Lecture 7:

Machining
Process and
Machining Tools
Lecture by Dr Suryani Ahmad
Prepared by:
Assoc. Prof Dr Siti Akhtar Mahayuddin
Learning Outcome for this topic:
• Apply and develop skill and methods : machining process and
machining tools
• Apply knowledge and skills towards machining process and machining
tools
• Adapt with parties involved in machining process and machining tools

2
Contents:
1. Introduction and definition
2. Fundamentals of machining process
3. Methods of machining process such as offsite or onsite production, offsite
or onsite manufacturing and offsite or onsite fabrication
4. Manufacturing tools, machineries and plant
5. Advanced machining process and manufacturing tools
Contents:
1. Introduction and definition
2. Fundamentals of machining process
3. Methods of machining process such as offsite or onsite production, offsite
or onsite manufacturing and offsite or onsite fabrication
4. Manufacturing tools, machineries and plant
5. Advanced machining process and manufacturing tools
Machining process

A controlled process that takes raw

material & transforms it into a
desired final shape & size - Includes
material removal or addition.
 Methods of Machining Process

Offsite or Onsite Offsite or Onsite Offsite or Onsite

production manufacturing fabrication
Offsite Production/manufacturing/fabrication is:

A process that includes the manufacture and assembly of parts or

systems at a location away from the project.

Offsite fabrication often provides a cost benefit, allowing the assembly

of units that would otherwise not be able to be completed on-site due
to cost, tooling or space restrictions.

Example: many decorative and finish pieces that appear in a building

have been produced through offsite fabrication and then installed in
the final stages of construction.
Advantages of offsite production/manufacturing/fabrication
Quality – Higher-quality finishes
with defects eliminated prior to
completion.
Waste – Reduced off-cuts from
formwork and the introduction of
prefabricated reinforcement bars.
Accuracy – Increased accuracy
with templates produced using
Computer Aided Design (CAD)
systems.
Cost – Repeated use of moulds
Safety – Safer working
through standardisation reduces
environment under factory
formwork materials, preliminaries
conditions.
, site storage and on-site facilities.
Programme – Increased Local disruption – Less
predictability due to reduced environmental impacts such as
external factors such as weather. dust and noise pollution.
Timescale – Components built off-
site leading to reduced on-site
construction time.
Disadvantages of production/manufacturing/fabrication

Requires careful supervision
and more skilled workers
for producing the IBS
components
Uniform spacing between Some members are broken
beams are required in the up and wasted during the
structure, which can time of transportation from
become difficult during the factory to the
production process construction site
Example of
offsite plant
layout
Steel Fabrication

Example:
Structural Steel Fabrication https://www.seb.net.my/facilities/
Basic stages of manufacturing process of
precast concrete in an offsite production.
2. 3. 4.
1. Reinforcement
Mould Pour concrete Compacting

5. 6. 7. 8.
Curing & Transfer Storage Transport to site Erection/installation

9.
Finished Building
1. Production of reinforced cages
and main connections:

The precast factory often has

specialist workshops for the
manufacture and maintenance of
moulds, and to produce jig-built
reinforcing cages and connections.
2. Assembly of moulds:

The reinforced cage is positioned in the partly

assembled mould, then the remaining mould
section is completed.
3. Mix being poured:

• Carefully specified concrete is

placed into the mould.
• Many precast works now employ
computer controlled batching
plants.
4. Compaction of concrete
using poker vibrator:

To ensure that optimum density is

obtained and that specified
strengths are achieved, concrete is
placed and compacted using high-
frequency external vibrators or
pokers.
5. Precast concrete being
moved to the storage
area:

• Once an appropriate strength has

been reached, the precast units
are moved to the storage area.
Units are usually handled within
hours of casting as part of the
rapid production cycle.
• The product exhibits a high
degree of dimensional accuracy
and quality of finish. Economies
of production are achieved
through the repetitive and
automated process.
6. Storage of high-quality
units in works area:

• The finished precast components

are stacked on clean battens or
plastic pads positioned to suit the
design of the component.
• Care is taken to keep the stacks
vertical and to ensure that
battens are placed directly above
one another within the stack.
7. Transport to site:
The components are delivered to site in a pre-
determined sequence to ensure that hardened
concrete are ready for instant erection
8. Erection at site:
• The components are erected
straight from the lorry.
• This leads to faster erection
times with reduced on-site
activity.
• installation of precast elements
includes hydraulic and
mechanic cranes
9. Finished Building

Source: https://www.buildingsolutions.com/projects/precast-accelerates-hotel-project-and-wins-construction-excellence-award
Pre-casting machineries for manufacturing of precast concrete
elements.
Tilting table Long-line Vertical battery formwork