COPY MILLING MACHINE 1

INDEX
TOPIC CONTENT PAGE NO
1.1-1.3 INTRODUCTION 3

2.1-2.2 MATERIAL SELECTION 8

3.1-3.8 CONSTRUCTION AND WORKING 12

4.1-4.5 DESIGN AND PROJECT 20

5.1-5.19 PROCESS SHEET 26

6.1-6.4 TESTING OF MACHINE 62

7.1-7.2 MAINTENANCE 65

8.1-8.6 COST ESTIMATION 67

9. SOURCE 70

10. BIBLOGRAPHY 72

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ACKNOWLEDGEMENT

We express esteemed gratitude and our sincere thanks to our worthy lecturer guide
Prof.Ambadekar, project incharge Prof V. P. Hiwanj, H.O.D. Prof R. O.
Gawande,and principal Prof A.P.Patil.Our vocabulary do not have suitable words
benefiting to high standard at knowledge and extreme sincerity , deviation and
affection with they have regularly encourage us to put heart and soul in this work
of manufacturing Copy Milling Machine.

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CHAPTER NO.01
INTRODUCTION

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1. Introduction
1.1 What is milling ?
Milling is a machine process in which material is removed by rotation multiple
tooth cutter. As the cutter rotates each tooth removes a small amount of material
from the advancing work for each spindle (rotation) revolution . The relative
motion between the work piece and the cutter can in be any direction. Surface
having any orientation can be machined in milling.

What is copy milling ?

Milling machine to produce complex shape like cam, die molds ,spectacles profile
or any other intricate profile for either piece or mass production requirement are
often equipped with copying capabilities through tracer control .A master or a
template is used as model to reproduce work piece shape .The co-ordinates of cuter
path are determined by tracing template through a stylus or pilot . The tracer
control is obtained by one of the following system:

1. Mechanical

2. Hydraulic

3. Electric

4. Optical control (light beam with electric eye sensor)

Copy milling machines with tow axis tracing are equipped with flat template .

Irregular countours , radial cam profile ,or constant depth grooves like that of
fixtures can be milled on this machine .This machine is provided with a tracer unit
having an manually controlled steering mechanism. In manual operation the
worker constantly sense the contract with the template or masterpiece and adjust

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the direction of the bias pressure applied to the stylus rod , so that always remain in
contact with template and guide itself automatically around the contour of template
in the longitudinal plane.

Mechanically controlled machine with 2 or 3 dimensional copy are known as

pantograph milling machine .These machine are used for engraving purpose where
fine details are to be obtained with good finishing.

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1.2 What our project deals with

 To day to satisfy the demand and increasing the productivity as whole we

require to have specialized machines which could manufacturing template of
better quality , at a higher rate of production thereby reducing the cost of
manufacturing.

 This lead to us to use copy milling machine for manufacturing of templates.

 The copy milling machine is used to cut contour of templates of different

shape and sizes depending on the master piece.

 This machine is used to prepare templates of acrylic and plastic (i.e.celluiod

acetate).

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1.3 What is our project made for

 The end milling operation of production of a flat surface which is horizontal

to the table surface can be perform very easily by even a unskilled machine
operator by use of our project.

 Also it facilitate increase in productivity as various feature such as simple

yet effective work holding devices ,no engraving or tapping on work pieces
is required prior to machining .

 Are to increase the productivity effectively without compensating with

safety features.

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CHAPTER NO.02
SELECTION OF MATERIAL

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2. Material Selection

 The proper material selection for the different parts of machine is main
objective in the fabrication of machine. For a design engineer it is must that
he is familiar with the effects which the manufacturing process and heat
treatment have on the material.

 Properties considered while designing of machine are

1. Strength

2. Stress

3. Stiffness

4. Elasticity

5. Plasticity

6. Ductility

7.Brittleness

8.Malliability

9.Toughness

10.Resilience

11.Creep

12.Hardness

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2.2 Material used for project

Serial COMPONENTS DIMENSIONS(mm) WEIGHT (kg)

no.
1 TABLE 255 X 200 X 162 7

Top & bottom guide ways 25 X 18 X 255 X 4

2 BASE 75 X 40 X 500 X 2 6

Channel M.S. Flat 40 X 10 X 260 X 3 3

M.S.Flat 100 X 10 X 230 X 1 2

3 FIXTURE 50 X 20 X 240 X 2 3

Bottom plate (M.S.) 25 X 25 X 160 X 1 0.35

Angel plate (5mm thk) 75 X 6 X 185 X 1 1

Top plate 75 X 6 X 170 X 2 2

Fixture plate
4 UPPER ARM

M.S.Flat(Bright) 75 X 6 X 325 X 1 1.5

M.S.Flat(Bright) 55 X 6 X 325 X 2 2.5

M.S.Flat(Bright) 75 X 6 X 150 X 1 1.1

M.S.Flat(Bright) 75 X 6 X 110 X 1 0.9

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5. COLUMN

Pipe (8mm thk) DIA 65 X 325 X 1 4

M.S.Flat(Bright) 100 X 10 X 160 X 1 1.5

M.S.Flat(Bright) 25 X 6 X 30 X 1

Dia 6 disc(6mm thk) DIA 65 X 6mm

6. SPINDLE UNIT

Spindle(EN-8) DIA 25 X 255 X 1 1

Housing DIA 75 X 126 X 1 4.5

Boss DIA 85 X 68 X 1 3.1

M.S.Flat(Bright) 30 X 8 X 30 X 2

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Chapter no.03
Construction and working

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3. CONSTRUCTION & WORKING OF COPY MILLING

MACHINE
This is manually operated tracer control milling machine which is used for profile
cutting of a templates or any easy shape the major parts of machine their
construction and working are discussed .

The structure of this machine is depend on function may be divided into

following three groups :

Group I : Bed and base upon which the various subassemblies are mounted .

Group II : Box type housing which individual units are assembled like spindle
and pinion mechanism.

Group III : Parts that serve for supporting and moving the workpiece like spindle
units and fixture for holding the component .

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 The structure of this machine tool consist of following

components
 Bed

 Table

 Column

 Spindle Units

 Tracer Arm

 Main Arm

 Pinion Mechanism

 Fixture

3.1 BED :- It is the bottom most part of machine on which various other
parts are mounted like table, column, arm. The bed of this machine is
manufactured from two c-channels on top of which three plates at right
angle are welded.

3.2 TABLE:- The table used in this machine is a manually operated

antifriction table. It is mounted on top of the bed and is fixed to it by helps
of Allen head holts. It has two degree of motion in x and y direction. The
table slides between two guide blocks v-grooves are cut in the table and
guides. The center of the grooves is slightly offsetted in the table and the
bed. The two tables are mounted one on another and at right angle to each
other so as to obtained the motion in two directions. In this antifriction ways
rolling members (rollers) are inserted between the sliding surfaces, thus
changing the nature of friction from sliding to rolling they have following
the features.

