STEP BY STEP CONVENTIONAL MACHINING

STEP BY STEP

CONVENTIONAL MACHINING

(POLITECHNIC e-MODULE (V0L1):GUIDE LINE
FOR DJF31022 – MANUFACTURING WORKSYOP

PRACTICE 2)

Our nation, Malaysia is being dedicated:

To achieve a greater unity of all her peoples;

To maintain a democratic way of life;

To create a just society, in which the wealth of the
nation shall be equitably shared;

To ensure a liberal approach for rich and diverse
cultural traditions;

To build a progressive society which shall be oriented
to modern science and technology;

We, her people, pledge our united efforts to attain
these ends guided by these principles;

BELIEF IN GOD
LOYALTY TO KING AND COUNTRY
UPHOLDING THE CONSTITUTION

RULE OF LAW
GOOD BEHAVIOR AND MORALITY

PUBLISHED BY:
Jabatan Kejuruteraan Mekanikal

Politeknik Port Dickson
06-662 2000 (Tel)

06-6622026 (No Fax)
Web: polipd.edu.my

All rights reserved. No part of this publication may be

reproduced, stored in a retrieval system, or

transmitted in any form or by any means, electronic,

mechanical, photocopying, photographing, recording

or otherwise, without prior written permission from

the publisher.

e-MODULE, 1st version, 2021
Design and Graphics: Author Design & Online Resources
Author : Anidah Binti Buang

Noor Hasanah Tham Shu Yin
Izuan Bin Ishak
Technical Reference:
Video Editor:
Language Editor : Nurul Ezzah Binti Abdul Jalil

Title:
Step by Step - Conventional Machining
(Polytechnic e-MODULE (Vol 1) Guidelines For
DJF31022 – Manufacturing Worksyop Practice 2)

Mode of access: Internet
eISBN 978-967-2246-93-0

i

This module is attempts to give a guideline in teaching and

learning for DJF31022 - Manufacturing Workshop Practice 2
especially in Polytechnics level . It is meant to provide a basic
knowledge about Milling and Grinding processes and Standard
Operation Prosedur (SOP). In this module , we provide an
information about Programme Learning Outcome(PLO) and
Course Learning Outcome(CLO) to be achieved at the end of
the course. We also discussed about Assessment Specification
Table (AST), the theory, the procedure for the practical task and
the rubric for mini project, practical task and report that to be
access. This module presents a visualized, more colourful
contents and it focuses on teaching and learning material with
consideration to apply STEAM (Science, Technology,
Engineering, Art and Mathematics) in this module. Hence, it is
hoped that the students could acquire better understanding
about the course. This module will be published as a e-
MODULE. Finally, the author would like to thank to all those that
who are involved directly or indirectly for their cooperation and
help in the production of this book.
The Authors

ii

Acknowledgement
Preface

1 INTRODUCTION OF DJF31022 – MANUFACTURING WORKSHOP PRACTICE 2

Course Synopsis 2-3
Teaching and learning outcome 4
Teaching and Learning Method and Delivery 5-6

Continuous Assessment 7

2 CONVENTIONAL MACHINING THEORY

Workshop Safety 9-12
Milling Theory and objectives 13-20
Grinding Theory and objectives 21-26

3 STANDARD OPERATION PROCEDURE (SOP)

Milling Machine Processes – SOP and procedur for practical task 28-30
Grinding Machine Processes - SOP and procedure for praktikal task 31-33
SOP for Lathe Machine and Electrical Cutting Machine 34-36

4 RUBRIC FOR ASSESSMENT 38-41
42-43
Rubric for Practical Task, Mini Project and Report
Grinding Assessment

Reference
About The Authors

iii

THE INTRODUCTION OF
DJF31022 MANUFACTURING

WORKSHOP PRACTICE 2

OUTCOME

Upon completion of unit 1, students will be
exposed to the Programme Learning Outcome
(PLO) , Course Learning Outcome (CLO) and
the assessment in this course.

