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Man Poo > O - Milling to Bandsaws > Flashcards

O - Milling to Bandsaws Flashcards

1
Q

vital to modern subtractive manufacturing, available in manual and CNC variants, can cut virtually any machinable shape when combined with TURNING.

A

VERTICAL MILLING

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2
Q

The 3 different names for the manual version of VERTICAL MILLING

A
  • vertical mill
  • knee mill
  • bridgeport
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3
Q

Used primarily for machines that are more compact in size and therefore suitable for smaller workshops where footprint and ceiling height are limited. Another name for a vertical milling machine.

A

KNEE MILL

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4
Q

A pioneering manufacturer of full-size machines founded in Bridgeport, Connecticut. Another name for a vertical milling machine.

A

BRIDGEPORT

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5
Q

In what way does a VERTICAL MILLING MACHINE resemble a DRILL PRESS?

A

since it has a single, driven vertical spindle that moves up and down

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6
Q

“Beefier” version of a press and has an x-y-z indexable table for work holding and positioning

A

MILL

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7
Q

Although it is possible to attach a drill to the spindle of a MILL (via a COLLET CHUCK), the tool bit of choice is the _______ ______.

A

MILLING CUTTER

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8
Q

The most common type of milling cutter, usually made of HSS, can be single, double, or triple-coated, usually have 3 or more blades, and can produce a fairly good surface finish.

A

END MILL

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9
Q

An END MILL with only 2 blades available, used to remove material quickly (rough cutting/roughing).

A

SLOT MILL

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10
Q

The ____ _____ is first used to rapidly remove material, followed by a tool swap to a 3+ bladed ___ ____ for a lighter finish cut with a superior surface finish.

A

SLOT MILL; END MILL

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11
Q

What can MILLING CUTTERS do that Shapers could not?

A

PLUNGE into the workpiece, changing path direction (L-shaped slot)

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12
Q

What must the MILLING CUTTER be capable of in order to plunge into the workpiece?

A

cutting all the way to the center of its face.

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13
Q

Characteristics of CENTER CUTTING

A
  • one or more cutting edges at the tip
  • allows cutter to plunge, drill, or ramp
  • greater variety of applications
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14
Q

Characteristics of NONCENTER CUTTING

A
  • used for side cuts of contouring an exterior surface
  • used where plunging is not necessary
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15
Q

Many modern tool bits, including INDEXABLE END MILLS, use the convenience of _______ _______.

A

CUTTING INSERTS

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16
Q

Unlike those used for single-point lathe tools, these are designed to cut along 2 edges at the same time.

A

CUTTING INSERTS

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17
Q

Another common milling operation used to quickly reduce the thickness of a workpiece.

A

FACE MILLING

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18
Q

Large discs with teeth on the periphery of the face, and are rarely ground from the solid material, use a ring of INSERTS.

A

FACE MILLS

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19
Q

A special type of groove often cut into machine tool tables or lathe face plates. They are milled in a 2-stage operation.

A

T-SLOTS

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20
Q

What are the 2 stages of malling a T-SLOT?

A
  1. multiple passes using a slender end mill to progressively cut the vertical groove
  2. use a special T-SLOT CUTTER to create the lower horizontal portion
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21
Q

A milling operation achieved with a single bit similar to the appearance of the T-SLOT cutter.

A

KEYWAY CUTTING

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22
Q

Has a shank with a curved reduction adjacent to the bladed end.

A

KEYWAY/KEYSEAT CUTTER

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23
Q

What is an advantage to KEYWAY CUTTERS?

A

They can cut the D-shaped seating groove needed for WOODRUFF KEYS

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24
Q

What kinds of odd shapes are MILLING CUTTERS available for special applications?

A
  • BALL END MILLS to cut round-bottomed grooves
  • DOVETAIL MILLS to make dovetail grooves
  • CHAMFERING MILLS to put a chamfer on an edge
  • CORNER ROUNDING MILLS to soften edges with a curve
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25
Q

What is the issue with VERTICAL MILLING that is addressed with the HORIZONTAL MILLING MACHINE?

A

the cutting tools on a vertical milling machine are only held at one end, which limits the depth of cut without tool breakage, and flexing can create poor accuracy

26
Q

Are HORIZONTAL MILLING MACHINES available in CNC and manual varients?