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(1) Low friction as compared to slide ways.

(2) Uniformity of motion at slow speed due to virtual absence of the

stick slip phenomenon

(3) High stiffness if the rolling member are preloaded and,

The travel of the table ‘x’ and ‘y’ direction are as follows :

1. X direction (lower table) = 200 mm

2. Y direction (upper table) = 160 mm

3.3 COLUMN :- The column of this machine holds the over arm
which in turn holds the spindle and spindle driving mechanism. During the
operation of the machine, tool the structures are subjected to compound
loading and their resultant deformation consist of torsion, bending and
tension or compression. Thus looking at all different constraints of loading
for clamping at arm and as the load, which is experienced by the column, is
less circular section of the column is chosen.

Column piped is welded to the plate perpendicular to its axis the outer face
of the plate is faced and the pipe is turned. Four web are welded to the bed
with the help of 4 bolts. The column is crome plated so as to increase the
appearance and the surface finish of the column, crome plating is done to
prevent corrosion.

3.4 SPINDLE UNITS :- The spindle units of the machine hold the
cutter in the spindle and satisfies the following requirement :

• Rotates at high degree of accuracy, which is determined by radial and

axial run out of the spindle nose.

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• Spindle units must have high dynamic stiffness.

• The spindle units must be hardened to reduce the wear.

• The deformation of the spindle due to heat transmitted to it by

bearing, cutting tools, work piece etc. Should not be larger, as this
has an adverse effect on the machining accuracy.

• The spindle units must have a fixture, which provide quick and
reliable centering and clamping of the cutting tool.

The spindle of machine is guided by the bearing which is turn is press

fitted in the housing . The threads are provided on housing to a length of
30mm from the top face . The travel of the spindle is adjustable with the
help of s ring which is threaded on the housing . Thickness of ring being
10mm. The total travel of spindle units is max = 45mm ,and min = 25mm.

Rack has been cut on housing surface to length of 95mm with the
rack and vertical motion of the tool is obtained as in the case of drilling
machine.

The assembly as a whole is held in a boss is further welded to the

horizontal arm . The length of the boss being 65mm . The housing gets a
sliding motion inside the boss .Thus the boss guided the housing assembly
as whole.

3.5 TRACER ARM :- A tracer arm of the silver steel is mounted in a

elongated bush which is further welded to the upper arm. The gunmetal
bushes , which have been press, fitted (one on either end) in elongated of the
tracer arm. A ‘y’ shaped plate connects the tracer arm with the spindle

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through the ring threaded to the housing. This facility the simultaneously
vertical movement of the spindle and the tracer arm.

A chuck has been threaded to the lower end of the tracer arm to
hold the pilots. However for extreme, accuracy and precision collects are
used. The operator always constantly senses the contact with the template of
master and adjusts the direction of the bios pressure applied to the
longitudinal plane.

3.6 MAIN ARM :- The upper arm is the most precision part of the
machine, as it has maintain parallelity between the column, tracer arm and
the spindle. The parallelity between the three parts is responsible for precise
and accurate operation of the machine, the achieve this objective two
complete holes and one semicircular hole is board in the upper arm. A slot
has been machined beyond hole on the end for effective champing the upper
arm to the column at right angle.

The boss of the spindle is then welded to the semicircular bore.

This assures a perfect/accurate perpendicularity between the spindle axis and
the arm. The bush of the tracer arm is then further welded in the small bore.

A small bore has been provided on the arm to accommodate the

pinion mechanism. Thus the upper arm of the machine holds the spindle
mechanism, pilot mechanism. The main arm itself is mounted on the
column as stated.

3.7 PINION MECHANISM :- A pinion is mounted on the stepped shaft,

which is turn is mounted on the arm. A space is used to positioned the gear

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in relation to the rack, which has been machined on the spindle housing.
This pinion meshes with rack on the housing. The gear has keyed to stepped
shaft to prevent its rotation relatives to the shaft. This pinion is used raised
or lower the spindle housing.

The bush no. 4 is fitted inside the bore in the upper arm. It
provides a greater supporting length to the rotating spacer and shaft

A spring loaded ball mechanism is used to lock the spindle

mechanism at a particular depth. The mechanism consist of a spring loaded
ball which is fixed inside the head of the head of pinion shaft and the
semicircular groove cut in the bush no. 7.

The cutter has three position viz.

• Top position

• Intermediate position

• Final position

Top Position :- The collar provided on spindle housing obtained the top
position of spindle , and it is the starting position of cutter.

Intermediate position :- Depending upon the position of the first cut and
the thickness of sheet this intermediate position is adjusted .This is obtained

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by adjusting the position of groove in bush no. 7 by rotating it. This is

provided for the initial or rough cutting of profile.

Final position :- The final position is obtained by adjusting the position of

ring on the spindle housing . Since the position of groove (for fixing or lens)
depends on thickness of sheet and whether the groove is offset from the
center.

3.8 FIXTURE :- Depending upon the operation to be performed on the

machine the fixture is changed. There are two fixtures mounted on two flat bars
at right angle to it and parallel to each other.

The front fixture, which the job or sheet is mounted , consists of

a bottom plate on the tope of which the sheet of plastic is mounted. The
sheet is positioned with the help of 3 dowel pins or stoppers. This ensures
proper position of the sheet. The top plate then clamp the sheet from the top
and clamping force is applied with help of the two wing nuts, on of each
end. As the cutting force is less the subsequent champing force required is
also less. Three set screws with pointed edged are fitted in the top plate such
that their pointed edges, protrude from the bottom. This provides additional
clamping force on the sheet and also avoids the slighter movement in the
sheet while cutting.

The rear fixture consists of the plate on the top of which the
template is directly mounted. The centre distance between the front and the
rear fixture is maintained to 120 mm apart.

There are two cuts in between fixture plates so as to provide space for cutter to
move inside the profile. Spring ate fitter in and dowel so as to provide auto lifting
of the top plate of fixture. This makes it easy to load and unload the work piece. In
this profile of the template is same as that is of the profile of the spectacles.

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CHAPTER NO :04
DESIGN OF PROJECT

Design of machine
4.1 Spindle
Material used for spindle=EN8(C-45)

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Tensile ultimate=600N/mm Yield=300N/mm2

Torque Calculation:

N=120rpm

Power of motion=1/2HP

=1/2 x 746 Watt

Torque =60P/2X3.14XN

=29.68N-mx1000 = 29.68X10^3N-mm

 Design as per ASME code

 Tensile strength for all material=0.18 X tensile

=0.18 X 600

=108Mpa

And shear strength of all material=0.35X shear

= 0.35 X 380

=68.8Mpa

As the spindle has no key way

68.8Mpa=(16 x T x1000)/d3

d3 68.8 =16 X 29.68 X 1000

d=19.07=20.00mm

Due to manufacturing difficulty and other consideration we have taken the

spindle diameter as 20mm at the bearing

We have chosen bearing No.6204 for the spindle. The diameter at which chuck is
bearing fitted is the minimum diameter i.e.10mm, which is also quite safe

4.2 .The travel of the table:

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The construction of the machine has been explained in the previous topic:

 The material used for the table is alluminium

 The guide are of anti friction type

 The roller ,which have been used are in the cage

Therefore the travel is restricted and is as follows

Let,

Lc = length of cage

l =length of guide way

therefore , total travel =2(L-Lc)

a) For bottom table

total travel=2(L-Lc)

L=230

LC=130

For bottom table total travel=2(230-130)=2(100)=200mm

b) For top table

Total travel=2(L=Lc)

L=230

Lc=150

=2(80)

=160mm

The equation is valid for when the roller cage is in the center of the guide
ways and the moving members.

