UNIVERSITY OF MAURITIUS – MECHANICAL AND PRODUCTION DEPARTMENT (FOE)

Assignment Report
Fabrication of a Lamp Holder

RAMANAH Dhavish Mahunthy - ID: 1510405

SULTOO Aniketsing – ID: 1515313

Submission Date : 28/03/16

This document depicts the fabrication method and setup needed to make a lamp holder
according to a given design. It also include a list of equipment needed to fulfill this task and
safety measures related to the apparatus and manufacturing process being used.
Assignment Report Lamp Holder 1510405 & 1515313

Table of contents.

1| a. Design context____________________________________________________________3
b. Design Brief________________________________________________________________ 3
c. Solution____________________________________________________________________3

2| Material Selection____________________________________________________________4

3| Machining process selection___________________________________________________4

4| Description of the Machining Process____________________________________________5

a. List of Apparatus _____________________________________________________________6

b. Preparation of Material _______________________________________________________6
c. Marking Out ________________________________________________________________8
d. Drilling Process ______________________________________________________________9
e. Tapping Process ____________________________________________________________10
f. Face Milling ________________________________________________________________11
g. Rough and Finish Turning_____________________________________________________11
h. External Threading__________________________________________________________13

5| Safety Measures____________________________________________________________15

6| References________________________________________________________________15

7| Appendix__________________________________________________________________16

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1|a. Design Context

A s an engineering student, we normally have a lot of works and assignments to attend to. Therefore
we spend a lot of the time behind our desks to complete those task, even burning the midnight oil.

Hence, to avoid using a fluorescent light tube/bulb (which in this context have comparatively large
power rating) to enlighten the whole room in which we are working, a small localized lighting on the
student desk will be more efficient and prone on energy savings.

b. Design Brief
“To construct a lamp holder to be placed on a table”

c. Solution
As the design was already provided, it is illustrated below in “Figure 1”.

Figure 1

Part A is the column and Part B is the base. Part A is made of aluminium and Part B is made of mild
steel.
Note: This artifact will be manufactured with machining process available in the workshop of the
Mechanical and Production Engineering Department.

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2| Material Selection
“Nearly every engineered item goes through a sequence of activities that includes: Design → Material
Selection → Process Selection →Production → Evaluation → and possible redesign…” [1]

As the material was already selected for us in the question itself, we will need standards dimensions of
material that are available on the market for this step. Thus, some research was done in order to obtain
the commonly available size on the market and is listed below.

a. For Part A

 Round Solid Rod: 5,6,8,10,12,16,20,25,32,40,50mmØ [2]

Therefore for the alluminium rod (Part A) a 12mmØ rod will be required for the finished artifact. Hence
the 16mmØ Solid Rod will be chosen for this part.

The reason being for choosing a larger diameter rod is that to compensated for the losses when it will be
machined. Moreover when manufacturers’ bulk-produces these item they have a relatively large
fluctuation in the measurement of the diameter. For this reason a larger diameter is machined to the
required size and ensures us a better uniformity to the true value, here being 12mm in diameter.

3| Machining process selection

Again, some more research was done on types of machining process for the presented material
(Aluminium and Mild Steel) and is shown below. The chart below illustrated the most used types of
machining process into three groups according to the type of cutting operation.

Type Wood Plastics Metal

Single-Point Centre Lathes
X X Shaping Machine
Multiple- Point Circular Saw
Band Saw
Reciprocating Saws
Planning/thicknessing Horizontal Milling
machine machine
Drilling Machine
Mortising Machine X X
Abrasive Disc Sanding Machine
Belt Sanding Machine
Orbital Finishing Machine X
Polishing Machine
X X Off-Hand Grinding
machine
X X Surface Grinding Machine
“The chart shows the similarities between machines for different materials, even where names differ,
and also for only one material” [3]

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After considering the table above and the machines available in the workshop of the Mechanical and
Production Engineering Department, the following processes have chosen.

