UNIT 41 SHAHKIL AHMED

MANUFACTURING SECONDARY MACHINING PROCESSES

DRILLING: this process uses a drill bit to cut into material as this works its way into the material by
rotating fast and causing the material to deform and change shape within the drilling industry there
are many types of drilling as this includes pillar drill, hammer drill, rotary, cables tool drill and
diamond core drilling. Within this project I will be using a 9mm drill bit as this was said on the
specification as I have to follow this as I will be drilling it into the base plate, however I will also be
using a lathe machine for the counter bore as this will have to be 60mm as it says in the
specification.

The reamer tool will also be used as this will be used for enlargement and precision of the holes I will
be drilling, making sure I drill the hole to 10mm and the holes tolerance does not exceed over 9.005
and min to 9.03. furthermore in the base plate there will be a blind hole and this will not fully go
through the base plate and I have to make sure that the size of this hole will have to be 9mm. the
manufacturing process this I will be using is primary are this is the base plate after I have worked on
this this will turn it into a secondary process as this will men aim taking the material for further
working.

TURNING: This is a process which is used to cut a material to its shape, sometimes using a non-
rotary tool bit, using this machine process you can use it to make items such as hammers and tools,
this done by the machine rotating the material fast and the tool starts to trim the material as this is
done by force then causes it to deform and change shape, you can make curves and angles while
doing this depending on the material and the tool bit you use. This process can be used to smooth of
the material and design it to how you like as while turning a counter bore is worked on and a
chamfer is produced and this is where the machine process happens.

Many types of turning includes:

Grooving(this is when you use the tool bit to change the shape of the material buy touching certain
bits and this causes a design on the material such as the handle for a hammer)

Profiling ( this is similar to grooving however this is the more smoothed option as you can use this to
make a round door handle)

Part off (this is literally to cut the material in two)

Tuning (this is the use the drill bit to the shape and size by adding force to the material while
rotating fast

Turning and grooving (this is grooving but for the longer time and to cut more of the material which
the material is going through the turning process at the same time)
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Broaching: this is a toothed tool called a broach and this removes material in this process the rotary
broach is pressed into the workpiece and this causes it to cut into an axis symmetric shape this is
done in a rotary broach or lathe screw machine. This makes the process quick and simple making it
efficient and cheap. The types for broaching could be horizontal and vertical, this is mostly
commonly used in doors, shutters and gates furthermore the tolerance for this is between 0.05mm
to 0.01mm.

Milling: this process uses rotary cutters to remove the material from the workpiece by advancing or
feeding the machine this is either done at an angle with the axis tool facing to material as the cutters
to its job. Milling could be done on a big or small scale depending on the material as this could be
used on heavy duty material also, however in machine shops and big industry you will find one of
these machines.

As there is many types such as universal horizontal, swivel and ram type. We will be using milling to
the base plate as we might have to make future components and the milling process will make us do
this as we need 10mm slots in the base plate, further slots will have to have the tolerance of o.1mm
to o.025m.

Presswork: this processes is when metal is pressed on hence the name presswork, this could either
be done from a metal sheet, tube and coil. The metal is manipulated to the shape on the design or
accurate components. This process is seen as cheap and efficient and this will only have a one off
cost and this produces large batches. As this is run by hydraulics and pressed on to the material the
different types could be trimming tool, piercing, forming and blanking.
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Honing and lapping: this machine process could be seen as abrasive and depending on the metal
surface as this will be done on a controlled path and be done to a precision surface on the metal. As
this will improve the surface texture and help the metal work.

Lapping is the finishing of honing as this procedure uses extreme dimensional accuracy, corrects
minor imperfections too as well as cleaning the surface this is joining another surface if you want to
by joining them together with an abrasive material there different types of would be laser horning,
flexible hone and micro.

PILLAR DRILL:

This machine is about 20 years old due to this the consumption of energy for this I really high
compared to machines made now as I will use this to drill the pillar drill this is a disadvantage as the
more energy this machines uses means more consumption of electricity and this si bad for the
environment. The volts that this can go up to is 420v, which is a huge amount this makes sense as
this is due to it being old, however this machine being old it still runs smoothly and still gets the job
done as this is due it is being serviced all the time and being maintained properly ass this has a
history of having no problems which is great which is an advantage. Making sure that the drill bit has
to be made sure is not worn out and maintained correctly this is due to the part waring out when
heavily used as if this is the case when I used the machine it will not drill the hole correctly. If the
drill bit is not correctly fastened to the machine is could be highly dangerous as this will rotae
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extremely fast and if lose this could fly and hit someone and fly into your eyes hence ppe is
extremely important and googles must be worn all the time. To prevent this the engineer must make
sure it this is securely put on by using the chuck key. Also another way to make sure the drill bit is
maintained well is making sure that you use the right speed for the right material such as slow speed
for wood and high speeds for metal, the fluid in the machine has to made sure it is disposed
correctly as this is due to it being harmless to the environment as this will have to be disposed by
takin git to the local dispose centres, furthermore the lubricant could be used in this machine as this
will improve the efficiently of the machine and make it run smoothly even more and extend it life
even more, the sustainability of this machine is very important, as the energy can be reduces as in
the hole on my base plate is done smaller as this will reduced the amount of energy going into the
machine making it for effective.