INTRODUCTION :

Machining covers a wide variety of actions that take a raw material and turn it into something else.
It could be defined as a controlled process that takes raw material and transforms it into a desired
final shape and size. This can include material-removal as seen with such actions such as cutting,
drilling or boring, or material addition.

The process in machining such as abrading, cutting, drilling, forming, grinding, and shaping of a
piece of metal or other material performed by machine tools such as lathes, power saws, and
presses.

Abrading is the classification of processes that involve grinding and polishing of surfaces by the act
of removing integral portions of the material substrate. It can be termed as the wearing off of the
high levels of a material's surface by the use of friction. It is a process used for trueing and leveling
the substrate surface during the finishing process.

Different cutting tool materials used for cutting operations in practice are high carbon steel, high
speed steel, non -ferrous cast alloys, cemented carbides, ceramics and sintered oxides, diamond,
cubic boron nitride, UCON and sialon.

Drilling is a cutting process that uses a drill bit to cut a hole of circular cross-section in solid
materials. The drill bit is usually a rotary cutting tool, often multi-point. The bit is pressed against
the work-piece and rotated at rates from hundreds to thousands of revolutions per minute.

Forming, metal forming, is the metalworking process of fashioning metal parts and objects through
mechanical deformation; the workpiece is reshaped without adding or removing material, and its
mass remains unchanged.

Grinding is an abrasive machining process that uses a grinding wheel or grinder as the cutting tool.
Grinding is a subset of cutting, as grinding is a true metal-cutting process. Grinding is very common
in mineral processing plants and the cement industry
In the machining class, we were given task to build a product which is Heavy Duty Trolley,
throughout the semester. We had been through a lot of processes to finish the product, such as
bending, cutting, welding and turning.

So, we prepared the project final report is intended to concisely summarize the outcomes,
communicate information which has been compiled as a result and the works flow of this project.
METHODOLOGY :

In the process of completing the work from individual parts to joining the parts together, a few
methods are used, viz. turning, bending, drilling and filing.

1.1.0

Bending

Bending is a manufacturing process that produces a V-shape, U-shape, or channel shape along a
straight axis in ductile materials, most commonly sheet metal. Commonly used equipment
include box and pan brakes, brake presses, and other specialized machine presses. Typical
products that are made like this are boxes such as electrical enclosures and rectangular ductwork.
Press brake forming, a work piece is positioned over the die block and the die block presses the
sheet to form a shape. Usually bending has to overcome both tensile stresses and compressive
stresses. When bending is done, the residual stresses cause the material to spring back towards
its original position, so the sheet must be over-bent to achieve the proper bend angle. The amount
of spring back is dependent on the material, and the type of forming. When sheet metal is bent, it
stretches in length. The bend deduction is the amount the sheet metal will stretch when bent as
measured from the outside edges of the bend. The bend radius refers to the inside radius. The
formed bend radius is dependent upon the dies used, the material properties, and the material
thickness. The U-punch forms a U-shape with a single punch.

1.1.1

Turning

Turning is a machining process in which a cutting tool, typically a non-rotary tool bit, describes
a helix tool path by moving more or less linearly while the work piece rotates. The tool's axes of
movement may be literally a straight line, or they may be along some set of curves or angles, but
they are essentially linear (in the non mathematical sense). Usually the term "turning" is reserved
for the generation of external surfaces by this cutting action, whereas this same essential cutting
action when applied to internal surfaces (that is, holes, of one kind or another) is called "boring".
Thus the phrase "turning and boring" categorizes the larger family of (essentially similar) processes
known as lathing. The cutting of faces on the work piece (that is, surfaces perpendicular to its
rotating axis), whether with a turning or boring tool, is called "facing", and may be lumped into
either category as a subset.

1.1.2

Aligning

For most straight turning operations, firstly, we have aligned the compound rest at an angle
perpendicular, 90° to the cross slide, and then swung 30° to the right and clamped in position. The
tool post should be set on the left-hand side of the compound rest T-slot, with a minimum of tool
bit and tool holder overhang. When the compound rest and tool post are in these positions, the
danger of running the cutting tool into the chuck or damaging the cross slide are minimized.
Position the roughing tool bit about 5° above center height for the best cutting action. The finishing
tool bit should be positioned at center height since there is less torque during finishing.