1

E-MODULE (VOL1) Information
STEP BY STEP – CONVENTIONAL MACHINING

Course

Name of Course :Manufacturing Workshop Practice 2

Course Code : DJF31022

Semester and Year Offered: Semester 3 / Year 2

Credit Value : 2

Prerequisite : Manufacturing Workshop Practice 1

SYNOPSIS:
MANUFACTURING WORKSHOP PRACTICE 2
exposes the students to the fundamental of
manufacturing processes, industrial environment,
cultural issues and hands-on experiences. This course
enables students to apply knowledge and develop
required technical skills on CNC machine, conventional
machining, surface grinding machine and TIG and MIG
welding. The workshop practice helps the students to
practice appropriate safety procedures and standard
operation on completing mini project and practical task.
The practical skills also cover the organizational and
housekeeping activity, schedule maintenance, planning
skills, supervising design, inspecting and testing
welding task in order to meet the quality requirements.

2

E-MODULE (VOL1)
STEP BY STEP – CONVENTIONAL MACHINING

Course Outcome

PLO5: apply appropriate techniques, resources, and
modern engineering and IT tools to well-defined
engineering problems, with an awareness of the
limitations (DK6)
PLO6: demonstrate knowledge of the societal,
health, safety, legal and cultural issues and the
consequent responsibilities relevant to engineering
technician practice and solutions to well-defined
engineering problems (DK7)

DK 6 : Codified practical engineering knowledge in
recognised practice area.
DK 7 : Knowledge of issues and approaches in
engineering technician practice: ethics, financial,
cultural, environmental and sustainability impacts

3

E-MODULE (VOL1) Learning

CourseSTEP BY STEP – CONVENTIONAL MACHINING
Outcome

Upon completion of this course, students should be
able to:

CLO1 :
Build a project using CNC machine, TIG and MIG
welding process based on standard operational
procedures and safety. (P3, PLO5)

CLO2 :
Perform contouring cutting operation using rotary
table attachment in milling machine processes.

(P4, PLO5)

CLO3 :
Demonstrate an understanding of the
responsibilities, societal, health, safety, legal and
cultural issues during practical work session.

(A3, PLO6)

4

Delivery E-MODULE (VOL1)
STEP BY STEP – CONVENTIONAL MACHINING

Method

NO COURSE LEARNING DELIVERY ASSESSMENT
CLO1 OUTCOMES METHOD METHOD
CLO2
CLO3 1-1-3 THE DEFINITION OF INDUSTRIAL

MANAGEMENT

Build a project using CNC Demonstration Mini Project

machine, TIG and MIG Workshop Workshop
Report
welding process based on Activity

standard operational Discussion
procedures and safety.

(P3, PLO5)

Perform contouring Demonstration Practical Task
cutting operation using Workshop
rotary table attachment Activity Workshop
in milling machine Report
processes. Discussion
(P4, PLO5)

CLO3 : Demonstration Mini Project
Demonstrate an Workshop Practical Task
understanding of the Activity
responsibilities, societal,
health, safety, legal and
cultural issues during
practical work session.
(A3, PLO6)

5

E-MODULE (VOL1) SYLLABUS
STEP BY STEP – CONVENTIONAL MACHINING

COURSE

1.0 Workshop Procedures and Safety

1.1 Explain the principle of safety in workshop a. Workshop rules
b. Clothing and footwear
c. Fires and other emergency
1.2 Follow safety procedures when operating machines a.
Machinery usage of conventional machine, CNC machine and
welding

2.0 Conventional Machining

2.1 Explain the procedure for machining works
2.2 Build a project using vertical and universal milling machines a.
Follow the following processes:
i. Flat milling
ii. Slot cutting
iii. Squaring flat bar operation
2.3 Calibrate speed and transmission for various machining
processes
2.4 Perform contour cutting operation to produce curve edges
2.5 Perform surface grinding process to grind a flat surface
2.6 Organize workshop in safe, clean and tidy condition

3.0 Workshop Housekeeping

3.1 Organize housekeeping activity in conventional machine,
CNC machine and welding workshop
3.2 Explain suitable schedule maintenance on machine in
conventional machine, CNC machine and welding workshop

6

E-MODULE (VOL1)
STEP BY STEP – CONVENTIONAL MACHINING

• Continuous Assessment

7

E-MODULE (VOL1) SHEET
STEP BY STEP – CONVENTIONAL MACHINING

WORKSHOP

LINK FOR WORKSHOP SHEET
MILLING :

LINK FOR WORKSHOP SHEET
DRILLING :

6

CONVENTIONAL MACHINING
THEORY

OUTCOME

Upon completion of Unit 2, students should
understand about conventional machining
theory and the machining task objectives.