4.3 Travel of spindle arm:

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 Total travel of the spindle arm has been calculated as follows :

1.Lenth of housing = lh=120mm

2.Length of boos = lb =65mm

3.Length of treads on the housing = lt = 30mm

4. Length of ring = lr = 10mm

a) Minimum travel of the spindle housing :

Travel of ring = Tr = lt- lr = 30-10

= 20mm

Minimum travel of the housing = lh - lb – lt =120 - 65 - 30

= 25mm

b) Maximum travel of the housing:

Maximum travel of the housing =lh- lb- lr = 120 - 65 - 10

= 45mm

Therefore , the position of the spindle can be set anywhere between 25mm
& 45mm

4 .4 Design of the travel of the pinion and the position of the groove
for locking the spindle
Pinion PCD = 29mm

Pinion circumstance = 3.14X 29= 91.106mm

For the travel of 18mmon PCD

Let Oc be the angle of rotation in radian

Oc X D = 25mm x 180/3.14

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= 25/29 x 180/3.14

Oc = 41.49

Hence the pinion has to rotated at an angle of 41.49 from its initial position such
that the spindle travels by 18mm downward the groove is cut at this angle from the
starting point on the bush in the pinion mechanism.

4.5 MACHINE SPECIFICATION

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1. Motor = 0.5hp/120rpm/Single Phase

2. Table Travel

Bottom Table = 200mm

Top Table = 160mm

3. Spindle Travel

Maximum=45mm

Minimum=25mm

4. Spindle rpm=120rpm

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CHAPTER NO:-05
PROCESS SHEET

TABLE NO. 1

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Part No. : SU.01

Part Name : SPINDLE

NET WEIGHT : 1.1
Material : EM-8 Kg

Blank Size : 255 X DIA 25

SR. OPERATION MACHINE & SPEED FEED TIME

NO. EQUIPMENT rpm Mm
USED ------- SET M/C
Rev UP ing

1. Load job on the Lathe - 200 -

lathe & turn the job
2. Facing AA Lathe, facing 509 0.4 - 3.68
tool
3. Mount center drill Lathe, center 509 0.4 60 5.00
Drill & Drill
chuck
4. Unload job & Lathe - - 60 -
overturn the Job
5. Face BB Lathe, Facing 509 0.4 - 3.68
Tool
6. Center Drill Lathe, center 509 - 40 5.00
drill & drill
chuck
7. Unload job and Lathe, Dog, - - 500 -
hold it center to face plate 7
center with the help dead 7 live
of dogs on the face center
place
8. Turn dia 21.6 to a Turning tool 509 0.4 - 59.00

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length of 200mm
9. Turn dia 19 to a Lathe & 509 0.4 - 31.00
length of 108 mm turning tool
10. Unclamp over turn Lathe - - 60 -
the job
11. Turn the remaining Lathe & 509 0.4 - 42.00
length to a dia of turning tool
20 mm
12. Relieve to dia 19 Lathe & 509 0.4 - 17.68
mm a length of 16 parting tool
mm
13. Turn the remaining Lathe & 509 0.4 - 6.40
length of 22 mm to turning tool
a dia of 10 mm
14. Threading of M10 Lathe & 90 0.8 - 36.60
on the dia 10 mm threading tool
for a length of 22
mm

TABLE NO. 2

Part No. : SU.02

Part Name : HOUSING

NET WEIGHT : 4.5
Material : M.S.C.-25 Kg

Blank Size : DIA 70 X 123 mm

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SR. OPERATION MACHINE & SPEED FEED TIME

NO. EQUIPMENT rpm Mm
USED ------- SET M/C
Rev UP ing

1. Mount & true the Lathe - - 200 0

blank
2. Face side AA Lathe, facing 182 0.4 - 28.84
tool
3. Mount center drill Lathe, center - - 60 5.00
& center drill on drill & drill
face AA chuck
4. Turn dia 65 to a Lathe, turning 182 0.4 - 20.00
length of 60 mm tool
5. Remove center Lathe, dia 10 - - 90 -
drill & put dia 10 drill, drill
drill chuck
6. Drill dia 10 on Lathe, dia 10 764 0.1 - 98.00
face AA drill, drill
chuck
7. Replace dia 10 Lathe, dia 25 - - 90 -
drill by dia 25 drill drill, drill
chuck
8. Drill dia 25 on Lathe, dia 25 764 0.1 - 100.00
face AA drill, drill
chuck
9. Boaring of dia 32 Lathe, boring 368 0.25 - 160.40
mm to a length of tool
123 mm
10. Boring of 50 to a Lathe, brong 235 0.25 - 61.20

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length of 15 mm tool
11. Remove the job & Lathe - - 200 -
load it
On other side
12. Do facing on other Lathe, facing 182 0.4 - 28.84
face tool
13. Turn the Lathe, turning 182 9,4 - 20.00
remaining length tool
to a dia 65 mm
14. Turn the collar to Lathe, turning 182 0.4 - 5.00
a length of 3 mm tool
& dia 69 mm
15. Bore dia 50 mm to Lathe, boring 235 0.25 - 61.20
a length of 15 mm tool
16. Do threading from Lathe, 90.8 0.8 - 75.00
end A to a length threading tool
30 mm
17. Remove the job & Milling - - 600 -
load it on a milling machine
machine
18. Index after every Milling - - 810 =
finishing machine
Cut
19. Cut rack to a Milling 140 0.1 90 250.00
length of 95 mm machine rack mm/toot
cutter h
20. Remove & unload Milling - - 90 -
the job machine

