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Machine Theory > Milling > Flashcards

Milling Flashcards

Module questions from the current module as well as last years module.

1
Q

As a general rule, the maximum depth of cut for an endmill is equal to:

A

1/2 the diameter of the endmill.

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2
Q

You can use V-Blocks on a milling machine? (T/F)

A

True

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2
Q

The _______________ is the amount of metal removed by each tooth per revolution.

A

Chip Load

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3
Q

What is the name of the taper used on milling machine spindles and what is its taper per foot?

A

The taper used is the Standard Steep Machine Taper, usually called the Milling Machine Taper, having a 3 1/2 inch taper per foot.

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4
Q

The purpose of the overarm is to support the __________, which in turn support the __________.

A

arbor supports

free end of the arbor.

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5
Q

The Plain horizontal milling machine is the most basic milling machine and is capable of doing most milling jobs. The two main features of this machine are:

A

1) The main spindle is Horizontal

2) The table cannot be swivelled. It moves only at right angles to the spindle

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6
Q

The universal horizontal milling machine is essentially the same as a plain horizontal milling machine except:

A

The table can be swivelled. This feature allows the universal horizontal milling machine to do helical milling.

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7
Q

The six basic components to a knee and column milling machine are:

A

1) Base
2) Column
3) Overarm
4) Knee
5) Saddle
6) Table

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8
Q

When should you tighten the backlash eliminator?

A

Before climb milling to prevent the workpiece from being drawn into the cutter.

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9
Q

The table hand wheel and the graduated collar allow the table to be moved and positioned by hand to what accuracy?

A

0.001 inch of 0.02 mm

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10
Q

Define and Locate: The longitudinal traverse direction lever.

A

Found on the saddle immediately in front of the table, determines whether the table will feed to the right or left.

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11
Q

Define and Locate: The longitudinal traverse handle.

A

Usually found on the saddle, engages the table power feed.

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12
Q

Define and Locate: The vertical feed handle.

A

Generally found on the side of the knee, moves the knee up and down.

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13
Q

Define and Locate: The cross traverse handle.

A

Found on the side of the knee, moves the saddle toward or away from the column.

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14
Q

The spindle nose has two drive keys to help drive the cutting tool and can be controlled in one of two ways:

A

1) Gear box located on the column

2) Variable speed hand wheel (variable speed drive)

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15
Q

There are four styles of milling cutters:

A

1) Solid high-speed steel
2) Solid Carbide
3) Carbid cutting edges brazed onto a solid shank
4) Indexable inserts clamped in a holder.

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16
Q

Metric RPM Formula is:

A

RPM = Cutting Speed x 320 / Diameter of Cutter

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17
Q

Imperial RPM Formula is:

A

RPM = Cutting Speed x 4 / Diameter of Cutter

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18
Q

Feed Rate Formula is:

A

Feed = Chip Load x Spindle Speed x Number of teeth.

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19
Q

A 6 inch x 1/2 inch x 1 inch cutter has:

A

A diameter of 6 inches, a width of 1/2 inch and a bore of 1 inch.

20
Q

A swivel base vise can:

A

swivel 360 degrees.

21
Q

Angle plates are used to clamp material parallel to the machine table. (T/F)

A

False. Angle plates are shaped like a capital L and allow a workpiece to be clamped on its side.

22
Q

A milling machine must be equipped with a __________ when climb milling.

A

Backlash Eliminator

23
Q

Keysets are found in:

A

A shaft.

24
Q

How should you handle the sharp milling machine cutters?

A

Handle the cutters with a rag when installing or removing them to keep from getting cut.

25
Q

What controls the feed rate on a milling machine?

A

The feed rate on most milling machines is controlled by a gearbox located in the knee and saddle. Some lighter milling machines have a feed motor and dial mounted on the end of the table or on the saddle.

26
Q

The spindle on a milling machine:

A

Supports and drives the milling cutter.

27
Q

What draws the arbor or collet chuck into the spindle of the milling machine?

A

The Draw Bolt

28
Q

Why must the feed rate for a flycutter be very low?

A

There is only one cutting edge, not two or more.

29
Q

How does a collet clamp onto the shank of the cutter?

A

Collets have a series of slits running almost their entire length. The outside of the collet is tapered to fit the tapered bore in the collet holder. The inside diameter is parallel and fits the shank of the milling cutter. When the collet is forced into the collet holder the taper squeezes the collet into the shank of the cutting tool.

30
Q

Which vise is the most rigid vise for a milling machine, the plain vise, the swivel base vise, or the universal vise? Why?

A

The plain vise is more rigid than the other two vises because the swivel base vise holds the work higher above the table and the universal vise holds it even higher.

31
Q

What is used to support the end of a strap clamp?

A

A step block.

32
Q

Which type of clamp has a unique design to clamp many different sized workpieces without using step blocks or packing?

A

A universal clamp

33
Q

What would you use to support the workpiece higher in the vise, or higher off the table, when drilling or milling through the workpiece?

A

Use parallels

34
Q

What would you use to support those extended parts of a workpiece that do not sit directly on the table of the milling machine?

A

Jackscrews

35
Q

What is a shim used for on a milling machine?

A

Shims are used as packing to fill the gap under the workpiece.

36
Q

What is the main purpose of stop blocks?

A

Stop blocks are used to keep the workpiece from shifting under heavy cutting pressures.

37
Q

To dial in a vise on the milling machine, you should:

A

Set the dial base on the column and the dial indicator on the solid jaw of the vise. Move the table.

38
Q

Keyseats are cut using a:

A

Side milling cutter, an end-mill, or a Woodruff keyseat cutter, depending on the style of keyseat required.

39
Q

The depth of a keyseat is always measured from the _________.

A

Flat

40
Q

When centring the shaft under the cutter, hold the paper between the __________ and the __________.

A

Rotating Cutter

Side of the Shaft

41
Q

Why should end mills be stored separate from one another?

A

If allowed to roll against each other, their cutting edges will chip and wear. Keep each end mill in its own container, or store it in a try with separate bins.

42
Q

What type of milling produces flat surface perpendicular to the spindle axis?

A

Face Milling

43
Q

What is the difference between an “A” style and “B” style milling machine arbor?

A

“B” style is suitable for heavy duty milling.

44
Q

What type of milling machine is the most versatile?

A

Ram-Type vertical Mill

45
Q

What type of milling is performed when the cutter rotation and the feed direction are in the same direction?

A

Climb Milling

46
Q

What type of milling machine has a table that may be swiveled 45° in either direction?

A

Universal horizontal type.

47
Q

What type of milling machine has an overarm?

A

Horizontal milling machine

48
Q

How should a strap clamp be correctly positioned to accurately and securely hold a workpiece?

A

The step block end of the clamp should be slightly higher than the work and the bolt positioned as close to the work as possible

Machine Theory (7 decks)

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