Department of Engineering | COE | MEFD211 | Special Semester 19/20

GROUP PROJECT
MEFD211 MANUFACTURING PROCESSES DATE OF ACTIVITY:
LAB
SPECIAL SEMESTER 2019/2020
Marks
SECTION: GROUP: 1 Objectives 5
Name ID .
2 Equipment and tools 10
.
3 Safety precaution 10
.
4 Manufacturing process 25
.
5 Drawing 25
.
6 Discussion 15
1 Objectives
List down the objectives of this group project

1. To theoretically design and manufacture a product using the drilling machine, lathe
machine and milling machine.
2. To successfully apply the knowledge gained form the previous labs in the group project.
3. To show our understanding in the manufacturing process.
4. To learn how to delegate tasks among teammates to achieve a product.

2 List and sketch of equipment and tools

List down all the equipment and tools used in this group project. Sketch the main equipment/tool and label the
important parts. You may attach additional paper if the space here in not sufficient.

Vernier Callipers Height Gauge

Centre Punch Radius Gauge

Any plagiarism will be heavily penalized.

 Department of Engineering | COE | MEFD211 | Special Semester 19/20

Hammer Spanner File

Double Ended Hardened
Steel Scriber

Lubricant Oil Hacksaw

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 Department of Engineering | COE | MEFD211 | Special Semester 19/20

Drilling Machine

Grinding Machine

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 Department of Engineering | COE | MEFD211 | Special Semester 19/20

Any plagiarism will be heavily penalized.

 Department of Engineering | COE | MEFD211 | Special Semester 19/20

3 Safety Precautions:
List and explain the safety precautions related to this group project

Safety attire must be worn before entering the lab such as goggles, safety boots and apron.

For Lathe:

1. Make sure entanglement hazards are removed.

2. Keep the floor free from obstruction.
3. Make sure the lathe machine has a start/stop button within easy reach of the operator.
4. Make sure the lathe machine has emergency stop button.
5. Centre the drill work deeply enough to provide support for piece while it is turning.
6. Adjust tool rest so that they are slightly above the centre of the work.
7. Stop lathe machine before taking measurements of any kind.
8. Keep working surface clean of scarps, tool and materials.
9. Keep floor around lathe machine clean and free oil and grease.

For Drilling:

1. The drilling machine must be tightened to avoid it from moving during the drilling process
which can injury.
2. Coolant is added during drilling process so that the drilling machine does not overheat, and
the drill bit does not break.
3. The drill bit is lifted when coolant is being added.
4. Can’t bring any food or beverages entering the lab.
5. Don’t play with friend when doing work.
6. Gloves must be worn when during cleaning process.

For milling:

1. Make sure the coolant is flowing properly and not disrupting the process.
2. Do not make any contact with the machine when it is running.

Any plagiarism will be heavily penalized.

 Department of Engineering | COE | MEFD211 | Special Semester 19/20

3 Manufacturing process:
Explain, as detail as possible, the procedures or steps taken, from start until the end of the group project. You may
attach additional paper if the space here in not sufficient.

The manufacturing process starts with the team picking a suitable material. The group decided to
make the tissue roller out of aluminium as it is cost effective and easily obtainable.

The manufacturing process starts with a solid block of aluminium where we will use it as the base of
the tissue roller.

We will be milling the solid block of aluminium.

3.1 Milling Process

1) Measure the work piece (block) using a Vernier calipers and record it dimensions, making
sure we have a work piece with excess material than our final dimensions.
2) Place the workpiece in the vice. Make sure work piece is secure and unable to move.
3) Set the cutter to 0 in relation to the workpiece.
4) Turn on the coolant and make sure the work piece is lubricated.
5) Using a torn piece of paper, place it on the work piece and then manually adjust the height
of the table until the cutter head touches the paper.
6) Set the current set up to 0.
7) Remove the paper and move the work piece away from the cutter blade horizontally and
turn on the machine.
8) Spin the handle to move the workpiece along the cutting blade twice to achieve an equal
and smooth surface (zeroing).
9) Assuming we have an excess of 0.5 on all sides of the workpiece, the height of the table is
adjusted by 0.02mm intervalley after every cut until we have removed the excess 0.5mm
material form the work piece
10) Zeroing is repeated every time when starting on a new side. (Repeat step 8)
11) Step 9 is repeated to remove the excess material from the workpiece.
12) After we have finished milling the work piece, the machine is turned off and the workpiece is
removed from the vice and the edges are filed using a file.

13) The workspace and the machine are cleaned removing the excess metal shavings and wiping
of the excess coolant.

After we have obtained the above dimensions from the block of solid aluminium, we proceed to
drilling where we will drill the necessary holes into our base and as well as our 2 brackets.

3.2 Drilling Process

1. The height and length of the base and the brackets are measured using the vernier callipers.

2. Based on the measured dimension, several measurements were calculated and marked
using the height gauge (Refer to drawings).

Any plagiarism will be heavily penalized.

 Department of Engineering | COE | MEFD211 | Special Semester 19/20

3. The four points is marked on the base by using a centre punch and hammer.

4. For the brackets, the three points are marked on surfaces by using centre punch and
hammer.

5. The edge with radius 5mm is marked on the 2 brackets using the radius gauge and double
ended hardened steel engineer scriber.

6. A spanner is used to tight the workpiecees to the holder so that is does not move during the
drilling process.

7. We used two sizes of drill bit to make the holes on the workpieces we marked which are
5mm and 6mm drill bits.

8. Coolant is poured frequently to the drilling area so that the drill bit does not overheat and
prevent the metal chip from flying out during the drilling process.

