IE

SIRINDHORN INTERNATIONAL INSTITUTE OF TECHNOLOGY

THAMMASAT UNIVERSITY
IES 301: MANUFACTURING TOOLS AND OPERATIONS
LAB MANUAL
REGULATIONS FOR LABORATORY
1. STUDENTS MUST DRESS PROPERLY (WEAR A LONG WORKSHOP SUIT, SHOES PREFERABLY
SAFETY SHOES, SOCKS, SAFETY GLASSES WHEN APPROPRIATE).
2. STUDENTS MUST COME TO IE WORKSHOP AT THE FACULTY OF ENGINEERING BUILDING
ON TIME. LATE COMING RESULTS IN A PENALTY OF 10% OF FULL MARKS. IF THE
LATENESS IS MORE THAN 15 MINUTES, THE STUDENTS WILL NOT BE ALLOWED TO
PRACTICE IN THAT LABORATORY-SESSION, AND THE MARK FOR THAT SESSION WILL BE
ZERO.
3. THERE IS NO MAKE-UP FOR THE LABORATORY SESSION. STUDENTS WHO MISS ANY
SESSION WILL GET ZERO MARK FOR THE SESSION.
4. THERE IS NO EXTENSION OF THE LABORATORY TIME. STUDENTS SHOULD TRY TO FINISH
THE ASSIGNMENT WITHIN THE REGULAR LABORATORY TIME. AT THE END OF THE
SESSION, THE WORK-PIECE MUST BE SUBMITTED REGARDLESS OF ITS COMPLETENESS.
THE MARKS WILL BE GIVEN BASED ON THE QUALITY OF THE WORK-PIECE.
5. STUDENTS MUST OBEY ALL INSTRUCTIONS FROM INSTRUCTORS. STUDENTS MUST NOT
TRY ANYTHING THAT IS CONSEQUENCE IS NOT CLEARLY KNOWN. BEFORE TRYING
ANYTHING, ASK THE INSTRUCTOR FIRST.
6. STUDENTS MUST AVOID ANY UNSAFE ACT, E.G., RUNNING, PLAYING, MISUSE OF THE
TOOLS, PRESSING AN UNKNOWN BUTTON, AND OPERATING AN UNKNOWN SWITCH OR
LEVER.
7. STUDENTS MUST USE PROTECTION EQUIPMENT SUPPLIED BY THE INSTRUCTOR.
8. FAIL TO COMPLY WITH THE INSTRUCTIONS, SAFETY RULES, AND COMMON SENSE, MAY
RESULT IN A SEVERE INJURY.

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LAB SCHEDULE

LAB NUMBER LAB SCHEDULE

1 LAB EXPLANATION,
BRIEF LECTURE ON PRINCIPLE AND THEORY
2 TURNING #1
3 TURNING #2
4 BENCHWORK #1
5 BENCHWORK #2
6 BENCHWORK #3
7 ELECTRIC WELDING
8 GAS WELDING
9 GENERAL TOOLS #1
10 GENERAL TOOLS #2
11 MILLING #1
12 MILLING #2

NOTE: PLEASE SEE THE ANNOUNCEMENT AT IE BOARD FOR YOUR GROUP NUMBER AND
SCHEDULE FOR YOUR LAB. EACH GROUP WILL BE ROTATED TO PERFORM ALL LABS.

CONTENTS

REGULATIONS FOR LABORATORY

LAB SCHEDULE
LAB DESCRIPTION
LAB 1 TURNING
LAB 2 BENCHWORK
LAB 3 ELECTRIC WELDING
LAB 4 GAS WELDING
LAB 5 GENERAL TOOLS
LAB 6 MILLING
LAB 7 CASTING

LAB DESCRIPTION

THIS LABORATORY MANUAL IS USED IN IES 301 COURSE, MANUFACTURING TOOLS AND
OPERATIONS, OF SIRINDHORN INTERNATIONAL INSTITUTE OF TECHNOLOGY, THAMMASAT
UNIVERSITY. A SERIES OF LABORATORY SESSIONS IS ORGANIZED AND DESIGNED TO ALLOW ALL
STUDENTS TO UNDERSTAND, EXPERIENCE, AND APPRECIATE A WIDE VARIETY OF ENGINEERING
OPERATIONS AND PRACTICES, AND MACHINE TOOLS AND EQUIPMENT.

THE TOPICS COVER FUNDAMENTALS OF CUTTING TOOLS, TURNING OPERATIONS, ELECTRIC

AND GAS WELDING, MILLING, AND BENCHWORK.

