TABLE OF CONTENTS

S. NO CONTENTS PG. NO

I LIST OF FIGURES i

1 ABSTRACT/EXECUTIVE SUMMARY 1

2 OBJECTIVES 1

3 DATA/OBSERVATIONS 1

4 RESULTS 6

5 DISCUSSIONS 7

6 CONCLUSION & RECOMMENDATION 8

7 REAL-LIFE APPLICATION OF THEORY 9

8 REFERENCES 10
 I. LIST OF FIGURES

S. No FIGURES Pg. No

3.1 Engineering drawing of Pen Holder 1

3.1.1 Workpiece mounted in Bandsaw machine 2

3.1.2 Workpiece being cut in Bandsaw machine 2

3.2.1 Facing being carried out on the lathe 3

3.2.2 Finished (facing) workpiece 3

3.3.1 Chamfering being carried out on lathe (1) 4

3.3.2 Chamfering being carried out on lathe (2) 4

3.4.1 Workpiece mounted for milling 4

3.4.2 Milling being carried out 4

3.4.3 Workpiece after milling operation 5

3.5.1 Holes being drilled into the chamfer 5

5.1 Measuring the final height of the product 6

5.2 The final product (pen holder) 6

7 Real-life example 9

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 1. ABSTRACT / EXECUTIVE SUMMARY
This report describes the manufacturing processes involved in the machining of an aluminum
piece. A detailed drawing of the part to be machined has been provided to produce it. The
processes to machine this part consist of the next operations: turning to obtain the desired height
and radius, chamfering at a given angle to produces the edges of the body, milling to generate the
flat surfaces, and drilling to produce the perforations. During the laboratory session, each of
these operations was executed to produce the required part. The procedures carried out during
the session provided the insights to learn the basic principles of operation of the turning, milling,
and drilling machines. It was also possible to understand the machining sequence and its
importance when producing a part.
2. OBJECTIVE
The objective of this laboratory session was to learn the basic principles and sequence to
machine a piece or part using three of the most important machines in the manufacturing
industry: turning, milling, and drilling machines.

3. DATA / OBSERVATIONS
 As per the drawing, need to make a pen
holder with different operations like
cutting, facing, chamfer, milling, and
drilling.
 The height of the aluminium piece should
be of length 2 inches after cutting from
the long rod.
 Facing should be done on both sides
equally till the material reaches the length
of 1.50 inches with a tolerance of +0.008
to -0.003.
 Chamfering should be carried out in a
lathe for the diameter of 0.375 from the
outer surface at 45°.
 3 Flats should be made using 60° set
square and three flats should be machined
from another milling machine again
parallel and total length should be 1.91
inches with a tolerance of +0.010 to -
0.015.
 Drilling of 6 drill holes using milling
machine with an angle of 60°.
 After all the process removes the sharp edges with a file.
Fig 3.1 Engineering drawing of Pen Holder

 The total height of the product should be 1.50 inch which should be measured using a
Vernier calliper.
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 OPERATION 3.1 – CUTTING

Fig 3.1.1 Workpiece mounted in Bandsaw machine Fig 3.1.2 Workpiece being cut in Bandsaw machine

 Before moving into operation, ensure that we wear metallic shoes, protective gloves, and
safety glasses for Safety purposes.
 Mark the workpiece with the marker for reference to make the required length of cut for 2
inches.
 Ensure that the correct type of blade is fixed to cut the workpiece.
 Place the workpiece rod inside the band saw machine to proceed with the cutting.
 Make sure the machine holds the workpiece firmly and tighten up the screws to avoid
slipping.
 Once the machine is switched on, wait for some time so the blade reaches the cutting
speed. Depending on the property of the materials the speed of the blade should be
adjusted accordingly.
 Firmly hold the object and slowly move the blade downwards to cut.
 Once the required size of the workpiece is cut down, make sure to remove the sharp
edges to avoid any hazards.
 Measure the length of the object with a measuring instrument like a vernier caliper to
ensure the correct dimension.

