FINAL PROJECTMADE A THERMOSTAT WITH A 4 AXIS CNC MACHINING Made A Thermostat With A 4 Axis Cnc Machining Process And Tooling Design.
FINAL PROJECT
MADE A THERMOSTAT WITH A 4 AXIS CNC MACHINING
PROCESS AND TOOLING DESIGN
A Graduation Project Report submitted by
Jony Kartikno
9999156135 / D200090207
In fulfillment of the requirement of
One-year course in Mechanical Engineering Department,
Wuxi Institute of Technology
A part of Undergraduate study in the Automotive Engineering,
Department of Machanical Engineering, Universitas Muhammadiyah Surakarta
Towards the degree of
Bachelor of Engineering (Mechanical)
MECHANICAL ENGINEERING DEPARTMENT
WUXI INSTITUTE OF TECHNOLOGY
WUXI, JIANGSU PROVINCE, P.R. CHINA
2016
CERTIFICATE OF EXCHANGE STUDY PROGRAM
MOTTO
“Indeed, Allah will not change the condition of a people until they change
what is in themselves.”
( QS. Ar Ra’d : 11 )
“Indeed, in the creation of the skies and the earth, and the changing
between the nights and the days there are the signs of Allah’s majesty
for those who have intelligence.”
(QS. Ali-Imran: 190).
“The strong believer is better and more beloved to Allah than a weak
believer in every good deeds.”
( HR. Muslim)
DEDICATION
This Final Project is dedicated to:
My Parents who won’t feel tired to give education for me
My beloved brother Safto Dwi Kartianto
And all of My Family
My Classmates
in UMS Automotive Engineering 2009
And
for All Readers
MADE A THERMOSTAT WITH A 4 AXIS CNC MACHINING PROCESS
AND TOOLING DESIGN
ABSTRACT
Also known as the thermostat thermostat, coolant flow path control valve.
As a thermostat device comprising temperature sensitive components generally,
by expansion or shrink to open, turn off the flow of air, gas or liquid. Its role is
automatically adjusted according to the level of the engine cooling water
temperature of water entering the radiator, change the water cycle range for
adjusting the cooling capacity of the cooling system to ensure the engine is
operating at a suitable temperature range. Thermostat body itself cast aluminum
alloy, five-sided machining body, processing contents, excellent air tightness
requirements of the finished product, the relative processing requirements are
relatively high. Processing thermostat body's need to use modern CNC machine
tools, CNC machine tools development trend of modern high-speed, highprecision, high reliability, multi-functional, complex, intelligent and open
architecture. The main developments in the research and development of software
and hardware with intelligent full-featured universal open architecture NC device.
CNC machining technology is the basis for automation, CNC machine tools is the
core technology, which is related to the level of national strategic position and
reflects the level of comprehensive national strength. It is with the development of
information technology, microelectronics technology, automation technology and
detection techniques and development of. CNC machining center with a magazine
and automatic tool change, the workpiece can be CNC machine tools, a variety of
processing operations within a certain range.
Key words 㸸 Thermostat 㸹 Computer numerical control machine tools 㸹
Conventional machining CNC machine
ABSTRAKS
Juga dikenal sebagai termostat adalah aliran pendingin katup kontrol
jalan. Sebagai perangkat termostat yang terdiri komponen sensitif suhu umumnya,
dengan ekspansi atau menyusut untuk membuka, mematikan aliran udara, gas atau
cair. perannya secara otomatis disesuaikan dengan tingkat mesin pendingin suhu
air dari air masuk radiator, mengubah rentang siklus air untuk menyesuaikan
kapasitas pendinginan sistem pendingin untuk memastikan mesin beroperasi pada
kisaran suhu yang sesuai. Thermostat tubuh sendiri cast aluminium alloy, lima-sisi
tubuh mesin, pengolahan isi, persyaratan sesak udara yang sangat baik dari
produk jadi, persyaratan pengolahan relatif relatif tinggi. Pengolahan kebutuhan
termostat tubuh untuk menggunakan peralatan mesin CNC modern, peralatan
mesin CNC pengembangan tren modern berkecepatan tinggi, presisi tinggi,
keandalan yang tinggi, multi-fungsional, kompleks, cerdas dan terbuka arsitektur.
Perkembangan utama dalam penelitian dan pengembangan perangkat lunak dan
perangkat keras dengan cerdas fitur lengkap yang universal arsitektur terbuka
perangkat NC. teknologi mesin CNC adalah dasar untuk otomatisasi, peralatan
mesin CNC adalah teknologi inti, yang terkait dengan tingkat posisi strategis
nasional dan mencerminkan tingkat kekuatan nasional yang komprehensif. Hal ini
dengan perkembangan teknologi informasi, teknologi mikroelektronika, teknologi
otomatisasi dan teknik deteksi dan pengembangan. pusat mesin CNC dengan
majalah dan perubahan alat otomatis, benda kerja dapat CNC peralatan mesin,
berbagai operasi pengolahan dalam kisaran tertentu.