SIIT FACULTY

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SIRINDHORN INTERNATIONAL INSTITUTE OF TECHNOLOGY

THAMMASAT UNIVERSITY

IES 362: Manufacturing Engineering Laboratory

Prepared by: Dr. Ruengsak Kawtummachai

Industrial Engineering Program

(1) REGULATIONS FOR LABORATORY

1. STUDENTS MUST DRESS PROPERLY (WEAR A LONG WORKSHOP SUIT, SHOES
PREFERABLY SAFETY SHOES, SOCKS, SAFETY GLASSES WHEN APPROPRIATE).
2. STUDENTS MUST COME TO THE WORKSHOP ON TIME.
3. THERE IS NO MAKE-UP FOR THE LABORATORY SESSION. STUDENTS WHO MISS ANY
SESSION WILL GET ZERO MARK FOR THE SESSION.
4. THERE IS NO EXTENSION OF THE LABORATORY TIME. STUDENTS SHOULD TRY TO
FINISH THE ASSIGNMENT WITHIN THE REGULAR LABORATORY TIME. AT THE END OF
THE SESSION, THE WORK-PIECE MUST BE SUBMITTED REGARDLESS OF ITS
COMPLETENESS. THE MARKS WILL BE GIVEN BASED ON THE QUALITY OF THE WORK-
PIECE.
5. STUDENTS MUST OBEY ALL INSTRUCTIONS FROM INSTRUCTORS. STUDENTS MUST NOT
TRY ANYTHING THAT IS CONSEQUENCE IS NOT CLEARLY KNOWN. BEFORE TRYING
ANYTHING, ASK THE INSTRUCTOR FIRST.
6. STUDENTS MUST AVOID ANY UNSAFE ACT, E.G., RUNNING, PLAYING, MISUSE OF THE
TOOLS, PRESSING AN UNKNOWN BUTTON, AND OPERATING AN UNKNOWN SWITCH OR
LEVER.
7. STUDENTS MUST USE PROTECTION EQUIPMENT SUPPLIED BY THE INSTRUCTOR.
8. FAIL TO COMPLY WITH THE INSTRUCTIONS, SAFETY RULES, AND COMMON SENSE, MAY
RESULT IN A SEVERE INJURY.

(2) Objective
The main objective of the lab is to understand the CAD/CAM facilities and measurement
instruments for working in manufacturing environment. Specially, the following objectives
are set up:

(1) To understand the data transfer from Computer-Aided Design (CAD) to Computer-
Aided Manufacturing (CAM). Specifically, the drawing from AutoCAD with DXF
format to Master CAM for developing NC program.
(2) To know how to use “Master CAM” software package for CAD/CAM linking and
develop NC programs for using at lab.
(3) To be familiar with CNC machines and advanced machines/facilities.
(4) To be familiar with instruments for measurement.

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(3) Procedures
The lab is composed of three sections, called CAD/CAM, CNC, and MEASUREMENT. The
CAD/CAM section aims to study about AutoCAD and Master CAM package. The CNC
section aims to study CNC turning machine and CNC milling machine. Finally, the
MEASUREMENT section aims to study the measurement tools and instruments.

Generally, the students are grouped in two groups called group A and B. (The list of group A
and B are announced in separate sheet). The first group A goes to work on CAD/CAM in five
weeks and then goes to study on CNC and MEASUREMENT for five weeks. Similarly, the
group B firstly goes to study CNC and MEASUREMENT sections for five weeks and then
goes to study CAD/CAM for five weeks. All detailed schedules for the lab are announced in
the separated sheet.

(4) Regulations
4.1) Each group must submit weekly lab report for each CNC lab and
MEASUREMENT lab after a week of the completion on that corresponding lab.
4.2) For CAD/CAM section, there will be assignments assigned by instructors. You
must follow the details that will be given by instructors.
4.3) No make-up classes are available due to tight schedules and therefore, please take
care for attending the lab class regularly.

(5) Scoring Policy

5.1) Attendance 10%
(Late 0-10 min. Î –50% and late more than 10 min. Ζ100%)
5.2) Lab report (CNC and Measurements) 40%
5.3) The assignment (CAD/CAM) 20%
5.4) Final Examination 30%

(6) Lab Explanations

CAD/CAM Lab Session (5 weeks)
This lab will be conducted at computer center located at fifth floor of lab building, SIIT. In
this lab session, the students will study “AutoCAD” and “Master CAM” software packages
for understanding the CAD and CAM.

During the lab session, the students will:

1. Understand and know how to use the software
2. Develop NC programs

CNC-1: CNC Lathe Machine (1 week)

This lab will conduct at IE lab room, SIIT lab building. In this lab session, the students will
study the CNC turning machine and will make a workpiece by the machine. The following
steps are included:
1. Understand operation procedures of the machine,
2. Understand G-code for CNC lathe machine,
3. Understand safety operations.