Part Proceses involved Machining Process Machine/ Description of

Required Equipment machines/ equipment
Required
Part A – Diameter reduction, Roughing and Finishing Centre Lathe As part A is a rod, a cetre
12mmØ thread (with dies) making Turning, Facing and machine lathe is used since it turns
Rod Tapper Turning accurate cylindrical and
conical shapes. [4]
M12 Threading Die and Die Stock Die and Die stock a used
(External) to cut external threads.
Part B - Straight and squaring, Face milling and End Vertical Milling A milling machine will
Base Slot making, Drilling and milling machine allow us to produce the
Tapping necessary cuts on the
base of the workpiece
Drilling Process Pillar Drill It will allow us to drill the
necessary hole for the rod
to be inserted into.
Threading (Internal) Taps and Tap Taps are used to make
Wrench internal threads
This table is illustrating the chosen type of machining operation, machines and a brief description of the
latter.

After highlighting the necessary machines needed, we can proceed to the description of the machining
process required to complete the task.

4| Description of the Machining Process

a. List of apparatus:

 Engineer Square
 Scriber
 Engineer Vice
 Surface gauge, angle plate and scribing block
 Ball-pein Hammer
 Flat file
 Center punch
 Steel rule
 Pillar drill and 12mm Ø drill bit
 Lathe Machine and tool
 Milling Machine and cutter
 Protective Clothing and Eye Goggles
 M12 Tap and Tap Wrench, Dies and Die Stock and Lubricant

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b. Preparation of Material
1) A solid mild steel block of 92x122x22mm and a 16mm Ø solid alluminium rod were acquired for this
project.

2)Machining the block square and parallel - The mild steel block is clamped in a machine vice and the
work should be seated in parallel on the worktable of a vertical milling machine. In order to mill the four
sides of a piece of work so that its sides are square and parallel, it is important that each side be
machined in a definite order.

The vice jaws are set parallel to the ram using a D.T.I Mounted in the tool post. (When the vice is
correctly set, the DTI reading should be constant as it travels along the parallel strip)

The work is
set on parallels in the center of the vice using
grips with the largest surface facing upwards.
The cutter is set onto the work surface [refer
to “Setting Cutter to Work” in the appendix
section ] and the work piece is raised by 1mm
using the elevating screw and the surface A
is machined as shown.

The workpiece is turned through 90o so that the

previously machined surface is against the fixed
jaw of the engineer vice. This will ensures that
surface A and B will be perpendicular to each
other. Cutter is set to work and workpiece is
raised by 1mm and surface B is machined as
shown.

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The workpiece is turned through 90o to machine

surface C. Again the cutter is set to work ,raised
by 1mm using the elevating screw and machined.
Workpiece will now be20mm thick.

The workpiece is turned through 90o to machine

surface D as shown. Again the cutter is set to work
,raised by 1mm using the elevating screw and machined.
Workpiece will now be20mmx 120mm

The workpiece is set in the vice as shown and

surface E is machined. Again the cutter is set to
work ,raised by 2mm this time using the
elevating screw and machined. Workpiece will
now be20mmx 120mm x 90mm all straight and
square.

3) Facing the alluminium rod- To check if ever the rod is perfectly straight, place it against an engineer
square as shown on a surface plate.

No or very little amount of light should be able to pass between the rod and the engineer square. Very
little amount of light is acceptable as the roughing tool will later be used on the centre lathe to reduce it
diameter which will , in turn make the rod parallel to the dead axis of the centre lathe.

Now, it is time to face both side of the rod to obtain a true surface which can be used as reference edge
later on.

(i) The work should be held in the 3 Jaws Self-Centering chuck such that at least an equal amount to the
diameter of the work is projecting out of the chuck jaws.

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(ii) The compound rest is rotated 300 to the right.

