FACULTY OF INDUSTRIAL AND MANUFACTURING

TECHNOLOGY AND ENGINEERING

UNIVERSITI TEKNIKAL MALAYSIA MELAKA
BMIS 1122 Manufacturing Workshop

NAME NURUL NADIA BINTI RAZAK

NURUL AUNI BINTI AZMAN

MATRIC NO. B142410103

B142410109

REPORT TITLE MILING REPORT

SUBMISSION DATE 4/11/2024

 A) BACKGROUND

Metal fabrication is a process that is commonly done to create and produce objects for everyday use. In
addition, it is widely used in the production of new inventions and materials. Metal fabrication work is
usually carried out in workshops because it requires the use of hand tools and machines. This is because
some of the machines used are too large and unsuitable to be placed in a home environment.
When carrying out metal fabrication work, the safety of individuals, materials, and the workspace is very
important to prevent accidents and injuries. If safety is not prioritized, the work being done may result in
disaster rather than contributing to daily use. This aspect must be given attention to ensure that the goals
and objectives of the metal fabrication process are achieved successfully.

B) PRODUCT PLANNING/STRATEGY
N PROCESS APPARATUS DIAGRAM PROCEDURE
O
1. Study the  Vernier 1. Look at the different
technical caliper views provided (e.g.,
drawing. top, front, side) to
understand the
geometry of the part
from multiple angles.
2. Carefully review the
dimensions in the
drawing to understand
the exact size
3. Use the technical
drawing as a reference
to identify the features
and dimensions of the
unfinished workpiece.
2. Cutting Cutting

1. Manual Cutting:
 In some cases,
hand tools like
saws or shears are
used to cut metal
into the required
dimensions.
2. Machine Cutting:
For more complex
or precise cuts,
machine tools such
as plasma cutters,
laser cutters, or
water jet cutters are
used. These
machines allow for
high accuracy and
the ability to cut
through thicker
materials.
3. Flame Cutting:
For very thick
metals, flame
cutting may be
used, where a
flame is used to
heat and cut the
metal.

3. Install  wrench 1. Loosen the tool

cutting tool. holder screws or
clamps using the
appropriate wrench
2. Place the cutting
tool into the tool
holder and ensure
that the cutting
edge of the tool is
typically aligned
with the centerline
of the lathe spindle.
3. Tighten the tool
holder screws or
clamps to secure
the cutting tool in
place.
4. Installing the  Chuck key 1. Ensure the machine is
Workpiece to turned off and
the Chuck on unplugged.
a Lathe 2. Place the workpiece
Machine between the chuck
jaws, ensuring it is
centered as accurately
as possible.
3. Use the chuck key to
turn the chuck jaws
clockwise to tighten
them around the
workpiece.

5. Switching on 1. Manually move the

the milling carriage to a
machine and starting position
selecting the where the cutting
appropriate tool is close to, but
speed for not touching, the
machine. workpiece.
2. Use the handwheel
located on the
apron of the lathe
to control this
movement.
3. Use the cross-slide
handwheel for fine
adjustments to
ensure the cutting
tool is aligned with
the desired starting
point on the
workpiece.
6. Run the FACING
machining 1. Use the cross-slide
process until handwheel to move
the desired the cutting tool
shape is towards the center
obtained. of the workpiece,
removing material
to create a flat face.
2. Make multiple
passes if necessary,
adjusting the depth
of cut each time
until the desired
length.

REDUCING
DIAMETER
1. Position the
cutting tool at
the starting
point along the
length of the
workpiece.
2. Use the
carriage
handwheel or
automatic feed
to move the
cutting tool
along the length
of the
workpiece,
reducing the
diameter.
3. Measure the
diameter
periodically
using calipers
or a micrometer
to ensure
accuracy.
DRILLING A HOLE
1. Replace the turning
tool with a drill bit
of the desired
 diameter.
 Secure the drill bit in
the tailstock chuck.
 Align the drill bit with
the center of the
workpiece.
 Move the tailstock
towards the workpiece
until the drill bit is close to
the surface.
 Set the spindle speed
appropriate for the drilling
operation.
 Power on the lathe and
use the tailstock
handwheel to advance the
drill bit into the workpiece.
 Apply consistent
pressure and use cutting
fluid if necessary to reduce
heat and improve cutting
efficiency.
1.  Drill to the
desired depth, then
retract the drill bit.
C) DISCUSSION
1. Workpiece successfully machined to the exact specified dimensions

