Tooling_U Chapter 2 Questions Flashcards
Describe various sawing methods
Hand Sawing:
Crosscut Saw: Designed for cutting wood across the grain, creating smooth and accurate cuts.
Rip Saw: Used for cutting wood along the grain, providing efficient and straight-line cuts.
Backsaw: A smaller, precision saw often used for fine woodworking and joinery.
Power Sawing:
Circular Saw: A versatile power saw with a circular blade, suitable for cutting wood, metal, and plastic.
Jigsaw: Equipped with a narrow, reciprocating blade for making curved and intricate cuts in various materials.
Reciprocating Saw: Features a straight, reciprocating blade for rough cutting tasks and demolition work.
Table Saw: A large, stationary saw with a flat table and a rotating circular blade, commonly used for precision woodworking.
Miter Saw: Ideal for making precise crosscuts and miter cuts in wood and other materials.
Scroll Saw: Used for intricate, precision cuts in wood, plastic, and thin metal.
Band Saw: Utilizes a continuous looped blade for cutting curves, resawing, and making irregular cuts.
Chop Saw: Also known as a miter saw, it is used for making accurate crosscuts and miter cuts in wood and metal.
Abrasive Sawing:
Abrasive Cut-Off Saw: Equipped with an abrasive disc, it is primarily used for cutting metal, concrete, and masonry.
Grinder with Cut-Off Wheel: Angle grinders fitted with cut-off wheels are versatile tools for cutting metal and other materials.
Chain Sawing:
Chainsaw: Primarily used for cutting wood, it features a chain with cutting teeth powered by a gasoline engine or electricity.
Wire Sawing:
Wire Saw: Utilizes a flexible wire with abrasive beads for cutting through hard and irregularly shaped materials, including concrete and stone.
Panel Sawing:
Panel Saw: Designed for cutting large sheets of materials like plywood, MDF, and melamine, providing clean and straight cuts.
Flush Cutting:
Flush-Cut Saw: Designed to cut flush with surfaces, making it useful for trimming dowels, plugs, and other protruding parts.
Scroll Sawing:
Scroll Saw: Ideal for intricate, fine-detail cutting, such as crafting and decorative work.
Resawing:
Resaw Bandsaw: Used for resawing wide boards into thinner pieces, often in woodworking.
Cold Sawing:
Cold Saw: Specifically designed for cutting metal, it operates at lower speeds and generates less heat compared to traditional abrasive saws.
Describe Metal Cutting Tools
Operations that use Single-Point Cutting Tools:
Turning: Single-point cutting tools are primarily used in turning operations on lathes. In turning, a cylindrical workpiece rotates, and the single-point tool removes material to create cylindrical, conical, or contoured shapes. It is used for tasks like facing, tapering, and creating external and internal grooves.
Boring: Boring operations involve enlarging existing holes or creating precise internal diameters. Single-point tools are used to achieve high accuracy and surface finish in these operations.
Threading: To create threads on a workpiece, single-point cutting tools are used. The tool follows a helical path to cut the threads, and this process is known as single-point threading.
Parting and Grooving: Single-point cutting tools are used for cutting off a workpiece to a specified length or creating narrow grooves on the surface.
Facing: Facing operations involve cutting a flat surface at right angles to the axis of rotation of the workpiece. It is commonly used to create flat end surfaces on cylindrical workpieces.
Operations that use Multi-Point Cutting Tools:
Milling: Milling is a versatile operation where a rotating multi-point cutting tool, known as a milling cutter, removes material from a stationary workpiece. Milling can produce a wide range of shapes, including flat surfaces, pockets, slots, gears, and complex contours.
Drilling: Drilling involves creating holes in a workpiece using a rotating drill bit with multiple cutting edges. It is a common operation in various industries, from metalworking to woodworking and beyond.
Broaching: Broaching is a machining process that uses a multi-point cutting tool called a broach to remove material in a linear fashion. It is often used to create keyways, splines, and other internal shapes.
Gear Cutting: Gear cutting involves using specialized multi-point cutting tools to create gears and splines. Methods include hobbing, gear shaping, and gear grinding.
