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SIRINDHORN INTERNATIONAL INSTITUTE OF TECHNOLOGY THAMMASAT UNIVERSITY IES 301: MANUFACTURING TOOLS AND OPERATIONS LAB MANUAL REGULATIONS FOR LABORATORY
1. STUDENTS MUST DRESS PROPERLY (WEAR A LONG WORKSHOP SUIT, SHOES PREFERABLY SAFETY SHOES, SOCKS, SAFETY GLASSES WHEN APPROPRIATE). 2. STUDENTS MUST COME TO IE WORKSHOP AT THE FACULTY OF ENGINEERING BUILDING ON TIME. LATE COMING RESULTS IN A PENALTY OF 10% OF FULL MARKS. IF THE LATENESS IS MORE THAN 15 MINUTES, THE STUDENTS WILL NOT BE ALLOWED TO PRACTICE IN THAT LABORATORY-SESSION, AND THE MARK FOR THAT SESSION WILL BE ZERO. 3. THERE IS NO MAKE-UP FOR THE LABORATORY SESSION. STUDENTS WHO MISS ANY SESSION WILL GET ZERO MARK FOR THE SESSION. 4. THERE IS NO EXTENSION OF THE LABORATORY TIME. STUDENTS SHOULD TRY TO FINISH THE ASSIGNMENT WITHIN THE REGULAR LABORATORY TIME. AT THE END OF THE SESSION, THE WORK-PIECE MUST BE SUBMITTED REGARDLESS OF ITS COMPLETENESS. THE MARKS WILL BE GIVEN BASED ON THE QUALITY OF THE WORK-PIECE. 5. STUDENTS MUST OBEY ALL INSTRUCTIONS FROM INSTRUCTORS. STUDENTS MUST NOT TRY ANYTHING THAT IS CONSEQUENCE IS NOT CLEARLY KNOWN. BEFORE TRYING ANYTHING, ASK THE INSTRUCTOR FIRST. 6. STUDENTS MUST AVOID ANY UNSAFE ACT, E.G., RUNNING, PLAYING, MISUSE OF THE TOOLS, PRESSING AN UNKNOWN BUTTON, AND OPERATING AN UNKNOWN SWITCH OR LEVER. 7. STUDENTS MUST USE PROTECTION EQUIPMENT SUPPLIED BY THE INSTRUCTOR. 8. FAIL TO COMPLY WITH THE INSTRUCTIONS, SAFETY RULES, AND COMMON SENSE, MAY RESULT IN A SEVERE INJURY.

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LAB SCHEDULE LAB NUMBER 1 2 3 4 5 6 7 8 9 10 11 12 LAB SCHEDULE LAB EXPLANATION, BRIEF LECTURE ON PRINCIPLE AND THEORY TURNING #1 TURNING #2 BENCHWORK #1 BENCHWORK #2 BENCHWORK #3 ELECTRIC WELDING GAS WELDING GENERAL TOOLS #1 GENERAL TOOLS #2 MILLING #1 MILLING #2

NOTE: PLEASE SEE THE ANNOUNCEMENT AT IE BOARD FOR YOUR GROUP NUMBER AND SCHEDULE FOR YOUR LAB. EACH GROUP WILL BE ROTATED TO PERFORM ALL LABS. CONTENTS REGULATIONS FOR LABORATORY LAB SCHEDULE LAB DESCRIPTION TURNING BENCHWORK ELECTRIC WELDING GAS WELDING GENERAL TOOLS MILLING CASTING LAB DESCRIPTION
LABORATORY MANUAL IS USED IN IES 301 COURSE, MANUFACTURING TOOLS AND OPERATIONS, OF SIRINDHORN INTERNATIONAL INSTITUTE OF TECHNOLOGY, THAMMASAT UNIVERSITY. A SERIES OF LABORATORY SESSIONS IS ORGANIZED AND DESIGNED TO ALLOW ALL STUDENTS TO UNDERSTAND, EXPERIENCE, AND APPRECIATE A WIDE VARIETY OF ENGINEERING OPERATIONS AND PRACTICES, AND MACHINE TOOLS AND EQUIPMENT.

LAB 1 LAB 2 LAB 3 LAB 4 LAB 5 LAB 6 LAB 7

THIS

THE TOPICS COVER FUNDAMENTALS OF CUTTING TOOLS, TURNING OPERATIONS, ELECTRIC AND GAS WELDING, MILLING, AND BENCHWORK.