A

YES

27
Q

driven around and supported at both ends; cutting tools in a HORIZONTAL MILLING MACHINE are attached to this

A

an ARBOR

28
Q

6 types of HORIZONTAL MILLING operations

A
  • straddle milling
  • form milling
  • slotting
  • slitting
  • gang milling
  • slab milling
29
Q

A manual machine with all the motion inputs handled by servos or stepper motors

A

CNC MILL (computer numerical control)

30
Q

The software language used in CNC MILLS, can be written directly by a skilled programmer generated as the output from a CAD/CAM package.

A

G-CODE

31
Q

How are instruction files input into the CNC MILL?

A

USB or downloaded from a network.

32
Q

An operator manually inputs parameters via a keyboard on the controller

A

CONVERSATIONAL PROGRAMMING

33
Q

safer to use than manual ones because the machining takes place in an enclosed space.

A

CNC MILLS

34
Q

CNC MILLS have at least _ ______ machines

A

3 AXIS (X, Y, and Z)

35
Q

Why is the W-AXIS not strictly necessary in a CNC MILL?

A

because the same motion can be achieved through coordination of the Z and X

36
Q

Nowadays it is common to see a ___ ____ combined with a ___ _____.

A

CNC MILL; CNC LATHE

37
Q

Multi-axis machines are expensive so they are limited to _-____ (X, Y, Z, A) or _-____(X, Y, Z, A, B) systems.

A

4-AXIS; 5-AXIS

38
Q

tool storage and automatic changing system in CNC MILLS and CNC MACHINE CENTERS

A

MAGAZINE or CAROUSEL (turret)

39
Q

Each tool in the MAGAZINE/CAROUSEL is fitted into a tapered (non-locking) holder and held in the spindle by a _________ _______.

A

pneumatic DRAWBAR

40
Q

Process used to manufacture simple external straight-cut gears

A

GEAR SHAPING

41
Q

a cylindrical BROACH configuration with teeth running down inside the bore

A

POT BROACHING

42
Q

A form of milling for gear cutting

A

GEAR MILLING

43
Q

for spiral or helical cut gears, it is necessary to use a gear-generating machine and this cutting tool

A

GEAR HOB

44
Q

A HAND TOOL made of hardened steel with a rough surface and comes in various cross-sections, used for deburring operations

A

FILES

45
Q

The course variant of the FILE.

A

BASTARD FILES

46
Q

Very small files for doing detailed work

A

NEEDLE FILES (US) OR SWISS FILES (UK)

47
Q

FILES are prone to getting clogged with chips stuck between the fine teeth when cutting soft metal like aluminum

A

LOADING

48
Q

Why is it recommended that FILES be coated in CHALK prior to and during use?

A

to prevent chips from sticking and loading

49
Q

A powered alternative to the FILE, a small handheld power tool that makes simple tasks like deburring or engraving effortless

A

ROTARY FILE or DREMEL TOOL

50
Q

Removing sharp edges and attached metal flakes left after machining operations

A

DEBURRING

51
Q

Rotary device that runs at a very high speed and makes a sound like a “dentist’s drill”

A

DREMEL TOOL

52
Q

Cutting tool bits that substitute for filing

A

BURRS/BURS or ROTARY FILES

53
Q

Very difficult to control when handheld and have the tendency to suddenly rip across the workpiece surface causing superficial damage

A

ROTARY TOOLS

54
Q

The body of the ROTARY TOOL stays on a solid surface away from the workpiece, while the cutter is securely held, but easily manipulated, like a pen

A

FLEXIBLE DRIVE SHAFT ATTACHMENT

55
Q

Common way of cutting material used a lot in carpentry (woodworking)

A

SAWING

56
Q

A hand tool that uses a removable blade that is always installed with the teeth angled towards the front, cutting only occurs on the forward stroke.

A

HACKSAW

57
Q

Compact configuration of the HACKSAW.

A

JUNIOR/MINI HACKSAW

58
Q

A metal sawing tool that uses a continuous loop blade that is driven between 2 pulleys

A

BANDSAW

59
Q

The portable and powered version of the BANDSAW

A

PORTA-BAND

60
Q

BANDSAW machine tool configuration good for cutting a sheet or plate, and can follow a curved path if desired

A

VERTICAL BANDSAW

61
Q

BANDSAW machine tool configuration designed specifically for cutting long bar stock or pipe/tube into manageable lengths.

A

HORIZONTAL BANDSAW

Man Poo (31 decks)

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