FACULTY OF MECHANICAL ENGINEERING,

UNIVERSITI TEKNOLOGI MARA (UiTM)

VIDEO DEMONSTRATION LABORATORY
REPORT

Program : Bachelor of Engineering (Hons) Mechanical (EM220)

Course : Engineering Workshop Practice
Course Code : MEM460
Lecturer/ Instructor Name : Dr Farrahshaida Binti Mohd Salleh
Group : EMD1M3A2
Title :
1. Muhamad Irfan Hafiz Bin Najeli (2020847394)
2. Halina Nadhirah Binti Khairol Anuar (2020847482)
Student’s Name & ID :
3. Affiq Qusyairi Bin Khairuddin (2020601918)
4. Muhammad Hail Irshad Bin Shariman (2020483056)

General Guidelines:

LEVEL Weak Marginal Satisfactory Good Excellent

Scale 1-2 3-4 5-6 7-8 9-10

Scale Marks
Criteria Weight
Achieved Obtained
Qualifying requirements:
Cover - Acceptable? * Yes / No
Introduction 0.5

Apparatus 0.5
CLO2
Experimental Procedure 1.0
Discussion and recommendation 1.5
Conclusion 0.5
CLO3 Safety rules 3
CLO4 Group management activities 2
References 0.5
CLO5
Report delivery 0.5
Total Marks (100%)

1
 LABORATORY REPORT ASSESSMENT FORM -VIDEO DEMONSTRATION

General Guidelines:
LEVEL Weak Marginal Satisfactory Good Excellent
Scale 1-2 3-4 5-6 7-8 9-10

CONTENTS OF THE LABORATORY REPORT & GRADING CRITERIA

Weightage Scale
Report Contents Content Description Score
(%) (1-10)
1.0 Title Refer to title of topic.
- - -

2.0 Objective(s) State the purpose that describes the

intention of the experiment, investigation
or accomplishment. - - -

3.0 Introduction Provide an understanding of the

(background & theory) experiment which includes necessary
diagrams, theory and equations. 0.5
[CLO2-PO10]

4.0 Apparatus List equipment, machine, accessories,

components, etc. May include a brief
description of the instrumentation / set-up 0.5
if necessary.
[CLO2-PO5]
5.0 Experimental • Describe standard operation procedures
Procedure or methods when using the
machine/equipment
1.0
• Equipment handling with picture or
diagram if necessary.
[CLO2-PO5]
6.0 Safety rules • Identify the safety precaution aspects
during handling the equipment in
workshop. (do and don’t during
experimental)
• 5S practice when performing
workshop.
• Safety regulation: List the standard
regulation related workshop topic (JIS;
3.0
OSHA; ASTM etc.)
• Any recommendation to improve the
workshop in term of societal, health,
safety, legal and cultural issues
• All the items above are supported with
relevant pictures, schematic diagrams
and sketches.
[CLO3-PO6]
 Weightage Scale
Report Contents Content Description Score
(%) (1-10)
• Discuss the findings; make
7.0 Discussion and comparisons with known information
recommendation if available.
• Support results with understanding of
theory. May also include alternative
methods, accuracy, sources of errors,
etc. 1.5
• Propose any possible improvements in
the project.
• Incorporate innovative ideas in the
experimental work or set-up.
[CLO2-PO5]
8.0 Conclusion Summarize the outcome of the experiment
based on the results and analysis. Relate
this to the objectives. 0.5
[CLO5 -PO10]

9.0 References List references to methods and related

studies in appropriate style. (at least 5)
0.5
[CLO5-PO10]

10.0 Report delivery • Report delivery, format and writing

skill
• The quality of English language in the
0.5
report
• Turnitin Report Form (below than 30%)
[CLO5-PO10]
11. Group
management activities • Task assigned for each member
• List out all the planning activities and
job delivery for report presentation
• Gantt chart (scheduled activities)
2.0
• Show the evidence of
discussion/meeting (google meet; ms
team)
[CL04-PO9]

Please note:
Compulsory to
include/attach this lab
report assessment TOTAL MARKS (100%)
form in your report
submission. NO
MARK be given if
failure to do so.
CONTENTS

1.0 TITLE………………………………………………………………………………….... 1

2.0 OBJECTIVES…………………………………………………………………………... 1

3.0 INTRODUCTION…………………………………………………………………… 1-2

4.0 APPARATUS…………………………………………………………………………… 3

5.0 EXPERIMENTAL PROCEDURES…………………………………………………... 4

6.0 SAFETY RULES……………………………………………………………………. 5-6

7.0 DISCUSSION AND RECOMMENDATIONS…………………………………..…… 7

8.0 CONCLUSION…………………………………………………………………………. 8

9.0 REFERENCES…………………………………………………………………………. 8

10.0 APPENDICES……………………………………………………………….…….. 9-10

TITLE: MILLING MACHINE PROCESS

1.0. OBJECTIVES:
- To apply practice workshop safety regulation during working in workshop.
- To describe the usage of conventional milling machine, various type of hand and
cutting tools used for measurement, marking and metal removed.
- To smoothing all surface of workpieces.

