MANUFACTURING PROCESS ARTICLE · 1. Read the study case well. Because the study case contained information that will be carried out. 2. Turn on CNC Machine Lathe, CNC Machine Milling,

i

ii

MANUFACTURING PROCESS

ARTICLE

2019

By: Rino Andias Anugraha and Assistant Team

School of Industrial Engineering

TelkomUniversity

iii

INTRODUCTION

Praise be to Allah Subhanahu wa Ta'ala, because with His grace and mercy, the writer and the

team were given the opportunity to complete the Article Module for the implementation of

the manufacturing process practicum in the 2019/2020 educational year.

In this module the authors and team re-designed our masterpiece of practicum products

namely Stirling Engine, where we added 2 pistons and enlarged the scale of parts that were

made in the previous version for the needs of integrated practicum activities in the Faculty of

Industrial and System Engineering

Prosman Laboratory Adviser

Rino Andias Anugraha, ST., MM

NIP : 99750032

iv

MANUFACTURING PROCESS LABORATORY ASSITANTS 2019/2020

Aldyan Nurfaizi B. Tau

Alia Agistina

Anak Agung Sri Nandini

Anggit Pratama

Bagas Arganto P.

Bela Pitria Hakim

Damario Haznam

Farras Burhanuddin

Gitanjali Widayu Diatri

Mario Adiprana Muki

Nafisha Herma Hanifha

Pangestu Rizky Purnama

Satria Rahmadani Putra

Sri Yuzarnimar

Tri Maisyah Nugrah Samudro

Zakaria Gunada

Abdurrahman Rashif

Annastasya Septiani

Aquilla Yunma Imaristha

Arief Tri Hendrayanto

Corie Ariesta Arbay

Dhiya Shafa Azizah

Dimas Rayhandika

Elisa Intan Puspitasari

Gamaliel Situmeang

Indah Ekanurhayati

Irfanul Zuhdi Nufrinal

Kholiq Giffari

M. Fachri Husamuddin

M. Arash Arisiah

M. Raihan Arrafi

M. Sohibul Wafa

Nisri Husna Faadhilah

Rafi Pragiwaka Gani

Tirza Ayu Nursazabillah

1

MANUFACTURING PROCESS

LABORATORY

Document

Number

MODUL 5 Form

Number

Valid 2019

Module Machining Process

Labwork Conventional and CNC Machine

Student Outcomes SO2. Able to apply mathematics, science and engineering

principles to solve complex engineering problems in

integrated systems (including human, material, equipment,

energy, and information)

Learning Outcomes LO15. Students are able to run a process plan made on real

work objects with the machining process

2

A. Tools and Requirements

Tools & Software Requirements

1. Fixture

2. Vice

3. Flat End Mill D16, D12, D10, D8, D6

4. Drill D3, D5, D6

5. Face Mill D100

6. Insert Knife

7. CNC Machine: Lathe

8. CNC Machine: Milling

9. Conventional Machine: Lathe

10. Conventional Machine: Milling

1. Mask

2. Stationary

B. References

DeGarmo, E., Black, J., & Kohser, R. A. (2014). DeGarmo's MATERIALS & PROCESSES IN

MANUFACTURING. Chichester, United Kingdom: John Willey and Sons Ltd.

Clark, D. A. (2014). Milling. Ramsbury,Malborough,Wiltshire: The Crowood Press Ltd..

Groover, M. P. (2014). Fundamentals of Modern Manufacturing Materials, Process and

Systems. John Wiley & Sons Inc.

Limited, D., Royd, B., & Yorkshire, W. (n.d.). G and M Programming for CNC Milling

Machines.

Manufacturing Process Laboratory, A. M. (2017). Modul Praktikum Proses Manufaktur.

Manufacturing Process Laboratory.

El-Hofy, H. A.-G. (2014). Fundamentals of Machining Processes Conventional and

Nonconventional Processes, Second Edition. London: CRC Press, Taylor & Francis Group.



Klocke, F. (2014). Manufacturing Processes. London: Springer Heidelberg Dordrecht .

