VIET NAM NATIONAL UNIVERSITY, HA NOI

INTERNATIONAL SCHOOL

SUBJECT REPORT
Fundamentals of Machinery Manufacturing
Technology

GROUP 6 -
Major: Automation and Informatics
Specialization: Automation

Supervisor: Associate Professor Nguyen Nhu Tung

Department: Faculty of Applied Sciences
Student: Nguyen Viet Huy Hoang - 21070639
Nguyen Huy Hoang - 21070193
Nguyen Huy Hoang - 21070186

Ha Noi, 03/2024
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Contents
Chapter 1: Introduce the product, technical requirement of the product........................ 3
1. Introduce the product. ............................................................................................. 3
2. Product specifications ............................................................................................. 4
3. Introduction to materials used: ............................................................................... 4
4. Conclusion of chapter 1 .......................................................................................... 5
Chapter 2: The shaping method that used to manufacture the products. ....................... 6
Principles of shaping: ................................................................................................. 6
1.Determine the types of production .......................................................................... 6
2. Select the workpiece ............................................................................................... 7
Chapter 3: The manufacturing menthod that were used to manufacture products ......... 8
1. Determine the type of production ........................................................................... 8
Chapter 4: Explain the steps to manufacture the products (Explain in detail by figures
and explanations) .......................................................................................................... 10
1: Design the progress operations............................................................................. 10
2. Detailed explanation with drawings and explanations: ........................................ 10
2.0. The main parameter in PTC Software ............................................................... 10
2.1. Operation I: Milling the TOP surface with a face milling cutter ....................... 11
2.2. Operation II: Make mill window. ...................................................................... 12
2.3. Operation III: Roughing (End Mill) .................................................................. 13
2.4. Operation IV: Profile Milling (Bull Mill) .......................................................... 15
2.5. Operation V: Profile Milling (Bull Mill) ........................................................... 16
2.6. Operation VI: Drilling (Ball Mill) ..................................................................... 18
2.7. Operation 7: Chamfer Milling (Chamfering) .................................................... 21
V. Conclusion. ............................................................................................................... 22
VI. Reference. ............................................................................................................... 23

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Chapter 1: Introduce the product, technical requirement of the

product.
1. Introduce the product.

Figure 1. Details to be processed

This is a box-shaped part with a complex shape with a rectangular block, but there
are no special details on the walls. The top surface of the box has a number of flat
surfaces that need to be machined with different precision and also has Some flat
surfaces may not need to be worked because we can take advantage of the workpiece
surface when the quality of the workpiece surface is good enough to be the surface of
the part. Therefore, when designing, you need to pay attention to the structure:
- The rigidity of the part is enough so that it does not deform during machining.
- The holes on the part have a simple structure, the holes are concentric and
smooth. The hole is large enough for us to be able to insert the knife when
milling, turning, drilling, boring, reaming...
- The part has symmetrical surfaces, perpendicular to the bottom surface, so it is
very convenient for the blank processing process.
- The part is responsible for supporting other machine parts. The main working
surface of the part is the bottom and top planes, so it needs to be machined
accurately.

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2. Product specifications
Data are automatically calculated by “CAD software - Autodesk Inventor” -In the
iProperties feature model.

Physical Properties for P05BYVIET

General Properties:

Material: {Steel}

Density: 7.850 g/cm^3

Mass: 2840.506 g (Relative Error = 0.002851%)

Area: 54787.451 mm^2 (Relative Error = 0.000000%)

Volume: 361847.871 mm^3 (Relative Error = 0.002851%)

Center of Gravity:

X: -60.000 mm (Relative Error = 0.002851%)

Y: 11.962 mm (Relative Error = 0.002851%)

Z: -71.180 mm (Relative Error = 0.002851%)

Principal Moments of Inertia with respect to Center of Gravity

I1: 4910280.733 g mm^2 (Relative Error = 0.002851%)

I2: 7668028.449 g mm^2 (Relative Error = 0.002851%)

I3: 3139001.444 g mm^2 (Relative Error = 0.002851%)

Rotation from Global to Principal

Rx: 1.68 deg (Relative Error = 0.002851%)

Ry: 0.00 deg (Relative Error = 0.002851%)

Rz: 0.00 deg (Relative Error = 0.002851%)