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TABLE NO. 3

Part No. : SU-03

Part Name : BOSS

NET WEIGHT :
Material : M.S 3.1 Kg

Blank Size : DIA 85 X 68 mm

: ( 30 X 30 X 8) X 2

SR. OPERATION MACHINE & SPEED FEED TIME

NO. EQUIPMENT rpm Mm
USED ------- SET M/C
Rev UP ing

1. Load the job on Lathe, facing 149.8 0.4 300 42.55

lathe 7 do facing tool

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on face AA
2. Turn to dia 82 a Lathe turning 149.8 0.4 - 40.05
length of 40mm tool
from AA
3. Mount center drill Lathe, center - - 60 5
& center drill on drill & drill
face AA chuck
4. Replace drill by Lathe, drill dia 382 0.1 60 102.00
dia 10 drill & drill 10 drill chuck
to a length of 65
mm
5. Replace dia 10 Lathe, drill dia 153 0.1 60 155.00
drill by dia 25 drill 25 drill chuck
& drill to a length
of 65 mm
6. Bore to dia 65 mm Lathe 7 boring 190 0.25 - 656.85
tool
7. Unload over turn Lathe - - 90 -
& true the job
8. Face BB Lathe & facing 149.8 0.4 = 8.51
tool
9. Turn the remaining Lathe & turning 149.8 0.4 = 25.03
length to dia 82 tool
10. Unload & mount it Drilling machine - - 90 -
drill machine
11. Mount dia 10 drill Drilling,machine 382 0.1 60 13.35
& drill dia 10 drill 7
drill chuck
12. Unload & mount it Slotting m/c - - 200 -
on a slotting m/c

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13. Machine the slot Slotting m/c - - 200 -

14. Unload the job & Arc welding m/c - - - 240.00
weld the two
pieces
15. Drill two holes of Drilling m/c 382 0.1 60 25.26
dia 8
16. Unload & mount it Milling m/c - - 400 -
on a milling m/c
17. Load slitting saw Slitting saw 140 0.22 - 400.00
& perform slitting
18. Unload - - - 60 -

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TABLE NO. 4

Part No. : SU.04

Part Name : RING

NET WEIGHT : 600
Material : M.S Gms

Blank Size : DIA 89 X12 mm 30

SR. OPERATION MACHINE & SPEED FEED TIME

NO. EQUIPMENT rpm Mm
USED ------- SET M/C
Rev UP ing

1. Mount the job on Lathe - - 200 -

lathe & true the job
2. Face AA Lathe, Facing 143 0.4 - 46.60
tool
3. Mount center drill Lathe, center 143 0.4 60 5.00
& center drill face drill & drill
AA chuck
4. Replace center drill Lathe, dia 10 1273 -/1 6- 7.07
by dia 10 drill & drill & drill
drill 15 mm chuck
5. Replace drill dia 10 Lathe, dia 25 509 0.1 60 17.68
by dia 25 drill & drill & drill
drill 15 mm chuck
6. Bore to dia 64 Lathe, boring 199 0.25 120 101.36

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tool199
7. Turn to dia 65 for a Lathe turning 143 0.4 = 15.73
length of 15 mm tool
8. Make a groove of Lathe, parting 143 0.4 - 12.60
dia 80 & length 6 tool
mm
9. Parting operation at Lathe, parting 143 0.4 - 33.00
distance of 10 mm tool
from outer end
10. Unload, over turn, Lathe - - 200 -
clamp & true the
job in the chuck
11. Face BB Lathe, facing 143 0.4 - 46.60
tool
12. Threading of M10 Lathe, 90 0.8 60 16.00
for a length of threading tool
10mm (internal
threading)

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TABLE No. 5

Part No. : PU.01

Part Name : PINION SHAFTFIXED

BUSH NET WEIGHT : 2.1
Kg
Material : C-25

Blank Size : DIA 55 X 115 mm

SR. OPERATION MACHINE & SPEED FEED TIME

NO. EQUIPMENT rpm Mm
SET M/C
USED -------
UP ing
Rev

1. Load job on the Lathe - - 200 -

machine & true the
job
2. Face AA Lathe, facing 231.5 0.4 - 17.81
tool
3. Turn a length of Lathe, turning 231.5 0.4 - 12
20mm to dia 50 tool
mm
4. Chamfering Lathe, turning 231.5 0.4 - 5
tool
5. Unload the job & Lathe - - 200 -
overturn the job
6. Turn a length of 93 Lathe, turning 231.5 0.4 - 482.00
mm from the face tool
BB to dia 12
7. Turn a length of 55 Lathe, turning 231.5 0.4 - 35.63

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mm from the face tool

bb to dia 8
8. Threading to a Lathe 90 0.8 - 33.33
length of 20 mm threading tool
from the face fBB

TABLE NO. 6

Part No. : PU.02

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Part Name : SPACER

NET WEIGHT : 100
Material : M.S Gms

Blank Size : DIA 19 X 40

SR. OPERATION MACHINE & SPEED FEED TIME

NO. EQUIPMENT rpm Mm
USED ------- SET M/C
Rev UP Ing

1. Load the job on the - - - 60 -

machine and true
the job
2. Face AA Lathe & 670 0.4 - 4.24
facing tool
3. Turn to dia 14 & Lathe & 670 0.4 - 8.95
length of 20 mm turning tool
from AA
4. Centre drill Lathe, centre - - 60 5.00
(mounting & drill & drill
drilling) chuck
5. Remove centre drill Lathe, drill & - - 90 -
& put dia & drill drill chuck
6. Drill dia to a length Lathe & dia 8 478 0.1 - 47.07
of 35 mm drill
7. Unload v 7 overturn - - - 60 -
7 true the job
8. Face BB Lathe & 670 0.4 - 5.00
facing tool
9. Turn to dia 14 a Lathe & 670 0.4 - 6.80
length of 15mm turning tool

SHREERAM POLYTECHNIC
COPY MILLING MACHINE 40

TABLE NO. 7
Part No. : PU.03

Part Name : FIXED BUSH

NET WEIGHT : 299
Material : M.S Gms

Blank Size : DIA 30 X 30

SHREERAM POLYTECHNIC
COPY MILLING MACHINE 41

SR. OPERATION MACHINE & SPEED FEED TIME

NO. EQUIPMENT rpm Mm
USED ------- SET M/C
Rev UP ing

1. Load & true the job Lathe - - 60 -

on the machine
2. Do facing on face Lathe, facing 425 0.4 - 10.60
AA tool
3. Turn to dia 25 a Lathe, turning 425 0.4 - 5.3
length of 15 mm tool
from AA
4. Load centre drill & Lathe, centre - - 60 5.00
centre drill drill, centre
chuck
5. Replace centre drill Lathe, drill 382 0.1 90 43.20
by drill dia 10 & dia 10, drill
drill chuck
6. Unload overturn & Lathe - - 60 -
true the job
7. Face BB Lathe, facing 425 0.4 - 3.88
tool

SHREERAM POLYTECHNIC
COPY MILLING MACHINE 42

TABLE N.08:
Part No. : PU -04
Part Name : M.S.
Material : M.S. NET WEIGHT :750
Blank size : DIA 63X30mm Gms
SR. MACHINE & SPEED FEED TIME
NO OPERATION EQUIPEMENT rpm mm/rev SET M/Cing
USED UP
1 Load the job & Lathe - - 80 -
true it
2 Face BB Lathe facing 202.1 0.4 - 46.74
tool