3

C. Labwork Steps

Flow Process Charts Process Description

1. Read the study case well. Because the study

case contained information that will be

carried out.

2. Turn on CNC Machine Lathe, CNC Machine

Milling, Conventional Machine Lathe, and

Conventional Machine Milling according to

the tutorial on labwork

3. Set the machine according to the part that

will be made.

4. Prepare the stock according to the part that

will be made.

5. Operate the machine according to the part

that will be made.

END

Operate the Machine

Prepare stock

Set up the machine

Turn on CNC Machine and Conventional

Machine

Read the Study Case

START

4

MODULE 5

MACHINING PROCESS : CONVENTIONAL & CNC MACHINE

1.1 Students are able to understand SOP Machine.

1.2 Students are able to understand about setup CNC Machine.

1.3 Students are able to understand CNC Milling.

1.1 Students are able to understand CNC Lathe.

1.2 Students are able to understand Conventional Milling.

1.3 Students are able to understand Conventional Lathe.

2.1 Machining Process.

2.2 Setup CNC and Conventional Machine.

2.3 Introduction of CNC Mill.

2.4 SOP of CNC and Conventional Mill Machine.

2.5 Types of Milling Machine.

2.6 Component of CNC Milling.

2.7 Introduction of CNC Lathe.

2.8 SOP of CNC and Conventional Lathe Machine.

2.9 Lathe Machine.

2.10 Process in CNC Lathe.

2.11 Component of CNC Lathe.

1. OBJECTIVES

2. OUTLINES

5

3.1 Machining Process

Machining is manufacturing process that involves removing materials using

cutting tools for getting rid of the unwanted materials from some work piece and

converting it into the shape you desire. A large piece of stock is used for cutting the

work piece. The large stock might be in any shape such as solid bar, flat sheet, beam

or even hollow tubes. The process can also be performed on some existing part like

forging or casting. Machining process has two types, they are conventional

machining and modern machining process. Conventional machining utilizes cutting

tools that must be harder than the work piece material. In modern machining

practice, harder, stronger, and tougher materials that are more difficult to cut are

frequently used. Therefore, directed toward machining processes where the

mechanical properties of the work piece material are not imposing any limits on the

material removal process.

In this regard, the nonconventional machining techniques came into practice

as a possible alternative concerning machine ability, shape complexity, surface

integrity, and miniaturization requirements. Innovative machining techniques or

modifications to the existing method by combining different machining processes

were needed. Any machining process has two types of interrelated variables these

are input (independent) and output (dependent).

Figure 5.1 Variables of a Machining Process (El-Hofy, 2014)

3. BASIC THEORY

6

On this module we use modern machine that is Computer Numerical Control

(CNC) and Conventional machine. CNC is a machine controlled by computer using a

numerical language as an input for the operation process, while for Conventional

machine controlled by direct operator. There are few components that works on

CNC System:

1. Computer-Aided Design (CAD) and Computer-Aided Manufacturing (CAM)

Designer makes their product through program called CAD, which the output is

an end item and CAM can be used for the machining process. On CAD, the

codes which built up the desired product can be generated, codes are labeled

as “G-code”.

2. Interface/USB flash drive

To transfer the program that has been made (the output of CAD and CAM), a

USB flash drive is needed as an interface between CNC Router Engraver and

computer.

3. Machine Controller

Machine controller works as an interpreter which is interprets part program

into cutting tools.

4. Drives

Drives works as an amplifier of the signal from machine controller so it can

operate the motor suitably.

There are a few things that must be considered for Conventional Machine:

1. Consider direction of spindle rotation, axis.

2. Do not select a cutting tools of larger diameter than is necessary.

3. Do not change feeds or speeds while the machine is in operation. When using

clamps or chuck to secure a workpiece, be sure that they are tight and that the

piece is held so it will not spring or vibrate under cut.