SIIT FACULTY

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SIRINDHORN INTERNATIONAL INSTITUTE OF TECHNOLOGY THAMMASAT UNIVERSITY IES 362: Manufacturing Engineering Laboratory
Prepared by: Dr. Ruengsak Kawtummachai Industrial Engineering Program

(1) REGULATIONS FOR LABORATORY

1. 2. 3. 4.
MUST DRESS PROPERLY (WEAR A LONG WORKSHOP SUIT, SHOES PREFERABLY SAFETY SHOES, SOCKS, SAFETY GLASSES WHEN APPROPRIATE). STUDENTS MUST COME TO THE WORKSHOP ON TIME. THERE IS NO MAKE-UP FOR THE LABORATORY SESSION. STUDENTS WHO MISS ANY SESSION WILL GET ZERO MARK FOR THE SESSION. THERE IS NO EXTENSION OF THE LABORATORY TIME. STUDENTS SHOULD TRY TO FINISH THE ASSIGNMENT WITHIN THE REGULAR LABORATORY TIME. AT THE END OF THE SESSION, THE WORK-PIECE MUST BE SUBMITTED REGARDLESS OF ITS COMPLETENESS. THE MARKS WILL BE GIVEN BASED ON THE QUALITY OF THE WORKPIECE. STUDENTS MUST OBEY ALL INSTRUCTIONS FROM INSTRUCTORS. STUDENTS MUST NOT TRY ANYTHING THAT IS CONSEQUENCE IS NOT CLEARLY KNOWN. BEFORE TRYING ANYTHING, ASK THE INSTRUCTOR FIRST. STUDENTS MUST AVOID ANY UNSAFE ACT, E.G., RUNNING, PLAYING, MISUSE OF THE TOOLS, PRESSING AN UNKNOWN BUTTON, AND OPERATING AN UNKNOWN SWITCH OR LEVER. STUDENTS MUST USE PROTECTION EQUIPMENT SUPPLIED BY THE INSTRUCTOR. FAIL TO COMPLY WITH THE INSTRUCTIONS, SAFETY RULES, AND COMMON SENSE, MAY RESULT IN A SEVERE INJURY.

STUDENTS

5.

6.

7. 8.

(2) Objective
The main objective of the lab is to understand the CAD/CAM facilities and measurement instruments for working in manufacturing environment. Specially, the following objectives are set up: (1) To understand the data transfer from Computer-Aided Design (CAD) to ComputerAided Manufacturing (CAM). Specifically, the drawing from AutoCAD with DXF format to Master CAM for developing NC program. (2) To know how to use Master CAM software package for CAD/CAM linking and develop NC programs for using at lab. (3) To be familiar with CNC machines and advanced machines/facilities. (4) To be familiar with instruments for measurement.

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(3) Procedures
The lab is composed of three sections, called CAD/CAM, CNC, and MEASUREMENT. The CAD/CAM section aims to study about AutoCAD and Master CAM package. The CNC section aims to study CNC turning machine and CNC milling machine. Finally, the MEASUREMENT section aims to study the measurement tools and instruments. Generally, the students are grouped in two groups called group A and B. (The list of group A and B are announced in separate sheet). The first group A goes to work on CAD/CAM in five weeks and then goes to study on CNC and MEASUREMENT for five weeks. Similarly, the group B firstly goes to study CNC and MEASUREMENT sections for five weeks and then goes to study CAD/CAM for five weeks. All detailed schedules for the lab are announced in the separated sheet.

(4) Regulations
4.1) 4.2) 4.3) Each group must submit weekly lab report for each CNC lab and MEASUREMENT lab after a week of the completion on that corresponding lab. For CAD/CAM section, there will be assignments assigned by instructors. You must follow the details that will be given by instructors. No make-up classes are available due to tight schedules and therefore, please take care for attending the lab class regularly.

(5) Scoring Policy

5.1) 5.2) 5.3) 5.4) Attendance 10% (Late 0-10 min. 50% and late more than 10 min. 100%) Lab report (CNC and Measurements) 40% The assignment (CAD/CAM) 20% Final Examination 30%

