Study Guide N: Marking Out (Broaching)

Question 1

Before drilling manually what must you do?

Answer 1

Hole placement must be marked out

Question 2

Before marking a hole, what must you do?

Answer 2

Paint the surface with an alcohol-based dye

Question 3

What are the different names for alcohol-based dyes?

Answer 3

Marking Blue, Layout Stain, Prussian Blue or Dykem

Question 4

What is used to scratch a cross on the desired location?

Answer 4

SCRIBER

Question 5

What are the parts of a SCRIBER?

Answer 5

Straight Point, Grip, and Bent Point

Question 6

What is used to make the indentation (Center Pot)?

Answer 6

CENTER PUNCH

Question 7

What are the 2 types of CENTER PUNCH?

Answer 7

Hammered or Automatic Hammerless type

Question 8

What tool is used after the CENTER PUNCH?

Answer 8

CENTER DRILL (It’s short and stubby, so it resists flexing), which makes a shallow conical hole

Question 9

What is the first twist drill that makes the hole and its size?

Answer 9

PILOT DRILL, which is “1/32” smaller than the desired hole

Question 10

What is the second twist drill that makes the hole and its size?

Answer 10

FINISH DRILL, and this is the actual size of the hole you want

Question 11

What three tools does a CNC machine need to drill a hole? (Doing so with just 2 tool switches)

Answer 11

CENTER DRILL - PILOT DRILL - FINISH DRILL

Question 12

What are other steps that can follow after drilling a hole?

Answer 12

COUNTERSINFING, COUNTERBORING,REAMING and TAPPING

Question 13

What is the process called for accommodations for screw heads for a hole?

Answer 13

HOLE MODIFICATIONS

Question 14

What is the modification process and tool for a FLAT HEAD SCREW that needs the head to sit flush?

Answer 14

Process: COUNTERSINKING
Tool used: COUNTERSINK TOOL (or CUTTER)

Question 15

What is the modification process and tool for a CAP SCREW that needs to sit flush?

Answer 15

Process: COUNTERBORING
Tool: COUNTERBORING TOOL

Question 16

When a hole needs to be cut in sheet metal what is the process called?

Answer 16

Punching

Question 17

To make THROUGH HOLES, what is the inefficient and annoying tool?

Answer 17

HOLE SAW (like a bell on steroids)

Question 18

What is the better tool to make THROUGH HOLES?

Answer 18

TREPANNING TOOL (they use Single Point Cutting Tools or Inserts)

Question 19

What tool does the hole modification of REAMING?

Answer 19

A REAMER (has no point and are precise in diameter)

Question 20

What is REAMING?

Answer 20

A process in which to make a hole very smooth and precise in dimension

Question 21

What is REAMING performed on?

Answer 21

On a FINISH DRILL HOLE

Question 22

If a hole will be REAMED, what must be done to it/

Answer 22

The hole must be drilled 1/64” undersized

Question 23

What is the most common MACHINE TOOL?

Answer 23

VERTICLE DRILL PRESS (SENSITIVE DRILL)
(Manually operated)

Question 24

What MACHINE TOOL is indexable, large, and heavy-duty?

Answer 24

A RADIAL ARM DRILL which is precise and has many degree of freedom

Question 25

What is an old non-existent MACHINE TOOL that is used in CNC machines?

Answer 25

TURRET DRILL (or CAPSTAN DRILL)

Question 26

What is a five-step process that a CNC DRILLING MACHINE might need to perform to create a hole for a CAP SCREW?

Answer 26

CENTER DRILL - PILOT DRILL - FINISH DRILL - REAM - COUNTERBORE

Question 27

Which MACHINE TOOL has multiple DRILL PRESSES lined up and is very expensive?

Answer 27

MULTIPLE SPINDLE DRILLING MACHINES and MULTIPLE SPINDLE DRILL HEAD ATTACHMENTS (only cost-effective if the product batch size is large)

Question 28

Which MACHINE TOOL has multiple DRILL PRESSES lined up and can be relatively cheap/done cheaply?

Answer 28

GANG DRILLING

Question 29

What is another process to create large holes and the tool used when done on a lather?

Answer 29

Process: BORING
Tool: BORING BAR

Question 30

What makes a BORING MACHINE different from cutting a hole on a lathe?

Answer 30

The BORING MACHINE is oriented VERTICALLY and makes the workpiece rotate on a table while the tool holder doesn’t rotate.

Question 31

What is an old antique MACHINE TOOL that doesn’t create a circular hole?

Answer 31

SHAPING MACHINE or SHAPER

Question 32

How does a SHAPING MACHINE cut a workpiece, and with what?

Answer 32

It uses a single-point cutting tool, and it cuts by moving back an forth by a ram.

Question 33

What are the operations performed on a SHAPER?

Answer 33

HORIZONTAL CUTTING, VERTICAL CUTTING, INCLINE CUTTING, and IRREGULAR CUTTING

Question 34

What is the “BIG BROTHER” of the SHAPER that is still used?

Answer 34

PLANING MACHINE or PLANER

Question 35

What is the difference between a SHAPER and PLANER apart from size?

Answer 35

PLANER has the bed/table move and has the cutting tool stay stationary

Question 36

What is a linear cutting process that makes non-circular holes?

Answer 36

Process: BROACHING
Tool: BROACH
(cannot cut blind holes)

Question 37

What is the most common way that BROACHING is done?

Answer 37

Creation of KEY WAYS in shaft hubs but it uses a special tool called KEYWAY BROACH that is inserted into a PLAIN or COLLARED KEYWAY BRUSHING

Question 38

What is the process that has emerged to replace a traditional linear cutting operation that is now done with CNC Machines?

Answer 38

Process: ROTARY BROACHING
Tool: ROTARY BROACHING BITS

Question 39

What machines can ROTARY BROACHING be done in?

Answer 39

CNC MILLS, CNC LATHERS, DRILL PRESS, or a DRILL MILL

Question 40

How is ROTARY BROACHING done?

Answer 40

In a lathe, both the workpiece and cutter rotate at the same speed and direction but the cutter is held at a small angle (1 degree) so the tip wobbles. In other machines the tool just wobbles