Reaming: Reaming is a finishing operation that improves the accuracy and surface finish of drilled holes. It uses a multi-point cutting tool called a reamer.
Tapping: Tapping is the process of creating internal threads in a hole. A tap, which has multiple cutting edges, is used to cut the threads as it is rotated into the hole.
Counterboring and Countersinking: These operations involve creating recesses or chamfers at the entrance of drilled holes to accommodate fasteners like screws or bolts.
Slotting: Slotting operations use slotting cutters, which are multi-point cutting tools, to cut slots or grooves in a workpiece.
Sawing: While sawing is typically associated with single-point cutting tools, it’s worth noting that circular saws and bandsaws use multi-point cutting tools (saw blades) to cut through materials, including metal, wood, and plastic.
Describe Broaching
Broaching is a specialized machining process used to create precise and complex internal and external shapes in workpieces. It is particularly well-suited for producing keyways, splines, gears, and other intricate profiles that are challenging to achieve with other cutting methods. Broaching tools, known as broaches, are designed with a series of cutting teeth that gradually increase in size, allowing them to remove material in a linear, incremental fashion. Here’s a more detailed description of the broaching process:
Broaching Process Steps:
Workpiece Setup: The workpiece, which can be made of various materials such as metal, plastic, or even some types of wood, is securely clamped in place. It must be positioned correctly to ensure that the broaching tool can access the desired location.
Broach Selection: Depending on the specific shape and size of the feature to be machined, the appropriate broach is selected. Broaches come in various types, including keyway broaches, spline broaches, and surface broaches.
Broaching Tool Alignment: The broach is inserted into a broaching machine, which may be horizontal or vertical, and aligned with the workpiece. The broach is guided precisely to ensure that it enters the workpiece at the correct location and orientation.
Initial Contact and Entry: The broach’s leading end, known as the pilot, makes initial contact with the workpiece. As the broach is pushed or pulled through the workpiece, the pilot guides the broach into the starting position.
Incremental Cutting: Once the broach is properly positioned, the cutting teeth come into contact with the workpiece. Each tooth removes a small, incremental amount of material with every pass. The cutting forces involved can be quite significant, so the broach and workpiece must be robust and securely held in place.
Return Stroke: After each pass, the broach is retracted or pulled back to its starting position. This return stroke does not cut material but prepares the broach for the next cutting pass.
Multiple Passes: Broaching typically involves multiple passes, each removing material slightly deeper or wider than the previous one, until the desired shape or depth is achieved. The broach is gradually advanced during each pass.
Coolant and Lubrication: Coolant or cutting fluid may be applied during the broaching process to dissipate heat, lubricate the broach, and flush away chips and debris.
Completion: Once all the passes are completed, the broach has created the intended shape or feature in the workpiece. The finished part may require additional finishing steps, such as deburring or polishing.
Advantages of Broaching:
Precision: Broaching can produce highly accurate and repeatable results.
Versatility: It can create complex internal and external shapes efficiently.
Efficiency: Broaching is often faster than other methods for producing similar features.
Cost-Effective: It can reduce the need for multiple tool changes and setups.
Limitations of Broaching:
Specialized Tooling: Broaches are specific to the desired shape, making tool changes necessary for different jobs.
Initial Setup: Setting up a broaching machine can be time-consuming.
Material Hardness: Broaching is most effective on softer materials and may require specialized broaches for hard materials.
Cutting Forces: High forces can be involved, which may necessitate sturdy workpiece clamping and machine structures.
Overall, broaching is a valuable machining process for creating precise, internal and external profiles in workpieces, particularly when high accuracy and efficiency are required
Describe Lathes
A lathe is a versatile machine tool used in metalworking, woodworking, and other machining processes to shape, cut, and manipulate cylindrical workpieces. Lathes are fundamental to manufacturing and are available in various sizes and configurations to accommodate a wide range of applications.
Turning: Turning is the primary operation on a lathe. It involves rotating the workpiece while a cutting tool removes material from its surface to create cylindrical shapes, such as shafts, pins, and tubes.