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 OPERATION 3.2 – FACING

Fig 3.2.1 Facing being carried out on lathe

Fig 3.2.2 Finished (facing) workpiece

 Facing is the process of removing material from the machined part to make the surface
flat and perpendicular concerning the axes, attaining a smooth surface.
 Lose the chunk and mount the workpiece at the center and tighten up the chunk till the
jaws hold the work material firmly. Ensure that the tool is hard enough to machine the
workpiece. After inserting the facing tool, slightly move the tool away from the
workpiece.
 Set the lathe machine with the correct speed and feed rate based on the material and
diameter of the part.
 Switch on the lathe machine and move the tool little by little closer to the cutting tool
using the handwheel to start cutting the part.
 From the outer surface, start giving the feed to the cutting tool to remove the material.
Slightly move the tool inwards to remove material till the center of the workpiece
diameter.
 Repeat the process on the backside of the workpiece and remove the sharp edges with the
file. Repeat the process until the piece gets the correct dimension of 1.5 inches in length.
Measure with a Vernier caliper for the correct dimension.
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 OPERATION 3.3 – CHAMFERING

Fig 3.3.1 Chamfering being carried out on lathe (1) Fig 3.3.2 Chamfering being carried out on lathe (2)

 Mount the workpiece in the lathe machine chuck and tighten the workpiece with the key.
 Using the protector of the tool post, set the angle to 45 degrees and start moving the
cutting tool towards the part to perform the chamfering with a total length of 0.375 in.
 Give the feed rate to the machine with the small handwheel to remove the material in an
angular manner.
 Repeat the process to get the desired dimension as per the drawing given. During
chamfering, more chips will be formed. Remove them to avoid a clog in the tool.

OPERATION 3.4 – MILLING

Fig 3.4.1 Workpiece mounted for milling

 Fig 3.4.2 Milling being carried out

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 Fix the workpiece in the milling machine.
 Cross transverse and vertical transverse
handwheels can be used to move the workpiece
table.
 Machine three flat surfaces. Each should be at
an angle of 60 degrees. Turn off the machine to
remove material from one side of the cylinder
and rotate the piece to machine other flat areas.
 Use the set square scale to measure the angle of
60 degrees and perform the two other milling
cuts like the first one.
 Remove the workpiece from the first milling
machine and place it on the other machine to
proceed with the next flat surface. Three of
these flat surfaces should be machined.
 Each cut should be made at an angle of 60
degrees. After operating ensure that the total
height of the piece is 1.91 inches. Fig 3.4.3 Workpiece after milling operation
 Finally, clean chips from the workpiece table.

OPERATION 3.5 – DRILLING

Fig 3.5.1 Holes being drilled into the chamfer

 Select the appropriate drill bit to make holes onto the product and the tool to be fixed on
the chuck and tighten it.
 Place the workpiece on the worktable and ensure that the holder holds the part firmly.
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 As per the drawing guidelines, six holes are to be drilled on the chamfer area and each
should be having a distance angle of 60°.
 Here the tool would be rotating, and the workpiece should be stable.
 First, switch on the green button from the control panel and slightly move the tool post
near the workpiece and drill the hole and ensure that turn off the drilling machine when
the first hole is done.
 Repeat the same process for making the rest of the 5 holes with an angle of 60°.

3.6 FINISHING & INSPECTION

 Finishing is the process of removing all the sharp edges from the product. Ensure that we
wear protective gear while doing this process.
 Take the workpiece and use a file to make the corners smooth and should use the
deburring edge removing tool to do finishing inside the holes drilled.
 Measure the length and height of the pen holder with the Vernier caliper, it should be
1.91 and 1.50 inches respectively.
 Ensure all the dimensions are correct and its tolerance should be within the limits as per
the 2-D drawing provided.

4. RESULTS
 After performing the different machining operations, we had as an output the pen holder.
Figure 5.1 shows the final height of the product. We can observe it is exactly the required
length as per the given drawing.
 Fig 5.2 Final product (pen holder)

Fig 5.1 Measuring the final height of the product

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 The radius of the holes is being measured but we don’t have a reference value to
conclude if the radius of the perforations has the appropriate size. We can also observe
the chamfering surface at 45 degrees from the flat face of the part.
 Figure 5.2, shows the final product that is required by the drawing.