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CNC-2: CNC Milling Machine (1 week)

This lab will conduct at IE lab room, SIIT lab building. For this lab, the students need to
understand the operational procedures of the CNC milling machines and during that time, the
students have to finish a workpiece. The following steps are included:
1. Understand operation procedures of the machine,
2. Understand G-code for CNC milling machine,
3. Understand safety operations.
MEASUREMENT-1: Coordinate Measuring Machine (CMM) (1 week)
This lab will conduct at SIIT lab building and the lab aims for students to understand about
advanced measuring machine for quality control. For this lab, the students needs to follow the
following procedures:
1. Understand the operations of CMM.
2. Understand the applications of those machines.
MEASUREMENT-2: Robotics (1 week)
This lab will conduct at the IE lab located at the first floor of SIIT lab building. During the
lab session, the students have to:
1. Understand the operational procedures of industrial robot, and
2. Understand the applications of robotics.
After the above mentioned lab session, the students will study the basic tools for
measurement such as Vernier caliper, micrometer, etc.
MEASUREMENT-3: Surface Roughness Measurement and Hardness Tester (1 week)
This lab will conduct at the IE lab located at the first floor of SIIT lab building. During the
lab session, the students have to:
1. Understand the concepts and procedures of the measurement of surface roughness,
2. Understand the concepts and procedures of the measurement of hardness.

(7) Guidelines for the lab reports

The lab report must contain the following parts:
(a) The objectives of the corresponding lab session,
(b) The main procedures carried out during the lab session,
(c) The workpiece done during the lab session or the result form the measurement,
(d) The knowledge gained from the lab session,
(e) The problems/difficulties met during the lab session,
(f) The suggestions for improving the lab session and conclusion of the lab report.

(8) Final Examination

There will be only one (final) examination (1 hour). Generally, the final examination is
appeared to be composed of short questions and multiple choices. The examination is closed
book type and all questions are generally from the lab.
If you are carefully study during the lab session and clearly understand about the lab
procedures, you can easily answer the final examination questions.

(9) Group and Schedule

There are two main groups called GROUP A and B for doing the lab. The student lists
appeared at GROUP A and B are announced in separate sheet. Please check to make sure
whether your name is appeared in a group. Please contact Dr. Ruengsak for any information.

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Sirindhorn International Institute of Technology

Industrial Engineering Program
IES 363: Manufacturing Engineering Lab II

Lecture: SIIT’s Main Building

Laboratory: SIIT’s IE Lab

Course description
The laboratory course provides practical integration between measuring and controlling
instrument used in manufacturing environment. Measuring instrument is focused on the
physical property measuring such as pressure, temperature and level. Controlling instrument
is emphasized in both mechanical and electrical control devices such as Programmable Logic
Control (PLC).

Lab Explanations:

The lab is divided into three sessions as explained below:

First and Second Session:

The students are required to have a tutorial class for the first two weeks, and then, followed
by Metrology sessions, part design and material purchasing. Students will be divided into
small groups (about 4 persons per group). Each group has to submit one design (CAD and
CAM) and its budget to be approved by the faculties. After that in the second session, the
group will start making the part. Finally, the group must submit the workpiece and report.

Third Session:
The students are required to have four laboratories conducted by IE faculties. Labs included
are Metrology Lab, Programmable Logic Control, Manufacturing Cost Estimation, and
Material and Metallurgy lab.

Student Group
There are four members per each group. Schedule of work assignment of each group will be
announced before the lab starts.

Grading Policy:

1. Parts 35%
2. Lab hand on exam 25%
3. Paper exam 40%

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Lab Schedules:

Week No. Subject Instructor Place

1 Tutorial CAM TBA TBA
2 Tutorial CAD TBA
3 Lab session 1
4 Metrology lab & Dr. Pisal/Dr. Navee IE Laboratory
5 Part design and
6 Material purchasing
7 Lab session 2: Part making
8
9 Technicians of IE IE Laboratory
10 Mid-term examination
11 Lab session 2:
12 Part making (cont.)
13 Dr. Navee
14 Lab session 3 Dr. Chakguy
15 Dr. Pisal IE Laboratory
16 Dr. Ruengsak
17 Lab hand-on examination IE Faculties IE Laboratory

Lab session 1 consists of metrology lab (advanced CMM), part design and material
purchasing. Your proposal report of part design, list of materials required and cost estimation
must be submitted for approval before ……………..
Lab session 2 is arranged for the part making. The deadline for submitting your finished part
and full report is ……………………
Lab session 3 consists of four separated labs as below:
Lab 1: PLC and instrumentation
Lab 2: Metrology lab (Roundness testing)
Lab 3: Material and Metallurgy lab
Lab 4: Manufacturing Cost Estimation
A report of each lab for each group must be submitted within one week after the lab.

Part Guidelines
There are conditions that students must follow in order to design the workpiece:
1. All components must be made from aluminum or copper.
2. Dimension of your part should not exceed W20cm x L20cm x H15cm
3. Your process must include both the machine processing and assembly. The following
regulations must be applied.
At least one component must be processed by Machining Center (CNC Lathe and CNC
Milling Machine)
At least one component (base unit) must be formed through casting.
Other components can be processed by other conventional machines such as turning,
milling, drilling, etc.

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