(6) Lab Explanations

CAD/CAM Lab Session (5 weeks) This lab will be conducted at computer center located at fifth floor of lab building, SIIT. In this lab session, the students will study AutoCAD and Master CAM software packages for understanding the CAD and CAM. During the lab session, the students will: 1. Understand and know how to use the software 2. Develop NC programs CNC-1: CNC Lathe Machine (1 week) This lab will conduct at IE lab room, SIIT lab building. In this lab session, the students will study the CNC turning machine and will make a workpiece by the machine. The following steps are included: 1. Understand operation procedures of the machine, 2. Understand G-code for CNC lathe machine, 3. Understand safety operations.
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IE CNC-2: CNC Milling Machine (1 week) This lab will conduct at IE lab room, SIIT lab building. For this lab, the students need to understand the operational procedures of the CNC milling machines and during that time, the students have to finish a workpiece. The following steps are included: 1. Understand operation procedures of the machine, 2. Understand G-code for CNC milling machine, 3. Understand safety operations. MEASUREMENT-1: Coordinate Measuring Machine (CMM) (1 week) This lab will conduct at SIIT lab building and the lab aims for students to understand about advanced measuring machine for quality control. For this lab, the students needs to follow the following procedures: 1. Understand the operations of CMM. 2. Understand the applications of those machines. MEASUREMENT-2: Robotics (1 week) This lab will conduct at the IE lab located at the first floor of SIIT lab building. During the lab session, the students have to: 1. Understand the operational procedures of industrial robot, and 2. Understand the applications of robotics. After the above mentioned lab session, the students will study the basic tools for measurement such as Vernier caliper, micrometer, etc. MEASUREMENT-3: Surface Roughness Measurement and Hardness Tester (1 week) This lab will conduct at the IE lab located at the first floor of SIIT lab building. During the lab session, the students have to: 1. Understand the concepts and procedures of the measurement of surface roughness, 2. Understand the concepts and procedures of the measurement of hardness.

(7) Guidelines for the lab reports

The lab report must contain the following parts: (a) The objectives of the corresponding lab session, (b) The main procedures carried out during the lab session, (c) The workpiece done during the lab session or the result form the measurement, (d) The knowledge gained from the lab session, (e) The problems/difficulties met during the lab session, (f) The suggestions for improving the lab session and conclusion of the lab report.

(8) Final Examination

There will be only one (final) examination (1 hour). Generally, the final examination is appeared to be composed of short questions and multiple choices. The examination is closed book type and all questions are generally from the lab. If you are carefully study during the lab session and clearly understand about the lab procedures, you can easily answer the final examination questions.

(9) Group and Schedule

There are two main groups called GROUP A and B for doing the lab. The student lists appeared at GROUP A and B are announced in separate sheet. Please check to make sure whether your name is appeared in a group. Please contact Dr. Ruengsak for any information.

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Sirindhorn International Institute of Technology Industrial Engineering Program

IES 363: Manufacturing Engineering Lab II Lecture: SIITs Main Building Laboratory: SIITs IE Lab Course description The laboratory course provides practical integration between measuring and controlling instrument used in manufacturing environment. Measuring instrument is focused on the physical property measuring such as pressure, temperature and level. Controlling instrument is emphasized in both mechanical and electrical control devices such as Programmable Logic Control (PLC).

Lab Explanations: The lab is divided into three sessions as explained below: First and Second Session: The students are required to have a tutorial class for the first two weeks, and then, followed by Metrology sessions, part design and material purchasing. Students will be divided into small groups (about 4 persons per group). Each group has to submit one design (CAD and CAM) and its budget to be approved by the faculties. After that in the second session, the group will start making the part. Finally, the group must submit the workpiece and report. Third Session: The students are required to have four laboratories conducted by IE faculties. Labs included are Metrology Lab, Programmable Logic Control, Manufacturing Cost Estimation, and Material and Metallurgy lab. Student Group There are four members per each group. Schedule of work assignment of each group will be announced before the lab starts. Grading Policy: 1. Parts 35% 2. Lab hand on exam 25% 3. Paper exam 40%

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Lab Schedules:
Week No. 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 Subject Tutorial CAM Tutorial CAD Lab session 1 Metrology lab & Part design and Material purchasing Lab session 2: Part making Instructor TBA TBA Dr. Pisal/Dr. Navee TBA Place

IE Laboratory

Technicians of IE Mid-term examination Lab session 2: Part making (cont.) Lab session 3 Dr. Navee Dr. Chakguy Dr. Pisal Dr. Ruengsak IE Faculties

IE Laboratory

IE Laboratory IE Laboratory

Lab hand-on examination

Lab session 1 consists of metrology lab (advanced CMM), part design and material purchasing. Your proposal report of part design, list of materials required and cost estimation must be submitted for approval before .. Lab session 2 is arranged for the part making. The deadline for submitting your finished part and full report is Lab session 3 consists of four separated labs as below: Lab 1: PLC and instrumentation Lab 2: Metrology lab (Roundness testing) Lab 3: Material and Metallurgy lab Lab 4: Manufacturing Cost Estimation A report of each lab for each group must be submitted within one week after the lab. Part Guidelines There are conditions that students must follow in order to design the workpiece: 1. All components must be made from aluminum or copper. 2. Dimension of your part should not exceed W20cm x L20cm x H15cm 3. Your process must include both the machine processing and assembly. The following regulations must be applied. At least one component must be processed by Machining Center (CNC Lathe and CNC Milling Machine) At least one component (base unit) must be formed through casting. Other components can be processed by other conventional machines such as turning, milling, drilling, etc.

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