements of important dimensions should also be included.
Observations such as chatter marks, poor surface finish or flash deposits
should also be included.
3. Discussion:
In this section, the results presented are analyzed and interpreted. (Explain
WHY you got those results!). Also discuss how to overcome undesirable results
in the future. The logic in the discussion section should support the conclusion
section.
98
Example:
Bad:- The surface is very rough because of poor machining practice.
Good:-Potential causes of the poor surface finish in this project are
excessive
vibration and built up edge on the cutting tool.
Vibration was mainly due to lack of stiffness in clamping of the

workpiece while built up edge was due to the high depth of cut
used. Surface finish therefore, can be improved by properly
clamping the workpiece and reducing the depth of cut.
4. Conclusion:
This section discusses the results in the context of the entire experiment; the
objectives mentioned are revisited/examined to determine whether the project
succeeded.
Example:
Good:- A workpiece was successfully machined according to the
specifications in the engineering drawing. The top surface
however, exibited somewhat poor surface finish due to built
up edge on the cutting tool and workpiece vibration. The
operations performed included face milling, tapping and end
milling.
5. References:
List of reference books or website used.
They should follow the following
format e.g.:
1. Timonshenko, S., Woinowsky-Krieger, 1959. Theory of Plates and Shells.
McGraw-Hill, New York. p 203 210.
2. www.plint.co.uk/at2/leaflet/te76.htm
99
APPENDIX I Safety Precautions

Introduction
Health and Safety at Work Act 1994, it is based on the self-regulation concept. It
is a legal requirement that:
To ensure safety and health of themselves as well as others who may be

exposed to risks arising from their work activities
Through effective and efficient safety management systems suited to the

nature of the work activity at the workplace
Safe Practice for Engineering Trainees

You should acquire and practice the safe methods of your chosen skill and by the
use of intelligence; initiative and knowledge ensure the safety of the workshop and
remove the risk of injury or disablement to yourself and your colleagues.
Safety Awareness
Genuine safety comes from following the example set by your instructor and
developing safety awareness which is the same as road sense when driving.
Major Potential Hazards

The lists below are the major potential hazard in the Materials Laboratory
1. Injury through misuse applies to all equipment
2. Poisoning from toxic materials Nital, HCl, etc.
3. Injury from electric shock All equipment
4. Injury from heavy equipment All equipment
5. Injury from sharp objects or edges Brittle Fracture Testing, etc.
100
General Instructions
The general instructions are given as follows:

1. Never misuse any equipment
2. Know the fire exit and locations of safety equipment
3. Avoid overcrowding at one place
4. Avoid closing to a source of heat/any high temperature component
5. Report any accident, damage or near miss to the laboratory staff.
Special Instructions
1. Wear suitable clothes (white lab coat is required)
2. Wear protective glasses, gloves or other protection equipment when required
3. Do not bring or consume foods/drinks in the laboratory.
4. Smoking is strictly prohibited.
5. Wear shoes. Sandals and slippers are not allowed.
6. Playful or prankish behavior will not be tolerated in the laboratory.
Additional Safety Instructions

1. You should be aware of the locations of the emergency switch buttons, which
can be used to cut off all electric circuits in the laboratory rooms, except the
lights.
2. You should be aware of the locations of fire extinguishers and fire alarms in
the laboratory.
3. Any malfunctioning of laboratory equipment should be promptly reported to
your instructor, as should plugged drains or other safety hazards.
4. You should be aware of the location of the first aid kit and know how to use
the emergency eyewash (and shower) in the materials lab.
6. Minor cuts or bums should not be neglected.
You should report them
immediately to the instructor, who will decide whether to carry out first aid
procedures or to send you to the university medical centre for treatment.
101
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