FOUR WEEKS SUMMMER TRAINING

Completed at

PUNJAB STATE AERONAUTICAL ENGINEERING COLLEGE

A Training Report Submitted as per

course curriculum requirements for
the Degree of

Bachelor of Technology
in
AERONAUTICAL ENGINEERING
By
ANKIT KUMAR
B.tech(aeronautical engg. 3rd sem.)
(230010001)

1
 DECLARATION
I hereby declare that the 4 weeks summer training report work is an authentic
record of my own work carried out at Punjab State Aeronautical Engineering
College as per the requirements of course curriculum of B.Tech. in Aeronautical
Engineering from Punjab State Aeronautical Engineering College Patiala, under the
guidance of Mr.
Himanshu Mishra and Mr. Harmesh Kumar from 1 July 2024 to 25 July 2024.

Ankit Kumar

230010001

(Aeronautical Engg.)

Date:
Place:

It is certified that the above statement made by the student is correct to the best of our
knowledge and belief.

Faculty Coordinator Name & Designation of Faculty Coordinator

2
 ACKNOWLEDGEMENT
I am highly grateful to Punjab State Aeronautical Engineering College, for providing
this opportunity to carry out the Four weeks summer training at the College
Workshops. I would like to express a deep sense of gratitude and thanks profusely to
Mr. Himanshu Mishra and Mr. Harmesh Kumar. Without their wise counsel and able
guidance, it would have been impossible to complete the report in this manner. The
help rendered by them is greatly acknowledged.

Sincerely,
Ankit Kumar
RollNo : 230010001

3
 CONTENT

PAGE
SR.NO. TOPIC
NO.
1 CHAPTER 1 - MATLAB 5-8

INTRODUCTION
KEY FEATURES OF MATLAB
BASIC COMPONENTS OF MATLAB
GETTTING STARTED WITH MATLAB BASICS
USEFUL MATLAB COMMANDS
MATLAB SIMULATION

2 CHAPTER 2 – WORKSHOP 9 - 20
INTRODUCTION TO VMM (VERTICAL MILLING MACHINE)
CONSTRUCTION
SPECIFICATIONS
ADVANTAGES DISADVANTAGES APPLICATIONS
SAFETY PRECAUTIONS

3 CHAPTER 3 – SOFT SKILLS 21 - 22

INTRODUCTION
IMPORTANCE OF SOFT SKILL
TYPES OF SOFT SKILLS
EXAMPLES OF SOFT SKILL IN ACTION
BENEFITS OF SOFT SKILLS
WAYS TO DEVELOP SOFT SKILLS
CHALLENGES IN SOFT SKILL DEVELOPMENT
CONCLUSION

4 CHAPTER 4 - AEROMODELLING 23 - 25
DEFINITION
TYPES OF AEROMODELS
KEY CONCEPTS OF AEROMODELLING
PURPOSE AND APPLICATIONS
ORNITHOPTER
CHARACTERSTICS
TYPES OF ORNITHOPTER
CHALLENGES IN ORNITHOPTER DESIGNS
APPLICATION OF ORNITHOPTERS

CHAPTER 1 - MATLAB
INTRODUCTION
MATLAB (short for MATrix LABoratory) is a high-level programming language and environment
primarily designed for numerical computing, data analysis, and visualization. It’s widely used in
academia, engineering, and scientific research for tasks involving mathematical computations,
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algorithm development, and data visualization. Here’s a beginner-friendly introduction to
MATLAB’s core aspects:

Key Features of MATLAB

1. Interactive Environment: MATLAB offers an integrated development environment (IDE)
that includes command windows, workspace, and editor, allowing for a seamless coding and testing
experience.
2. Matrix-Based Language: MATLAB is designed around matrix and array mathematics,
making it particularly powerful for linear algebra and other matrix operations.
3. Toolboxes and Functions: MATLAB includes a vast library of built-in functions for
different applications (e.g., signal processing, image processing, machine learning).
4. Visualization and Graphics: MATLAB has excellent support for data visualization, with
functions for plotting 2D and 3D graphs and creating customized data plots.
5. Application Development: With tools for creating user interfaces (UIs) and deploying
applications, MATLAB supports rapid prototyping and application development.

Basic Components of MATLAB

• Command Window: The main area where you enter commands and execute code
interactively.

• Editor: An area where you can write, edit, and save scripts and functions in `.m` files.

• Workspace: Displays variables created in the current session, showing their names, sizes,
and values.

• Command History: Logs all commands you’ve executed, allowing easy re-execution or
reference.

Getting Started with MATLAB Basics

1. Basic Arithmetic Operations

MATLAB handles basic operations like addition, subtraction, multiplication, and division:

a = 5 + 3; % Addition
b = 10 - 2; % Subtraction c = 4 * 3; % Multiplication d =

20 / 5; % Division

2. Matrix and Array Operations

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Arrays and matrices are fundamental in MATLAB. Operations like addition, multiplication, and
transposition can be performed directly.

A = [1, 2; 3, 4]; % 2x2 matrix

B = [5, 6; 7, 8];

% Matrix addition

C = A + B;

% Matrix multiplication

D = A * B;

% Element-wise multiplication

E = A .* B;

% Transpose

F = A';

3. Variables and Data Types

Variables store data in MATLAB, and data types include doubles, integers, strings, and logicals.

x = 10; % Integer y = 3.14;

% Floating-point (double) z = 'Hello

MATLAB'; % String

logicalValue = true; % Logical type (Boolean)

4. Plotting and Visualization

MATLAB’s plotting functions make it easy to visualize data. Here’s an example of a simple 2D

plot: x = 0:0.1:10; % Creates an array from 0 to 10 with step size 0.1

y = sin(x); % Calculate the sine of each element in x

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plot(x, y); % Plot y versus x

title('Sine Wave'); % Title of the plot

xlabel('x'); % Label for the x-axis

ylabel('sin(x)'); % Label for the y-axis

grid on; % Turn on grid

5. Loops and Conditionals

MATLAB supports common control structures such as for loops, while loops, and if statements.

% For loop example for i = 1:5

disp(['Iteration: ', num2str(i)]);

end

% If statement example a = 10; if a

>5 disp ('a is greater than 5');

else

disp ('a is less than or equal to5');

end

6. Creating Functions
Functions in MATLAB are created in (.m) files and are useful for modularizing code. Here’s a
simple function that calculates the square of a number:

% Save this as squareNumber.m

function result = squareNumber(x)

result = x^2;

end
You can call this function in the Command Window or another script:

square_of_4 = squareNumber (4);

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Useful MATLAB Commands

• help <function_name>: View documentation for a specific function.

• clear: Clear all variables from the workspace.

• clc: Clear the Command Window.

• who / whos: Display variables currently in the workspace.

• save <filename>: Save variables to a file.

• load <filename>: Load variables from a file.

MATLAB SMULATION

1. Define the Objective: Describe what the simulation is meant to achieve (e.g., testing a
control system, modeling a physical process).

2. Set Up the Simulation:

Create or set up your MATLAB script (.m file) or Simulink model that runs the simulation.

Define key parameters, initial conditions, and any equations involved.

3. Run the Simulation:

Execute the simulation in MATLAB, either directly in code or by running your Simulink
model.

4. Capture Results:

Gather outputs from the simulation, like graphs, data arrays, or any other results.
Save outputs, often using commands like save, write ,or exporting figures with save as or
print for images.

5. Write the Report:

Title and Objective: Summarize the purpose of the simulation.

Methodology: Explain how the simulation was set up, including any key parameters.

Results: Present the results with graphs or tables generated from MATLAB.

Discussion: Analyze the results, explaining their significance.

Conclusion: Summarize findings and potential improvements.

6. Generate Report in MATLAB:

Use the MATLAB Report Generator or export data and figures for use in a word processor.

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 CHAPTER 2 – WORKSHOP
Introduction to various workshops in the college

1. Machine shop - A machine shop or engineering workshop is a room, building, or company

where machining, a form of subtractive manufacturing, is done. In a machine shop, machinists use
machine tools and cutting tools to make parts, usually of metal or plastic (but sometimes of other
materials such as glass or wood). A machine shop can be a small business (such as a job shop) or a
portion of a factory, whether a tool room or a production area for manufacturing. The building
construction and the layout of the place and equipment vary, and are specific to the shop; for
instance, the flooring in one shop may be concrete, or even compacted dirt, and another shop may
have asphalt floors. A shop may be air-conditioned or not; but in other shops it may be necessary to
maintain a controlled climate. Each shop has its own tools and machinery which differ from other
shops in quantity, capability and focus of expertise.

The parts produced can be the end product of the factory, to be sold to customers in the machine
industry, the car industry, the aircraft industry, or others. It may encompass the frequent machining of
customized components. In other cases, companies in those fields have their own machine shops.

2. Carpentry shop - Carpentry may be designed as the process of making wooden articles and
components such as roots, floors, partitions, doors and windows. Carpentry involves cutting, shaping

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and fastening wood and other materials together to produce a finished product. Preparation of joints
is one of the important operations in wood work. Joinery denotes connecting the wooden parts using
different points such as lap joints, mortise and T- joints, bridle joints, etc.

Tools used in carpentry shop-

1. Marking tools

2. Measuring tools

3. Holding tools

4. Cutting tools
5. Planning tools

7. Striking tools

8. Miscellaneous tools
3. Fitting shop - Fitting Shop involves a large number of hand operations to finish the work to
desired shape, size and accuracy. The various operations performed are marking, chipping,
sawing, filing, scraping, drilling, tap (Internal threading) and die (External threading). Students
acquire skills in using tools and basic fitting equipment, identification of materials, description
and demonstration of various bench vices, holding devices and files, drilling and threading tools.
Shop is also equipped with mechanized hydraulic bending attachment. The basic operations
performed in fitting shop are drilling, reaming, boring, counter sinking, tapping, threading and
grinding etc.

4. Foundry Shop - In foundry shop the students are practicing mould making with the help of
various types of Moulding Sands, different types of patterns are used in the preparation of
moulds. Shop consists of state of the art Induction Furnace to have melting of different types of
metals (ferrous & non-ferrous) and alloys. Sand preparation Muller is also available in foundry
shop to prepare sand for moulds. Students learn the processes of hot metal casting. The various
testing equipment for sand & mould are also available in the sand testing laboratory.
Temperature of the mould is judged with the help of portable pyrometer. The basic operations
performed in foundry shop are preparation of mould, melting of different metal like Aluminium,
Brass, Copper and Steel in induction furnace and preparation of casting by using sand casting
process. Different jobs in which the students are practicing are gating system, testing of mould,

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 permeability test and use of sieve shaker to obtain different mesh size of sand and study the rate
of solidification of metal in Mould.

5. Sheet Metal Shop: The sheet metal implies metal and alloys in sheets rolled to thickness
ranging from 10 S.W.G. and thinner. Sheet and Folate metal work has its own importance in
manufacturing industry and it plays an essential role in various aspects of our day to day needs.
The indispensable engineering articles made of sheet metal find their application in agriculture,
building construction, house hold, offices, laboratories and shop equipment, heating and air
conditioning, transportation, decorative work, toys and many other such areas. Using specialized
sheet metal tools the various concepts from development of surface to actual fabrication are
practiced. The various operations performed during sheet metal jobs are cutting, rolling,
bending, and shaping. Different jobs are seam joint, lap joint, cylinder fabrication, tray
fabrication, riveting and soldering applications.

6. Smithy Shop: Forging is the processes of shaping steel to desired form by heating them to
forging temperatures (plastic condition) and by the application of hammer blows. This is one of
the oldest manufacturing process. The working of small objects heated in an open furnace,
operated manually is known as Smithy. Technical knowhow is imparted on Blowers, Open
Hearth Furnace, Anvil Blocks, and Swage Blocks. The various black smith operations
performed in the shop are Fullering. Setting Up, Setting Down, Bending, Hot & Cold Forging
etc. The jobs undertaken by the students in smithy shop are conversion of shape from raw
material such as square shape, hexagonal, round shape and making letter by steel bars of
different diameter and size of rod, screw driver, chisels etc.

7. Welding Shop: Shop comprises Submerged Arc Welding, Gas Tungsten Arc Welding, Gas
Metal Arc Welding, Spot Welding, Arc Welding, Abrasive Wheel Cutter, Gas Welding and
Cutting apparatus. The welding shop is equipped with Fume Extractor System to provide the
eco-friendly environment for working.

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Introduction to Vertical Milling Machine

.A vertical milling machine is a type of machine tool commonly used in machining operations to mill or shape
material, typically metal. This machine is called "vertical" because the spindle (the part that holds and drives the
cutting tool) is oriented vertically. It is one of the most versatile and widely used machines in manufacturing,
particularly in industries such as aerospace, automotive, and precision engineering.
Key Features of a Vertical Milling Machine
1. Vertical Spindle Orientation:
o The spindle is positioned vertically, allowing for precise vertical cuts.
o The cutting tool typically moves up and down along the Z-axis.
2. Table Movement:
o The workpiece is typically secured on a rectangular table, which moves horizontally along the X
and Y axes.
o The table’s movement, along with the spindle's action, enables the machine to perform a wide
variety of operations.
3. Tooling:
o The vertical milling machine uses various types of cutting tools, such as end mills, drills, and face
mills, which are mounted on the spindle.
o These tools rotate at high speeds to remove material from the workpiece.
4. Adjustability:
o The machine allows for the adjustment of the spindle speed, feed rate, and the depth of the cut.
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 o This adaptability allows for a wide range of operations such as drilling, slotting, boring, and
contour milling.

Construction of a Vertical Milling Machine

The construction of a vertical milling machine involves several components, each designed to perform a
specific function in the machining process. These parts work together to ensure precision, stability, and
accuracy during various milling operations. Below is a breakdown of the key components and their
construction:

1. Base
 Function: The base is the foundational part of the vertical milling machine. It supports the entire
machine structure and absorbs vibrations from the cutting process.
 Construction: Typically made from a rigid, heavy casting, the base is designed to provide maximum
stability. Cast iron is commonly used for its ability to absorb vibrations, reducing any potential
inaccuracies in machining.
 Design Considerations: The base will often include mounting holes for securing the machine to the
floor or a workbench to ensure it remains stable during operation.

2. Column
 Function: The column is a vertical support structure that houses and supports the machine's moving
parts, including the spindle, quill, and feed mechanisms.
 Construction: Made from cast iron or steel, the column is a large, sturdy piece designed to provide
structural rigidity. Its size and weight contribute to the machine's overall stability, ensuring that the
spindle and cutting tools can operate with minimal deflection.
 Features:
o The spindle is housed in the column and is driven by a motor mounted on the machine.
o The column typically has a vertical guideway to allow movement of the knee and other
components.

3. Knee
 Function: The knee is a movable part that supports the worktable and allows for vertical adjustment.
It can be raised or lowered, enabling fine-tuning of the workpiece position relative to the cutting
tool.
 Construction: Typically, the knee is made from cast iron or steel and is designed to be heavy enough
to maintain stability while still allowing for smooth vertical motion.
 Movement: The knee is moved vertically using a manual or powered mechanism, often with a lead
screw or ball screw system. The precise adjustment of the knee allows the operator to control the
depth of cut.

4. Saddle
 Function: The saddle supports the knee and enables horizontal movement of the worktable in the X-
axis direction. It allows the table to move sideways to position the workpiece under the cutting tool.
 Construction: Made from cast iron or steel, the saddle is mounted on top of the knee. The saddle is
typically equipped with sliding guideways that permit smooth movement along the X-axis.
 Movement: The saddle is moved horizontally by a handwheel or powered feed mechanism, which
provides precise control of the workpiece's position.

5. Worktable

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  Function: The worktable is where the workpiece is placed and held in position for machining
operations. The table can be moved in both the X and Y axes (horizontal movement) to position the
workpiece under the rotating cutting tool.
 Construction: The table is typically made from steel or cast iron and is often hardened to resist wear.
It typically includes T-slots for clamping the workpiece securely in place.
 Movement: The worktable can be moved manually using handwheels or automatically with a CNC
system. The Y-axis movement is generally achieved by sliding the worktable along the saddle, while
the X-axis movement occurs along the saddle itself.

6. Spindle
 Function: The spindle holds and rotates the cutting tool. It is one of the most critical components of
the milling machine, as it controls the speed and rotation of the cutting tool during operations.
 Construction: The spindle is typically made from steel or other high-strength alloys and is mounted
within the column. It is supported by bearings or ball bearings to ensure smooth and stable rotation.
 Design:
o The spindle may be designed for manual or automatic tool changes, depending on whether
the machine is a manual or CNC mill.
o Spindle speed is adjustable and is typically controlled via pulleys or gears, allowing for
various speeds to be selected for different cutting operations.

7. Quill
 Function: The quill is the part of the machine that houses the spindle and can be moved up and
down to control the depth of the tool into the workpiece. The quill is primarily used for drilling and
boring operations.
 Construction: The quill is a hollow, cylindrical component that slides within the column, allowing the
spindle to move vertically. It is typically mounted in bearings to ensure smooth movement.
 Operation: The quill can be moved manually with a handwheel or automatically with a powered feed
system. It often includes a depth stop to control the depth of the cut.

8. Head (Ram Head or Milling Head)

 Function: The head contains the motor and the spindle, and it houses the cutting tool. The head is
attached to the column and can often be tilted to allow for angular milling operations.
 Construction: The head is typically made of cast iron or steel for strength and rigidity. It contains
gears and pulleys for controlling spindle speed and may include a gearbox for different speed
settings.
 Types of Heads:
o Ram head: The head can move along the column for longitudinal positioning.
o Fixed head: The head is stationary and is not capable of moving along the column.
 Tilting Capability: Some vertical milling machines have heads that can tilt horizontally, enabling
angular milling operations.

9. Feed Mechanism
 Function: The feed mechanism controls the movement of the worktable, knee, and quill during the
milling process, allowing for precise and smooth feed of the workpiece under the tool.
 Construction: The feed system can be either manual or automatic:
o Manual feed uses handwheels for adjusting the positions of the table and knee.
o Automatic or powered feed uses geared motors or servo motors to move the components
under CNC control or through a feed lever in manual machines.

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  Components: The feed mechanism usually involves lead screws or ball screws that control the
movement of the worktable and knee. These components ensure smooth and precise movement to
achieve the desired cut.

10. Power Drive and Motor

 Function: The motor provides the rotational force required for the spindle and, in some cases, for
the feed mechanism.
 Construction: Vertical milling machines typically use an electric motor that drives the spindle via a
belt system or a direct gear drive. Motors are generally rated for specific power levels depending on
the machine’s size and capacity.
o The motor may be integrated into the head, or it may be mounted separately on the column
or base.
o The speed control of the motor can be manual or electronic, depending on the complexity of
the machine.

11. Control System (for CNC Machines)

 Function: The control system, commonly seen in CNC (Computer Numerical Control) vertical milling
machines, automates the movements of the machine. It allows for highly precise, repeatable milling
operations.
 Construction:
o CNC systems consist of a computer controller that interprets G-code or other programming
languages to direct the movement of the machine components.
o The system controls X, Y, and Z axis movements, the spindle speed, and other parameters
based on the programmed instructions.
 Components:
o Touchscreen interface or manual input devices (e.g., keyboard, mouse) for user interaction.
o Servo motors and encoders to provide feedback and precise movement control.

Specifications of a Vertical Milling Machine

The specifications of a vertical milling machine can vary depending on the machine's size, type (manual or
CNC), and intended use. However, there are several key specifications that are commonly found across most
vertical milling machines. These specifications determine the machine's capabilities, precision, and range of
operations. Below is an overview of the typical specifications for a vertical milling machine.

1. Table Size
 Length: The overall length of the worktable.
o Example: 900 mm (35.4 inches)
 Width: The overall width of the worktable.
o Example: 400 mm (15.7 inches)
The table size determines the maximum size of the workpiece that can be mounted on the machine for
milling operations.

2. Travel Distance (Axes Movement)

 X-Axis Travel (Table Longitudinal Movement):
o Range: Typically ranges from 400 mm to 1,200 mm depending on the machine.
o Example: 900 mm (35.4 inches)

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  Y-Axis Travel (Cross Movement):
o Range: Typically ranges from 300 mm to 800 mm.
o Example: 500 mm (19.7 inches)
 Z-Axis Travel (Vertical Movement):
o Range: Typically ranges from 300 mm to 600 mm.
o Example: 450 mm (17.7 inches)
 Quill Stroke: The vertical movement of the spindle within the quill, often for drilling operations.
o Range: Typically ranges from 100 mm to 200 mm.
o Example: 150 mm (5.9 inches)
These movements specify how far the table and spindle can travel in each direction, determining the size of
workpieces the machine can handle and the complexity of operations it can perform.

3. Spindle Speed (RPM)

 The spindle speed defines how fast the cutting tool can rotate during the milling operation, which
affects material removal rates and finish quality.
 Range: Spindle speeds typically range from 50 RPM to 5,000 RPM, although some high-speed
machines may go up to 12,000 RPM or more.
 Example:
o Low speed: 50–500 RPM (for cutting harder materials like steel)
o Medium speed: 500–2,000 RPM (for general milling operations)
o High speed: 2,000–5,000 RPM (for fine finishing or softer materials)
Spindle speed is often adjustable to suit different materials and types of cuts (e.g., face milling, end milling,
drilling, etc.).

4. Spindle Taper
 Spindle Taper refers to the type and size of the spindle's taper, which holds the milling cutter. The
taper type ensures that the cutting tool is securely mounted and allows for tool changes.
 Common Tapers:
o R8 Taper (widely used in smaller machines)
o NT (National Taper) or NMTB (National Machine Tool Builders) Taper
o ISO 30, ISO 40, or ISO 50 (for larger machines)
 Example: ISO 40 or 50, depending on the machine size and tool compatibility.

5. Motor Power
 The motor power determines the strength and torque that the machine can apply to the cutting tool,
affecting the material removal rate and cutting performance.
 Range: Typically ranges from 1.5 kW (2 hp) to 15 kW (20 hp), depending on the machine size and
application.
 Example:
o Small machines: 2 HP (1.5 kW)
o Medium machines: 5 HP (3.7 kW)
o Large machines: 10 HP (7.5 kW) or more.
Higher motor power is often required for machining harder materials or for heavy-duty production tasks.

6. Table Load Capacity (Max Workpiece Weight)

 This specification defines how much weight the worktable can support without compromising
stability or accuracy during machining.
 Range: Typically ranges from 100 kg (220 lbs) to 1,000 kg (2,200 lbs), depending on the size and
design of the machine.
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  Example: A common load capacity for medium-sized vertical mills is 500 kg (1,100 lbs).

7. Tool Change Mechanism

 Manual Tool Change: In manual vertical mills, the operator changes tools by hand.
 Automatic Tool Changer (ATC): In CNC vertical mills, the machine automatically changes tools using a
tool magazine and a robotic arm.
o The tool magazine capacity can range from 10 to 40 tools, or more in high-end CNC
machines.
o Tool changing time: Typically between 1 to 10 seconds.

8. Feed Rates
 Rapid Traverse Rate (Unloaded Movement): The maximum speed at which the table, saddle, or
knee can move when not cutting. This is important for positioning the workpiece and tool quickly
between cuts.
o Range: Typically ranges from 5,000 mm/min to 15,000 mm/min (200 to 600 ipm).
o Example: 6,000 mm/min (236 ipm) for a medium-sized machine.
 Cutting Feed Rate: The rate at which the cutting tool moves into the workpiece, affecting the
material removal rate and finish.
o Range: Typically ranges from 100 mm/min to 2,000 mm/min.
o Example: 500 mm/min (20 ipm) for general milling operations.
Feed rates are adjustable to allow for different cutting conditions and materials.

9. Precision and Accuracy

 Positioning Accuracy: This refers to the ability of the machine to position the workpiece accurately,
typically stated as ±0.005 mm (±0.0002 inches) or better for high-precision machines.
 Repeatability: The ability of the machine to return to the same position after multiple cycles.
o Range: ±0.002 mm (±0.00008 inches) or better for CNC vertical mills.

10. Machine Dimensions and Weight

 Length: The overall length of the machine.
o Example: 2,000 mm (78.7 inches)
 Width: The overall width of the machine.
o Example: 1,000 mm (39.4 inches)
 Height: The overall height of the machine.
o Example: 2,000 mm (78.7 inches)
 Weight: The total weight of the machine, which can impact stability and setup.
o Example: A medium-sized vertical milling machine may weigh around 2,000 kg (4,400 lbs),
while larger machines can weigh upwards of 10,000 kg (22,000 lbs).

11. Control System (for CNC Machines)

 CNC Type: Most modern vertical milling machines use CNC (Computer Numerical Control) for
automatic operation.
o Control System: Popular systems include Fanuc, Siemens, Heidenhain, and Haas.
 Number of Axes: Common vertical milling machines are 3-axis machines, but advanced models can
have 4 or more axes for more complex operations (e.g., 4-axis CNC for simultaneous milling and
rotation).
 Programming Language: Most CNC vertical milling machines use G-code for programming.

12. Coolant System

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  Coolant Tank Capacity: The size of the coolant tank that supplies coolant to the cutting tool during
machining.
o Range: Typically ranges from 30 liters (8 gallons) to 200 liters (52 gallons).
 Coolant Pump: Pumps to deliver coolant to the cutting tool at the appropriate flow rate and
pressure.
o Range: Flow rates typically range from 10 L/min to 100 L/min, depending on the machine
size and application.

Advantages:
1. Precision and Accuracy:
o Vertical milling machines offer high precision in machining, making them ideal for producing
parts with tight tolerances.
o Suitable for operations that require fine finishes such as drilling, boring, and milling.
2. Versatility:
o These machines can perform a variety of tasks such as face milling, end milling, drilling,
boring, and tapping.
o Can be used on a wide range of materials including metals, plastics, and wood.
3. Ease of Setup:
o Vertical mills are relatively easy to set up, particularly manual versions where adjustments
can be made quickly.
o Tool changes are also straightforward, especially on manual mills.
4. Compact Design:
o Vertical milling machines are generally smaller and take up less space compared to horizontal
mills, making them ideal for workshops with limited space.
5. Cost-Effective (Manual Machines):
o Manual vertical mills are relatively affordable compared to CNC machines, making them a
cost-effective option for smaller shops and low-volume work.
6. Accessibility and Visibility:
o The vertical spindle design allows operators to easily view the cutting area and adjust the
workpiece or tool as needed during operations.

Disadvantages:
1. Slower Production Rates (Manual Machines):
o Manual vertical mills are generally slower compared to CNC machines, especially for large,
repetitive tasks.
o Requires more operator input for each operation, which can limit productivity.
2. Limited Workpiece Size:
o Vertical mills typically have smaller worktables compared to horizontal milling machines,
limiting the size of workpieces they can accommodate.
3. Less Rigid (Manual Machines):
o Manual vertical mills may not have the same level of rigidity as horizontal mills or CNC
machines, which can impact the quality of cuts in tougher materials or during high-load
operations.
4. Skill Dependent:
o Manual vertical milling requires skilled operators to set up and control the machine
accurately. In contrast, CNC machines automate much of the process, reducing human error.
5. Maintenance and Wear:
o Over time, the wear on parts such as the spindle, bearings, and lead screws can affect the
accuracy of the machine, requiring more frequent maintenance.
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Applications of Vertical Milling Machines:
1. Aerospace Industry:
o Milling parts such as turbine blades, airframe components, and engine housings.
o The precision and versatility of vertical milling are essential for the complex geometries
found in aerospace components.
2. Automotive Industry:
o Manufacturing engine components, gearbox parts, transmission housings, and prototypes.
o Vertical mills are used to machine parts requiring tight tolerances and fine finishes.
3. Medical Device Manufacturing:
o Milling titanium and stainless steel for surgical tools, implants, and medical device
components.
o Used for creating highly detailed, precision parts required in medical applications.
4. Tool and Die Making:
o Essential in the production of molds, dies, and jigs used in casting, forging, and stamping
operations.
o Vertical mills are often used for fine milling, drilling, and engraving on tool steel.
5. Metalworking and Fabrication:
o Used for cutting and shaping metal components in general fabrication and machinery repair.
o Ideal for small to medium-sized parts in manufacturing shops.
6. Prototyping and Small Batch Production:
o Vertical milling machines are often used in prototyping and low-volume production runs,
where flexibility and speed of setup are important.
o Small to medium-sized workpieces can be produced quickly for test runs and product
validation.
7. Education and Training:
o Common in technical schools and vocational training centers to teach students about
machining and CNC programming.
o Manual vertical mills are frequently used to help beginners understand the basic concepts of
machining and tool handling.

Safety Precautions for Operating a Vertical Milling Machine

Working with a vertical milling machine involves potential hazards due to rotating parts, sharp tools, and
heavy workpieces. It’s crucial to follow safety guidelines to prevent accidents, protect the operator, and
ensure a safe working environment. Below are important safety precautions to consider:

1. Personal Protective Equipment (PPE)

 Wear Proper Clothing: Avoid loose clothing, jewelry, or accessories that could get caught in moving
parts. Tight-fitting clothing is essential to prevent accidents.
 Eye Protection: Always wear safety goggles or a face shield to protect your eyes from flying debris,
coolant splashes, and dust.
 Hearing Protection: Use earplugs or earmuffs to protect against high noise levels, especially in
industrial settings where milling machines can produce loud sounds.
 Gloves: While gloves should generally be avoided near rotating parts (to prevent entanglement),
protective gloves can be worn for handling rough materials or sharp tools.
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  Footwear: Wear steel-toed shoes or boots to protect your feet from falling tools or heavy
workpieces.

2. Machine Setup and Inspection

 Check the Machine Before Use:
o Ensure all components, such as the spindle, worktable, and cutting tools, are properly
installed and secure.
o Inspect the machine for any damaged parts, loose fasteners, or wear that could cause
malfunctions.
o Verify that the coolant system is functioning correctly and that there’s sufficient coolant for
the operation.
o Make sure the spindle speed is set to an appropriate level for the material being worked on.
 Proper Tool Selection: Choose the right cutting tool for the material being machined and the type of
operation. Incorrect tool choice can lead to poor machining results and potential accidents.
 Check Workpiece Mounting: Ensure the workpiece is securely clamped to the worktable using
proper fixtures. A loose workpiece can move unexpectedly, causing damage or injury.

3. Operating the Milling Machine

 Keep Hands and Body Clear of Moving Parts: Always keep hands, tools, and any part of your body
away from rotating parts such as the spindle, tool, and table. Use non-contact methods (e.g.,
handwheels) to adjust the position of the workpiece when the machine is running.
 Do Not Override Safety Features: Many vertical mills come equipped with safety features like
emergency stop buttons, interlocks, and protective shields. Always respect these and avoid
bypassing or disabling them.
 Start the Machine Slowly: When starting the machine, ensure it begins slowly to check for any
unusual noises or vibrations that could indicate issues with alignment or tool condition.
 Use Proper Handling Techniques:
o Use a push stick or tool handle when working with tools to maintain a safe distance from
rotating parts.
o When adjusting the workpiece, always turn off the machine to avoid accidents.
 Feed Rates and Speed Control: Set the proper feed rate and spindle speed based on the material
being cut. Too high a feed rate or speed can result in tool breakage or poor finishes, while too low a
speed can cause overheating or poor material removal.

4. Working with Coolant

 Use Coolant Properly: Coolants help reduce friction and heat during cutting. Ensure the coolant is
directed at the cutting area to avoid burning or overheating the tool and workpiece.
 Avoid Spills and Slips: Clean up any coolant spills on the floor to avoid slips. Keep the work area dry
and clean at all times.
 Dispose of Waste Coolant Correctly: Follow proper procedures for handling and disposing of waste
coolant to avoid environmental contamination.

5. Tool Handling and Maintenance

 Handle Tools Safely: Always handle cutting tools with care. Use a tool holder or a tool grip to avoid
direct contact with sharp edges.
 Check Tool Condition: Regularly inspect tools for wear, chips, or cracks. Replace damaged tools
immediately to avoid accidents or poor-quality cuts.
 Secure Tool Changes: When changing tools, ensure the spindle is not running to prevent injury.
Make sure the new tool is correctly installed and securely tightened.

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6. General Workplace Safety
 Clean Work Area: Keep the milling machine and surrounding work area free of debris, cutting fluids,
and tools. A clutter-free space reduces the risk of accidents and allows for easier machine operation.
 Lighting: Ensure proper lighting in the workspace to maintain clear visibility of the workpiece and the
cutting area. Poor lighting can lead to mistakes or mishandling of tools.
 Stay Focused and Alert: Milling requires constant attention. Avoid distractions, and never leave the
machine running unattended. Always maintain a clear focus on the task at hand.

7. Emergency Procedures
 Know the Emergency Stop Location: Familiarize yourself with the location of the emergency stop
button or emergency switch on the milling machine. In case of malfunction, it’s crucial to be able to
stop the machine immediately.
 In Case of an Accident:
o If a tool or workpiece breaks loose, shut down the machine immediately.
o If an injury occurs, seek medical attention immediately and follow the workplace’s safety
protocol.
o Keep a first-aid kit readily accessible near the machine.

8. Operator Training
 Proper Training: Ensure that all operators are properly trained in the use of the milling machine,
including:
o Basic machine functions.
o Tool setup and adjustments.
o Safety procedures.
o Proper maintenance routines.
 Supervision for Inexperienced Operators: Novice operators should work under the supervision of an
experienced machinist until they gain adequate proficiency in operating the machine safely

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 CHAPTER 3-SOFT SKILLS
1. Introduction
• Purpose of the Report: State the goal of the report, such as understanding the role
of soft skills in professional and personal development or how they impact teamwork
and productivity.
• Definition of Soft Skills: Briefly define soft skills and explain how they differ from
technical or hard skills. For example, soft skills are non-technical skills that relate to
how individuals interact with others and manage their work.

2. Importance of Soft Skills

• In the Workplace: Discuss why employers value soft skills, highlighting their role in
improving communication, collaboration, and conflict resolution.
• For Career Growth: Explain how soft skills are essential for leadership roles, client
relationships, and adapting to workplace changes.
• For Personal Development: Mention how soft skills contribute to self-confidence,
empathy, and emotional intelligence.

3. Types of Soft Skills

• Communication Skills: Verbal and non-verbal communication, active listening, and
presentation skills.
• Teamwork and Collaboration: Working effectively within a team, understanding
roles, and contributing constructively.
• Adaptability and Flexibility: Ability to manage change, handle new challenges, and
stay resilient.
• Problem-Solving and Critical Thinking: Approach to resolving conflicts, finding
solutions, and making informed decisions.
• Time Management and Organizational Skills: Prioritizing tasks, managing deadlines,
and staying organized.
• Leadership and Responsibility: Taking charge when necessary, motivating others,
and owning up to responsibilities.
• Emotional Intelligence: Recognizing emotions in oneself and others, and using this
awareness to guide behavior and relationships.

4. Examples of Soft Skills in Action

• Include real-life scenarios or case studies where specific soft skills led to a positive
outcome. For example, how active listening in a team meeting led to a collaborative
breakthrough.

5. Benefits of Soft Skills

• For Individuals: Improved job satisfaction, higher adaptability, and better career
advancement.
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 • For Teams: Enhanced collaboration, reduced conflicts, and improved group
dynamics.
• For Organizations: Increased productivity, higher employee retention, and a positive
work environment.

6. Ways to Develop Soft Skills

• Training and Workshops: Describe available workshops, seminars, and online
courses.
• Practical Experience: Volunteering, participating in team projects, or role-playing
scenarios.
• Self-Assessment and Feedback: Tools like personality assessments, peer feedback,
and self-reflection.
• Mentoring and Coaching: Importance of learning from mentors or coaches to gain
insights and improve soft skills.

7. Challenges in Soft Skill Development

• Subjectivity: Difficulty in measuring soft skills compared to technical skills.
• Lack of Emphasis: Some individuals or organizations may overlook the importance
of soft skills.
• Continuous Development: Soft skills require ongoing practice and refinement, unlike
technical skills which can be mastered and applied directly.

8. Conclusion
• Summarize the critical role of soft skills in professional success and personal
growth.
• Highlight that developing soft skills is a continuous journey that enhances not only
workplace effectiveness but also overall quality of life.

9. Recommendations
• Offer practical advice for readers to start or continue developing soft skills.
• Suggest integrating soft skill training in educational programs or workplace training.

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 CHAPTER 4 – AEROMODELLING

DEFINITION: - Aeromodelling is the hobby, sport, or educational activity of designing,

building, and flying model aircraft. These aircraft can be miniature replicas of real
airplanes or entirely original designs, and they vary in complexity from simple gliders to
sophisticated radio-controlled (RC) planes and drones.

Types of Aeromodels

1. Static Models: Models that are built for display purposes only and are not meant to fly.
These often focus on details and realistic appearances.

2. Flying Models: These are designed to achieve actual flight and can be further classified
into:

o Free-Flight Models: Fly without any external control after launch. They
rely on initial power or gliding capabilities. o Control Line Models: Are
connected to the operator by wires or strings and controlled manually
during flight.
o Radio-Controlled (RC) Models: Controlled remotely by a radio
transmitter, allowing for advanced maneuvers and adjustments in real time.
o Gliders: Non-powered models that rely on their aerodynamic design and

environmental factors (like wind currents) to stay airborne.

Key Concepts in Aeromodelling

1. Aerodynamics: Understanding how forces like lift, drag, thrust, and weight
impact flight is essential for effective model design.

2. Stability and Control: Ensuring the model is stable in the air and can be
maneuvered properly, often involving control surfaces such as ailerons,
rudders, and elevators.

3. Propulsion Systems: Many models use electric or gas-powered motors for

propulsion, while gliders rely purely on aerodynamic design.

Purpose and Applications of Aeromodelling

• Educational Tool: Teaches fundamental principles of aerodynamics,
engineering, and flight.
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 • Hobby and Recreation: A creative and enjoyable activity for enthusiasts who
love aviation.
• Competitive Sport: Aeromodelling competitions involve various challenges
like endurance, distance, or precision flying.
• Professional Training: For aspiring pilots or aerospace engineers, it provides
practical insights into aircraft dynamics.

ORNITHOPTER
An ornithopter is a type of aircraft that achieves flight by mimicking the flapping-
wing motion of birds, bats, and insects. Unlike traditional fixed-wing aircraft, which
rely on steady airflow over stationary wings, ornithopters generate lift and propulsion
through wing movement. This design aims to replicate the natural mechanics of
animal flight, offering unique advantages and challenges in aerodynamics and
engineering.

Key Characteristics of an Ornithopter

1. Flapping Wings: The primary feature of an ornithopter is its wings, which flap
up and down (and sometimes with rotational motion) to generate both lift and
thrust.

2. Biomimicry: Ornithopters are inspired by the biomechanics of birds and

insects, aiming to copy their efficiency and maneuverability.

3. Materials and Mechanics: Lightweight materials such as carbon fiber, balsa

wood, and advanced polymers are often used to replicate the flexibility and
durability of organic wings.

4. Power Source: Ornithopters can be powered by rubber bands (for small

models), electric motors, or, in some experimental designs, even fuel engines.
Types of Ornithopters
• Toy and Model Ornithopters: Small, often rubber-band powered models that fly
by simple mechanisms.
• Remote-Controlled Ornithopters: These are more complex, using electric
motors and often controlled by a transmitter to perform flight maneuvers.

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 • Experimental and Research-Oriented Ornithopters: Larger, highly engineered
ornithopters designed for research into flapping-wing flight, which can help
advance aerodynamics and robotics. Challenges in Ornithopter Design

1. Aerodynamic Complexity: The flapping motion creates complex airflow

patterns that are challenging to model and control.

2. Energy Efficiency: Flapping wings are less energy-efficient than rotating

propellers, so designing an energy-efficient ornithopter remains a research
challenge.

3. Structural Stress: The repetitive flapping motion introduces significant stress

on materials, necessitating durable yet lightweight materials. Applications of
Ornithopters
• Research and Development: Ornithopters help scientists study the mechanics of
animal flight and explore new aerodynamics concepts.
• Surveillance and Reconnaissance: Small, bird-like ornithopters can be used in
military or environmental monitoring to blend into natural settings.
• Educational Purposes: Building and flying ornithopters can help students and
hobbyists learn about aerodynamics, mechanical engineering, and biology.

Famous Examples

1. Leonardo da Vinci's Ornithopter: One of the earliest concepts of a flapping-

wing aircraft, although it was never built.

2. Modern RC Ornithopters: Today, various remote-controlled ornithopters are

available commercially, often modeled after birds or insects for realistic flight.
Ornithopters remain a fascinating field of study, combining biology, engineering, and
physics to explore one of nature’s most intriguing flight mechanisms.

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