FACULTY OF MANUFACTURING ENGINEERING

UNIVERSITI MALAYSIA PAHANG

26600 PEKAN
PAHANG

REPORT ON THE FABRICATION OF THE MINI PRECISION VISE

BFF1811 MACHINING 2

Nurul Syima Jafri (FA11057), Siti Aisyah Saahri (FB11021), Nur Najwafatima Yusaini
(FA11059), Nur Anis Arina binti Mokhzan (FA120031)

1.0 INTRODUCTION
In this project we need to produce a Mini Precision Vise using some suitable process.
For this project, we mainly use two processes which are milling process and grinding process.
For that, there are two main machines that we used. There are milling machine and grinding
machine.
A milling machine is a machine tool used to machine solid materials. Milling
machines are often classed in two basic forms, horizontal and vertical, which refer to the
orientation of the main spindle. Both types range in size from small, bench-mounted devices
to room-sized machines. Unlike a drill press, this holds the work piece stationary while
cutting as the drill moves axially to penetrate the material, milling machines also move the
work piece radially against the rotating milling cutter that cuts on its sides as well as its tip.
Work piece and cutter movement are precisely controlled to less than 0.001 in (0.025 mm),
usually by means of precision ground slides and lead screws or analogous technology.
Milling machines may be manually operated, mechanically automated, or digitally automated
via computer numerical control. Milling machines can perform a vast number of operations,
from simple (e.g., slot and keyway cutting, planning, drilling) to complex (e.g., contouring,
die sinking). Cutting fluid is often pumped to the cutting site to cool and lubricate the cut and
to wash away the resulting chips.
Then, a grinding machine often shortened to grinder, is a machine tool 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. Grinding is used to finish work pieces that must show high surface quality (e.g.,
low surface roughness) and high accuracy of shape and dimension. As the accuracy in
dimensions in grinding is on the order of 0.000025 mm, in most applications it tends to be a
finishing operation and removes comparatively little metal, about 0.25 to 0.50 mm depth.
However, there are some roughing applications in which grinding removes high volumes of
metal quite rapidly. Thus, grinding is a diverse field.
The grinding machine consists of a power-driven grinding wheel spinning at the
required speed (which is determined by the wheels diameter and manufacturers rating,
usually by a formula) and a bed with a fixture to guide and hold the work-piece. The grinding
head can be controlled to travel across a fixed work piece or the work piece can be moved
while the grind head stays in a fixed position. Very fine control of the grinding head or

tables position is possible using a vernier calibrated hand wheel, or using the features of
numerical controls.
Grinding machines remove material from the work piece by abrasion, which can
generate substantial amounts of heat; they therefore incorporate a coolant to cool the work
piece so that it does not overheat and go outside its tolerance. The coolant also benefits the
machinist as the heat generated may cause burns in some cases. In very high-precision
grinding machines (most cylindrical and surface grinders) the final grinding stages are
usually set up so that they remove about 200 nm (less than 1/100000 in) per pass - this
generates so little heat that even with no coolant, the temperature rise is negligible.

2.0 METHODOLOGY

PROCESS PERFORM BY MILLING MACHINE ON OUR PRODUCT

Up Milling:
Also known as conventional milling, the cutter rotation's direction is opposite to that of
the feed motion. For example, if the cutter rotates clockwise, in up milling, the
workpiece is fed to the right.

Down Milling:
This is also known as climb milling. Here, the cutter's direction is same as the feed
motion. For example, if the cutter rotates counter clockwise, in down milling, the
workpiece is fed to the right.

MACHINE USEED
Computer Numerical Control (CNC) Milling Machines: Makino KE55

- Various milling machine components are being replaced rapidly with computer
numerical control (CNC) machines. These machine tools are versatile and are capable of
milling, drilling, boring and tapping with repetitive accuracy.

CUTTING FLUID: COOLANT

The cutting fluid used is a type of coolant designed specifically for metalworking and
machining processes. Metal cutting operations generate heat due to tool friction and
energy lost deforming the material. The surrounding air is a poor coolant for the cutting
tool because it conducts heat poorly and has low thermal conductivity. Ambient-air
cooling is adequate for light cuts and low duty cycles typical of maintenance, repair and
operations (MRO) or hobbyist work. However, production work requires heavy cutting
over long time periods and typically produces more heat than air cooling can remove.
Rather than pausing production while the tool cools, using liquid coolant removes
significantly more heat more rapidly, and can also speed cutting and reduce friction and
tool wear.