8

E-MODULE (VOL1)
STEP BY STEP – CONVENTIONAL MACHINING

SAFETY PROCEDURE

Involve three category of safety;
1. Human – used PPE
2. Machine/Equipment – follow SOP , clean after used,

arangement of machine
3. Enviroment – Clean place, good ventilation, follow

Workshop rules

9

E-MODULE (VOL1)
STEP BY STEP – CONVENTIONAL MACHINING

SAFETY FOR ME

1. Human – used PPE

10

E-MODULE (VOL1)
STEP BY STEP – CONVENTIONAL MACHINING

SAFETY FOR MACHINE
& EQUIPMENT

11

E-MODULE (VOL1)
STEP BY STEP – CONVENTIONAL MACHINING

SAFETY IN WORKPLACE

12

E-MODULE (VOL1)
STEP BY STEP – CONVENTIONAL MACHINING

MILLING MACHINE

13

E-MODULE (VOL1)
STEP BY STEP – CONVENTIONAL MACHINING

OBJECTIVES MILLING
PRACTICAL TASK

2-1 Milling Operation task Objectives

At the end of the course student should be able to;
1. Making a project by milling process from a bar
shaped workpiece to a rectangular shaped according to
the specified dimensions given.
2. Can operate a milling machine to produce practical
tasks according to Standard Operation Procedures
(SOP).
3. Can operate the milling machine according to the
prescribed safety rules.

14

E-MODULE (VOL1)
STEP BY STEP – CONVENTIONAL MACHINING

MILLING MACHINING
OPERATIONS

2-1 INTRODUCTION

Milling is the machining process in which the removal of
metal takes place due to the cutting action of a rotating
milling cutter. In a milling machine, the cutter is rotating due
to workpiece is fed against it. This machine can hold more
than one tool at a time. The cutter rotates at high speed, and
because of the many cutting edges, it removes metal at a
very fast rate.
The machine can also hold one or a number of cutters at a
time. Thus, the milling machine is one of the most
important machines in the workshop. In this machine, all the
operations can perform with high accuracy.

15

E-MODULE (VOL1)
STEP BY STEP – CONVENTIONAL MACHINING

MILLING MACHINING
OPERATIONS

HORIZONTAL VERTICAL

16

E-MODULE (VOL1)
STEP BY STEP – CONVENTIONAL MACHINING

MILLING MACHINING
OPERATIONS

2-2 The difference between Vertical and

Horizontal Milling Machine

The biggest difference between these two types of milling
machines is the orientation of the spindle. While vertical
milling machines usually have long and thin cutting tools,
horizontal milling machines have shorter and thicker
cutting tools

VERTICAL MILLER

17

E-MODULE (VOL1)
STEP BY STEP – CONVENTIONAL MACHINING

MILLING MACHINING
OPERATIONS

2-2 TYPES OF MILLING MACHINE

18

E-MODULE (VOL1)
STEP BY STEP – CONVENTIONAL MACHINING

TYPES OF MILLING
MACHINE

1. VERTICAL MILLING MACHINE

Here the position of the spindle is vertical or
perpendicular to the table. This type of machine
is adapted for machining grooves, slots,
and flat surfaces.

2. HORIZONTAL MILLING MACHINE

Horizontal milling machines feature a similar
design in which a spindle containing a rotating
cutting tool presses against a workpiece to
remove material from the workpiece.

3. UNIVERSAL MILLING MACHINE

It can be adapted to a wide range of milling
operations. Here the table can be swiveled to
any angle up to 45-degrees on either side of
the normal position. The capacity of this type
of machine is increased by using special
attachments such as dividing head or
index head, vertical milling attachment,
rotary attachment and slotting attachment.
This machine can produce spur, bevel, spiral, twist drill, reamer,
milling cutter.