(iii) The height of the facing tool bit is set to that of the dead centre.
(iv) The carriage is locked in position.
(v) The depth is controlled by the graduated collar on the compound rest screw.
(vi) The work is faced as shown below with a facing tool and repeated on the other side.

Now that the block of mild steel has been machined straight and square and that the rod have been
faced we can start the marking out process.

c. Marking out process

Now that the 6 datum faces were obtained for the mild steel block all markings will be made with
respect to these sides.

4) The workpiece is placed on a surface plate against an angle plate as shown.

The faces of the workpiece are annotated for

illustration purposes only as shown below.

In the 1st set up, taking as reference the longer datum

side the horizontal center mark 45mm from the datum
edge is marked out with the scribing block.

In the 2nd set up, taking face B as datum face, the

vertical position of the center mark for the hole is
marked out with the scribing block.

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When finished, chalk is smeared on the job to make markings more visible for later use.

5) The rod is placed on one of its faced edges against in angle plate on a surface plate as shown.
Furthermore 10mm and 310mm markings form the datum edge is marked out on the rod as shown.

10mm marking – depth of thread

310mm marking – Total length of rod

6) A center punch is then used to mark out the

center for the hole on the mild steel block.

d. Drilling of the hole in the mild steel block.

1. Spot the hole location using a centre punch since the chisel edge at the end of the web on most drills
is generally wider than the centre punch mark on the work to prevent the drill from wandering off
centre, it is considered good practice to first spot every centre punch mark and provide a guide for the
larger drill which will be used.

2. Mount the 12mm Ø drill in the drill chuck(chosen for M12 Tap[Refer to appendix] )

3. Set the drill press to [B]1020rpm for the size of drill and the type of material to be drilled.

4. Fasten a clamp.

5. The work is mounted on parallels in a drill vice and tighten securely.

6. With the vice against the table top, the spotted hole is located under the centre of the drill.

7. The hole is drilled.

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[A] Machine Speed: 1020 rpm

Feed Rate: 0.35mm/rev
Cutting Time: 2.51 sec
Material Removal Rate: 20.3 x 103 mm3/min

8. The drill is rose occasionally,the machine is stopped and the depth of blind hole is measured using a
depth micrometer start the drill press again and apply cutting fluid during the drilling operation. Stop
the drilling operation when the hole has reached a depth of 11mm

9. A counter-sink drill bit is used to counter sink the hole to a diameter slightly larger than the major
diameter of the threads. This allows the tap to be started more easily, and it protects the start of the
threads from damage.

e. Tapping process
1. Mount the workpiece in a bench vice so that the hole is in a vertical position.

2. Tighten the M12 tap in the tap wrench, for the plug tap first.

3. Cup your hand over the center of the wrench and place the tap in the hole in a vertical position. Start
the tap by turning two or three turns in a clockwise direction for a right-hand thread. At the same time,
keep a steady pressure downward on the tap.

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4. After the tap is started for several turns, remove the tap wrench without disturbing the tap. Place the
blade of the engineer square against the solid shank of the tap to check for squareness. Check from two
positions 90 degrees apart.

5. Soluble cutting oil is poured on the tap and into the hole occasionally when cutting threads to
prevent clogging of chips and easy removal of the chips

6. Turn the tap clockwise one-quarter to one-half turn and then turn it back three-quarters of a turn to
break the chips. This motion is continued until the depth of thread of 10mm is obtained.

7. The intermediate tap is placed in the wrench and the above steps(2 -6) is repeated. All the chips left in
the hole is removed and the bottoming tap is inserted into the tap wrench and the above steps (2-6) is
repeated.

f. Face Milling on the Mild Steel Block

1.All burrs are removed and the vice and workpiece are cleaned.