Properties important :
Material: {Steel C45}
Density: 7.850 g/cm^3
Mass: 2840.506 g (Relative Error = 0.002851%) (1)
Area: 54787.451 mm^2 (Relative Error = 0.000000%)
Volume: 361847.871 mm^3 (Relative Error = 0.002851%) (2)
3. Introduction to materials used:
Properties of C45 steel:
• High hardness: C45 steel has Brinell hardness (HB) from 207 - 269, Rockwell
hardness (HRC) from 58 - 64.
• High durability: C45 steel has tensile strength (Rm) from 630 - 800 MPa, yield
strength (Rp0.2) from 340 - 460 MPa.
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• Good pressure resistance: C45 steel has the ability to withstand high pressure
in many different environments.
• Easy to process: C45 steel can be easily processed by cutting, peeling, turning,
milling, etc.
Applications of C45 steel:
• Casting molds for mechanical products and equipment.
• Manufacturing bolts, screws, and fittings.
• Production of crankshafts, rolling shafts, gears.
• Used in load-bearing structures in construction

Chemical
(C) (Si) (Mn) (P) (S) (Cr) (Cu) (Ni)
composition

0,42- 0,16- 0,5- ≤ ≤ ≤ ≤ ≤

CONTENT (%)
0,5 0,36 0,8 0,04 0,04 0,4 0,3 0,3

NOTICE:
• C45 steel does not have good corrosion resistance so it needs to be stored and used in
a suitable environment.
• When machining C45 steel, pay attention to cutting speed and milling cutter quantity
to avoid damaging the material.

4. Conclusion of chapter 1
The detail is a rectangular box with a complex shape.
Material used is C45 steel.
Technical requirements:
o High rigidity.
o Holes are clear and concentric.
o Precision machined surface

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Chapter 2: The shaping method that used to manufacture the

products.
Asbtract:The shaping method is Focused on creating the desired shape for the part.
Principles of shaping:
• Cutting shaping method: Removing excess material from the workpiece to form
the desired product. By cutting tools with cutting mesh of defined and undefined
shapes. For example: milling, turning, planing, boring,...
• Plastic deformation shaping method: Change the shape and size of the workpiece
without changing the nature of the material. For example: stamping, rolling,
drawing,...
• Casting shaping method: Using a mold to shape the product from molten
material. For example: sand casting, metal mold casting,...
• Electrophysical and electrochemical shaping methods: Connecting parts together
by melting. For example: electric arc welding, TIG welding,...
• 3D printing shaping method: Shape the product layer by layer from the printed
material. For example: FGM printing, SLA printing,...

1.Determine the types of production

The detailed volume is determined:

Properties important :
Material: {Steel C45}
Density: 7.850 g/cm^3
Mass: 2840.506 g (Relative Error = 0.002851%) (1)
Area: 54787.451 mm^2 (Relative Error = 0.000000%)
Volume: 361847.871 mm^3 (Relative Error = 0.002851%) (2)

Figure: Detailed parameter code P05

From the detailed volume and production quantity the importan parameter the volume
(Q) and the number of product 200 (N). Check table in appendix The production form
of the part is a typical, medium mass production form for this type of production are:
• Easy to use universal machine tool equipment
• Product series can be produced periodically
• Easy to adjust the machine automatically to size

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• Using skilled workers with many levels of workers suitable for many
operation

2. Select the workpiece

Size of the workpiece:

Parameter Details

Blank type Example: Steel, cast iron, aluminum, copper

Shape Example: Rectangular, cylindrical, circular

Size Length (L) x Width (W) x Height (H) or Diameter (D)

Size tolerance Example: ±0.1mm, ±0.2mm

Material type Example: Steel CT3, gray cast iron FC200, aluminum A6061

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Chapter 3: The manufacturing menthod that were used to

manufacture products
Production method: Includes all stages to create the finished product, from raw material
preparation to finishing.