5. DISCUSSIONS
The experiment carried out during the laboratory session is a perfect example of a manufacturing
process. The task is to transform a piece of raw material into a product that will serve a specific
purpose. During the lab session, we observed the sequence of processes that allowed us to
manufacture the pen holder.
To be able to transform the raw bar of aluminum into the final product, we had to analyze and
follow a defined sequence of different machining operations. First, the raw material had to be cut
from a long bar of aluminum using the band saw machine. We observed that the piece had 0.5
extra inches of material in length. It is important to define how much material will be removed to
create the final part and how much will that cost when producing large quantities of parts. In the
end, the material that will be removed will become waste.
We continued the sequence by observing the procedure to machine the part using the turning
machine to adjust the height of the part to 1.50 inches and then performing the chamfering to
generate a flat surface at 45 degrees from one of the faces of the cylinder. The next operations
had the aim to create flat surfaces on the part for which we used the milling machine. Finally, the
use of the drilling machine allowed us to create the holes where the pens will rest.
During the drilling operation, we could observe that the diameter of the holes was not included in
the drawing of the part. This situation generates uncertainty as we could not determine what
measure should the drilling tool be. We saw that the instructor at the laboratory selected a
drilling tool but most likely the selection was based only on the material to be cut and not on the
size requirements of the holes.
The production of the pen holder is the result of the different manufacturing processes required
to produce value-added goods. In this lab session, we had to use the drawing of the pen holder,
then we had to utilize some raw material to generate the part, then we had to proceed with a
sequence of operations carried out in the tool shop to finally have a final product.
During the session, we also learned that to machine a part in a workshop, usually, if not always,
we require different general-purpose machines to obtain the desired output. Even a simple
product such as the pen holder cannot be machined using only the lathe machine or the milling
machine. Moreover, we also need some additional machines like the driller. This is a relevant
observation because when a piece is designed and is considered for production, the
manufacturing processes that it requires have to be considered from the very beginning of the
designing process.
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There is no point to design a part that will be very complex and therefore, very complicated to
machine. Instead, we as experts in manufacturing should try to propose solutions for such
eventualities.

6. CONCLUSION & RECOMMENDATIONS

The final piece demonstrates the different processes that raw material has to undergo to become
the desired final product that has a market value.
During this lab session, we were exposed to a real-life manufacturing process. We were given a
drawing to create a product, we had the raw material and we used machines to manufacture the
part. It was a complete exercise of a real-life sequence that has to be carried out to manufacture a
part.
Considering the drawing that was given in the lab session had missing information we came to
the next conclusions.
1. The radius of the holes was not available in the drawing and therefore, there was
confusion in our team. We could not determine what measure that the drilling tool should
have.

2. We saw that the instructor at the laboratory selected a drilling tool most likely based on
his experience.

3. Having this into consideration, we also agreed that there is a big impact on the
manufacturing process if the drawing is incorrect or incomplete.

This reasoning also takes us to conclude that nowadays it is crucial the use proper tools and
software to design products through the use of a CAD/CAM system. The designing stage of a
product is crucial for a successful manufacturing process.
Finally, we conclude that the greatest contribution of this laboratory session is that we were able
to observe that even a single product has to be created and manufactured following a complex
and structured procedure. It encompasses the initial design of the parts to the different machining
processes that have to be conducted to get the final product as a result.
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7. REAL-LIFE APPLICATION OF THEORY

 Pen holders are using everywhere in schools, colleges, shops,
factories etc. It is very easy for us to segregate our stationary items
like pens, pencils and other smaller stationary items.
 The pen holder is made up of Aluminum and it is non-breakable
and easily portable and its six flat surfaces avoid rolling out from
the table.

Fig 7.1 Real-life example

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REFERENCES
Mirza Foisal Ahmed. (2021, September 24). Lecture Slides [Slides]. Sheridan College.

https://slate.sheridancollege.ca/d2l/le/content/886380/Home

Open Oregon. (n.d.-b). Manufacturing Process. Retrieved October 1, 2021, from

https://openoregon.pressbooks.pub/manufacturingprocesses45/chapter/unit-4-turning/
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