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I. Introduction

1. Turning Machine

1.1 Installation of Cutting tool

-Cutting tool: For installing the

cutting tool of turning machine, first

we should choose the cutting tool

which has a good cutting edge and fit

to the work. Then we install the

cutting tool in to the Tool post.

-Tool post: Take the cutting tool to

touch the dead center of tailstock

quill for reference. Make sure that the cutting edge is at the center of the

dead center. Then tight the cutting post and make sure that the cutting tool

is fixe. Put the tool post between 300-450 angle (with axe X) to avoid

crashing with the spindle chuck. Next tight up all the screws to make sure

that they are all tight.

1.2 Installation of Working part

-Work part: For install the work part, first we cut the work part which

depends on our requirement.

-Spindle Chuck: Setup work part in the

chuck in length 10mm-15mm in the right

position and tight up. Check the work part

by use the cutting tool as reference for

makes sure that the work part is in the

center of spindle.

1.3 Operation of Turning machine

After install the cutting tool and the work part, first we choose the

velocity of spindle by spindle speed which is confirm to the metal of

work part. Turn on the machine for give the real speed to the work

part. Next we give the speed to feed rate that response to the material

of the work part and also the cutting tool. The various angles, shapes,

and sizes of a single-point cutting tool have direct relation to the

resulting surface of a work piece in machining operation. Different

types of angle such as rake angle, side rake angle, cutting-edge angle,

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relief angle, nose radius exist

and may be different with

respect to the work piece. Also,

there are many shapes of single-

point cutting tool, such as –

shaped and square. Usually, a

special tool holder is used to

hold the cutting tool firmly

during operation.

The relative forces in a turning operation are important in the design

of machine tools. The machine tool and its component must be able

to withstand these forces without causing significant deflection,

vibration, or chatter during the operation. There are three principal

forces during a turning process.

The cutting or tangential force acts downward on the tool tip

allowing deflection of the work piece upward. It supplies the energy

required for the cutting operation. The specific cutting force required

to cut the material is called specific cutting force. Cutting force is

depends on the material.

The axial or feed force acts in the longitudinal direction. It is also

called the feed force because it is in the feed direction of the tool.

This force tends to push the tool away from the chuck.

The radial or thrust force acts in the radial direction and tends to push

the tool away from the work part.

Speeds and feed for turning are chosen based on cutter material, Work

piece material, setup rigidity, machine tool rigidity and spindle power,

coolant choice, and other factors. The distance the tool advances into the

material in one revolution is called feed. It is specified as mm per

revolution (mm/rev).

2. Milling Machine

2.1 Installation of Cutting tool

Firstly, turn off the machine before install the cutting tool.

Then, screw the bolt on the top of machine and hold the head of

machine by a fabric or piece of cloth to avoid rotation of the knife.

We use wrench to screw the bolt and if the bolt is too tight, we can

use aluminum hammer to hit the wrench for loosen the bolt easily.

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Check the knife if it has metal pieces stick on

it or not. You have to clean it and apply the

lubricant every time you use it.

Take out the old cutting tool and put your new

knife to the hole properly to avoid cutting your

hand or finger.

Finally, we screw the bolt tightly.

2.2 Installation of Working part

First of all, you need to have two steels

rectangular-shaped for deposit the work part.

After put these two steels below the work part, you have to use axis

Y (move toward and backward) or the table cross hand wheel to

make the work part stable during work.

Use steel perpendicular ruler to measure the work part and make sure

that it is perpendicular to the plan.

Then, use axis X (move to the left and to the right) or table feed hand

wheel and axis Z (move up and down) or knee elevating handle to

adjust the work part close to the cutting tool.

2.3 Operation of Milling machine

Check out the cutting tool and the work part again if they are

installed incorrectly. If not, it causes some problem such as the knife

breaks, the work part has been damaged…etc.

Set the scale (mm) on the wheel of axis X,Y,Z for the size we want

to cut on the work part’s surface (0.1mm; 0.2mm;…).

When you already adjusted the scale on axis X and Z, you have to

lock these two tables by the lock handle of each axis. This can

protect from sliding of table work.

Adjust the speed of the knife and the speed of tables.

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Check the water. If the machine runs out the water, put the water in

and press the green button.

Turn on the water, set the faucet near the knife (not too close).

In front of the machine, on the bottom part, there are two buttons

“Red Button” and “Blue Button”. When we start our operation, we

just press the blue button. And if the machine has problem or you

want to stop the process, we just press the red button.

After pressed the blue button, rotate the wheel of axis X to push the

work part near the cutting tool.

Moreover, just spin the table feed hand wheel slowly to move left

or right for cut the surface of work part.