1.2.1

Drilling

Drilling is a cutting process that uses a drill bit to cut a hole of circular cross-section in solid
materials. The drill bit is usually a rotary cutting tool, often multi-point. The bit is pressed against
the work-piece and rotated at rates from hundreds to thousands of revolutions per minute. This
forces the cutting edge against the work-piece, cutting off chips (swarf) from the hole as it is
drilled.In rock drilling, the hole is usually not made through a circular cutting motion, though the
bit is usually rotated. Instead, the hole is usually made by hammering a drill bit into the hole with
quickly repeated short movements. The hammering action can be performed from outside the
hole (top-hammer drill) or within the hole (down-the-hole drill, DTH). Drills used for horizontal
drilling are called drifter drills.In rare cases, specially-shaped bits are used to cut holes of non-
circular cross-section; a square cross-section is possible.

1.4.0

Draw filing

When the file is grasped by the ends and moved sidewise across the work, the action is known as
draw filing. This produces a smooth finish on narrow surfaces and edges and is used on turned
work to remove any tool marks. Draw filing is light filing - used to produce a smooth surface. A
second-cut or smooth file should be used; a single-cut file is better than a double cut file because
the single-cut is less likely to scratch the surface of the work. For most filing operations, begin with
a coarse file and continue using successively finer grades of file, finishing with a smooth or dead
smooth file, according to the degree of finish desired.

1.4.1

Filling

Filing is a material removal process in manufacturing. Similar, depending on use, to both sawing
and grinding in effect, it is functionally versatile, but used mostly for finishing operations, namely
in deburring operations. Filing operations can be used on a wide range of materials as a finishing
operation. Filing helps achieve workpiece function by removing some excess material and
deburring the surface. Sandpaper may be used as a filing tool for other materials, such as wood.

PROCESS PLAN :
PART 1
(FRAME LEFT)

Step No Description Process Remark

1 Prepare the blank for Shearing Use a metal which has a thickness of 3mm
the required dimension machine, (use the vernier calipers to measure it).After
Vernier
(750mm,70mm,3mm) calipers
that,shearing by follow the dimension state.
2 Mark the cutting area Scriber Mark it with length 750mm at the middle of
and the bending line the metal and mark 45-degree angle at the
end of 2 side edges and then mark a straight
line from the middle to the end of the
opposite 2 edges
3 Mark the drilling point Scriber Marking for 2 holes on one side of the metal
for the required with distance 150mm from the edge and
dimeter (ø6×2holes) 23mm from the bending line.
and (ø8×2holes)
Furthermore ,also mark of a hole on the
other side with distance 80mm and another
mark with distance 70mm from the first hole
and 17.5mm from the edge
4 Hacksaw and drill the Hacksaw, hacksawing the unneeded area part and
holes then do file Drill, File drilling at marked point then start filing the
edges of the metal
5 Bend parts at 90- Press Set up the machine then bend the metal on
degree angle Brake the bending line with 90-degree angle
machine

PART 2
(FRAME RIGHT)

Step Description Process Remark

No
1 Prepare the blank for Shearing Use a metal which has a thickness
the required machine, of 3mm (use the vernier calipers
dimension Vernier to measure it).After that,shearing
(750mm,70mm,3mm) calipers by follow the dimension state.
2 Mark the cutting area Scriber Mark it with length 750mm at the
and the bending line middle of the metal and mark 45-
degree angle at the end of 2 side
edges and then mark a straight
 line from the middle to the end of
the opposite 2 edges
3 Mark the drilling point Scriber Marking for 2 holes on one side
for the required of the metal with distance
dimeter (ø6×2holes) 150mm from the edge and 23mm
and (ø8×2holes) from the bending line.

Furthermore ,also mark of a hole

4 Hacksaw and drill the
holes then do file
5 Bend the metal
on the other side with distance
80mm and another mark with
distance 70mm from the first hole
and 17.5mm from the edge
Hacksaw, hacksawing the unneeded area
Drill, File part and drilling at marked point
then start filing the edges of the
metal
Bending Set up the machine then bend the
machine metal on the bending line with
90-degree angle

PART 3
(FRAME FRONT & REAR)
Step Description Process Remark
No
1 Prepare the blank for 1. Vernier calipers Get a metal that has a
the required dimension thickness of 3mm ( Mesure
(500mm,70mm,3mm) 2. Shearing machine with vernier calipers ), shear
the metal using the ( the
Shearing machine ) .

