ITMT 286

Laboratory Report

Shane Holbrook

Date: 4/30/15

OVERVIEW
In my general opinion the purpose of this activity is to help us relate the design process with the
manufacturing process through the actual processes of designing a part and then fabricating it. The
experience is defiantly one that I will take along with me not only through my school career, but also
during my professional career. The ideal that we were given a design from nothing more than a simple
sketch with general dimensions, and then told to draw the part in 3D software, and then to actually make
the part, gives us a realistic ideal of exactly how things work and will work in the industry. Throughout the
book we were exposed to procedures, processes, and even equations throughout our text book in order to
understand the processes and how they work. Although I have done similar exercises in ITMT 186
fabricating a pen, and also with a USB housing, in this experiment I was forced not only to learn RPMs of
the lathe and milling machine, but I was also exposed to a more hands on approach of the actual
manufacturing process.

Procedure/ Steps
Materials Used:
Aluminum Stock
Equipment Used:
Metal Lathe
Milling Machine
Horizontal Bandsaw
Solidworks
Drill Bits
Reamers
Jacobs Chuck
Morse Taper
Various Cutting Tools (Right Angle, General Cutting, Cutoff)
Six Inch Ruler
Digital Caliper
Pencil
Center Drill
Dead center
Wrench
Brush
Cutting Fluid
Drill Drift Keys
Dead Blow Hammer
Safety Equipment Used:
Safety Glasses
Apron
List of procedures used:
Drawing of Part
Cutting of stock with horizontal bandsaw
Centering of cutting tool (with six inch rule and dead center of tailstock)
Facing off (end of part)
RPM of lathe (equation)
RPM of milling machine (equation)
Measuring with calipers
Part cut off
Removal of material
Drilling of hole
Reaming of hole
Milling of holes

ITMT 286
Shane Holbrook

Laboratory Report
Date: 4/30/15

Tapping of holes
Step-by-Step of process used to make part:
Gained dimensions of the part to be made
Part was drawn in Solidworks
Obtained safety glasses
Put on apron
Received work instructions
Obtained Aluminum stock
Cut Aluminum stock to six inches with horizontal bandsaw
Obtained correct chuck key and tool post for desired lathe
Placed Aluminum stock in lathe
Studied work instructions to obtain best course of action
Used standard RPM calculation for lathe to set speed
Faced off front portion of the stock
Cut entire aluminum stock to maximum diameter dimension of desired part (0.875 inches)
Marked part with pencil at designated locations to indicate starting/ending points of part on stock
Systematically cut diameters of the various parts using the marked locations (0.500 Inches, 0.750 Inches,
and the already cut 0.875 Inches)
Obtained center drill, Jacob chuck, and Morse taper and inserted it into the tailstock.
Used wrench to undo tailstock nut and move tailstock to optimal position for drilling
Changed RPM for optimal drilling speeds for the center drill and then with the help of cutting fluid, began
to drill center drill into aluminum stock in order to get optimal angle for drill bit.
Used drill drift key to remove Morse taper from Jacobs chuck, then returned it to designated locations.
Knowing the optimal dimension of the center hole through part was 0.375 Inches, using the Inch/Metric
Tap Drill Sizes & Decimal equivalents chart on page 263 of the Machining and CNC Technology Book, I
determined the drill size was approximately 3/8. Although I knew I would be reaming and cut it back by
0.015 to allow for better reaming. So ultimately went with a 23/64 sized drill bit.
With the help of cutting fluid, began to slowly feed the drill bit into the aluminum stock and retract whilst
systematically adding cutting fluid when needed and using a brush to remove Build up edge (BUE) until
drilled to desired length
After drilling hole with 23/64 drill bit and removing needed Morse tapers with drill drift keys and dead
blow hammer, I obtained a 3/8 sized reamer and began to ream out hole through center with cutting fluid
once again in a slow manner
It is to be noted that with each process a digital caliper and the six inch rule was used to determine how
close/far away I was from the optimal dimensions.
After analyzing the part I had realized that it had formed fillets on each step from sizes. I then turned the
tool post and added a right angle tool to remove the fillets and form an actual right angle in each step up
and down in sizes.
After determining the actual sizes were to my liking, I changed to a cut off tool and then fed the tool into
the bottom of the part until it fell from the chuck holding it on the lathe.
From this point it was moved to the milling machine where the RPMs were calculated and it was fastened
into the clamp of the machine
Using the desired dimensions of 3.3 mm I then drilled the four holes desired for the part.
After removing the part from the milling machine I then tapped the holes to the new desired dimensions.