2. Using parallels the workpiece is held in the vice.

3. An helical gear is selected wider than the workpiece to be used.

4. A coated carbide cutter of diameter 30mm (4 teeth) is selected and mounted in the chuck.

5. The cutter is which set to the top surface of the workpiece [refer to appendix: “Setting Cutter to
Work”] and also set onto the front side of the workpiece.
6. The workpiece is raised by 5mm at first with the knee elevating screw and using the cross feed handle
the workpiece is moved by 10 mm.
7. The machine is set to [B]1330 rpm for the 5mm depth of cut and machine is started.
8. The table transverse handle is used to move the workpiece trough the cutter. When the cutter
emerges from the other side, it is returned to its original position.
9. This step is repeated 5 times. The workpiece is moved again by 10mm with cross feed handle and the

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table transverse handle is used to move the workpiece trough the cutter. When the cutter emerges
from the other side, it is returned to its original position. This will obtain the length(60mm) of the slot.

7. The workpiece is raised by another 4mm with the knee elevating screw and the steps 8 and 9 is done
again to do another cut.

8. The machine is set to [B]1330 rpm for finishing cut for a smaller feed rate and the work’s surface is
thinned by 1mm as described above.

g. Rough and finish turning of the rod

1. The work is mounted in the chuck, with no more than three times the diameter extending beyond the
chuck jaws.

2. A general purpose toolbit is fastened in the toolholder and set to the centre point.
3. The toolpost screw is tightened securely.
4. The lathe is set to [C]1800 rpm and feed 1.1 mm/rev for rough turning.
5. The cross feed graduated collar is increased to make a depth of cut of 0.95mm(0.95mm deep cut will
reduce the diameter by 1.9mm) on one pass.
6. The diameter is rough turned.

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7. Steps 5 and 6 is repeated once more for the diameter to reached 12.2mm Ø.
8. The lathe speed is set to [C]1800 rpm and feed 0.15mm/rev for finish turning.
9. The cross feed graduated collar is increased to make a depth of cut of 0.1mm(0.1mm deep cut will
reduce the diameter by 0.2mm on one pass).
10. The diameter is finished turned and the diameter is measured and checked with a vernier caliper.
11. The cross feed graduated collar is set to zero with the new diameter (12.0mmØ).
12. The compound slide is rotated by 30o and for tapper turning to be made on the rod.

11. The lathe is set to the proper speed and the hole is spotted with a centre drill. The 5mm Øtwist drill
is now mounted in the tailstock spindle. The machine is set to [D]1800rpm
12. The drilling operation is performed. The graduations on the tailstock spindle are used to gauge the
depth of the hole to 8mm. The drill should be withdrawn frequently to remove the chips. Cutting fluid
should also be used.

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13. The rod is then moved so as 160mm of the rod is accessible for turning, the tailstock is bought near
and centre drill is placed against the previously drilled hole using the tailstock handwheel. The tailstock
is then locked in place with its spindle free to rotate.

14. The steps 3-10 are repeated for the whole accessible length (160mm)
15. The rod is removed and the other side is place into chuck and secured.
16. The steps 1-10 ,11-13 are repeated for the other side of the rod.

h. External Threading.
1. An M12 die is selected and mounted in the die stock and mount the work piece in an engineer vice.

2. To start the thread, the die was placed over the workpiece. Holding the diestock with one hand,
downward pressure was applied and the die was turned in a clockwise fashion.

3. When the cut has started, cutting fluid was applied to the workpiece and die, and the diestock was
then turned with both hands. After each complete revolution forward, the die was reversed one-half
turn to break the chips.

4. Check to see that the thread is started square, using a machinist’s square. Make any necessary
corrections by applying slight downward pressure on the high side while turning.

5. When several turns of the thread have been completed, the fit of the thread was checked with the
tapped hole in the mild steel block. If the thread fit is incorrect, adjust the die with the adjustment
screws and take another cut with the adjusted die. Continue making adjustments until the proper fit is
achieved.

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6. Continue threading to the length of 10mm.

When cutting threads close to a shoulder, invert
the die after the normal threading operation and
cut the last two or three threads with the side of
the die that has less chamfer.