19

E-MODULE (VOL1)
STEP BY STEP – CONVENTIONAL MACHINING

PARTS OF
VERTICAL AND UNIVERSAL

MILLING MACHINE

20

E-MODULE (VOL1)
STEP BY STEP – CONVENTIONAL MACHINING

GRINDING MACHINE

21

E-MODULE (VOL1)
STEP BY STEP – CONVENTIONAL MACHINING

OBJECTIVES GRINDING
PRACTICAL TASK

2-1 Grinding Operation task Objectives

At the end of the course student should be able to;
1. Can operate a Surface Grinding Machine to produce
practical tasks according to Standard Operation
Procedures (SOP).
2. Can operate the Surface Grinding machine according
to the prescribed safety rules good etiquette.

14

E-MODULE (VOL1)
STEP BY STEP – CONVENTIONAL MACHINING

GRINDING MACHINING
OPERATIONS

2-1 INTRODUCTION

A grinding machine, often shortened to grinder, is one
of power tools or machine tools used for grinding, it 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 workpiece via shear deformation.
Grinding is used to finish workpieces that must show high
surface quality and high accuracy of shape and dimension.

23

E-MODULE (VOL1)
STEP BY STEP – CONVENTIONAL MACHINING

GRINDING MACHINING
OPERATIONS

2-2 TYPES GRINDING MACHINE

A CYLINDIRICAL GRINDER

A SURFACE GRINDER

A BENCH GRINDER

24

E-MODULE (VOL1)
STEP BY STEP – CONVENTIONAL MACHINING

TYPES OF GRINDING
MACHINE

1. SURFACE GRINDER

Surface grinding is a finishing process that uses a
rotating abrasive wheel to smooth the flat
surface of metallic or nonmetallic materials to
give them a more refined look by removing the
oxide layer and impurities on work piece
surfaces. This will also attain a desired surface for
a functional purpose.
2. BENCH GRINDER

A bench grinder is a benchtop type of grinding
machine used to drive abrasive wheels.
A pedestal grinder is a similar or larger version of
grinder that is mounted on a pedestal, which
may be bolted to the floor or may sit on rubber
feet. These types of grinders are commonly used
to hand grind various cutting tools and perform
other rough grinding.

3. CYLINDRICAL GRINDER

The cylindrical grinder is a type of grinding
machine used to shape the outside of an
object. The cylindrical grinder can work
on a variety of shapes, however the object
must have a central axis of rotation.

25

E-MODULE (VOL1)
STEP BY STEP – CONVENTIONAL MACHINING

PARTS OF
GRINDING MACHINE

26

STANDARD OPERATION
PROCEDURE (SOP)

Upon completion of Unit 3, students should
be able to applying the Standard Operation
Prosedure saftey for Conventional Machining
process to perform practical task.

27

E-MODULE (VOL1)
STEP BY STEP – CONVENTIONAL MACHINING

S.O.P USING MILLING MACHINE

28

E-MODULE (VOL1)
STEP BY STEP – CONVENTIONAL MACHINING

PRACTICAL TASK
FOR MILLING PROCESS

No Procedure Figure/Step

1 Cutting the cylinderical Dimension cutting:
workpiece according to Diameter – 32mm
dimension by using Length – 5.5 cm
Electrical Disc Cutting
Machine.

2 Remove sharp parts and Final Length:
excess workpiece by using 5.0 cm
lathe machine according
to specified dimension A 45 deg.
0 BC
3 Mark on the workpiece to
obtain a rectangular shape
using the appropriate
method according to the
specified measurement.

4 Perform calculation to A
45
obtain the dimension of Step 1:
B Find OB?
an equal square using the Step 2:
Find BC?
method of tringle law.

( Dertemine BC ?) 0

5 Sketch a line to perform
retangular shape on the
workpiece surface.

29

STEP BY STEP – CONVENTIONAL MACHINING

PRACTICAL TASK
FOR MILLING PROCESS

No Procedure Figure/Step

6 Check before use the
Universal Milling Machine,
make sure the machine in a
good condition.

7 Demonstration using milling 1) Turn on power supply

machine with SOP. 2) Start the milling machine

3) Put the workpiece on the vice on the

work table

4) Adjust the tool point and the workpiece

5) Start the cutting processess until getting

the retangular shape arcodding to the

exact dimension.

