3.

0 PREPARATIONS

3.1 RAW MATERIAL

TEFLON

PTFE based formulas is teflon by chemours. PTFE is polymerized from the chemical
compound tetrafluoroethylene or TFE.

The main raw materials PTFE are Chloroform, Fluorspar, and hydrochloric acid.

TFE is synthesized from fluorspar, hydrofluoric acid, and chloroform. These

ingredients are combined under high heat, an action known as pyrolosis. TFE is a colorless,
odorless, nontoxic gas which is, however, extremely flammable. It is stored as a liquid, at low
temperature and pressure. Because of the difficulty of transporting the flammable TFE, PTFE
manufacturers also manufacture their own TFE on site. The polymerization process uses a
very small amount of other chemicals as initiators. Various initiators can be used, including
ammonium persulfate or disuccinic acid peroxide. The other essential ingredient of the
polymerization process is water.

Figure: The Workpiece of PTFE

Aluminium 6063

Figure : Aluminium 6063 that has been used in or work

Aluminum compounds occur in all types of clay, but the ore that is most useful for
producing pure aluminum is bauxite. Bauxite consists of 45-60% aluminum oxide, along with
various impurities such as sand, iron, and other metals. Although some bauxite deposits are
hard rock, most consist of relatively soft dirt that is easily dug from open-pit mines. Australia
produces more than one-third of the world's supply of bauxite. It takes about 4 lb (2 kg) of
bauxite to produce 1 lb (0.5 kg) of aluminum metal.

Caustic soda (sodium hydroxide) is used to dissolve the aluminum compounds found
in the bauxite, separating them from the impurities. Depending on the composition of the
bauxite ore, relatively small amounts of other chemicals may be used in the extractionof
aluminum. Starch, lime, and sodium sulphide are some examples.

Cryolite, a chemical compound composed of sodium, aluminum, and fluorine, is used as the
electrolyte (current-conducting medium) in the smelting operation. Naturally occurring
cryolite was once mined in Greenland, but the compound is now produced synthetically for
use in the production of aluminum. Aluminum fluoride is added to lower the melting point of
the electrolyte solution.
3.2 EQUIPMENT
Table: List of equipment use during operating the machine
FIGURE USES
Brush

To clean the workplace

after complete the task

Cutting Tool

To remove material by
their movement within the
machine or directly from
the cutter's shape.

Vernier Caliper
A precision instrument that
measures internal
dimensions, outside
dimensions, and depth. It
can measure to an accuracy
of one thousandth of an
inch and one hundredth of
a millimeter.
Chuck Opener

To tighten the chuck or clamp

File Tool

Used to remove fine amounts of

material from a workpiece.
3.3 SAFETY
3.3.1 MEANING OF SAFETY

A safe work environment is a productive one. No matter the size or type of the
business, procedures for safety in the workplace are a necessity for all staff. Safety measures
protect employees as well as equipment and business property. Avoiding or minimizing
injuries and damage to equipment and facilities will result in fewer expenses and more profit
for a business.

Safety is the state of being "safe" (from French sauf), the condition of being protected
from harm or other non-desirable outcomes. Safety can also refer to the control of recognized
hazards in order to achieve an acceptable level of risk.

There are two slightly different meanings of safety. For example, home safety may
indicate a building's ability to protect against external harm events (such as weather, home
invasion, etc.), or may indicate that its internal installations (such as appliances, stairs, etc.) are
safe (not dangerous or harmful) for its inhabitants.

3.3.2 SAFETY IN WORKSHOP

Identifying workplace safety hazards and issues is the first step in protecting
employees. Common work safety concerns can include ergonomics, presence of hazardous
chemicals, mechanical problems, noise pollution, restricted visibility, dangers of falling and
weather-related hazards. Issues with non-ergonomic equipment may cause human health
problems, including sore backs and carpal tunnel syndrome. Chemicals can explode, causing
burns, or pose the danger of poisoning.

Milling machines can be dangerous if not used properly. Make sure to understand
instructions and are properly trained before operating a milling machine. There are some safe
work principle to follow when using a milling machine .

Principles:

1. Make sure all machines have a start/stop button within easy reach of the operator.
2. Make sure that all machines have an emergency stop button (e-stop).
3. Make sure that the work piece and cutter are mounted securely before taking a cut.
4. Check that work is mounted squarely.
 5. Mount work in a vise that is bolted or held magnetically to the table. Use proper hand
tools to make adjustments. Refer to Hand Tools for more information.
6. Hold milling cutters with a cloth to avoid being cut when handling them.
7. Move table as far as possible from cutter while setting up work to avoid injuring your
hands.
8. Mill the largest surface first.
9. Keep hands, brushes and rags away from the revolving milling cutter.
10. Use a vacuum, brush or rake to remove cuttings only after the cutters have stopped
moving.
11. Change cutting compounds periodically.
12. Keep cutters sharpened correctly and in good condition.
13. Keep working surface clear of scraps, tools and materials.
14. Remove cutting tools from spindle when cleaning the machine.
15. Keep floor around the milling machine free of oil and grease.
16. Use lifting equipment when appropriate to move heavy work to or from milling
machines. Refer to Materials Handling for more information.
17. Make sure the power is off before changing cutters.
18. Always stay at the machine when it is in operation.

3.3.3 ATTIRE WHEN IN WORKSHOP

 Table: List equipment of attire based on figure above.

NO EQUIPMENTS

1 Wear Comfortable Pants

2 Protect Your Eyes Wear Safety Goggle

3 Wear Hearing Protection

4 Protection For The Feet By Wearing Safety Boots

5 Wear The Correct Work Clothing Or Wear Safety Jacket In Workshop

6 Do Not Wear Any Cap