To protect yourself especially your eyes from the splash of hot

metal pieces during cutting, you should wear safety goggles.

In the conclusion, when the work part is finished, we press the red

button.

3. Drilling Machine

3.2 Installation of Cutting tool

First, we should choose the twist drill

which has a good drilling edge and fit

to the work (starting from small to

big). Then we install the twist drill

into the drill chuck.

Then, take the twist drill tang to touch

the dead center of drill chuck slot for

reference. Make sure that the twist drill tang is at the center of the

dead center. Then tight the twist drill and make sure that the twist

drill is fixe. Next tight up all the screws to make sure that they are

all tight.

3.2 Installation of Working part

First of all, you need to have two steels rectangular-shaped for

deposit the work part.

After put these two steels below the work part, you have to use

axis Y (move toward and backward) or the table cross hand wheel

to make the work part stable during work.

Use steel perpendicular ruler to measure the work part and make

sure that it is perpendicular to the plan.

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Then, use axis X (move to the left and to the right) or table feed

hand wheel and axis Z (move up and down) or knee elevating

handle to adjust the work part close to the cutting tool.

Use feed hand to handle for feed and during drilling hand it down

and up often to avoid the twist drill broken.

3.3 Operation of Drilling machine

Check out the twist drill and the work part again if they are

installed incorrectly. If not, it causes some problem such as the

knife breaks, the work part has been damaged…etc.

Adjust the speed of the knife

Move the machine vice that is

equipped with jaws which

clamps the work piece to where

you want the drilling machine

do on your work steel. The vice

is bolted to the drilling table and

you can swivel through 360° on

a horizontal plane.

Ensure for the cutting tools

running straight before starting

the operation and spin the hand

feed up and down to make the

twist drill in the spindle cut your steel.

Avoid loose clothing and protect the eyes.

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II. Operation in Laboratory

1. Power Piston Cylinder

In this work part we have to use

cutting tool machine, turning machine,

drilling machine to process it.

First, we cut metal for our

operation with length 40

mm with cutting tool

machine (include 15mm

for chuck)

Second, we take our piece of metal to the chuck and start turning

machine to get the result with diameter Ø 29 mm.

Third, we start turning process again with depth 11 mm and length

18 mm

Fourth, Drilling process with diameter Ø 13 mm

Threading 4 through holds.

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2. Displacer Cylinder

In this work piece we have to use cutting tool machine, turning machine, drilling

machine to process it.

First, we cut metal for our operation with length 49 mm with cutting

tool machine (include

15mm for chuck)

Second, we take our

piece of metal to the

chuck and start turning

machine to get the result

with diameter Ø 29 mm.

Third, we start turning process again with depth 13 mm and length

28 mm

Fourth, Drilling process with diameter Ø 14 mm length 26 mm

Threading 4 through holds.

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3. Displacer Piston

In this work part we need to process in cutting tool machine, turning machine,

drilling machine.

First, we cut metal for our

operation with length 82 mm

with cutting tool machine

(include 15mm for chuck).

Second, sawing

Third, drilling process with

diameter M 3.

4. Power Piston

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In this work part we need to process in cutting tool machine, turning machine,

drilling machine.

First, we cut metal for our operation with length 33 mm with cutting

tool machine (include 15mm for chuck).

Second, sawing

Third, drilling process with diameter M 3.

5. Flywheel

In this work part we need to process in cutting tool machine, turning machine,

drilling machine.

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We need to take the cylinder

that has diameter D= 27 mm

and length L= 35 mm, we

need 4 cylinder.

Practice: Turning (facing, cut

off, drilling) and Drilling (1

through hold).

6. UPPER BASE

We need to take it that has length L= 74 mm, W= 34 mm, H= 12 mm

Practice: Drilling (12 through holds, 1 blind hold) and Milling (facing)

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7. Body

We need to take the body that has L= 124 mm, W= 34 mm, H= 12

mm, N= 2.

Practice: Threading (4 blind holds, 1 through hold) and Milling.

8. Base

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We need to take the base that has L= 100 mm, W= 69 mm, H= 12

mm, N= 2.

Practice: Drilling (2 through holds) and Milling.

9. Power Piston Connection Rod and Displacer Connection Rod

We need to take the rod that has L= 58 mm, W= 10 mm, H= 2 mm,

N= 4.

Practice: Drilling (2 through holds) and Sawing.

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III. Conclusion

After finish the work, we should remove some tools such as cutting tool,

wrench, steel ruler, aluminum hammer and other tools in to the place origin

and clean up all the metal pieces and the water in the machine by using brush

and fabric. Clean the surface around the machine and lubricate some parts in

the machine to make it clean and available for the next use.