7

3.2 Setup CNC and Conventional Machine

Set up for CNC machine contains:

1. Machining Power Up

2. Programing Introduction

3. Numbered Program

4. Part Setup

Set up for Conventional machine

contains:

1. Machining Power Up

2. Part Setup

Part setup is necessary to properly secure the part to the table. This can be

done various ways, using vices, chucks, or using T-Bolts and toe clamps.

a. Workholding Devices

Milling Machine VS Lathe Machine

Vice

Figure 5. 2 Vice Retrieved from (Alibaba Group, 2019)

Vice is a mechanical apparatus

used to secure an object to

allow work to be performed on

it. This part usually use on CNC

machine.

Chuck

Figure 5. 3 Chuck Retrieved from (Alibaba Group, 2019)

A chuck is a specialized type of

clamp. It is used to hold an

object with radial symmetry,

especially a cylinder. This part

usually use Conventional

machine

8

b. Other Workholding Devices


Clamp

Figure 5. 4 Toe Clamp Retrieved from

(Alibaba Group, 2019)

A clamp is a fastening devices

used to hold or secure object

tightly together to prevent

movement or separation

through the application of

inward pressure. This part

usually use on CNC machine.

Tailstock

Figure 5.5 Tailstock Retrieved from

(Haas Automation, 2019)

A tailstock usually used to apply

support to the longitudinal

rotary axis of a workpiece being

machined. This part usually use

on Conventional machine.

9

c. Tooling

Tool Functions with T-nn code is used to select the next tool to be placed

in the spindle from tool changer.


Tool Magazine

Figure 5. 6 Tool Magazine Retrieved from

(Haas Automation, 2019)

In CNC milling machine a tool

change can be commanded with

the X, Y, and Z axis in any position.

Turret

Figure 5. 7 Turret Retrieved from (Haas Automation, 2019)

In CNC, Lathe machine tool

change can be commanded with

the X and Z axis in any position.

10

d. Tool Holders

There are several different spindle options for the Haas mills. Each of these

types requires a specific tool holder. The most common spindles are 40 mm

and 50 mm taper. This part usually use on CNC and Conventional Machine.

Figure 5. 8 Tool Holder Retrieved from (Alibaba Group, 2019)

e. Pull Studs

A pull stud or retention knob is required to secure the tool holder into the

spindle. Pull studs are threaded into the top of the tool holder and are

specific to the type of spindle. This part usually use on CNC and Conventional

Machine.

Figure 5. 9 Pull Studs Retrieved from (Haas Automation, 2019)

f. Tool Holder Assembly

Tool holders and pull studs must be in good condition and tightened using

wrenches or they may stick in the spindle. This part usually use on CNC and

Conventional Machine.

11

3.3 Introduction of CNC Mill

Milling is a basic machining process by which a surface is generated by

progressive chip removal. The workpiece is fed into a rotating cutting tool.

Sometimes the workpiece remains stationary, and the cutter is fed to the work.

Figure 5. 5 CNC Mill Machine Retrieved from (Haas Automation, 2019)

Figure 5. 6 Some of the feature shown of CNC Mill (Haas Automation, Inc., 2012)

12

Figure 5.6 Some of the feature shown of CNC Mill (cont.) (Haas Automation, Inc., 2012)

3.4 SOP of CNC and Conventional Mill Machine

Table 5. 1 SOP of CNC and Conventional Mill Machine (Turn ON)

CNC Mill Conventional Mill

Procedure to Turn On HAAS CNC Mill

1. Turn on the compressor.

a. Check the oil engine level first, the oil must be upper than the red point.

2. Rotate the lever of gas flow to the open position (parallel).

3. Wait until the gas pressure is 5.5 - 8.5 bar.

4. Turn on the main power of CNC Machine.

a. Check the oil of machine, between min and max point.

b. Check the lubricants tube of machine.

c. Scroll the lever of main power to the on side.

Procedure to Turn On HAAS CNC Mill 1. Rotate the vertical spindle to on.

Red arrow on vertical spindle is a direction.

2. Calibration machine will be starting.

3. There is set-up for make a spindle spinning path. Counter-clockwise (CCW) and Clockwise (CW).

13

Table 5. 4 SOP of CNC Mill Machine (cont.)

CNC Mill

5. Press the emergency stop.

6. Press power on button.

7. Release emergency stop.

8. Press reset button.

9. Turn on the lamp engine.

10. Press the power up button.

11. Start the program. How to start the program.

a. Press list prog button.

b. Choose the program.

c. Press cycle start button.

12. Set the stock to the clamping.

a. The stock must be suitable with the program.

13. Set the offset tool.





Table 5. 2 SOP of CNC and Conventional Mill Machine (Turn Off)

CNC Mill Conventional Mill

Procedure to Turn Off HAAS CNC Mill 1. Clean the remaining chips on the

machine. 2. Change the tool to T7.

a. Press MDI DMC button.

b. Write T07.

c. Press ATC REV button. 3. Move the table in to the middle of

the machine.

a. Press HAND JOG button.

b. Choose the scale of movement (.1 100.).

c. Press the selected axis (X / Y / Z).

d. Rotate the handle jog until the table work in the middle of machine.

4. Close the door. 5. Press the emergency stop. 6. Press the power off button. 7. Turn off the main power CNC

Machine. 8. Rotate the lever gas flow to the

closed position (perpendicular).

9. Turn off the compressor.

Procedure to Turn Off Conventional Mill 1. Rotate the vertical spindle to off. 2. The machine will be stop

automatically. 3. If there is emergency, there is E-

Stop (emergency stop) to make machine stop automatically.

14

3.5 Types of Milling Machine

a. Vertical Mill

The vertical milling machine is basically the same as turret milling machine,

but the turret milling machine is much more versatile. Vertical milling machine

have their spindles in the vertical plane. The plain vertical milling machine can

usually only be tipped to the left and the right, often by tilting the whole vertical

column that the head is mounted on. A vertical mill has a stationary spindle and

the table is moved both perpendicular and parallel to the spindle axis to

accomplish cutting.

Figure 5. 7 Vertical Mill Retrieved from (Alibaba Group, 2019)

Figure 5. 8 Some of the feature of Vertical Mill Machine

15

b. Horizontal Mill

A horizontal mill has the same sort of x–y table, but the cutters are mounted

on a horizontal arbor across the table. Many horizontal mills also feature a built-

in rotary table that allows milling at various angles; this feature is called a

universal table. Some horizontal milling machines are equipped with a power-

take-off provision on the table. This allows the table feed to be synchronized to

a rotary fixture, enabling the milling of spiral features such as hypoid gears.

Figure 5. 9 Horizontal Mill Retrieved from (Alibaba Group, 2019)

Figure 5. 10 Some of the feature of Horizontal Mill Machine

16

c. UP and DOWN Process Milling

Figure 5. 11 UP and Down Milling (DeGarmo, Black, & Kohser, 2014)

In up milling, the chip is very thin at the beginning, where the tooth first

contacts the work; then it increases in thickness, becoming a maximum where

the tooth leaves the work. In down milling, maximum chip thickness occurs close

to the point at which the tooth contacts the work.

17

3.6 Component of CNC Mill

There are eleven main program components of HAAS CNC Mill, there are:

Table 5. 3 Component of CNC Mill

No. Name Picture Function

1 Control Panel

To explain machine control and various other functions that use instructions by the electronic control system. Where there is program the G-Codes

into the machine.

2 Tool

The cutting tool is attached to the column and is the part that actually cuts the piece in the way that the operator specifies.

3 Spindle

The spindle hold the cutting tool in place.

4 Coolant

Coolant is pumped through in order to keep the metal cool and the cutting tool lubricated.

18

Table 5. 3 Component of CNC Mill (cont.)


5 Table

Table is an area that the workpiece will be attached either using a clamp or a vacumm during processed.

6 Vice

A mechanical apparatus used to secure an object to allow work to be performed on it.

7 Tool Magazine

The T-nn code is used to select the next tool to be placed in the spindle from tool changer. It can be commanded with the X, Y, and Z axes in any position.

8 Tool Holder

The most common spindles are 40 mm and 50 mm taper.

9 Pull Stud

Pull studs are threaded into the top of the tool holder and are specific to the type of spindle.

19

Table 5. 3 Component of CNC Mill (cont.)


10 Fixture

Fixtures designed to specifically hold a part in the correct location with respect to the tool are used for larger volumes.

11 Jig

Frequently used on large parts, where it is necessary to drill one or more holes that must be spaced accurately with respect to each other.

20

3.7 Introduction of CNC Lathe

Turning process is a machining process which procedure the cyclindrical

workpiece. The machine which uses to this process is Lathe Machine. The principle

of turning are :

a. Workpiece is spinning in one axis

b. With a single point cutting tool

c. The tool has parallel path with the workpiece, and it will throw away the surface

of workpiece

Figure 5. 12 HAAS CNC Machine Lathe Retrieved from (Haas Automation, 2019)

21

Figure 5. 13 Some of the feature shown of CNC Lathe (Haas Automation, Inc., 2012)

22

Figure 5. 14 Some of the feature shown of CNC Lathe (Haas Automation, Inc., 2012)

23

3.8 SOP of CNC and Conventional Lathe Machine

Table 5. 4 SOP of CNC Lathe and Conventional Machine (Turn ON)

CNC Lathe Conventional Lathe

Procedure to Turn On HAAS CNC Lathe 1. Turn on the compressor.

a. Check the oil engine level first, the oil must be upper than the red point.

2. Rotate the lever of gas flow to the open position (parallel).

3. Wait until the gas pressure is 5.5 - 8.5 bar. 4. Turn on the main power of CNC Machine.

a. Check the oil of machine, between min and max point.

b. Check the lubricants tube of machine. c. Scroll the lever of main power to the

on side. 5. Press the emergency stop. 6. Press power on button. 7. Release emergency stop. 8. Press reset button. 9. Turn on the lamp engine.

10. Press the power up button.

Procedure to Turn On Conventional Lathe 1. Make sure the emergency stop

condition is locked before connecting with the electric current.

2. Turn on the electricity. 3. Setting the spindle speed to be

used, then press the switch on or unlock emergence stop machine.

4. Drag up the direction lever for clockwise spindle spin, and down

for counter clockwise spindle spin. 5. The machine is on.

Table 5. 7 SOP of CNC Lathe Machine (cont.)

CNC Lathe





16. Set the stock to the clamping. The stock must be suitable with the program.

17. Set the offset tool.



b. Choose the program. Press cycle start button.

Table 5. 8 SOP CNC Lathe and Conventional Lathe

CNC Lathe Conventional Lathe

Procedure to Turn Off HAAS CNC Lathe These are the procedures to turn off HAAS CNC Lathe Machine. 1. Press [RESET] to clear all the program that

was run before. 2. Press [EMERGENCY STOP] 3. Press [POWER OFF]

Turn [EMERGENCY STOP] to the right

Procedure to Turn Off Conventional Lathe

1. Make sure the spindle spin is in neutral condition, with drag to normal condition of direction lever.

2. Lock the spindle spin with breaker in downside.

3. Press the emergency stop, and make sure the emergence stop is in locked condition.

4. Disconnect the electricity power from the conventional lathe machine.

24

3.9 Lathe Machine

Turning is the process of machining external cylindrical and conical surfaces. It is

usually performed on a machine tool called a lathe, using a cutting tool. The

workpiece is held in a work holder. Different from CNC Lathe, to running the turning

conventional did not use NC code or G-code but to run this machine should be

undertaken in a manual.

Figure 5. 15 Lathe Machine Conventional Retrieved from (Alibaba Group, 2019)

Figure 5. 16 Some of the feature of Conventional Lathe Machine

25

3.10 Process in CNC Lathe

Below are six process in CNC Lathe.

a. Face Turning

Face turning is one of the methods used in the turning process to the

products which has the surface perpendicular to the axis of rotation. Face

turning process divided by transverse face turning, transverse parting off,

turning and cylindrical face.

Figure 5. 17 (a) Transverse Face Turning, (b) Transverse Parting Off, (c) Cylindrical Face Turning (Klocke, 2014)

b. Cylindrical Turnig

Cylindrical turning is used to produce a surface which has a surface that is

parallel to the axis of rotation. This method is used for finishing products that

has very small size. There are three types of cylindrical turning are longitudinal

cylindrical, centerless rough turning and transverse turning.

Figure 5. 18 Longitudinal Cyclindrical Turning, Centreless Rough Turning, and Transverse Turning. (Klocke, 2014)

26

c. Helical Turning

Helical turning is process of turning which produce helical surface

workpiece. This method usually uses to make bolt and the other product which

has screw thread on the surface. Variants of helical turning process is thread

turning which has singular point cutting tool in the process.

Figure 5. 19 Types of Helical Turning (Klocke, 2014)

d. Profile Turning

Profile turning is to produce rotation symmetrical workpiece shapes by

reproducing the tool profile. Most of profile turning are happened in the model

of turning process and this process is the main process because it can produce

the complex shape of product.

Figure 5. 20 Types of Profile Turning (Klocke, 2014)

27

e. Form Turning

Form turning is used to produce wokpiece shapes by controlling the feed

movements. Form turning is categorized as in figure 5. 17 into NC form turning,

copy turning and kinematic form turning. NC form turning, the feed movement

is realized by electronically linked feed drives. Copy turning involves deriving

the feed movement from a reference shape. Kinematic form turning was often

used in the past to produce ball heads.

Figure 5. 21 Types of Form Turning (Klocke, 2014)

f. Further Process

Variant process was basically explicated using the example of external

machining. Kind of internal machining process are boring, undercutting,

internal grooving. Boring process is used to make a bigger diameter of a hole.

Before the operator use boring process, the workpiece should have a hole first.

Undercutting process is the process to remove the center of a workpiece.

Internal grooving is the grooving movement which located in the internal side.

Figure 5. 22 Types of Further Process Variant (Klocke, 2014)

28

3.11 Component in CNC Lathe

There are nine main components of HAAS CNC Lathe.

Table 5. 5 Component of CNC Lathe


1. Controller

To explain machine control and various other functions that use instructions by the electronic control system. Where there is program the G-Codes into the

machine.

2. Turret

Placing the tool according the dimension or list.

3. Chuck

Holding workpiece on machining process.

4. Collet

To hold the workpiece.

29

Table 5. 5 Component of CNC Lathe (cont.)


5. Spindle

Holding and spinnning tool in the workpiece.

6. Insert Knife

To hold the eye of knife and it can be inserted to the holder.

7. Holder

To hold the tool and insert knife.

8. Tool

Combined insert knife and holder, to dispose the selecting surface of workpiece.

30

Table 5. 8 Component of CNC Lathe (cont.)


9. Nozzle Coolant

Coolant is pumped through in order to keep the metal cool and the cutting tool lubricated.

31

DeGarmo, E., Black, J., & Kohser, R. A. (2014). DeGarmo's MATERIALS & PROCESSES IN

MANUFACTURING. Chichester, United Kingdom: John Willey and Sons Ltd.

Clark, D. A. (2014). Milling. Ramsbury,Malborough,Wiltshire: The Crowood Press Ltd..



Limited, D., Royd, B., & Yorkshire, W. (n.d.). G and M Programming for CNC Milling

Machines.

Manufacturing Process Laboratory, A. M. (2017). Modul Praktikum Proses Manufaktur.

Manufacturing Process Laboratory.

El-Hofy, H. A.-G. (2014). Fundamentals of Machining Processes Conventional and

Nonconventional Processes, Second Edition. London: CRC Press, Taylor & Francis

Group.



Klocke, F. (2014). Manufacturing Processes. London: Springer Heidelberg Dordrecht .

4. REFERENCES

Documents

MANUFACTURING PROCESS ARTICLE · 1. Read the study case well. Because the study case contained information that will be carried out. 2. Turn on CNC Machine Lathe, CNC Machine Milling,