From this point the only thing left was the end point on the back of the part from the cut off tool. I
reinserted it into the lathe and faced off the back end of the part in order to remove the flash from the part.
This being done resulted in a finished product.

Data Collection
Formulas used (Taken from powerpoint on blackboard and also from Machining and CNC
Technology Book):
2

ITMT 286

Laboratory Report

Shane Holbrook

Date: 4/30/15

12 x ( CS )
(This general equation was used for the lathe, milling
x Diameter
machine and most of the work I used).
For reaming the equation was simply the same as the cutting speed of the
material, although to reduce chatter it was brought down slightly.
RPM=

Figure 1shows the initial dimensions of the work instructions for the drawings.

Holes
2x 3.3 mm
2x 0.75
0.375 (Through
All)

Diameters
(Inches)
0.375
0.500
0.750

Lengths (Inches)

Threads

0.350
0.750
(Not Given)

- 10 NC

0.875

2.300

ITMT 286

Laboratory Report

Shane Holbrook

Date: 4/30/15

Figure 2 shows the work instructions given to me (Designed by Greg Bussell)

Holes
2 x 3.3 mm
2x M4 x 0.75
0.375 (Through All)

Diameters (Inches)
0.375
0.500
0.750
0.875

Lengths (Inches)
0.350
0.750
0.188
0.663
(Overall Dimension
not given)

Threads
(Not Given)

ITMT 286

Laboratory Report

Shane Holbrook

Date: 4/30/15

Figure 3 shows the finished part standing upright

Figure 4 shows the finished part from the side view

ITMT 286

Laboratory Report

Shane Holbrook

Date: 4/30/15

Holes

Holes
Difference
s

Diameter
s (Inches)

Diameter
Difference
s

Length
Difference
s

Thread
s

Length
s
(Inches
)
0.3535

2x 3.3 mm

0.375

+0.0035

(Not
Given
in
Drawin
g not
placed
on part)

2x 3.35 mm
0.375
inches(Throug
h All)

0
0

0.495
0.760

-0.005
+0.01

0.7475
0.1925

-0.0025
+0.0045

0.872

-0.003

0.663
2.35

Conclusion
The overall objective of the lab was to complete the part within +-0.500 of the given
dimensions following the constraints of the drawing given to us, considering my overall
dimensions in relation to the required drawing. In fact my dimensions were considerably
lower than the tolerance given. ITMT 286 is more commonly known as Machine Tool
Processes, this lab in relation to its name, gives a valid understanding of the hardships
and actual work that goes in to not only design, but also the manufacturing process. In
this class I have learned not only how to use various machines and their bits and pieces
that go with them, but I have also gained a great understanding of the knowledge of math,
precision, and work that actually goes into each piece that is designed.

Technical Article Correlation

o Rahou, M., Cheikh, A.,

& Sebaa, F. (2010). Real Time Compensation of Machining

Errors for Machine Tools NC Based on Systematic Dispersion. Jordan Journal Of
Mechanical & Industrial Engineering, 4(5), 597-604.

This article covers some of the errors made during machining. It covers mostly the uncontrollable
parameters such as heat, wear of cutting tool and so forth. Although with the consideration that the labs
general outline was to make the designated part within a 0.500 tolerance, this article gives a good
understanding of just how hard it is even when you are exactly precise with your work.