Kata kunci: Thermostat; Komputer kontrol numerik alat mesin; mesin
konvensional mesin CNC
FOREWORD
Thanks to Allah SWT who gives his-mercy and blessing, so author can
finish this report of Machine Design Project with the planed time. Blessings and
greetings may keep to our Prophet Muhammad SAW and all his family and
friends in enforcing Dinullah on this earth.
This report is written to part of my undergraduate study in mechanical
Engineering department of Universitas Muhammadiyah Surakarta.
In writing this report, of course, many people who have provided support
both morally and materially. Therefore, the authors would like to express
gratitude boundless to:
1.
Mr. Tri Widodo Besar Riyadi, ST, M.Sc. Ph.D as the head of
Mechanical Engineering Department Universitas Muhammadiyah
Surakarta.
2.
Wijianto, ST. M.Eng.Sc as the secretary of Internatiaonal Program
Automotive Engineering Universitas Muhammadiyah Surakarta.
3.
Mr. Zhang Zheng as the head of Mechanical Engineering
Department Wuxi Institute of Technology.
4.
Mr. Zou Yeas suvervisor 1 in making graduation paper at Wuxi
Institute of Technology.
5.
Jack and Mei as my Chinese friends who always help me to study
Chinese language.
6.
And all of my friends and also my family.
Finally, the author hopes this report is useful for everyone that read it.
Wuxi Jiangsu, 29th June 2016
Author
TABLE OF CONTENTS
TITLE .................................................................................................................. i
VALIDATION SHEET ...................................................................................... ii
CERTIFICATE OF EXCHANGE STUDY PROGRAM .................................. iii
DECLARATION OF RESEARCH AUTHENTICITY...................................... iv
MOTTO .............................................................................................................. v
DEDICATION .................................................................................................... vi
ABSTRACT ........................................................................................................ vii
FOREWORD ...................................................................................................... ix
TABLE OF CONTENTS .................................................................................... x
LIST OF FIGURES ............................................................................................ xii
LIST OF TABLES ..............................................................................................xiii
CHAPTER I INTRODUCTION...................................................................... 1
1.1 Background .............................................................................................. 1
1.2 Problem Statement ................................................................................... 2
1.3 Problem Limitations ................................................................................. 2
1.4 Objective of Research .............................................................................. 3
1.5 Benefit ...................................................................................................... 3
1.6 Writing Systematics ................................................................................. 3
CHAPTER II LITERATURE REVIEW ........................................................ 5
2.1 Thermostat Body ...................................................................................... 5
2.2 Box Parts .................................................................................................. 6
2.3 Thermostat Material Analysis .................................................................. 11
2.4 Determination and Rough Handling......................................................... 12
2.5 Parts Process Planning to Develop ........................................................... 16
2.6 Locating Datum Selection ........................................................................ 20
2.7 Select Processing Method ........................................................................ 20
2.8 Arrange Auxiliary Procedures .................................................................. 21
2.9 Focus Decentralized Process .................................................................... 22
2.10 Process Route Development ................................................................... 23
2.11 Fixture, Measuring Tools, Tool Selection .............................................. 24
CHAPTER III RESEARCH METHODOLOGY .......................................... 28
3.1 Flow Chart of Research ............................................................................ 28
CHAPTER IV RESULT ANALYZE .............................................................. 31
4.1 Determine The Step Size and The Machining Allowance ....................... 31
4.2 Determine Cutting Parameters and Process Time Quota ......................... 34
CHAPTER V CONCLUSSION ....................................................................... 38
5.1 Conclusion ................................................................................................ 38
5.2 Suggestion ................................................................................................ 38
REFERENCES
APPENDIX
LIST OF FIGURES
Figure 2.1 Several Cabiinet Structure . .................................................................. 6
Figure 2.2 Lathe Heanstock. ................................................................................... 8
Figure 2.3 Thermostat Body Jig With A Base Plane View................................... 23
Figure 2.4 Thermostat Body Parts Diagram ......................................................... 24
Figure 2.5 Block B Basis. ..................................................................................... 26
Figure 2.6 Thermostat Body Jig With A Base Elevation View ............................ 27
Figure 3.1 Thermostat Workshop. ........................................................................ 29
LIST OF TABLES
Table 2.1 Routing Table. ....................................................................................... 23
Table 4.1 Margin Calculation and Dimensional Tolerances ................................. 33
Table 4.2 Cutting Parameters. ................................................................................ 36
MADE A THERMOSTAT WITH A 4 AXIS CNC MACHINING
PROCESS AND TOOLING DESIGN
A Graduation Project Report submitted by
Jony Kartikno
9999156135 / D200090207
In fulfillment of the requirement of
One-year course in Mechanical Engineering Department,
Wuxi Institute of Technology
A part of Undergraduate study in the Automotive Engineering,
Department of Machanical Engineering, Universitas Muhammadiyah Surakarta
Towards the degree of
Bachelor of Engineering (Mechanical)
MECHANICAL ENGINEERING DEPARTMENT
WUXI INSTITUTE OF TECHNOLOGY
WUXI, JIANGSU PROVINCE, P.R. CHINA
2016
CERTIFICATE OF EXCHANGE STUDY PROGRAM
MOTTO
“Indeed, Allah will not change the condition of a people until they change
what is in themselves.”