6) Switch of the miling machine and power

supply

7) Filling the workpiece with the file tools to

get clean surface.

8 Example Squaring Flat bar
operation

9 Example Slot cutting

10 Finish product

29

STEP BY STEP – CONVENTIONAL MACHINING

VIDEO PRACTICAL TASK
FOR MILLING PROCESS

30

E-MODULE (VOL1)
STEP BY STEP – CONVENTIONAL MACHINING

S.O.P USING GRINDING MACHINE

31

STEP BY STEP – CONVENTIONAL MACHINING

PRACTICAL TASK
FOR GRINDING PROCESS

No Procedure Figure

1 Wear Personal Protective
Equipment (PPE)
Goggle
Safety jacket
Safety shoe

2 Power on the surface grinding
machine to make sure magnet
is functioning.

32

E-MODULE (VOL1)
STEP BY STEP – CONVENTIONAL MACHINING

PRACTICAL TASK
FOR GRINDING PROCESS

No Procedure Figure

3 Place the workpiece given on
the table of surface grinding
machine and on the magnet
button.

4 Pull manually on the driver of
i. x-axis (left and right
direction)
ii. y-axis (forward and
backward direction)
iii. z-axis (up or down
direction)
-pull only about two bar each
time to complete a round of x-
axis, each bar measuring is
0.005mm)

32

STEP BY STEP – CONVENTIONAL MACHINING

PRACTICAL TASK
FOR GRINDING PROCESS

No Procedure Figure

5 After each adjustment of z-
6 axis (each surface of the same
old rusty workpiece is not
7 even)
8
Move y-axis half round of the
driver and begin move x-axis
until the row of workpiece
don’t have fireworks anymore,
then move another half round
of y-axis again

Repeat step 5 and step 6
several time until all surface of
old rusty workpiece become
shiny.

Clean up the table and power
off after finish grinding
process.

32

E-MODULE (VOL1)
STEP BY STEP – CONVENTIONAL MACHINING

PRACTICAL TASK
FOR GRINDING PROCESS

No Safety Procedure

1 Wear Personal Protective Equipment (PPE)
Goggle
Safety jacket
Safety shoe

2 Power on the surface grinding machine to make sure magnet is functioning.
3 Place the workpiece given on the table of surface grinding machine and on the magnet button.
4 Pull manually on the driver of

i. x-axis (left and right direction)
ii. y-axis (forward and backward direction)
iii. z-axis (up or down direction)
-pull only about two bar each time to complete a round of x-axis, each bar measuring is
0.005mm)
5 After each adjustment of z-axis (each surface of the same old rusty workpiece is not even)
6 Move y-axis half round of the driver and begin move x-axis until the row of workpiece don’t
have fireworks anymore, then move another half round of y-axis again
7 Repeat step 4.5 and 4.6 several time until all surface of old rusty workpiece become shiny.
8 Clean up the table and power off after finish grinding process.

32

STEP BY STEP – CONVENTIONAL MACHINING

VIDEO PRACTICAL TASK
FOR GRINDING PROCESS

https://youtu.be/gA3AJ4HoNFc

https://youtu.be/71ZNR1FaZos

33

E-MODULE (VOL1)
STEP BY STEP – CONVENTIONAL MACHINING

OTHER MACHINES/EQUIPMENTS
INVOLVE

LATHE
MACHINE

ELECTRICAL
CUTTING
MACHINE

HAND TOOLS

34

STEP BY STEP – CONVENTIONAL MACHINING

S.O.P USING LATHE MACHINE

35

STEP BY STEP – CONVENTIONAL MACHINING

S.O.P ELECTRICAL CUTTING MACHINE

36

RUBRIC FOR
ASSESSMENT

Students should be able to produce practical
task (psychomotor), mini project (affective)
and report . The rubrics will be use to access
their capabilities.

37

E-MODULE (VOL1)
STEP BY STEP – CONVENTIONAL MACHINING

RUBRIC FOR REPORT

PART A

38

STEP BY STEP – CONVENTIONAL MACHINING

RUBRIC FOR REPORT

PART B & C

39