Coplex Engineering Problem

(Metal Forming and Cutting Analysis)

Process capability of the Milling Process

Submitted To:
Engr. Muhammad Jawad
Submitted By:
Ammad Nadeem 17-IE-08
Usman Ansar 17-IE-24
Muhammad Naeem 17-IE-28

Industrial Engineering Department

 Acknowledgement

All praise to Allah Almighty, who guided us throughout this whole journey and given us the
strength of determination to do work on the topic “Process Capability of the Milling Process”
We would like to acknowledge the people who helped and guided us. We want to thank our
supervisor Engr. Muhammad Jawad who is very much generous and kind and has a lot of
expertise in this regard. Special thanks to Dr. Mirza Jahanzaib, the Dean of Department of
Industrial Engineering and Dr. Waseem Ahmad, the Chairman at Industrial Engineering
Department UET Taxila.
 Abstract
The Milling process in different industrial sectors is involved in manufacturing of metal parts.
Quality control helps industries for improvements of milling operation product quality and
productivity. A repeated milling process is done, and it is required to observe whether
dimensions are in controlled limits. Process capability indices are effective tools for the
continuous improvement of quality, productivity and managerial decisions. In this study, a
process capability analysis was carried out in the milling operation to find the precision and
accuracy in dimensions of the machine part.
Table of Contents
Acknowledgement............................................................................................................................i
Abstract............................................................................................................................................ii
1 Background Knowledge..........................................................................................................1
2 Problem Statement...................................................................................................................1
3 Objectives................................................................................................................................1
4 Tasks to be Performed.............................................................................................................1
5 Introduction to Milling............................................................................................................1
1 Background Knowledge
Machining is a general-purpose manufacturing process for the manufacture of machine
components and the performance evaluation of metal cutting machine tools is often based on
their capability in machining work piece to specified details. The process capability is the
ability of the combination of the equipment to produce a product that will consistently meet
the design requirements and the customer expectation. This exercise is designed for the
students to experience a production environment and analyze the process control in a
production scenario where in different machining processes, operator’s skill level and
operating/ machining conditions are encountered.

2 Problem Statement
It is desired to analyze the behavior of milling process has been employed to produce
30 .The dimensions of shafts are (24 ± 0.1) mm.

3 Objectives
 Selection of appropriate tool and work piece.
 Analyze the behavior of milling process by using correct statistical tool.

4 Tasks to be Performed
1. On milling machine, we machined 30 parts as per dimensions.
2. The corrected quality characteristic’s measurement is to be recorded by using
appropriate measuring instrument.
3. Carefully setting of machine parameters in order to achieve controlled size.
Procedure:
The steps for the experiment are as follow:

Step 1:

First, MS-1045 material is selected for the process capability analysis and 30 impressions
were made having depth of cut of 0.5mm.

Step 2:

The cutter that is used for the milling operation is 4 teeth side and face milling cutter with 4
mm in dia. The material for the rotary cutter is High Speed Steel.

Step 3:

Adjust the machine cutting parameters for the milling operation. To check the process
capability for the milling operation the cutting parameters are; Cutting speed is 450 RPM,
depth of cut is 0.5 mm.

Table 1-Parameters for milling machining

Parameters Value

Feed Rate 0.15 mm/tooth

Depth of Cut o.5 mm

Spindle Speed 450 rpm

Step 4:

The slab milling operation is performed on the cut parts and the required thickness of 14
mm is obtained by specified operation.

Step 5:

By use of Vernier caliper, the thickness of the parts is measured and then used for the
process capability purpose and control charts are generated.

Step 6:
The measurements by using the Vernier caliper of the thickness of the parts are given in the table

Thickness of Thickness of
Sr # Sr #
milling parts milling parts
1 0.49 16 0.49
2 0.51 17 0.52
3 0.51 18 0.53
4 0.6 19 0.58
5 0.53 20 0.53
6 0.56 21 0.5
7 0.5 22 0.5
8 0.46 23 0.56
9 0.47 24 0.56
10 0.6 25 0.51
11 0.5 26 0.51
12 0.54 27 0.51
13 0.56 28 0.51
14 0.49 29 0.51
15 0.44 30 0.51