ASSIGNMENT / LABORATORY /

CASE STUDY / PROJECT

KOLEJ KEMAHIRAN TINGGI MARA

KUANTAN PAHANG

AS03 REPORT

SESSION: JAN – JUN 2023

NAME AHMAD ZAMEER BIN AHMAD ZUBIR
CLASS DKA2A
MATRIX NO 2225925 SEMESTER 3
CODE & COURSE DMV20163 CADCAM
LECTURER / VTO ABDUL RAHMAN BIN ABAS
SUBMISSION DATE 4/6/2023

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1) Process sequence.
2) Operation name.
3) Tool name/number.
4) Tool description.
5) Machining parameters (Spindle speed and feed rate).

Figure 1

Figure 2

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 Table 2a: Cutting Tool Database for Drilling [unit: mm]
Tool Register
Flute Overall
Ø Material Z offset No. at
Length Length
Machine
2 22 44 HSS 0 1

6 50 83 HSS 15.88 3

10 73 114 HSS 25.92 15

12 80 138 HSS 29.85 16

Table 2b: Cutting Tool Database for Milling [unit: mm]

Flute Overall Tool Register No.

Ø Material Z offset
Length Length at Machine
1 (measuring
3 10 15 - 0
probe/tool)
3 25 65 HSS 21.4 4 (4 Flute End Mill)

10 38 100 Solid Carbide 28.92 6 (3 Flute End Mill)

20 75 150 HSS 60.95 8 (4 Flute End Mill)

2 2.9 40 Solid Carbide 7.8 7 (Center Drill)

6 35 80 HSS 55.5 9(Ball End Mill)

3 26 65 HSS 25.4 11(Ball End Mill)

2 (6 Tooth Face
50 150 Solid Carbide 28.92
Mill)

Table 2c: Surface Cutting Speed (V) [m/min]

Part Material
Tool
Material
Mild Steel Cast Iron Aluminium Alloy Brass

Carbide 170 100 250 180

HSS 28 18 120 75

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 Table 2d: Feed Rate (ft) for Milling [mm/tooth]

HSS Carbide
Work Material
Material Face & Shell Face & Shell
End Mills End Mills
End Mills End Mills
Mild Steel 0.25 0.15 0.3 0.18

Cast Iron 0.3 0.18 0.5 0.21

Aluminium
0.4 0.17 0.6 0.25
Alloy
Brass 0.35 0.15 0.4 0.19

Table 2e: Feed rate (f) for HSS Drills [mm/rev]

Drill
2 4 6 8 10 12 14 16 18 20
Size
Feed
0.05 0.1 0.12 0.15 0.18 0.21 0.24 0.26 0.28 0.3
Rate

Mathematical Relationship of Machining Parameters

1. Spindle speed
s = (1000 × v )
π×d where: s [rev/min]; spindle speed
v [m/min]; cutting speed
d [mm]; diameter of cutting tool

2. Feed, Feed Rate

vf=f×s
f = f t × N teeth
where: f [mm/rev]; feed
v f [mm/min]; feed rate
N teeth ; number of teeth (milling)
f t [mm/tooth]; milling cutter with number of teeth

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REFERENCE:

1. 1. Michel Michaud, Catia Core Tools : Computer Aided Three-Dimensional Interactive

Application, McGraw Hill, 2012
2. 2. Kristie Plantenberg, Introduction to CATIA V5 : Release 19 (A Hands-on Tutorials
Approach), Schroff, 2009
3. 3. Richard Cozzens, CATIA V5 Workbook : Release 19, Schroff, 2009
4. 4. P N Rao, CAD/CAM Principles and Applications, 3rd Edition, McGraw Hill, 2004.

Prepared by : Checked by
:

Signature : Signature :

Name :
Designation : Name :
Date : Designation :
Date :

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=
PART
DATE:9/4/2023
NO.:KKTMKu/363/06/1

PART NAME: Base PROGRAMMER:DKA MACHINING PROCESS PLAN

MACHINE: ROBODRILL
MATERIAL: MILD STEEL
FANUC
OPERATION
SEQ TOOL DECSRIPTION STATION SPEED FEED NOTES
DESCRIPTION
FACING Face Mill,Diameter 50,Solid Carbide 2
S=
1000 � 250 f=0.6 x 6
� � 50 f=3.6
250000
S= �� =3.6 x 1591
157.1
1 �� =5727 mm
S=1591 rpm

POCKETING End Mill,Diameter 10,Solid Carbide 6

S=
1000 � 250 f=0.17 x 4
� � 10 f=0.68
250000 �� =0.68 x 7959
S=
31.41
2 �� = 5412 mm
S= 7959 rpm
 PROFILE End Mill,Diameter 3,HSS 11
S=
1000 � 120 f=0.17
CONTOURING ��3
�� =0.17 x 12738
120000 �� =2165 mm
S=
9.42
3

S=12738 rpm

CURVE End Mill,Diameter 3,HSS 4

S=
1000 � 120 f=0.17 x 4
FOLLOWING ��3 f=0.68
120000 �� =0.68 x 12738
S=
9.42 �� =8661 mm
4

S=12738 rpm

SIDE End Mill,Diameter 20,HSS 8

S=
1000 � 120 f=0.17 x 4
MILLING � � 20 f=0.68
120000
5 S= �� =0.68 x 1909
62.83
�� =1298 mm
S=1909 rpm
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