( QS. Ar Ra’d : 11 )
“Indeed, in the creation of the skies and the earth, and the changing
between the nights and the days there are the signs of Allah’s majesty
for those who have intelligence.”
(QS. Ali-Imran: 190).
“The strong believer is better and more beloved to Allah than a weak
believer in every good deeds.”
( HR. Muslim)
DEDICATION
This Final Project is dedicated to:
My Parents who won’t feel tired to give education for me
My beloved brother Safto Dwi Kartianto
And all of My Family
My Classmates
in UMS Automotive Engineering 2009
And
for All Readers
MADE A THERMOSTAT WITH A 4 AXIS CNC MACHINING PROCESS
AND TOOLING DESIGN
ABSTRACT
Also known as the thermostat thermostat, coolant flow path control valve.
As a thermostat device comprising temperature sensitive components generally,
by expansion or shrink to open, turn off the flow of air, gas or liquid. Its role is
automatically adjusted according to the level of the engine cooling water
temperature of water entering the radiator, change the water cycle range for
adjusting the cooling capacity of the cooling system to ensure the engine is
operating at a suitable temperature range. Thermostat body itself cast aluminum
alloy, five-sided machining body, processing contents, excellent air tightness
requirements of the finished product, the relative processing requirements are
relatively high. Processing thermostat body's need to use modern CNC machine
tools, CNC machine tools development trend of modern high-speed, highprecision, high reliability, multi-functional, complex, intelligent and open
architecture. The main developments in the research and development of software
and hardware with intelligent full-featured universal open architecture NC device.
CNC machining technology is the basis for automation, CNC machine tools is the
core technology, which is related to the level of national strategic position and
reflects the level of comprehensive national strength. It is with the development of
information technology, microelectronics technology, automation technology and
detection techniques and development of. CNC machining center with a magazine
and automatic tool change, the workpiece can be CNC machine tools, a variety of
processing operations within a certain range.
Key words 㸸 Thermostat 㸹 Computer numerical control machine tools 㸹
Conventional machining CNC machine
ABSTRAKS
Juga dikenal sebagai termostat adalah aliran pendingin katup kontrol
jalan. Sebagai perangkat termostat yang terdiri komponen sensitif suhu umumnya,
dengan ekspansi atau menyusut untuk membuka, mematikan aliran udara, gas atau
cair. perannya secara otomatis disesuaikan dengan tingkat mesin pendingin suhu
air dari air masuk radiator, mengubah rentang siklus air untuk menyesuaikan
kapasitas pendinginan sistem pendingin untuk memastikan mesin beroperasi pada
kisaran suhu yang sesuai. Thermostat tubuh sendiri cast aluminium alloy, lima-sisi
tubuh mesin, pengolahan isi, persyaratan sesak udara yang sangat baik dari
produk jadi, persyaratan pengolahan relatif relatif tinggi. Pengolahan kebutuhan
termostat tubuh untuk menggunakan peralatan mesin CNC modern, peralatan
mesin CNC pengembangan tren modern berkecepatan tinggi, presisi tinggi,
keandalan yang tinggi, multi-fungsional, kompleks, cerdas dan terbuka arsitektur.
Perkembangan utama dalam penelitian dan pengembangan perangkat lunak dan
perangkat keras dengan cerdas fitur lengkap yang universal arsitektur terbuka
perangkat NC. teknologi mesin CNC adalah dasar untuk otomatisasi, peralatan
mesin CNC adalah teknologi inti, yang terkait dengan tingkat posisi strategis
nasional dan mencerminkan tingkat kekuatan nasional yang komprehensif. Hal ini
dengan perkembangan teknologi informasi, teknologi mikroelektronika, teknologi
otomatisasi dan teknik deteksi dan pengembangan. pusat mesin CNC dengan
majalah dan perubahan alat otomatis, benda kerja dapat CNC peralatan mesin,
berbagai operasi pengolahan dalam kisaran tertentu.