Clean the rod and mild steel block with a brush and dry towel and insert the rod into the mild steel rod.

5| Safety Measures
 Protective clothing and goggles were worn to protect the clothes and eyes from chips, oil or dirt.
 Make sure, before switching on the pillar drill that the chuck key is not in the chuck.
 To increase efficiency, decrease man hours and production time and also unnecessary
wandering in the workshop that may be a hazard we should plan the work in such a way that all
marking, cuts, filling, etc is each done at once. This will prevent trips to obtain previously used
equipment.

 Using appropriate coolant absorbs heat, acts as a lubricant and washes away chips and increase
the life span of the tool.

6| References
[1] J.T Black & Ronald A. Kohser|DeGarmo’s Material and Processes in Manufacturing, 10th Edition, John
Wiley and Sons, inc : Chapter 9 - Page 200

[2] Colin Caborn, Ian Mould & John Cave| Design and Technology, Revised Edition, Nelson: Unit 22 –
Page 337

[3], [4] Colin Caborn, Ian Mould & John Cave. Design and Technology. Revised Edition, Nelson: Unit 17 –
Page 240 & 245

[5] Avallone, E.A. (ed.) & Baumeister, T. (ed.). 1997. Marks’ Standard Handbook for Mechanical
Engineer. 10th edition. New York: McGraw Hill: Unit 13 (Turning)

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7| Appendix
a. Setting Cutter to Work Procedure

1. The work is raised to within 6 mm of the cutter and directly under it.

2. A long piece of thin paper is held on the surface of the work.

3. The work is then moved up slowly with the elevating knee screw until the cutter (set rotating) grips
the paper.

4. The paper is removed and the knee is raised by 0.05 mm to cater for the paper thickness.

5. The graduated collar on the elevating screw handle is set to zero.

6. The work can now be raised to the desired depth of cut.

Note: For setting cutter to work on a vertical face, same procedure except all movements are done by
using the cross feed handle.

b. Tap and Dies size chart

Image 1 - Source: Workshop of the Mechanical and Production Engineering Department at UoM.

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c. Available Machine Speeds

Image 2 - Pillar Drill Speed Chart -

Source: Workshop of the Mechanical and Production Engineering Department at UoM.

Image 3 - Centre Lathe Speeds- Image 4 - Vertical Milling Machine Speeds -

Source: Workshop of the Mechanical and Production Engineering Department at UoM

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d. Handbook Values

Table 1 – Table illustrating recommendations for drilling

Table 2 – Table illustrating recommendations for milling operations

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Table 3 – Table illustrating recommendations for turning operations

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 Calculation Description of Formula Handbook Other Answer Available

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________________________________End of document_______________________________
Reference machining process Values Values Machine

* “N” is taken from Available Machine Speed in Workshop rather than answer as we are interested in
Speed

actual time it would take to complete that process in the workshop not the theoretical time. [For
[A] Drilling 12mmØ in K = 1000 D=12mm 1392 rpm 1020 rpm
Mild Steel for CS = 35 Ø
tapping m/min**
L = 11mm
N = 1020* 2.51
fr = rpm Seconds
0.35mm/re
v A = 6mm
20.3 x 103
mm3/min

** Handbook values are taken from table shown in appendix d.

Lamp Holder

[B] Face Milling of Mild K = 1000 D = 30 mm 1273 rpm 1330 rpm

Steel Block V = 120 n=4
m/min LA = L 0 = 452
Ft = 0.085 D/2 = 10 mm/rev
mm/tooth mm
13.26
seconds
[C] Turning of K = 1000 D=16 mm 1790 rpm 1800 rpm

available speeds refer to appendix].

alluminium rod CS =
90m/min
Assignment Report

[D] Centre Drilling K = 1000 D = 5 mm 1909 rpm 1800 rpm

e. Calculations

CS =
30m/min