2.0. INTRODUCTION

In the field of machine tools application, the miller stands in a place opposite to the lathe
machine. These two machines representing the foremost versatile producers in their
respective domains. For instance, the lathe is employed for creating material cylindrical,
whereas the miller is for plane surfaces. Some millers claim that milling machines are
more versatile than a lathe. Milling machines are machine tools that want to produce one
or more machined surfaces accurately on a bit of fabric or a workpiece. This is often
done by one or more rotary milling cutters by having single or multiple cutting edges.

The workpiece is held securely on the worktable of the machine or during a device that
clamped to the table. Then, the workpiece is brought into contact with a revolving cutter.
Generally, the miller removes metal with a revolving cutter called a milling cutter. With
various attachments, milling machines are often used for boring, slotting, circular
milling dividing, and drilling. This machine also can be used for racks and gears, cutting
keyways, and for fluting taps and reamers. The milling process was understood by the
French clockmakers within the 18th century, particularly for cutting teeth geared wheels.
The commercially viable milling machines were first invented in 1820 and developed by
Whitney. The miller at that point was wont to mass-produce interchangeable musket
parts. Although crude, these machines assisted man in maintaining accuracy and
uniformity while duplicating parts that might not be manufactured with the use of a file.
Most of the milling machine are constructed of column and knee structure and they are
classified into two main types namely Horizontal Milling Machine and Vertical Milling
Machine. The name Horizontal or Vertical is given to the machine by virtue of its spindle
axis. Horizontal machines can be further classified into Plain Horizontal and Universal
Milling Machine. The main difference between the two is that the table of a Universal
Milling Machine can be set at an angle for helical milling while the table of a Plain
Horizontal Milling Machine is not.

The first milling cutters were handmade with a hammer and chisel, and it had been a
little quite rotary file. Present milling machines bear little resemblance to those early
machines. Their robustness, power, rate of metal removal, and accuracy of finish are far
better than the sooner models. Development and enhancements of the miller and
components continued, which resulted within the manufacturing of heavier arbores and
hot-work steel and carbide cutters. These components allowed the operator to get rid of
metal faster, and with more accuracy, than previous machines. Different sort of milling
machines was also developed to perform special milling operations. During this era,
computerized machines are developed to alleviate errors and supply better quality within
the finished product.
3.0. APPARATUS

1. Milling Machine

2. Hammer
-To knock the cube (work piece) slightly to ensure the tightness and
parallel positioning.

3. Spacer
-To support the cube (work piece) from the bottom so that it is at a
parallel and

tight position.

4. Wire Brush
-To clean away ashes, dust, chips or excess materials from the table.

5. Goggle
-To protect our eyes from ashes, dust or chips produced during the
process.

6. Bench Vise
As a clamp, this is bolted to hold the work piece during the milling
processes

7. Rough stock

8. Machine controller
4.0. PROCEDURE
• The speed of the machine was justified first weather it will be used in low or high
speed. (the spindle was switched on first and the speed was adjusted to the speed
that we want)
• The rotation of the spindle was justified either in clockwise or anti-clockwise.
• The workpiece material was measured and adjust it in a good condition before
starting the process.
• Make sure we know how to handle the machine that consists some axis. (the table
can move manually using the handles)
• The axis handles were manipulated to let the workpiece material at the surface
removed completely.
• Keep the part of the moving machine clear when the process happens.
• Switch off the machine when the milling process were done.
• The milling cutters was removed and safely stored them.
• Clean the working area after finished all the work.
5.0. SAFETY RULES

6.1. Safety precaution aspects during handling the equipment in the workshop.
(do and don’t during experimental)

• Always wear safety goggles, apron, and safety shoes before doing the milling process.

• Do not wear baggy clothes, rings, watches, or necktie. Tie back and confine long hair.
• Do not attempt to touch or move the work while the cutter is not completely stopped.
• Do not use excessively heavy work or cut as it can cause the cutter to break as to
cause flying pieces from the cutter could cause serious injuries.
• The student must be always precaution with the movement of the hand as to not be
near the cutter while the milling machine is still working.
• Do not lean on the machine when it is working.

• Do not use paper shims to check the distance from the cutter to the stock.
• Do not move the operating levers without knowing what they control and what action
is going to take place.
• Do not leave the milling machine unattended while it is running.
• Make sure the surrounding area of the milling machine is safe such as make the floor
is clean and dry to avoid slipping.

6.2 5S practice when performing workshops.

A system of management based on the principle that every member must be committed to
maintaining a high standard of work is called total quality management (TQM). Therefore,
the 5S rule is one of the best methods that can be used when performing workshop practice.
5S is a set of Japanese words. Each word starts with a sound of "sei” or “shi”.