SHREERAM POLYTECHNIC
COPY MILLING MACHINE 43

3 Turn a lathe of 202.1 0.4 - 13.36

18mm to a Lathe ,turning
dia.25mm
4 Load centre drill & tool - - 60 5.00
drill chuck Lathe ,centre
5 Drill dia. 12 to a drill & drill 318.3 0.1 - 50.80
length of 25mm chuck
Lathe dia. 12
6 Unload , overturn drill & chuck - - 60 -
& true the job Lathe
7 Face AA Lathe facing 202.1 0.4 - 18.9
tool
8 Turn a length of Lathe ,turning 202.1 0.4 - 4.45
6mm to dia60 tool
9 Turn a length of Lathe ,turning 254.6 0.4 - 7.04
3mm from AA to tool
dia.50

TABLE NO. 09:

Part No. : TU -01
Part Name : BOTTOM TABLE
Material : ALLUMINIUM NET WEIGHT :2.6
Blank size : 255X200X16 KG
SR. MACHINE & SPEED FEED TIME
NO OPERATION EQUIPEMENT rpm mm/rev SET M/Cing
USED UP
1 Load the job on Milling - - 300 -
milling machine machine
2 Milling edge at Milling 140 0.22 200 1800

SHREERAM POLYTECHNIC
COPY MILLING MACHINE 44

right angles machine side

milling cutter
3 Milling of v Milling 120 0.22 - 568.00
grooves of length machine
of 250 on side A Milling cutter
4 Unload & overturn Milling - - 300 -
the job machine
5 Milling of v Milling 120 0.22 - 568.00
grooves of length machine,
of 250 on side B milling cutter
6 Unload the job & Drilling - - 300 -
mount it on drilling machine
machine
7 Drill 4 inclined Drilling 3600 0.075 200 3.55
holes of dia. 4 machine

8 Unload & overturn Drilling 3600 0.075 500 3.55

the job & drill machine
another 4 inclined
holes of dia.4
9 Drill 4 holes of dia. Drilling 3600 0.075 200 14.20
8 to a length of machine dia. 7
16mm drill & drill
chuck
10 Unload &tap all 8 Tap of M5 - - 200 1800
inclined holes of
M5
11 Unload the job - - - 60 -

SHREERAM POLYTECHNIC
COPY MILLING MACHINE 45

TABLE NO. 10:

Part No. : TU -02
Part Name : TOP TABLE
Material : ALLUMINIUM NET WEIGHT :2.6
Blank size : 255X200X16 KG
SR. MACHINE & SPEED FEED TIME
NO OPERATION EQUIPEMENT rpm mm/rev SET M/Cing
USED UP
1 Load the job on Milling - - 300 -
milling machine machine
2 Milling edge at Milling 140 0.22 200 1800
right angles machine side

SHREERAM POLYTECHNIC
COPY MILLING MACHINE 46

milling cutter
3 Milling of v Milling 120 0.22 - 568.00
grooves of length machine
of 250 on side A Milling cutter
4 Unload & overturn Milling - - 300 -
the job machine
5 Milling of v Milling 120 0.22 - 568.00
grooves of length machine,
of 250 on side B milling cutter
6 Unload the job & Drilling - - 300 -
mount it on drilling machine
machine
7 Drill 4 inclined Drilling 3600 0.075 200 3.55
holes of dia. 4 machine

8 Unload & overturn Drilling 3600 0.075 500 3.55

the job & drill machine
another 4 inclined
holes of dia.4
9 Replace dia.4 drill Drilling 3600 0.075 200 30.72
by dia.8 drill & 6 machine dia. 7
holes of dia.8 to drill & drill
length of 6mm
10 Replace dia. 8 by Drilling 3600 0.075 300 16.00
dia.4 & drill 4 machine, dia.4
holes of dia.4 drill, drill
chuck
11 Replace dia. 4 drill Drilling 3600 0.075 300.00
by dia. 7 drill & machine dia.8
drill 2 holes of 7 drill & tap
do tapping ofM8
12 Unload the job Drilling
machine

SHREERAM POLYTECHNIC
COPY MILLING MACHINE 47

TABLE NO. 11 :
Part No. : TU -03
Part Name : GUIDE WAYS
Material : ALLUMINIUM NET WEIGHT :
Blank size : (255X200X18)4PIECES 450Gms
SR. MACHINE & SPEED FEED TIME
NO OPERATION EQUIPEMENT rpm mm/rev SET M/Cing
USED UP
1 Load the job on Milling 140 0.22 300 97.40
milling machine & machine side
do side milling on milling cutter
both ends (AA-
BB)
2 Milling V grooves Milling 120 0.22 200 568.00

SHREERAM POLYTECHNIC
COPY MILLING MACHINE 48

to a length of 250 machine

mm 90angle
milling cutter
3 Unload & mount it Drilling - - 300 -
on drilling machine machine
4 Drill 4 inclined Drilling 3600 0.075 200 3.55
holes of dia.4 machine dia. 4
drill
5 Replace the dia.4 Drilling - - 200 -
drill 7 put dia.8 machine
drill
6 Drill 2 holes of dia. Drilling 2500 0.075 100 10.24
8 & 140mm apart machine dia.8
drill
7 Unload the job Drilling - 60 -
machine

TABLE NO.12:
Part No. : TU -04
Part Name : ROLLER CAGE
Material : ALLUMINIUM NET WEIGHT :
Blank size : 400Gms
(8X8X140)X2&(8X8X150)X2
SR. MACHINE & SPEED FEED TIME
NO OPERATION EQUIPEMENT rpm mm/rev SET M/Cing
USED UP
1 Finishing the edges Hand file - - - 300
at right angle
2 Mount it on Drilling - - 60 -
drilling machine Machine

SHREERAM POLYTECHNIC
COPY MILLING MACHINE 49

3 Mount centre drill Drilling 764 0.1 500 80.00

& drill Machine
centre drill &
drill chuck
4 Replace centre drill Drill machine - - 120 -
by dia. 5 drill dia.5 drill &
drill chuck
5 Drill dia. 5 to a Drill machine 2500 0.075 500 16.00
length of 6mm dia. 5 drill ,
drill chuck
6 Unload & mount it Milling - - 300 -
in a milling machine
machine
7 Mount end milling Milling 2387.3 1.32 900 800.00
cutter and mill the machine
8 holes

TABLE NO.13:
Part No. : BA -01
Part Name : BASE (BED)
Material : M.S. NET WEIGHT :11 KG
Blank size : CHANNEL
75X40X430X2pcs
PLATE
40X6X260X2pcs
SR. MACHINE & SPEED FEED TIME
NO OPERATION EQUIPEMENT rpm mm/rev SET M/Cing
USED UP
1 Welding of all - - - 1800
three plates on top