2 Mark the cutting area 1. Scriber Mark square dimension with

and the bending line (35mm) at the top of 2 metal
edges, mark 45 degrees at
the bottom of 2 metal edges

3 Cut off the square 1. Hacksaw Start hacksawing the

dimension with the unneeded area
hacksaw then cut 45- then start filing the edges of
degree edges of a the metal
metal
 4 Bend the metal 1.Bending machine bend the metal from the long
middle line with 90-degree
angle

PART 4
(REAR SHAFT HOLDER)

PART 5
(SLEEVE)

PART 6 & 7
(WHEEL SLEEVE)

PART 8
(STEEL SHAFT)

PART 9 & 10
(HANDLE & HANDLE BAR)

PART 13
(PLAYWOOD)
FABRICATION :

Grinding Machine

A grinding machine, often shortened to grinder, is any of various power tools or machine tools
used for grinding, which is a type of machining using an abrasive wheel as the cutting tool. Each
grain of abrasive on the wheel's surface cuts a small chip from the work piece via shear
deformation.

Step To Use ; -

1. W A R N I N G - If a grinding wheel is permitted to exceed the maximum safe speed, it may

disintegrate and cause injury to the operator and damage to the grinding machine!
2. Wear goggles for all grinding machine operations.
3. Check grinding wheels for cracks (Ring Test Figure 5-11) before mounting.
4. Never operate grinding wheels at speeds in excess of the recommended speed.
5. Never adjust the work piece or work mounting devices when the machine is operating.
6. Do not exceed recommended depth of cut for the grinding wheel or machine.
7. Remove work piece from grinding wheel before turning machine off.
8. Use proper wheel guards on all grinding machines.

9.On bench grinders, adjust tool rest 1/16 to 1/8 inch from the wheel.

PROCESS OF PROJECT

1) Cutting metal by use Shearing machine and waterjet cutting

machines are used to cut sheet materials or
remove materials from a surface by generating
a focused stream of fluid mixed with abrasive
particles

2) Bend metal by use bending maching Its purpose is to assemble a bend on a

workpiece. A bends is manufactured by using
a bending tool during a linear or rotating
move. The detailed classification can be done
with the help of the kinematics.

3) Drilling hole for screw A drilling machine, called a drill press, is used
to cut holes into or through metal, wood, or
other materials .Drilling machines use
a drilling tool that has cutting edges at its point
4) Welding process by use MIG welding
5) Turning process for wheel holder
6) Cutting metal by use headsaw
Gas metal arc welding (GMAW), sometimes
referred to by its subtypes metal inert gas
(MIG) welding or metal active gas
(MAG) welding, is a welding process in which
an electric arc forms between a consumable
wire electrode and the workpiece metal(s),
which heats the workpiece metal(s), causing
them to melt and join
Turning is a form of machining, a material
removalprocess, which is used to create
rotational parts by cutting away unwanted
material. The turning process requires
aturning machine or lathe, workpiece, fixture,
and cutting tool.
saw is a tool consisting of a tough blade, wire,
or chain with a hard toothed edge. It is used to
cut through material, very often wood though
sometimes metal or stone. The cut is made by

7) Filling for get smooth surface
8) Measured the diameter by use vernier
placing the toothed edge against the material
and moving it forcefully forth and less
forcefully back or continuously forward.
A file is a tool used to remove fine amounts of
material from a workpiece. It is common
in woodworking, metalworking, and other
similar trade and hobby tasks. Most are hand
tools, made of a case hardened steel bar of
rectangular, square, triangular, or round cross-
section, with one or more surfaces cut with
sharp, generally parallel teeth.
Vernier Calipers are precision instruments that
measure the distance between two opposite
sides of a circular or straight object. A typical
Vernier caliper is composed of two internal and
external jaws each, a depth measurement
prong, one locking screw, and imperial and
metric scales. The primary aim of a Vernier
caliper is to measure internal and outside
dimensions as well as the depth of an object.
RESULT :