CLAMPING TECHNIQUES
Direct Mounting

The taper of cutting tool fitted directly into the taper of the work spindle. It may have
morse taper or steep shape.

Indirect Mounting

Cutter not inserted directly into the taper of the work spindle

Mounted to the correct attachment

Shell end arbor

Mainly use to mount shell end mill and cutter head.

Adapter self locking chuck

Use to reduce the internal taper in the work spindle so that its fits on the required
arbor or cutter.

Collet chuck

Design to take small cylindrical cutter to various cutter. Widely use at industries'
ER40,ER32,ER16 used with BT40 and R8 arbor

MILLING MACHINE TOOL AND ITS PARAMETER

In milling, the speed and motion of the cutting tool is specified through several
parameters. These parameters are selected for each operation based upon the workpiece
material, tool material, tool size, and more.

Cutting feed
- The distance that the cutting tool or workpiece advances during one revolution of the
spindle and tool, measured in inches per revolution (IPR). In some operations the tool
feeds into the workpiece and in others the workpiece feeds into the tool. For a multipoint tool, the cutting feed is also equal to the feed per tooth, measured in inches per
tooth (IPT), and multiplied by the number of teeth on the cutting tool.
- The speed of the workpiece surface relative to the edge of the cutting tool during a cut,
measured in surface feet per minute (SFM).

Spindle speed
- The rotational speed of the spindle and tool in revolutions per minute (RPM). The
spindle speed is equal to the cutting speed divided by the circumference of the tool.

Feed rate
- The speed of the cutting tool's movement relative to the workpiece as the tool makes a
cut. The feed rate is measured in inches per minute (IPM) and is the product of the
cutting feed (IPR) and the spindle speed (RPM).

Axial depth of cut

- The depth of the tool along its axis in the workpiece as it makes a cut. A large axial
depth of cut will require a low feed rate, or else it will result in a high load on the tool
and reduce the tool life. Therefore, a feature is typically machined in several passes as
the tool moves to the specified axial depth of cut for each pass.

3.0 PROCESS PLAN

Base
Num.

Process

Tool

1.

Marking, cutting Measuring ruler

Machine

Week

Vertical band saw

machine
2.

Face milling

Vernier calipers, Face mill

Milling machine

6&7

3.

Hole drilling

Drill (5, 4)

Milling machine

4.

Slotting

End mill (8)

Milling machine

5.

Hole drilling &

Drill (8)

Malling machine

milling

End mill (8, 16)

6.

Squaring

End mill (16)

Milling machine

7.

Tapping

Tap (M5), tap wrench

16

8.

Grinding

Grinding machine

16

Movable Jaw
Num.

Process

Tool

1,

Marking, cutting Measuring

Machine

Week

Vertical band saw

Ruler

machine

2.

Face milling

Vernier calipers, Face mill

Milling machine

10

3.

Hole drilling

Drill (2,5)

Milling machine

11

4.

Slotting

End mill (12)

Milling machine

12

5.

V-Slotting

End mill (12), Angle vise

Milling machine

13

Milling machine

14

(45)
6.

Chamfering

End mill (12), Angle vise

(45)

7.

Hole Drilling

Drill (8), Angle vise (45)

Milling machine

14

8.

Borring

Borr (14), Angle vise (45)

Milling machine

14

9.

End milling

End Mill (8),

Milling

15

Angle vise (45)

machine

10.

Grinding

Grinding machine

16

4.0 RESULT & DISCUSSION

Please refer to appendix for the precision vise manual sheet.

5.0 FABRICATION
Milling Process
1)

Prepare 2 blocks of raw material workpiece (43x35x100) mm and (24x35x30) mm

actual size.

2)

Cut the raw material by using horizontal bend saw.

3)

Remove the burr from the workpiece by filling process using file.

4)

Run, set up and warming up the milling machine.

5)

After set up the origin, face milling was used to square the raw material.

6)

The raw material is clamped with a cylinder rod and parallel bar to get square surface.

7)

Make sure the spindle is feed by using Allen Key.

8)

Operate the machine manually with spindle speed of 639 rpm

9)

Use a piece of paper to determine the origin of Z-direction.

10)

As soon as the spindle touch the paper,the origin was set in Z-direction.

11)

Take a depth of 0.5 mm on the surface of raw material

12)

Repeat the same process of 11 to second surface to get the square

13)

Engineering square was used to ensuret the surface is flatted.

