Post on 24-Mar-2020
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MANUFACTURING PROCESS
ARTICLE
2019
By: Rino Andias Anugraha and Assistant Team
School of Industrial Engineering
TelkomUniversity
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INTRODUCTION
Praise be to Allah Subhanahu wa Ta'ala, because with His grace and mercy, the writer and the
team were given the opportunity to complete the Article Module for the implementation of
the manufacturing process practicum in the 2019/2020 educational year.
In this module the authors and team re-designed our masterpiece of practicum products
namely Stirling Engine, where we added 2 pistons and enlarged the scale of parts that were
made in the previous version for the needs of integrated practicum activities in the Faculty of
Industrial and System Engineering
Prosman Laboratory Adviser
Rino Andias Anugraha, ST., MM
NIP : 99750032
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MANUFACTURING PROCESS LABORATORY ASSITANTS 2019/2020
Aldyan Nurfaizi B. Tau
Alia Agistina
Anak Agung Sri Nandini
Anggit Pratama
Bagas Arganto P.
Bela Pitria Hakim
Damario Haznam
Farras Burhanuddin
Gitanjali Widayu Diatri
Mario Adiprana Muki
Nafisha Herma Hanifha
Pangestu Rizky Purnama
Satria Rahmadani Putra
Sri Yuzarnimar
Tri Maisyah Nugrah Samudro
Zakaria Gunada
Abdurrahman Rashif
Annastasya Septiani
Aquilla Yunma Imaristha
Arief Tri Hendrayanto
Corie Ariesta Arbay
Dhiya Shafa Azizah
Dimas Rayhandika
Elisa Intan Puspitasari
Gamaliel Situmeang
Indah Ekanurhayati
Irfanul Zuhdi Nufrinal
Kholiq Giffari
M. Fachri Husamuddin
M. Arash Arisiah
M. Raihan Arrafi
M. Sohibul Wafa
Nisri Husna Faadhilah
Rafi Pragiwaka Gani
Tirza Ayu Nursazabillah
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MANUFACTURING PROCESS
LABORATORY
Document
Number
MODUL 5 Form
Number
Valid 2019
Module Machining Process
Labwork Conventional and CNC Machine
Student Outcomes SO2. Able to apply mathematics, science and engineering
principles to solve complex engineering problems in
integrated systems (including human, material, equipment,
energy, and information)
Learning Outcomes LO15. Students are able to run a process plan made on real
work objects with the machining process
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A. Tools and Requirements
Tools & Software Requirements
1. Fixture
2. Vice
3. Flat End Mill D16, D12, D10, D8, D6
4. Drill D3, D5, D6
5. Face Mill D100
6. Insert Knife
7. CNC Machine: Lathe
8. CNC Machine: Milling
9. Conventional Machine: Lathe
10. Conventional Machine: Milling
1. Mask
2. Stationary
B. References
DeGarmo, E., Black, J., & Kohser, R. A. (2014). DeGarmo's MATERIALS & PROCESSES IN
MANUFACTURING. Chichester, United Kingdom: John Willey and Sons Ltd.
Clark, D. A. (2014). Milling. Ramsbury,Malborough,Wiltshire: The Crowood Press Ltd..
Groover, M. P. (2014). Fundamentals of Modern Manufacturing Materials, Process and
Systems. John Wiley & Sons Inc.
Limited, D., Royd, B., & Yorkshire, W. (n.d.). G and M Programming for CNC Milling
Machines.
Manufacturing Process Laboratory, A. M. (2017). Modul Praktikum Proses Manufaktur.
Manufacturing Process Laboratory.
El-Hofy, H. A.-G. (2014). Fundamentals of Machining Processes Conventional and
Nonconventional Processes, Second Edition. London: CRC Press, Taylor & Francis Group.
Groover, M. P. (2014). Fundamentals of Modern Manufacturing Materials, Process and
Systems. John Wiley & Sons Inc.
Klocke, F. (2014). Manufacturing Processes. London: Springer Heidelberg Dordrecht .
3
C. Labwork Steps
Flow Process Charts Process Description
1. Read the study case well. Because the study
case contained information that will be
carried out.