1. Determine the type of production

In machine manufacturing, three types of production are distinguished:
- Single production
- Mass production (Large, medium and small batches)
- Mass production

Production Type > 200 4+ 200 < 4 <4

Single Piece <5 < 10 < 100

Small Batch 5-10 10-200 100-500

Medium Batch 100-300 200-500 500 – 5000

Large Batch 300-1000 500-1000 5000- 50000

Mass Production > 1000 > 5000 > 50,000

2. Some tool in CNC technology.

End Mill
Shape Application Advantages Disadvantages
Type

Long cylindrical Face milling, Wide variety of Limited ability to

End Mill shank, cutting slotting, profiling, types, suitable for machine complex
edge at the tip chamfering many applications parts

Long cylindrical Can machine

Ball Nose 3D contour More expensive
shank, spherical complex parts, create
End Mill milling, finishing than end mills
cutting edge smooth surfaces

Bull Long cylindrical Slotting, Creates rounded

Not as good for face
Nose End shank, ball nose chamfering, face corners, reduces risk
milling as end mills
Mill cutting edge milling of tool breakage

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Long cylindrical Increased machining

Double Slotting, Not as good for face
shank, two cutting efficiency, reduced
End Mill chamfering milling as end mills
edges at the tip machining time

Limited ability to
Slitting Thin cutting edge, Creates narrow,
Slotting face mill and
Saw thick shank precise slots
chamfer

Disc-shaped Increased face Limited ability to

Face Mill Face milling
cutting edge milling efficiency slot and chamfer

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Chapter 4: Explain the steps to manufacture the products

(Explain in detail by figures and explanations)
Because the parts produced are in the form of mass production, we choose the
technological path of dispersing the operations and using CNC machines with
specialized jigs to process the parts.

1: Design the progress operations

- Operation 1: Face Milling (End Mill)
- Operation 2: Make Mill Window
- Operation 3: Roughing (End Mill)
- Operation 4: Finishing (Ball Mill)
- Operation 5: Profile Milling (Bull Mill)
- Operation 6: Drilling (Ball Mill)
- Operation 7: Chamfer Milling (Chamfering)

2. Detailed explanation with drawings and explanations:

2.0. The main parameter in PTC Software
• CUT_FEED: is the value specifies the rate at which material is removed by
the cutting tool along a particular path.
• RETRACT_FEED: is crucial for optimizing tool movement efficiency,
ensuring tool and machine safety, and controlling the overall machining
process.
• STEP_DEPTH: By setting the appropriate STEP_DEPTH value, users can
achieve the desired surface finish, accuracy, and tool life while optimizing
machining time and minimizing the risk of tool breakage or excessive wear.
• TOLERANCE: typically refers to the allowable variation from a specified
dimension or geometric characteristic on a part or assembly.
• ROUGH_STOCK_ALLOW: This parameter defines the additional
material allowance left on the workpiece surface before performing rough
machining operations.
• CLEAR_DIST : is the distance by which the tool must clear the surrounding
features, fixtures, or clamps while moving between machining operations or
retracting from the workpiece.
• SPINDLE_SPEED: represents the rotational speed of the spindle, which
holds the cutting tool during machining operations

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2.1. Operation I: Milling the TOP surface with a face milling cutter

Figure 2.1.1. The line tool motion in operation 1.

• Face milling: is a machining process where the axis of the tool is parallel to
the surface of the workpiece, to create a flat surface on the workpiece.
• End Mill is a type of milling cutter that has the primary cutting edge on the
end face of the tool and is parallel to the work surface.

Figure 2.1.2 The diameter of tool in Operation 1.

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This type of cutter produces a smooth finish on the workpiece and is used for
finishing and smoothing grooves, edges, and rad. They are used for machining
various types of mild steel, cast iron, alloy steel, and stainless steel. They are used
in milling applications such as slot milling, face milling, and hole milling with high
efficiency.

Figure 2.1.3.The table of diameters for operation I.

2.2. Operation II: Make mill window.

Mill Window in PTC Creo: is a powerful machining feature in PTC Creo that is used
to define the machining area in milling operations. It allows users to limit the
machining area by creating a bounding box around the area to be milled. Allows you
to create the window by projecting the silhouette of the reference part on the Mill
Window start plane, in the direction parallel to the z-axis of the Mill Window
coordinate system. If the manufacturing assembly contains more than one reference
part, you must select the part that you want to use to create the silhouette.
Additionally, if a reference part used for creating the silhouette contains cuts or holes,
you can specify whether you want Creo NC to keep or remove these loops by clicking
the Keep Inside Loops check box in the Options slide-up panel.i

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Figure 2.2.1. The mill window .