14)

Use the third surface and cut 0.5 mm on the surface step by the step using the same
speed of spindle until the actual size is achieve.

15)

Tolerance of 0.01mm was taken into account during this cutting process.

16)

Repeat the process for other side of the metal workpiece to get (35x45x100) mm
for the big workpiece and (24x35x30) for small workpiece.

17)

The raw material was the filled after cutting to remove the burr.

18)

Two flat metal workpiece with different sizes was produced.

Drilling process
1)

Find axis-x and y by edge-finder

2)

Clamping edge-finder at head machine to identify x=0 and y=0 of the product
(identify x=y=0 by push button POST RESET at the operator panel)

3)

Use center-drill to find axis z by pushing button POST RESET, and z0 at the operator
panel

4)

Use Center drill to drill a few piece of product where at the drill spot to reduce the
impact when drilling.

5)

Change chuck to drill chuck, select the suitable bit, clamp the drill chuck properly into
chuck holder by pressing TOOL UNCLAMPED button

6)

Turn the cross travel hand wheel x,y and z where the drill spot need to be taken.

7)

Press CYCLE START button;

(makes sure wares safety goggles to avoid chips fly into eyes)

8)

Handling by normal method;

9)

Slowly raise the table by controlling the hand wheel of z axis and drill (make sure the
table are raised and lowered drilling to reduce the impact of drilling so that drill bit is
not cracked or broke.

10)

Handling by automatic method;

11)

Push PATTERN MODE button at the operator panel

12)

Push PREV. button twice until the screen had highlighted the words x-y axis
manual and auto. Drill.

13)

Push NEXT button, then, push PATTERN MODE again

14)

Insert wanted depth to be drill. Press INPUT. (make sure the inserted depth wont
make drill the product through the parallel bar)

15)

Insert pev. Distance +_0.5000, finally, turn cross travel auto z to ve (upwards)

16)

Push CYCLE START button. (make sure the spindle speed is suitable)

17)

Let the machine continue drilling until its stopped after finished.

Grinding process
1)

Replace the wheel on the bench grinder with a diamond wheel.

2)

Start the bench grinder. Most bench grinders run at only one speed. But it can change
the speed, use the lowest setting possible.

3)

Hold the end mill in the horizontal position and locate the spot flat. Push the end mill
against the moving diamond wheel, applying moderate pressure to start the flat. This
will leave a scuff so it can see if the spot is where would like it to be. Hold the end
mill tightly but do not cut on the very sharp flutes.

4)

Continuously push the end mill up against the moving wheel a few seconds at a time
in the same location until a flat is ground into the shank of the end mill. If it hold in
one spot too long, the end mill will be too hot to hold. After 30 seconds between
grinding cycles, the air will dissipate the heat enough to hold the end mill.

5)

Place the end mill in a precision vice underneath a parallel bar or precision block so
that 40% of the diameter of the end mill is above the vice jaws.

6)

Place the vice on the grinding table of a manual grinder. Place one side of the vice
against a flat surface and engage the magnet to hold the vice in place.

7)

Start the machine and bring the grinding wheel down to just touch the surface of the
highest point on the end mill. Crank the wheel quickly back and forth while slowly
lowering the wheel in .001" increments.

8)

Lower the diamond grinding wheel until the flat is of the desired depth while moving
the table back and forth on the X axis, left to right. Use gloves to remove the end mill
as it will be hot then run it underwater or drop in a plastic container filled with water.

6.0 CONCLUSION & RECOMMENDATION

As a conclusion, during the process of fabrication of the mini precision vise we have
gained a lot of knowledge in machining processes and also able to experienced the
bench-working and machining operations first-hand during class. However, there are
also some constraints such as limited tools for milling operation and technical problem
of the machine. We hope that the problem can be solved. We are proud to say the class
has increased our confident in handling the machines.

7.0 REFERENCES
Walsh, R.A., (2006).McGraw-Hill Machining and Metalworking Handbook, 3rd ed.,
McGraw-Hill, USA.
Kalpakijan, S., Schmid, S.R., (2010).Manufacturing Engineering and Technology, (6th ed).,
Pearson Education South Asia Pte Ltd, Singapore.
Milling machine, (n.d.).In Wikipedia.Retrieved on January 3rd, 2013, from
http://en.wikipedia.org/wiki/Milling_machine.

8.0 APPENDIX