9. The drilling machine is used to drill the place we marked by the center punch.

10. The grinding machine is used to grind the edges of the 2 brackets where w marked the spots
with radius 5mm.

11. The machines are turned off when the work is finished.

12. Fine amount of material was removed from the edges and drilled holes part of the
workpieces using file(tools).

13. The area around the machine was cleaned once the machines were turned off completely

Now we have our base and the brackets done, we shall proceed to making the roller. A solid
cylindrical piece of aluminium with excess material from the dimensions required is selected. We
proceed to the Lathe machine where we will make our roller.

4.3 Lathe Process

1. The cylindrical workpiece is measured by using a Vernier caliper to obtain its dimensions.
2. fter obtaining dimensions, the material is placed in the chunk and the tool holder is adjusted
until the point of the facing tool is near to the work piece and there is space left along the
side.
3. A trial cut is performed to smooth the diameter of the workpiece so that it is even. The cross
feed graduated collar is set to 0.
4. The workpiece is removed from the chunk.
5. With the final goal, we used the height gauge to mark the workpiece at a height of 2.7mm
from both ends.
6. After doing so, the workpiece is placed in the chunk and step 2 is repeated.
7. In order to obtain the desired diameters at both ends, cuts were performed internally
starting from 0.5mm for about 40 times to the not exceeding the length of 2.7mm.
8. Then, we adjust the cross feed graduated collar to 0.1mm and perform the final cut where it
will give the surface a smooth finish as well as give us the dimensions we want.
9. Steps 6, 7 and 8 are repeated for the other end of the workpiece.
10. After completing the cuts on the workpiece, the workpiece is measured using the Vernier
calliper.
11. Thus, our workpiece has been cut, the work area around the lathe machine is cleaned.

Any plagiarism will be heavily penalized.

 Department of Engineering | COE | MEFD211 | Special Semester 19/20

12. Rubbish iron are swept, and the coolant is wiped dry off and lastly the floor is mopped.

After completing the manufacturing process for the parts of tissue roller, we move to the assembly
part where the brackets are fastened onto the base with nuts and bolts while the roller sits in
between the brackets as shown in the Assembly Drawing.

4 Drawing
Refer to template below

5 Discussions
Please discuss issues and shortcomings that you have learnt in this group project. Include suggestions as well.

This project is based on theory and experience gained from the prevision sessions before the
MCO. Hence, everything discussed is based on said experiences and the internet.

As with all industrial machines, safety should be taken seriously as these machines can

cause serious injuries. There are many precautions that need to be taken during the

operation of these machines.

Sometimes the cuts may not be precise. This maybe caused by a human error in measuring
or even a machine error such as the backlash error on the lathe machine.

Cleanliness was important after each session was done, this so the next operator does not

have to operate with a machine that has metal bits lying everywhere on it. It is important

to remove all the metal chips that are lying around on the machine or close by it. These

chips are not to be handled by hand as they are very sharp.

6 Conclusions

All the objectives that our group sought out were achieved through this report. By recalling and
referring to prevision lab sessions and reports, we were able to recall and together with the internet

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 Department of Engineering | COE | MEFD211 | Special Semester 19/20

better our knowledge in the manufacturing process. Going through previous reports, we were able
to recall the various operations that these machines are able to carry out. Everything was done
through a group chat on WhatsApp. With this report we were able to have a glimpse of how the
manufacturing process is.

Reference List:
List down all the references that you use.

1. https://en.wikipedia.org/wiki/Manufacturing
2. https://en.wikipedia.org/wiki/Milling_(machining)
3. https://en.wikipedia.org/wiki/Lathe
4. https://en.wikipedia.org/wiki/Drill

Any plagiarism will be heavily penalized.

 Projection Date Drawn: 15/5/20202
UNLESS STATED Drawn By: Kamal UNIVERSITI TENAGA NASIONAL
OTHERWISE Dwg No. 1 TITLE
ALL DIMENSION Sheet …1… of …5…. Sheets ROLLER PART
IN mm Scale Material: Aluminium

Any plagiarism will be heavily penalized.

 Projection Date Drawn: 15/5/20202
UNLESS STATED Drawn By: Kamal UNIVERSITI TENAGA NASIONAL
OTHERWISE Dwg No. 2 TITLE
ALL DIMENSION Sheet …2… of …5…. Sheets BRACKET PART
IN mm Scale Material: Aluminium

Any plagiarism will be heavily penalized.

 Projection Date Drawn: 15/5/20202
UNLESS STATED Drawn By: Kamal UNIVERSITI TENAGA NASIONAL
OTHERWISE Dwg No. 3 TITLE
ALL DIMENSION Sheet …3… of …5…. Sheets BASE PART
IN mm Scale Material: Aluminium

Any plagiarism will be heavily penalized.

 Projection Date Drawn: 15/5/20202
UNLESS STATED Drawn By: Kamal UNIVERSITI TENAGA NASIONAL
OTHERWISE Dwg No. 4 TITLE
ALL DIMENSION Sheet …4… of …5…. Sheets ASSEMBLY OF TISSUE ROLLER
IN mm Scale Material: Aluminium

Any plagiarism will be heavily penalized.

 Projection Date Drawn: 15/5/20202 1 BASE PART
UNLESS STATED Drawn By: Kamal 2
UNIVERSITI TENAGA ROLLER PART
NASIONAL
OTHERWISE Dwg No. 5 TITLE 3 BRACKET PART
ALL DIMENSION Sheet …5… of …5…. Sheets 4 VIEW OF TISSUENUTS
EXPLODED ROLLER
IN mm Scale Material: Aluminium 5 BOLTS

Any plagiarism will be heavily penalized.