2. Turn on CNC Machine Lathe, CNC Machine
Milling, Conventional Machine Lathe, and
Conventional Machine Milling according to
the tutorial on labwork
3. Set the machine according to the part that
will be made.
4. Prepare the stock according to the part that
will be made.
5. Operate the machine according to the part
that will be made.
END
Operate the Machine
Prepare stock
Set up the machine
Turn on CNC Machine and Conventional
Machine
Read the Study Case
START
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MODULE 5
MACHINING PROCESS : CONVENTIONAL & CNC MACHINE
1.1 Students are able to understand SOP Machine.
1.2 Students are able to understand about setup CNC Machine.
1.3 Students are able to understand CNC Milling.
1.1 Students are able to understand CNC Lathe.
1.2 Students are able to understand Conventional Milling.
1.3 Students are able to understand Conventional Lathe.
2.1 Machining Process.
2.2 Setup CNC and Conventional Machine.
2.3 Introduction of CNC Mill.
2.4 SOP of CNC and Conventional Mill Machine.
2.5 Types of Milling Machine.
2.6 Component of CNC Milling.
2.7 Introduction of CNC Lathe.
2.8 SOP of CNC and Conventional Lathe Machine.
2.9 Lathe Machine.
2.10 Process in CNC Lathe.
2.11 Component of CNC Lathe.
1. OBJECTIVES
2. OUTLINES
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3.1 Machining Process
Machining is manufacturing process that involves removing materials using
cutting tools for getting rid of the unwanted materials from some work piece and
converting it into the shape you desire. A large piece of stock is used for cutting the
work piece. The large stock might be in any shape such as solid bar, flat sheet, beam
or even hollow tubes. The process can also be performed on some existing part like
forging or casting. Machining process has two types, they are conventional
machining and modern machining process. Conventional machining utilizes cutting
tools that must be harder than the work piece material. In modern machining
practice, harder, stronger, and tougher materials that are more difficult to cut are
frequently used. Therefore, directed toward machining processes where the
mechanical properties of the work piece material are not imposing any limits on the
material removal process.
In this regard, the nonconventional machining techniques came into practice
as a possible alternative concerning machine ability, shape complexity, surface
integrity, and miniaturization requirements. Innovative machining techniques or
modifications to the existing method by combining different machining processes
were needed. Any machining process has two types of interrelated variables these
are input (independent) and output (dependent).
Figure 5.1 Variables of a Machining Process (El-Hofy, 2014)
3. BASIC THEORY
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On this module we use modern machine that is Computer Numerical Control
(CNC) and Conventional machine. CNC is a machine controlled by computer using a
numerical language as an input for the operation process, while for Conventional
machine controlled by direct operator. There are few components that works on
CNC System:
1. Computer-Aided Design (CAD) and Computer-Aided Manufacturing (CAM)
Designer makes their product through program called CAD, which the output is
an end item and CAM can be used for the machining process. On CAD, the
codes which built up the desired product can be generated, codes are labeled
as “G-code”.
2. Interface/USB flash drive
To transfer the program that has been made (the output of CAD and CAM), a
USB flash drive is needed as an interface between CNC Router Engraver and
computer.
3. Machine Controller
Machine controller works as an interpreter which is interprets part program
into cutting tools.
4. Drives
Drives works as an amplifier of the signal from machine controller so it can
operate the motor suitably.
There are a few things that must be considered for Conventional Machine:
1. Consider direction of spindle rotation, axis.
2. Do not select a cutting tools of larger diameter than is necessary.
3. Do not change feeds or speeds while the machine is in operation. When using
clamps or chuck to secure a workpiece, be sure that they are tight and that the
piece is held so it will not spring or vibrate under cut.
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3.2 Setup CNC and Conventional Machine
Set up for CNC machine contains:
1. Machining Power Up
2. Programing Introduction
3. Numbered Program
4. Part Setup
Set up for Conventional machine
contains:
1. Machining Power Up
2. Part Setup
Part setup is necessary to properly secure the part to the table. This can be
done various ways, using vices, chucks, or using T-Bolts and toe clamps.
a. Workholding Devices
Milling Machine VS Lathe Machine
Vice
Figure 5. 2 Vice Retrieved from (Alibaba Group, 2019)
Vice is a mechanical apparatus
used to secure an object to
allow work to be performed on
it. This part usually use on CNC
machine.