2.3. Operation III: Roughing (End Mill)

Roughing: is an important step in the machining process, used to remove most of the
excess material from the workpiece, creating a near-net shape of the finished part.
Removes all material inside a Mill Window boundary, with additional depth control
based on the depth of the Mill Window. The thickness of the stock to remain on the
reference geometry after machining is specified by the “ROUGH_STOCK_ALLOW”
parameter value.

Figure 2.3.1. The line tool motion in operation III.

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Figure 2.3.2 The diameter of tool in Operation III.

Figure 2.3.3.The table of diameters for operation III.

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2.4. Operation IV: Profile Milling (Bull Mill)

- Finishing: is the final step in the machining process, used to create a smooth and
accurate surface for the finished part.
- Ball Mill: With a ball-shaped end, ball mills are used for applications such as
slotting, milling, and creating curved profiles for molds and dies to avoid sharp
corners.

Figure 2.4.1. The line tool motion in operation IV.

Figure 2.4.2 The diameter of tool in Operation IV

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Figure 2.4.3: The table of diameters for operation IV.

2.5. Operation V: Profile Milling (Bull Mill)

- Profile Milling is a machining process that uses a milling cutter with a shape
corresponding to the desired profile to create parts with complex shapes.
- Bull Mill: is a special type of milling cutter used in PTC Creo software to
machine internal corners of a part.

Figure 2.5.1. The diameter of tool in Operation V

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Figure 2.5.2. The line tool motion in operation V.

Figure 2.5.3: The table of diameters for operation V

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2.6. Operation VI: Drilling (Ball Mill)

- Drilling (also known as boring) is a machining process used to create holes in a
workpiece. The process uses a cutting tool called a drill bit to remove material
from the workpiece and create a hole with the desired size and shape.
A, punch 4 small holes

Figure 2.6.1. The line tool motion in operation IV.

Figure 2.6.2. The diameter of tool in Operation VI

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Figure 2.6.3: The table of diameters for operation VI

B, Punch a large hole in the middle

Figure 2.6.4. The line tool motion in operation IV.

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Figure 2.6.5. The diameter of tool in Operation VI

Figure 2.6.6: The table of diameters for operation VI

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2.7. Operation 7: Chamfer Milling (Chamfering)

- Chamfer Milling is a machining process that uses a milling cutter to create
chamfers on the edges of a workpiece.

Figure 2.7.1. The line tool motion in operation VII.

Figure 2.7.2: The table of diameters for operation VII

Figure 2.7.2. The diameter of tool in Operation VII

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V. Conclusion.
Summary Report:
Product: A complex rectangular box-shaped machine part with multiple flat surfaces
and holes to be machined.
Material: C45 steel
Manufacturing method:
• Production type: Medium batch production
• Technology: Dispersion of operations, using CNC machines and specialized jigs
• Operations:
1. Face milling (End Mill)
2. Window milling (End Mill)
3. Rough milling (End Mill)
4. Finish milling (Ball Mill)
5. Profile milling (Bull Mill)
6. Drilling (Ball Mill)
7. Chamfering (Chamfering)
Conclusion: The report presents a detailed description of the manufacturing process of
the machine part, including material selection, machining methods, and specific
operations. The use of CNC machines and specialized jigs ensures accuracy and
efficiency in the manufacturing process.

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VI. Reference.
1. T. V. Dich, N. T. Binh, N. T. Dat, N. V. Tiep, and T. X. Viet, *Công Nghệ Chế
Tạo Máy* [Machine Manufacturing Technology], 1st ed. Hanoi, Vietnam: Nha
Xuat ban Khoa hoc Ky thuat, 2008.
2. T. V. Dich, *Thiết kế đồ án công nghệ chế tạo máy* [Machine Manufacturing
Technology Project Design], NXB Khoa Học và Kỹ Thuật, Ha Noi, Vietnam,
2007.
3. The 3D model of the assembly was created using Creo Parametric 10.0.3.0 (PTC
Inc., Waltham, MA, USA).
4. Autodesk Inventor Professional 2023. Autodesk, Inc. 2022.

https://support.ptc.com/help/creo/creo_pma/r10.0/usascii/index.html#page/manufacturing/nc/About_Mill_Wind
ow_User_Interface.html

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