The workpiece's specified size and shape were effectively achieved through the
machining process. The finished product met the required tolerances and surface finish
by following the specified spindle speeds and feed rates, as well as making sure that the
right tools were chosen and installed. To achieve the exact dimension, the milling
machine is calibrated to make sure all parts are in line and operating properly before the
machining process starts. This involves confirming that the worktable is flat, and the
machine's spindle is square. However, maintaining dimensional precision during the
milling process depends on the workpiece not moving, which is ensured by proper
clamping using the proper clamping tools, the workpiece is securely secured in a vise or
directly on the machine table. Nevertheless, it takes constant monitoring and
confirmation throughout the process to achieve precise dimensions in milling processes.
By doing this, any deviations that can affect the final quality are minimized and the
workpiece is guaranteed to keep the required tolerances.

2. Issues with workpiece’s squareness or alignment.

During the milling machine operation, the workpiece was successfully machined to the
exact specified dimensions. Despite this precision, the workpiece did not fit the L-square,
indicating issues with squareness or alignment. This might happen because improper
installation of the cutting tool can lead to deviations in the machined surfaces. The
workpiece and the machine spindle are not correctly aligned with the cutting tool.
Uneven cutting pressures could result through this, creating surfaces that are neither
symmetrical nor perpendicular. Despite these issues with squareness also might occurred
from improper clamping which can lead to significant issues with the squareness and
alignment of the workpiece, resulting in parts that do not meet the required
specifications.
 3. Non-Smooth Workpiece Surfaces.

We are aware that the surface finish of our workpiece is not

smooth. This issue may arise due to several factors that can
affect the quality of machine operations. The cutting
tool may leave noticeable scratches or marks on the
workpiece's surface if the depths are inconsistent. These marks result from a non-uniform
cutting action caused by the tool's ability to maintain a consistent engagement with the
material. The smoothness of the surface finish is affected by these tool markings.

D) CONCLUSION AND SUGESTION FOR IMPROVEMENT

A systematic approach to tool installation and workpiece fixturing is necessary to address
the squareness and alignment problems that were identified during the milling process.
Start by making sure the cutting tool is firmly in place and precisely aligned with the
machine spindle. We can verify the correct setup using precision alignment tools and
Improve clamping methods by using appropriate fixtures that give the workpiece steady
support and reduce movement while it is being machined. Maintain the accuracy of the
milling machine by regularly inspecting and calibrating it. We should also think about
using precise measuring tools to keep an eye on squareness during the machining
process. To further enhance alignment and guarantee that workpieces continuously fulfill
the necessary specifications, we should improve our clamping techniques.
Consistent cutting depths and regular engagement with the material are essential for
enhancing the workpiece's surface smooth and resolving the problem of visible scratches
or marks. To ensure that the tool works effectively, we must adjust cutting parameters,
like feed rates and spindle speeds, to the workpiece being machined. Vibrations and
movement during machining can be further reduced by putting in place a comprehensive
setup procedure that involves verifying tool alignment and securely fastening the
workpiece. Lastly, to improve surface quality and give the workpiece a smoother finish,
consider using advanced machining methods or equipment.

In conclusion, even if the workpiece's dimensions were effectively met the standards, the
issues with squareness and surface polish highlight the necessity for methodical
improvements. A complex strategy is needed to address these problems, including
making sure that the tools are installed and aligned precisely, using efficient clamping
techniques, and keeping the cutting tools in good condition to encourage constant
engagement with the material. By prioritizing training and implementing stringent
inspection practices, we can foster a culture of continuous improvement that will enhance
product quality and operational efficiency. However, the laboratory activities also
provide us the information about the various types of milling machines and cutters
available for different milling processes in the manufacturing world process. In addition,
we had gained the knowledge of understanding their usage and function where it can
produce different shapes of work piece with different types of surfaces, smooth or rough.
The purpose behind this is to improve their skills and give more confidence once they do
that. Besides that, students also should be neat, tidy, and safely dressed, and develop a
responsibility for personal safety and the safety of other students. We should never think
that because we are wearing safety goggles our eyes are safe. If the lenses are not made
of approved safety shatterproof glass, serious eye injury can occur. All safety precautions
are also taken seriously with a clear explanation from the instructor.

Signature of supervisor/examiner

Name
Date: