Design And Fabrication Of

Mini Milling Machine

FINAL YEAR PROJECT BOOK

AL-Almeria Integrated Technical Education Cluster.

MECHANICAL ENGINEERING DEPARTMENT
MINI MILLING MACHINE
Submitted by:
IBRAHIM EL KELANY
REDA EBAID

NEVEEN ABO GHAZALA

SARA HELAL

Project supervisor:
PROF. AHMED GAEFAR.

ABSTRACT

Design and fabricating the mini milling machine is a conceptual

understanding of mechanical engineering.
With the on-going development of technology and economy, new industrial
requirements such as high precision, good quality, high production rates and
low production costs are increasingly demanded. Most of such requirements,
including dimensional accuracy, conformance to tolerances of finished
products and production rate can be met with better machine tools such as
mini milling machine with multiple functions on either face mill or drill.
The purpose of this project is to design and fabricate a mini milling machine.
Material that is strong and could withstand the weight and the vibration of
moving parts of the machine. Tests have been done to ensure the mini
milling machine has meet the objective stated.
The progress of this project needs documenting, as it can be a reference for
the next student who will make this project as well as for a research related
to the mini milling machine.

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ACKNOWLEDGEMENTS
We would like to express our gratitude and appreciation to all those who gave us the
possibility to complete the project. A special thanks to our project supervisor,
PROF.AHMED GAAFAR. , we are very grateful for the encouragement, guidance,
stimulating suggestions and assistance that he accorded us from the beginning of the
project to its successful completion.

A special thanks with much appreciation the crucial role of the metal cutting & forming
work shop staff, who gave the permission to use all required machinery and the necessary
material and tools that we need to complete the project parts.

Last but not least, many thanks go to The Dean PROF.TAREQ ABD EL MALAK,
PROF. EL AWADY ATTIA the head of Mechanical department, and all people whose
have given their full effort in guiding the team in achieving the goal as well as their
encouragement to maintain our progress in track. I would to appreciate the guidance
given by other supervisor as well as the panels especially in our project presentation that
has improved our presentation skills by their comment and tips.

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TABLE OF COTENTS
Chapter 1: Background

page no.

1.1 Introduction

1.2

Application of the Mini Milling Machine

1.3 Market Study

1.4 Project Planning

Chapter 2: Project Design

2.1 Computer-aided design and

Computer-aided manufacturing

2.2 comparison between Solid works, Inventor and AutoCAD

11

2.3 Project Design

15

Chapter 3: Machine Element Design

3.1 V belts types.

25

3.2 Advantages and Disadvantages of v belts

27

3.3 Relationship between v belts and pulleys

28

3.4 Types of v belts and pulley

29

3.5 The design problem of mini milling machine

30

3.6 forms of threads used in power screws

33

3.7 Calculate torque to raise and lower power screw

38

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Chapter 4: MANUFACTRING PROCESSES

4.1

Manufacturing

53

4.2

Core and Pattern Making

70

4.3

Metal Cutting And Forming

93

Chapter 5: Health and safety

5.1 Health And Safety Rules

136

5.2

Maintenance

156

5.3

Troubleshooting

157

Result

159

Conclusion

161

Future Work

162

References

168

List of Figure
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