SHREERAM POLYTECHNIC
COPY MILLING MACHINE 50

of channel
2 L oading on Shaper - - 300 -
shaping machine
3 Shaping bottom Shaper - - - 1500
face of the C
channels
4 Unload & overturn Shaper - - 300 -
the job
5 Shaping on the top Shaper - - - 4000
surface of the base
(three plate)
6 Unload & remove Shaper - - 60 -
the job
7 Mount the job on Drilling - - 60 -
drilling machine machine
8 Drilling of dia. (8 Drilling 477.46 0.1 180 120
holes) machine dia.8
drill, drill
chuck
9 Unload the job & vice - - 180 -
clamp It in vice
10 Do tapping in 4 Tapping tool , - - - 1800
holes oil, tap holder
11 Unload the job - - - 15 -

TABLE NO.14:
Part No. : co-01
Part Name : column
Material : M.S. NET WEIGHT :5.5
Blank size : PIPE-Dia.62.5x142x8mm KG
SR. MACHINE & SPEED FEED TIME
NO OPERATION EQUIPEMENT rpm mm/rev SET M/Cing
USED UP
1 Drill 4 holes of dia. Drilling 382 0.1 220 60.00
10 in plate machine

SHREERAM POLYTECHNIC
COPY MILLING MACHINE 51

2 Welding of pipe in Welding - - - 350.00

the centre of the machine
plate
3 Welding the cap to Welding - - - 350.00
the open end of the machine
pipe
4 Load job on the Lathe - - 180 -
machine
5 Face BB Lathe, facing 205.5 0.4 -
tool
6 Centre drill Lathe, centre - - 60
drill& drill
chuck
7 Unload job Lathe - - 30 -

8 Holding the job Lathe ,dog face - - 300 -

centre to centre on plate
face plate
9 Turning to dia. 61 Lathe, turning 205.5 0.4 - 222.70
a length of 305mm tool

10 Unload ,overturn Lathe - - 180 -

& true the job
11 Face AA Lathe , facing 205.5 0.4 - 60.00
tool

12 Unload - - - - -
13 Weld 4 webs to the Welding - - - 1800
pipe machine

SHREERAM POLYTECHNIC
COPY MILLING MACHINE 52

TABLE NO.15:

Part No. : MA-01

Part Name : MAIN ARM NET WEIGHT :6.2
Material : M.S. BRIGHT PLATE KG
Blank size : 75X6X325X1pcs
55X6X325X1pcs
75X6X150X1pcs
75X6X110X1pcs
SR. MACHINE & SPEED FEED TIME
NO OPERATION EQUIPEMENT rpm mm/rev SET M/Cing
USED UP

SHREERAM POLYTECHNIC
COPY MILLING MACHINE 53

1 Making all the File - Manual - 1200

edges
perpendicular to
each other for all
plate
2 Welding of all the Arc welding - - 500 1800
5 plates machine
3 Mounting & Lathe do face - - 600 -
centering the job plate clamp
on face plate at
position one
4 Mount centre drill Lathe, centre - - 60 10
drill
5 Remove centre Lathe, centre - - 30 -
drill & put dia. 10 drill dia.10 drill
drill
6 Drill dia10 Lathe dia.10 382 0.1 20
drill
7 Replace dia. 10 rill Lathe dia.25 - - 30 -
by dia. 25 drill
8 Drill dia.25 Lathe dia. 10 153 0.1 - 50.00
drill
9 Bore to dia. 82 Lathe boring 144 0.25 - 240
tool

10 Unclamp the job & Lathe boring - - 500 -

set it for the tool
second position
11 Mount centre drill Lathe centre - - - 70
& drill drill

12 Replace dia. 10 Lathe dia.10 382 382 60 9.50

drill & drill drill
13 Bore to dia.25 Lathe boring 471 471 - 10.00
tool
14 Unclamp & set it Lathe - - 500 -
for third position
15 Mount centre drill Lathe centre - - - 70.00
mounted

SHREERAM POLYTECHNIC
COPY MILLING MACHINE 54

16 Replace it by dia. Lathe dia.10 382 382 60 20.00

10 drill drill
17 Replace dia.10 Lathe dia.25 153 153 60 96.00
drill by dia.25 drill
18 Bore to dia.62 Lathe boring 190 190 - 400.00
tool
19 Set it position Lathe - - 200 -
fourth
20 Mount centre drill Lathe centre - - - 60
drill
21 Replace it by dia. Lathe dia.10 382 0.1 60 20.00
drill drill
22 Bore to dia. Lathe boring 471 - 0.25 20.00
throughout tool
23 Unload & it on Drilling 382 0.1 500 60.00
drilling machine & machine dia. 10
drill 4 holes of drill
dia.10
24 Unload & mount it Milling - 0.22 - -
on milling machine machine ,metal
slitting saw
25 Do slitting Milling 140 - - 400.00
operation machine ,metal
slitting saw
26 Remove the job & Arc welding - - - 900.00
weld the boss in
the position

27 Weld the bush at Arc welding - - - 400.00

the position

SHREERAM POLYTECHNIC
COPY MILLING MACHINE 55

TABLE NO.:16
Part No. : FX-01
Part Name : BASE PLATE
Material : M.S. NET WEIGHT :11 KG
Blank size : 50X20X240 (2pcs)

SR. MACHINE & SPEED FEED TIME

NO OPERATION EQUIPEMENT rpm mm/rev SET M/Cing
USED UP
1 Finishing of edges File - - 60 1800
at right angle
2 Mount it on Drilling - - 60 -
drilling machine machine
3 Load drill dia.7 & Drilling 545.6 0.1 120 88.00
drill 4 holes to a machine dia.7
length of 20mm drill , drill

SHREERAM POLYTECHNIC
COPY MILLING MACHINE 56

chuck
4 Unload drill Drilling - - 60 -
dia.7& mount machine,
counter boring tool counter boring
tool
5 Counter bore all 5 Drilling 955 0.1 80 50.00
holes machine,
counter boring
tool
6 Unload the counter Drilling - - 60 -
bore and mount machine dia.5
dia.5 drill drill
7 Drill dia.5 (2 Drilling 955 0.1 80 50.00
holes) to a length machine dia.5
of 20 mm drill
8 Drill dia. 4 to Drilling 955 0.1 130 25.13
length of 20mm(2 machine dia.4
holes) drill
9 Counter bore dia. Drilling - - 60 30
10 in two holes of machine
dia.5 to a length of Counter boring
10mm tool
10 Unload and tap Tap set - - 60 1200
M5 in dia. 4 holes
M8 in dia.7 holes
11 Unload the job - - - 30 -

SHREERAM POLYTECHNIC
COPY MILLING MACHINE 57

TABLE NO.17:
Part No. : FX-02
Part Name : FIXTURE PLATE FOR
JOB NET WEIGHT :1 KG
Material : M.S.
Blank size : 75X6X174

SR. MACHINE & SPEED FEED TIME

NO OPERATION EQUIPEMENT rpm mm/rev SET M/Cing
USED UP
1 Mount it on File - - 180 -
drilling machine
2 Cut out the profile Drilling 764 0.1 - 9000.00
for the spectacle machine
with the help of