Kata kunci: Thermostat; Komputer kontrol numerik alat mesin; mesin
konvensional mesin CNC
FOREWORD
Thanks to Allah SWT who gives his-mercy and blessing, so author can
finish this report of Machine Design Project with the planed time. Blessings and
greetings may keep to our Prophet Muhammad SAW and all his family and
friends in enforcing Dinullah on this earth.
This report is written to part of my undergraduate study in mechanical
Engineering department of Universitas Muhammadiyah Surakarta.
In writing this report, of course, many people who have provided support
both morally and materially. Therefore, the authors would like to express
gratitude boundless to:
1.
Mr. Tri Widodo Besar Riyadi, ST, M.Sc. Ph.D as the head of
Mechanical Engineering Department Universitas Muhammadiyah
Surakarta.
2.
Wijianto, ST. M.Eng.Sc as the secretary of Internatiaonal Program
Automotive Engineering Universitas Muhammadiyah Surakarta.
3.
Mr. Zhang Zheng as the head of Mechanical Engineering
Department Wuxi Institute of Technology.
4.
Mr. Zou Yeas suvervisor 1 in making graduation paper at Wuxi
Institute of Technology.
5.
Jack and Mei as my Chinese friends who always help me to study
Chinese language.
6.
And all of my friends and also my family.
Finally, the author hopes this report is useful for everyone that read it.
Wuxi Jiangsu, 29th June 2016
Author
TABLE OF CONTENTS
TITLE .................................................................................................................. i
VALIDATION SHEET ...................................................................................... ii
CERTIFICATE OF EXCHANGE STUDY PROGRAM .................................. iii
DECLARATION OF RESEARCH AUTHENTICITY...................................... iv
MOTTO .............................................................................................................. v
DEDICATION .................................................................................................... vi
ABSTRACT ........................................................................................................ vii
FOREWORD ...................................................................................................... ix
TABLE OF CONTENTS .................................................................................... x
LIST OF FIGURES ............................................................................................ xii
LIST OF TABLES ..............................................................................................xiii
CHAPTER I INTRODUCTION...................................................................... 1
1.1 Background .............................................................................................. 1
1.2 Problem Statement ................................................................................... 2
1.3 Problem Limitations ................................................................................. 2
1.4 Objective of Research .............................................................................. 3
1.5 Benefit ...................................................................................................... 3
1.6 Writing Systematics ................................................................................. 3
CHAPTER II LITERATURE REVIEW ........................................................ 5
2.1 Thermostat Body ...................................................................................... 5
2.2 Box Parts .................................................................................................. 6
2.3 Thermostat Material Analysis .................................................................. 11
2.4 Determination and Rough Handling......................................................... 12
2.5 Parts Process Planning to Develop ........................................................... 16
2.6 Locating Datum Selection ........................................................................ 20
2.7 Select Processing Method ........................................................................ 20
2.8 Arrange Auxiliary Procedures .................................................................. 21
2.9 Focus Decentralized Process .................................................................... 22
2.10 Process Route Development ................................................................... 23
2.11 Fixture, Measuring Tools, Tool Selection .............................................. 24
CHAPTER III RESEARCH METHODOLOGY .......................................... 28
3.1 Flow Chart of Research ............................................................................ 28
CHAPTER IV RESULT ANALYZE .............................................................. 31
4.1 Determine The Step Size and The Machining Allowance ....................... 31
4.2 Determine Cutting Parameters and Process Time Quota ......................... 34
CHAPTER V CONCLUSSION ....................................................................... 38
5.1 Conclusion ................................................................................................ 38
5.2 Suggestion ................................................................................................ 38
REFERENCES
APPENDIX
LIST OF FIGURES
Figure 2.1 Several Cabiinet Structure . .................................................................. 6
Figure 2.2 Lathe Heanstock. ................................................................................... 8
Figure 2.3 Thermostat Body Jig With A Base Plane View................................... 23
Figure 2.4 Thermostat Body Parts Diagram ......................................................... 24
Figure 2.5 Block B Basis. ..................................................................................... 26
Figure 2.6 Thermostat Body Jig With A Base Elevation View ............................ 27
Figure 3.1 Thermostat Workshop. ........................................................................ 29
LIST OF TABLES
Table 2.1 Routing Table. ....................................................................................... 23
Table 4.1 Margin Calculation and Dimensional Tolerances ................................. 33
Table 4.2 Cutting Parameters. ................................................................................ 36