Part 1 : Frame L , Frame R & Sleeve

Part Required Actual

Dimension Dimension
(mm) (mm)
1 750+0.1
2 750+0.1
3 500+0.1
5 35+0.1

Part 2: Shaft Holder

Part Required Actual

Dimension Dimension
(mm) (mm)
4 100+0.1
140+0.1
40+0.1
30+0.1
20+0.1
17.5+0.1

Part 3: Wheel Shaft, Steer Wheel Shaft & Steer Shaft

Part Required Actual
Dimension Dimension
(mm) (mm)
6 432+0.1
7 400+0.1
8 172+0.1

Part 9 and Part 10 : Handle Bar & Handle

Part Required Actual

Dimension Dimension
(mm) (mm)
9 550+0.1
10 214+0.1

Part 11 and Part 12 : Handle Frame & U-Plate

 Part Required Actual
Dimension Dimension
(mm) (mm)
11 210+0.1
12 30+0.1

Part 13: Plywood

Part Required Actual Dimension

Dimension (mm)
(mm)
13 750+0.1
515+0.1

Part 1 , Part 2 , Part 3 & Part 5 : Frame R , Frame L & Sleeve

Part 4 : Shaft Holder

Part 8, Part 9, Part 10 , Part 12 & Part 13 : Steer Shaft , Handle Bar , Handle , U-Plate &
Plywood

DISCUSSION :

From my discussion in this project , this trolley is a device which is important in order to
ease transportation and to decrease the load when we want to lift or transport heavy items from
one place to another. The process of development is initiated from designing the shape of the
trolley by considering the function as well. From this project too , we have learned how to used
the machine properly and the apply to our project processing .
 Firstly , We had to know the dimension of each part before to start the cutting process.
This also need to do some calculation for get the same as actual size to avoid error while do
another step later . Then we do process planning to get know clearly what to do for the next step
by step . After that , we start cutting the material by use machine and by use handsaw with follow
the dimension given . Next , after cutting we do the next process such as , binding ,welding , turning
and also drilling . Bending is a process by which metal can be deformed by plastically deforming
the material and changing its shape. The material is stressed beyond the yield strength but below
the ultimate tensile strength. The surface area of the material does not change much. Bending
usually refers to deformation about one axis. So that before bending we make sure the angle part
for been bending is correctly to avoid error while bending it by machine .

In adition , the process that involved is cutting, welding, and others need to do the testing
and evaluation process. The trolley will be test to see if it fulfills the requirement such as
ergonomic aspect, safety, strength and manoeuvrability. During the testing, if problem occur such
as malfunction or unstable platform, the trolley will step back to the previous process, where the
error is fixed. The trolley is expected to have an error that may cause the part to be re-designed
and re-fabricate again.

Lastly , the precision of length measurements may be increased by using a device that uses
a sliding vernier scale. Two such instruments that are based on a vernier scale which you will use
in the laboratory to measure lengths of objects are the vernier callipers and the micro meter screw
gauge. However , while used these two measurement instrument ,there are still some error can
happened because of our reading . As example while reading we not put eyes perpendicular to
the scale of the vernier caliper .So that , error will come in many ways , either in measurement or
depends on how we manage some instrument while doing the project . Member of group is
important to take responsible by helping each other while finishing the project together .
Teamwork and discipline is the key to successful in all work .

CONCLUSION AND RECOMMANDATION :

 In my conclusion ,project for machining 1 is really important to practice the knowledge and
skill of the student that have been gathered before in solving problem using academic research,
to born an engineer that have enough knowledge and skill. Beside, this project also important to
train and increase the student capability to get know, research, data gathering, analysis making
and then solve a problem by research or scientific research. Next ,the project also will educate the
student in communication like in a presentation and educate them to defend their research in the
presentation. Furthermore , the project also will generate students that have capability to make a
good research report in thesis form or technical writing. This project also can produce and train
student to capable of doing work with minimal supervisory and more independent in searching,
detailing and expanding the experiences and knowledge. Lastly , I think this project is really
reasonable to be continue for next student to help them more practical and used to do machine
at industries later .

REFERENCES :

1) https://en.wikipedia.org/wiki/Cutting_tool_(machining)

2)http://www.me.nchu.edu.tw/lab/CIM/www/courses/Manufacturing%20Processes/Ch22-
MachiningOps-Wiley.pdf

3) https://science.howstuffworks.com/welding3.htm