SHREERAM POLYTECHNIC
COPY MILLING MACHINE 58

drill & file

3 Mount it on Drilling - - 180 -
drilling machine machine dia.7
drill , drill
chuck
4 Mount center drill Drilling 764 0.1 50 25.00
machine, center
drill, drill
chuck
5 Replace center Drilling 764 0.1 80 23.56
drill by dia. 5 drill machine dia. 5
& drill 5 holes of drill
depth of 6mm
6 Replace dia. 5 drill Counter sunk 764 0.1 60 10.00
by a counter
sinking tool &
counter sunk dia.8
7 Unload the - - - - -
machine
8 Place fit three - - - - 60.00
dowels in dia. 5
holes

TABLE NO.18:
Part No. : FX-03
Part Name : CLAMPING PLATE
Material : M.S. NET WEIGHT :1.5
Blank size : 25X25X75(2NOS) KG

SR. MACHINE & SPEED FEED TIME

NO OPERATION EQUIPEMENT rpm mm/rev SET M/Cing
USED UP
1 Mount it on Drilling - - 180 -
drilling machine machine
2 Cut out the profile Drilling 764 0.1 - 9000.00
for the spectacle machine, drill
with the help of ,file
drill & file

SHREERAM POLYTECHNIC
COPY MILLING MACHINE 59

3 Weld angle to Electric arc - - 180 300.00

plate welding
4 Mount it on Drilling - - 180 -
drilling machine machine,
5 Mont center drill Drilling 764 0.1 50 45.00
& drill machine center
drill
6 Replace center Drilling 764 0.1 90 15.70
drill by a dia. 5 machine dia. 5
drill& drill 4 holes drill
2 a length of 5mm
7 Replace dia.5 drill Drilling 955 0.1 90 9.42
by dia. 4 drill & machine dia. 4
drill 3 holes to the drill
length of 5 mm
8 Replace dia.4 drill Drilling 477.46 0.1 90 3.42
by dia. 8 drill & machine dia. 4
drill 2 holes to the drill
length of 6 mm
9 Counter sunk three Drilling 477.46 0.1 70 15.08
holes of dia. 5 with machine dia. 4
the drill of dia.8 drill
10 Tap two holes of Tap set - - - 360.00
dia.8
11 Unload - - - 30 -

SHREERAM POLYTECHNIC
COPY MILLING MACHINE 60

TABLE NO.19:
Part No. : FX-04
Part Name : FIXTURE PLATE FOR
TEMPLATE NET WEIGHT :0.5
Material : M.S. KG
Blank size : 75X6X175

SR. MACHINE & SPEED FEED TIME

NO OPERATION EQUIPEMENT rpm mm/rev SET M/Cing
USED UP
1 Mount it on Drilling - - 180 -
drilling machine machine
2 Cut out the profile Drilling 764 0.1 - 9000.00
for the spectacle machine
with the help of
drill & file

SHREERAM POLYTECHNIC
COPY MILLING MACHINE 61

3 Mount it on Drilling - - 180 -

drilling machine machine dia.7
drill , drill
chuck
4 Mount center drill Drilling 764 0.1 50 25.00
machine, center
drill, drill
chuck
5 Replace center Drilling 764 0.1 100 23.56
drill by dia. 5 drill machine dia. 5
& drill 3 holes of drill
dia.5
6 Unload the job - - - 30 -

SHREERAM POLYTECHNIC
COPY MILLING MACHINE 62

CHAPTER NO:-06
TESTING OF MACHINE

6. TESTING OF MACHINE PARTS:-

6.1 TESTING OF BASE OR FRAME-

The testing of the body or frame is mainly depends upon the load which the
machine is going to take. The legs of the body should be at right angle to ground.
And the accuracy of alignment depends on the perpendicularity

Bevel protractor takes this test. Before testing the machine it is kept on surface
plate . Then it is leveled by spirit level. Then keeping the bevel protractor on
surface plate, which is already leveled to ground . Then attached to the protector
leg . We proceed for another leg . In this way test the perpendicularly of frame of
our copy milling machine.

SHREERAM POLYTECHNIC
COPY MILLING MACHINE 63

6.2 TESTING THE FLATENESS OF TABLE PLATE :- flatness of table is

very essential in copy milling. Table consists of two directions.

A. Longitudinal direction.

B. Transverse direction.

Measuring instrument:- spirit level.

Procedure:- a spirit level is placed directly On the table for the longitudinal as
well

As transverse test. The readings are noted

6.3 PERPENDICULARITY OF COLUMN:- The perpendicularity of

column to the base plate is tested i.e. in a plane at 90 to the axis of the spindle. The
test is performing by placing the spirit level at one end of the column and the error
is noted by taking the difference between the readings obtained.

6.4 TESTING OF OVER ARM:-

INSTRUMENT:- Dial Gauge, Spirit Level.

Procedure:- The over hanging arm is claimed in its extreme extended position.
Dial gauge is set to zero position, then moved along the over arm and the deviation
from parallelism observed on dial gauge or spirit level.

SHREERAM POLYTECHNIC
COPY MILLING MACHINE 64

CHAPTER NO:07
MAINTENANCE
SHREERAM POLYTECHNIC
COPY MILLING MACHINE 65

7.1 MAINTENANCE :-
 For smooth sliding movement of base greasing is required.

 The milling cutter is required to replace if it get warms out.

 The pulleys are replaced if they slip or sometime reconditioned.

 The milling cutter is required to be ground or it required to make it true after

being periodical used.

 It is required to color the equipment periodically to protect from corrosion

 The rack is required to be replace the teeth are damaged.

 Fixtures screw should be replace periodically.

SHREERAM POLYTECHNIC
COPY MILLING MACHINE 66

 The linkages should be welded or replaced as per requirement in warm out

condition

7.2 SAFETY PRECAUTIONS:-

 Do not touch milling cutter when machine is in operation.

 Always put the best guard on the pulleys. Use to have small of feel to save
cutter and motor.

SHREERAM POLYTECHNIC
COPY MILLING MACHINE 67

CHAPTER NO:08
COST ESTIMATION

8. COST ESTIMATION:- Budget estimation may be defined as the

process of forecasting the expenses take into consideration all expenditure
involved in a design and manufacturing with all related services facilities
such as pattern making as well as portion of the general administrative and
selling costs.

8.1 PURPOSE OF COST ESIMATION:-

1. To determined the selling price of product for a quotation or contract so
as to ensure a reasonable profit to the company.

2. Check the quotation supplied by vendors.

SHREERAM POLYTECHNIC
COPY MILLING MACHINE 68

3. Determined the most economical process or material to manufacture the

product.

4. To determined standards of production performance that may be used to

control the cost.

8.2 BASICALLY THE BUDGET ESTIMATION IS OF TWO

TYPES :-

1. Material Cost Estimation-

• Material For Fabrication

• Standard Purchase Part

2. Machine Cost Estimation-

8.3 MATERIAL COST ESTIMATION :- Material cost estimation

gives total amount required to collect the raw material which has to be
processed or fabricated to desire size and functioning of the components .