• Seiri (Sort)
Any unnecessary item is to dispose of properly and other items to be sort.
Seiton (Set in Order)
Every item that has been used is to be sorted at its specific or designated storage so it can be
easy to find.
 • Seiso (Shine)
Item must be clean and inspect before storing to ensure the item is not left damage and to
make sure the working place is clean
• Seiketsu (Standardize)
demonstrate or instruct the people that will be using the lab to the rules and procedure when
in the lab to ensure standard behaviour among the people
• Shitsuke (Sustain)
Maintain one's workplace so that its productivity and comfortability does not change by
repeating Seiri-Seiton-Seiso.

6.3. Safety Regulation (OSHA and ASTM)

Managers should educate representatives within the secure implies of milling as follows:

- Make sure that the workpiece and cutter are mounted securely before taking a cut.

- Move the table as far as possible from the cutter while setting up work to avoid injuring
your hands.

- Report the defective equipment or any faulty to the supervisor quickly.

- Safety trip control. A safety trip control shall be provided in front and back of each mill. It
shall be accessible and shall operate readily on contact.

6.4. Recommendations - First aid

The milling area should always be equipped with a well-stocked first aid kit. One person
should be trained in first aid to treat the minor injuries that may occur. All injuries no matter
how minor they may seem can become more serious if not properly treated by trained
medical personnel.
6.0. DISCUSSION AND RECOMMENDATION

- Milling machine are machine tools wont to produce one or more machined surfaces
accurately on a bit of fabric, the work piece; this is often done by one or more rotary
milling cutters having single or multiple cutting edges. The work piece is held securely on
the worktable of the. it is then brought into contact with a revolving cutter.

-The miller may be a versatile machine which may handle a spread of operations
normally performed by other machine tools. it's used not just for the milling of flat and
irregular shaped surfaces but also for gear and thread cutting, drilling, boring, reaming,
and slotting operations. Its versatility makes it one among the foremost important
machine tools used in machine shop work.

-The milling process comes on the brink of turning extensive industrial since the
geometrical possibilities are enormous and therefore the removal rates are high. Its
performances depend upon the cutting speed, machining time and its length of cut.
Milling cutter resemble gears but with cutting teeth. it's made from high-carbon steels,
hot-work steel tungsten carbides, cerement and ceramics. The hot-work steel tungsten
carbide cutter, on the opposite hand, is employed for low quality requirements machining
process. it's a kind of sentimental material or special shaped cutters.

-Getting the appropriate feeds and speeds for the work piece material, tooling, and cutting
conditions is the most important first step. Consistent speeds and feeds will make a huge
difference on the surface finish. Getting the right speeds and feeds is just as important to
obtain a good surface finish.
7.0. CONCLUSION

To conclude, milling is a particularly important component in various industries including

the construction industry, automotive, aviation industry and the list goes on. There are
many types of milling and one of them is vertical milling machine or sometimes called
machining centers. This type of milling uses cutters and cut into the workpiece vertically
on a movable table. To summarize the procedure of vertical milling machine, this type of
milling begins with positioning the workpiece onto the movable table which can be
position precisely as there 3 axes that can move such as the table in the S, Y-axis while
the cutter is the Z-axis. First of all, we need to read the user manual of the vertical milling
process. Next, ensure we are wearing proper protective equipment that includes safety
goggles, safety jackets, and safety boots. After that, ensure that the milling equipment is
set up, position workpiece correctly onto the movable table which can move in Y and X-
axis according to the dimension that has been task with to make. Also, identify the tip
which uses clockwise rotation or anticlockwise rotation. Then start the milling process.
After finish, the milling process stops the milling machine before taking the workpiece.

8.0. REFERENCES

1) Kalpakjian, S., and R.S. Schmid, “Automation of Manufacturing Process”, Manufacturing

Engineering and Technology, 4th. Edition, Prentice Hall, 2000.

2) Youssefi, K, “Computer Numerical Control (CNC)”, Product Design and Manufacturing

Minicurriculum, 6 Oct. 2004.

3) Mikell P. Groover, Principles of Modern Manufacturing, 4th Edition, Wiley 2011.

4) via internet http://www.technologystudent.com/despro2/cncsys1.htm

 9.0. APPENDICES

Group management activities

Muhamad Irfan Hafiz Bin

Najeli (leader)
- Apparatus
-Discussion and recommendation

10.0.
Affiq
11.0.
Qusyairi Bin Halina Nadhirah Binti Muhammad Hail Irshad
12.0. Khairuddin Khairol Anuar Bin Shariman
- Procedures - Introduction - Safety Rules
a
- Group management activities - Conclusion

Gantt Chart

Act no. Task Period (days) Predecessors

1 Observation
2 Discussion and meeting
3 Research
4 Preliminary idea
5 Idea analysis
6 Refining
7 Decision making
8 Develop final report
1 -
1 Observation
4 Discussion and meeting
1 Research
3 Preliminary idea
4 Idea analysis
1 Refining
4 Decision making

Days
No Tasks
1 2 3 4 5 6 7 8 9 10
1 Observation
2 Discussion and meeting
3 Research
4 Preliminary idea
5 Idea analysis
6 Refining
7 Decision making
8 Develop final report
Discussion meeting