Chuck
Figure 5. 3 Chuck Retrieved from (Alibaba Group, 2019)
A chuck is a specialized type of
clamp. It is used to hold an
object with radial symmetry,
especially a cylinder. This part
usually use Conventional
machine
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b. Other Workholding Devices
Milling Machine VS Lathe Machine
Clamp
Figure 5. 4 Toe Clamp Retrieved from
(Alibaba Group, 2019)
A clamp is a fastening devices
used to hold or secure object
tightly together to prevent
movement or separation
through the application of
inward pressure. This part
usually use on CNC machine.
Tailstock
Figure 5.5 Tailstock Retrieved from
(Haas Automation, 2019)
A tailstock usually used to apply
support to the longitudinal
rotary axis of a workpiece being
machined. This part usually use
on Conventional machine.
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c. Tooling
Tool Functions with T-nn code is used to select the next tool to be placed
in the spindle from tool changer.
Milling Machine VS Lathe Machine
Tool Magazine
Figure 5. 6 Tool Magazine Retrieved from
(Haas Automation, 2019)
In CNC milling machine a tool
change can be commanded with
the X, Y, and Z axis in any position.
Turret
Figure 5. 7 Turret Retrieved from (Haas Automation, 2019)
In CNC, Lathe machine tool
change can be commanded with
the X and Z axis in any position.
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d. Tool Holders
There are several different spindle options for the Haas mills. Each of these
types requires a specific tool holder. The most common spindles are 40 mm
and 50 mm taper. This part usually use on CNC and Conventional Machine.
Figure 5. 8 Tool Holder Retrieved from (Alibaba Group, 2019)
e. Pull Studs
A pull stud or retention knob is required to secure the tool holder into the
spindle. Pull studs are threaded into the top of the tool holder and are
specific to the type of spindle. This part usually use on CNC and Conventional
Machine.
Figure 5. 9 Pull Studs Retrieved from (Haas Automation, 2019)
f. Tool Holder Assembly
Tool holders and pull studs must be in good condition and tightened using
wrenches or they may stick in the spindle. This part usually use on CNC and
Conventional Machine.
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3.3 Introduction of CNC Mill
Milling is a basic machining process by which a surface is generated by
progressive chip removal. The workpiece is fed into a rotating cutting tool.
Sometimes the workpiece remains stationary, and the cutter is fed to the work.
Figure 5. 5 CNC Mill Machine Retrieved from (Haas Automation, 2019)
Figure 5. 6 Some of the feature shown of CNC Mill (Haas Automation, Inc., 2012)
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Figure 5.6 Some of the feature shown of CNC Mill (cont.) (Haas Automation, Inc., 2012)
3.4 SOP of CNC and Conventional Mill Machine
Table 5. 1 SOP of CNC and Conventional Mill Machine (Turn ON)
CNC Mill Conventional Mill
Procedure to Turn On HAAS CNC Mill
1. Turn on the compressor.
a. Check the oil engine level first, the oil must be upper than the red point.
2. Rotate the lever of gas flow to the open position (parallel).
3. Wait until the gas pressure is 5.5 - 8.5 bar.
4. Turn on the main power of CNC Machine.
a. Check the oil of machine, between min and max point.
b. Check the lubricants tube of machine.
c. Scroll the lever of main power to the on side.
Procedure to Turn On HAAS CNC Mill 1. Rotate the vertical spindle to on.
Red arrow on vertical spindle is a direction.
2. Calibration machine will be starting.
3. There is set-up for make a spindle spinning path. Counter-clockwise (CCW) and Clockwise (CW).
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Table 5. 4 SOP of CNC Mill Machine (cont.)
CNC Mill
5. Press the emergency stop.
6. Press power on button.
7. Release emergency stop.
8. Press reset button.
9. Turn on the lamp engine.
10. Press the power up button.
11. Start the program. How to start the program.
a. Press list prog button.
b. Choose the program.
c. Press cycle start button.
12. Set the stock to the clamping.
a. The stock must be suitable with the program.
13. Set the offset tool.
14. Start the program. How to start the program.
a. Press list prog button.
b. Choose the program.
c. Press cycle start button.
Table 5. 2 SOP of CNC and Conventional Mill Machine (Turn Off)
CNC Mill Conventional Mill
Procedure to Turn Off HAAS CNC Mill 1. Clean the remaining chips on the
machine. 2. Change the tool to T7.
a. Press MDI DMC button.
b. Write T07.
c. Press ATC REV button. 3. Move the table in to the middle of
the machine.
a. Press HAND JOG button.
b. Choose the scale of movement (.1 100.).
c. Press the selected axis (X / Y / Z).
d. Rotate the handle jog until the table work in the middle of machine.
4. Close the door. 5. Press the emergency stop. 6. Press the power off button. 7. Turn off the main power CNC
Machine. 8. Rotate the lever gas flow to the
closed position (perpendicular).
9. Turn off the compressor.
Procedure to Turn Off Conventional Mill 1. Rotate the vertical spindle to off. 2. The machine will be stop
automatically. 3. If there is emergency, there is E-
Stop (emergency stop) to make machine stop automatically.
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3.5 Types of Milling Machine
a. Vertical Mill
The vertical milling machine is basically the same as turret milling machine,
but the turret milling machine is much more versatile. Vertical milling machine
have their spindles in the vertical plane. The plain vertical milling machine can
usually only be tipped to the left and the right, often by tilting the whole vertical
column that the head is mounted on. A vertical mill has a stationary spindle and
the table is moved both perpendicular and parallel to the spindle axis to
accomplish cutting.
Figure 5. 7 Vertical Mill Retrieved from (Alibaba Group, 2019)
Figure 5. 8 Some of the feature of Vertical Mill Machine
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b. Horizontal Mill
A horizontal mill has the same sort of x–y table, but the cutters are mounted
on a horizontal arbor across the table. Many horizontal mills also feature a built-
in rotary table that allows milling at various angles; this feature is called a
universal table. Some horizontal milling machines are equipped with a power-
take-off provision on the table. This allows the table feed to be synchronized to
a rotary fixture, enabling the milling of spiral features such as hypoid gears.
Figure 5. 9 Horizontal Mill Retrieved from (Alibaba Group, 2019)
Figure 5. 10 Some of the feature of Horizontal Mill Machine
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c. UP and DOWN Process Milling
Figure 5. 11 UP and Down Milling (DeGarmo, Black, & Kohser, 2014)
In up milling, the chip is very thin at the beginning, where the tooth first
contacts the work; then it increases in thickness, becoming a maximum where
the tooth leaves the work. In down milling, maximum chip thickness occurs close
to the point at which the tooth contacts the work.
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3.6 Component of CNC Mill
There are eleven main program components of HAAS CNC Mill, there are:
Table 5. 3 Component of CNC Mill
No. Name Picture Function
1 Control Panel
To explain machine control and various other functions that use instructions by the electronic control system. Where there is program the G-Codes
into the machine.
2 Tool
The cutting tool is attached to the column and is the part that actually cuts the piece in the way that the operator specifies.
3 Spindle
The spindle hold the cutting tool in place.
4 Coolant
Coolant is pumped through in order to keep the metal cool and the cutting tool lubricated.
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Table 5. 3 Component of CNC Mill (cont.)
No. Name Picture Function
5 Table
Table is an area that the workpiece will be attached either using a clamp or a vacumm during processed.
6 Vice
A mechanical apparatus used to secure an object to allow work to be performed on it.
7 Tool Magazine
The T-nn code is used to select the next tool to be placed in the spindle from tool changer. It can be commanded with the X, Y, and Z axes in any position.
8 Tool Holder
The most common spindles are 40 mm and 50 mm taper.
9 Pull Stud
Pull studs are threaded into the top of the tool holder and are specific to the type of spindle.
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Table 5. 3 Component of CNC Mill (cont.)
No. Name Picture Function
10 Fixture
Fixtures designed to specifically hold a part in the correct location with respect to the tool are used for larger volumes.
11 Jig
Frequently used on large parts, where it is necessary to drill one or more holes that must be spaced accurately with respect to each other.
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3.7 Introduction of CNC Lathe
Turning process is a machining process which procedure the cyclindrical
workpiece. The machine which uses to this process is Lathe Machine. The principle
of turning are :
a. Workpiece is spinning in one axis
b. With a single point cutting tool
c. The tool has parallel path with the workpiece, and it will throw away the surface
of workpiece
Figure 5. 12 HAAS CNC Machine Lathe Retrieved from (Haas Automation, 2019)
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Figure 5. 13 Some of the feature shown of CNC Lathe (Haas Automation, Inc., 2012)
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Figure 5. 14 Some of the feature shown of CNC Lathe (Haas Automation, Inc., 2012)
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3.8 SOP of CNC and Conventional Lathe Machine
Table 5. 4 SOP of CNC Lathe and Conventional Machine (Turn ON)
CNC Lathe Conventional Lathe
Procedure to Turn On HAAS CNC Lathe 1. Turn on the compressor.
a. Check the oil engine level first, the oil must be upper than the red point.
2. Rotate the lever of gas flow to the open position (parallel).
3. Wait until the gas pressure is 5.5 - 8.5 bar. 4. Turn on the main power of CNC Machine.
a. Check the oil of machine, between min and max point.
b. Check the lubricants tube of machine. c. Scroll the lever of main power to the
on side. 5. Press the emergency stop. 6. Press power on button. 7. Release emergency stop. 8. Press reset button. 9. Turn on the lamp engine.
10. Press the power up button.
Procedure to Turn On Conventional Lathe 1. Make sure the emergency stop
condition is locked before connecting with the electric current.
2. Turn on the electricity. 3. Setting the spindle speed to be
used, then press the switch on or unlock emergence stop machine.
4. Drag up the direction lever for clockwise spindle spin, and down
for counter clockwise spindle spin. 5. The machine is on.
Table 5. 7 SOP of CNC Lathe Machine (cont.)
CNC Lathe
15. Start the program. How to start the program.
a. Press list prog button.
b. Choose the program.
c. Press cycle start button.
16. Set the stock to the clamping. The stock must be suitable with the program.
17. Set the offset tool.
18. Start the program. How to start the program.
a. Press list prog button.
b. Choose the program. Press cycle start button.
Table 5. 8 SOP CNC Lathe and Conventional Lathe
CNC Lathe Conventional Lathe
Procedure to Turn Off HAAS CNC Lathe These are the procedures to turn off HAAS CNC Lathe Machine. 1. Press [RESET] to clear all the program that
was run before. 2. Press [EMERGENCY STOP] 3. Press [POWER OFF]
Turn [EMERGENCY STOP] to the right
Procedure to Turn Off Conventional Lathe
1. Make sure the spindle spin is in neutral condition, with drag to normal condition of direction lever.
2. Lock the spindle spin with breaker in downside.
3. Press the emergency stop, and make sure the emergence stop is in locked condition.
4. Disconnect the electricity power from the conventional lathe machine.
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3.9 Lathe Machine
Turning is the process of machining external cylindrical and conical surfaces. It is
usually performed on a machine tool called a lathe, using a cutting tool. The
workpiece is held in a work holder. Different from CNC Lathe, to running the turning
conventional did not use NC code or G-code but to run this machine should be
undertaken in a manual.
Figure 5. 15 Lathe Machine Conventional Retrieved from (Alibaba Group, 2019)
Figure 5. 16 Some of the feature of Conventional Lathe Machine
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3.10 Process in CNC Lathe
Below are six process in CNC Lathe.
a. Face Turning
Face turning is one of the methods used in the turning process to the
products which has the surface perpendicular to the axis of rotation. Face
turning process divided by transverse face turning, transverse parting off,
turning and cylindrical face.
Figure 5. 17 (a) Transverse Face Turning, (b) Transverse Parting Off, (c) Cylindrical Face Turning (Klocke, 2014)
b. Cylindrical Turnig
Cylindrical turning is used to produce a surface which has a surface that is
parallel to the axis of rotation. This method is used for finishing products that
has very small size. There are three types of cylindrical turning are longitudinal
cylindrical, centerless rough turning and transverse turning.
Figure 5. 18 Longitudinal Cyclindrical Turning, Centreless Rough Turning, and Transverse Turning. (Klocke, 2014)
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c. Helical Turning
Helical turning is process of turning which produce helical surface
workpiece. This method usually uses to make bolt and the other product which
has screw thread on the surface. Variants of helical turning process is thread
turning which has singular point cutting tool in the process.
Figure 5. 19 Types of Helical Turning (Klocke, 2014)
d. Profile Turning
Profile turning is to produce rotation symmetrical workpiece shapes by
reproducing the tool profile. Most of profile turning are happened in the model
of turning process and this process is the main process because it can produce
the complex shape of product.
Figure 5. 20 Types of Profile Turning (Klocke, 2014)
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e. Form Turning
Form turning is used to produce wokpiece shapes by controlling the feed
movements. Form turning is categorized as in figure 5. 17 into NC form turning,
copy turning and kinematic form turning. NC form turning, the feed movement
is realized by electronically linked feed drives. Copy turning involves deriving
the feed movement from a reference shape. Kinematic form turning was often
used in the past to produce ball heads.
Figure 5. 21 Types of Form Turning (Klocke, 2014)
f. Further Process
Variant process was basically explicated using the example of external
machining. Kind of internal machining process are boring, undercutting,
internal grooving. Boring process is used to make a bigger diameter of a hole.
Before the operator use boring process, the workpiece should have a hole first.
Undercutting process is the process to remove the center of a workpiece.
Internal grooving is the grooving movement which located in the internal side.
Figure 5. 22 Types of Further Process Variant (Klocke, 2014)
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3.11 Component in CNC Lathe
There are nine main components of HAAS CNC Lathe.
Table 5. 5 Component of CNC Lathe
No. Name Picture Function
1. Controller
To explain machine control and various other functions that use instructions by the electronic control system. Where there is program the G-Codes into the
machine.
2. Turret
Placing the tool according the dimension or list.
3. Chuck
Holding workpiece on machining process.
4. Collet
To hold the workpiece.
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Table 5. 5 Component of CNC Lathe (cont.)
No. Name Picture Function
5. Spindle
Holding and spinnning tool in the workpiece.
6. Insert Knife
To hold the eye of knife and it can be inserted to the holder.
7. Holder
To hold the tool and insert knife.
8. Tool
Combined insert knife and holder, to dispose the selecting surface of workpiece.
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Table 5. 8 Component of CNC Lathe (cont.)
No. Name Picture Function
9. Nozzle Coolant
Coolant is pumped through in order to keep the metal cool and the cutting tool lubricated.
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DeGarmo, E., Black, J., & Kohser, R. A. (2014). DeGarmo's MATERIALS & PROCESSES IN
MANUFACTURING. Chichester, United Kingdom: John Willey and Sons Ltd.
Clark, D. A. (2014). Milling. Ramsbury,Malborough,Wiltshire: The Crowood Press Ltd..
Groover, M. P. (2014). Fundamentals of Modern Manufacturing Materials, Process and
Systems. John Wiley & Sons Inc.
Limited, D., Royd, B., & Yorkshire, W. (n.d.). G and M Programming for CNC Milling
Machines.
Manufacturing Process Laboratory, A. M. (2017). Modul Praktikum Proses Manufaktur.
Manufacturing Process Laboratory.
El-Hofy, H. A.-G. (2014). Fundamentals of Machining Processes Conventional and
Nonconventional Processes, Second Edition. London: CRC Press, Taylor & Francis
Group.
Groover, M. P. (2014). Fundamentals of Modern Manufacturing Materials, Process and
Systems. John Wiley & Sons Inc.
Klocke, F. (2014). Manufacturing Processes. London: Springer Heidelberg Dordrecht .
4. REFERENCES