These are divided into two categories :

• Material for fabrication

SHREERAM POLYTECHNIC
COPY MILLING MACHINE 69

• Standard purchase parts

8.4 MACHINING COST ESTIMATION :- This cost estimation is an

attempt to forecast the total expenses that may include manufacturing cost
apart from material cost . Cost estimation of manufactured parts can be
considered as judgment on and after careful consideration , which includes
labor , material and factory services required to produce the required parts .

8.5 PROCEDURE FOR CALCULATION OF MATERIAL

COST:-
1. After designing a project a bill is prepared which is divided into categories.

 a. Fabricated components.

 b. Standard purchased components.

2. The rates of all standard items are taken and added up.

3. Cost of raw material purchased taken and added up.

8.6 LABOUR COST:- it is the cost remuneration (wages, salaries,

commission bonus etc) of the employees of concern or enterprises.

Labour cost is classified as :

1. Direct labour cost

2. Indirect labour cost

SHREERAM POLYTECHNIC
COPY MILLING MACHINE 70

Chapter no :09
Source

9. SOURCE :- we have collected the information & necessary technology from

following industries and places .

9.1 M/S STYLRITE OPTICAL INDUSTRIES , MALAD.

SHREERAM POLYTECHNIC
COPY MILLING MACHINE 71

Here we are observed the manufacturing of spectacle frames and various

methods of manufacturing . We get the idea and related information from
Mr.Ketan Parmar who is working in ASSOSSIATED CAPSULES PVT. LTD. As
a executive assistant situated at kandivali.

SHREERAM POLYTECHNIC
COPY MILLING MACHINE 72

Chapter no:10
Biblography

10. BIBLOGRAPHY :-
Following different references we are taken to make our project a successful
creation.

We are take a literature from following books:-

SHREERAM POLYTECHNIC
COPY MILLING MACHINE 73

1. Production technology :- HMT Publication

2. Machine tool design :- N. K. Mehta

3. Cutter pilots and accessories catalogue :- Y Belin

4. Machine design :- R. S. Kurmi

5. Workshop technology :- R. K.Jain.

www.wikipedia.com

BILL OF MATERIAL :-

SR NO. PART NO PART NAME QUANTITIY MATERIAL

SHREERAM POLYTECHNIC
COPY MILLING MACHINE 74

1 BA-01 BASE 1
2 CO-01 COLUMN 1
3 MA-01 MAIN ARM 1
4 TU-01 BOTTOM PLATE 1
5 TU-02 TOP PLATE 1
6 TU-03 GUIDE WAYS 4
7 TU-04 ROLLER CAGE 4
8 SU-01 SPINDLE 1
9 SU-02 HOUSING 1
10 SU-03 BOSS 1
11 SU-04 RING 1
12 PU-01 PINION SHAFT 1
13 PU-02 SPACER 1
14 PU-03 FIXED BUSH 1
15 PU-04 ADJUSTABLE 1
BUSH
16 FX-01 BASE PLATE 1
17 FX-02 FIXTURE PLATE 1
FOR JOB
18 FX-03 CLAMPING 1
PLTE
19 FX-04 CLAMPING 1
PLATE –
TEMPLTE
20 MOTOR ADJ. 1
MECH
21 MOTOR 1
CLAMPING
PLATE
22 MOTOR 1
0.5H.P.14215RPM
23 SPRING 5
24 ALEEN SCREW 22 S.T.D.
25 BALL OF DIA.8 1 S.T.D
26 ROLLERS 16 S.T.D
27 CHEESE HEAD 32 S.T.D
SCREW
28 WING NUTS 2 S.T.D
29 NUTS & BOLTS - S.T.D

SHREERAM POLYTECHNIC
COPY MILLING MACHINE 75

30 DOWELS & 16 S.T.D

STOPPERS
31 HANDLE 3 S.T.D

MATERIAL COST:-

SR COMPONENTS DIMENSIONS WEIGHT RATE COST

NO
1 TABLE
Top & bottom 255X200X16X2pcs 7.00 250.00 1750.00
Guideways 25X18X255X4pcs
2 BASE
Channel 75X40X500X2pcs 6.00 40.00 240.00
M.S.Flat (bright) 40X10X260X3pcs 3.00 60.00 180.00
M.S.Flat 100X10X230X1pcs 2.00 65.00 130.00
3 FIXTURE
Bottom 50X20X240X2pcs 3.00 60.00 180.00
plate(M.S.B.) 25X25X160X1pcs 0.35 60.00 21.00
Angle 75X6X185X1pcs 1.00 60.00 60.00
plate(5mm) 75X6X170X2pcs 2.00 60.00 120.00
Top plate
Fixture plate
4 UPPER ARM
M.S. Flat(bright) 75X6X325X1pcs 4.00 65.00 65.00
M.S. Flat(bright) 55X6X325X2pcs 1.50 55.00 248.00
M.S. Flat(bright) 75X6X150X1pcs - 50.00 155.00
M.S. Flat(bright) 75X6X110X1pcs - - 20.00

5 COLUMN
Pipe(8mm) Dia65X325X1pcs 1.00 65.00 65.00
M.S. Flat(bright) 100X10X160X1pcs 4.50 55.00 248.00
M.S. Flat(bright) 25X6X30X1pcs 3.10 50.00 155.00
Dia.6 disc(6mm) 30X8X30X2pcs - 20.00

6 SPINDLE UNIT
spindle(EN-8) Dia25X255X1pcs 1.00 65.00 65.00

SHREERAM POLYTECHNIC
COPY MILLING MACHINE 76

Housing Dia75X126X1pcs 4.50 55.00 248.00

Boss Dia85X68X1pcs 3.10 50.00 155.00
M.S. Flat(bright) 30X8X30X2pcs - - 20.00

7 PINION Module 2.5 - - 70.00

MECHANISM &10mm wide - - 45.00
GEAR OTHER
PARTS
8 MOTOR
CLAMPING
PLATE 120X160X10X1pcs 1.5 50.00 75.00
M.S. 50X50X50X2pcs 0.70 35.00 25.00
Flate(Black)
ANGLE
PLATE(6mm)
9 ROUND BAR Dia.12X450mm 0.5 - 30.00
10 NUTS & - - - 100.00
BOLTS

TOTAL COST ESTIMATION:

SR NO. PARTICULARS AMOUNT IN
Rs.
1 TOTAL MACHINING COST 2495.0/-

SHREERAM POLYTECHNIC
COPY MILLING MACHINE 77

2 TOTAL MATERIAL COST 5327.00/-

3 COST OF MOTOR (5HP & 2000.00/-
1440RPM)
4 OVERHEADS (INCLUDING 2500.00/-
TRANSPORT,OCTRY,
PAINTING,ELECTROPLATING,
PRINTING & BINDING
5 TOTAL MANUFACTURING 12322.00/-
COST

SHREERAM POLYTECHNIC