Facing: Facing is the process of cutting a flat surface perpendicular to the workpiece’s axis. It is often the first step in turning operations to create a clean, flat end surface.
Taper Turning: Taper turning involves cutting a conical shape on the workpiece, either gradually or uniformly. This is achieved by adjusting the angle of the compound rest.
Thread Cutting: Lathes can be used to cut threads on cylindrical workpieces, such as bolts and screws. This is accomplished by engaging the lead screw and synchronizing its rotation with the workpiece’s rotation.
Drilling: A tailstock with a drilling attachment or a live center can be used to perform drilling operations on the lathe.
Boring: Boring is the process of enlarging an existing hole in a workpiece using a single-point cutting tool.
Parting: Parting is the operation of cutting off a workpiece to a specified length using a parting tool or cutoff tool.
Knurling: Knurling is a decorative or functional operation where a pattern is impressed onto the workpiece’s surface, often for improved grip.
Describe Basic Components of a Lathe
Bed: The bed is the base of the lathe, providing a rigid foundation for all other components. It usually has prismatic or box-like construction and supports the headstock and tailstock.
Headstock: Located at one end of the bed, the headstock houses the main spindle, which rotates the workpiece. It often contains gears and a mechanism for changing spindle speeds. The headstock may also include a chuck for holding the workpiece.
Tailstock: Positioned at the opposite end of the bed from the headstock, the tailstock provides support to the workpiece, especially during longer workpieces. It can be adjusted along the bed to accommodate different workpiece lengths and may have a quill for drilling or centering operations.
Carriage: The carriage is a movable assembly that slides along the bed and carries the cutting tool. It includes the tool post, which holds the tool holder and tool bit, and the apron, which contains mechanisms for controlling the tool’s movements.
Cross Slide: The cross slide is mounted on the carriage and allows the tool to move perpendicular to the workpiece’s axis, enabling facing and other transverse operations.
Compound Rest: The compound rest is another assembly on the carriage that provides angular adjustment to the tool, allowing for taper turning and angle cutting.
Lead Screw: The lead screw, often located beneath the bed, is threaded and connected to the carriage. It enables the carriage to move longitudinally along the bed, facilitating threading and longitudinal cutting.
Describe how the lathes carriage and compound rest operates
The carriage and compound rest are critical components of a lathe, and they work together to control the movement and orientation of the cutting tool as it engages with the workpiece. These components enable various machining operations, including turning, facing, taper turning, and threading.
Positioning the Tool: To set up for a machining operation, the operator adjusts the tool post on the carriage to hold the desired cutting tool. The height and orientation of the tool are adjusted using the tool post and compound rest as needed.
Moving the Carriage: For longitudinal (lengthwise) movements, the operator can engage the carriage’s feed mechanisms, typically by engaging the half-nuts with the lead screw. This allows the carriage to move along the bed at controlled feed rates, which are crucial for turning and threading.
Cross Slide Movement: For transverse movements (perpendicular to the workpiece’s axis), the operator uses the cross slide to position the carriage and tool for facing and other lateral cuts.
Compound Rest Swiveling: When taper turning or creating angled cuts is required, the operator adjusts the compound rest’s angle by turning the handwheel. This action tilts the compound rest slide and, consequently, the cutting tool to the desired angle.
Identify different cutting tools for the lathes
Turning Tools:
Roughing Tool: Used for heavy material removal during initial cuts.
Finishing Tool: Designed for achieving a smooth surface finish on the workpiece.
Cut-Off or Parting Tool: Used to cut off a workpiece to a specific length.
Thread Cutting Tool: Designed to create threads on the workpiece.
Boring Tools:
Boring Bar: Used to enlarge or finish existing holes in a workpiece.
Internal Facing Tool: Designed for facing operations on the inner surfaces of a workpiece.
Grooving Tools:
Internal Grooving Tool: Used to create internal grooves or recesses in a workpiece.
External Grooving Tool: Used to create external grooves or recesses on the workpiece.
Threading Tools:
Thread Cutting Tool: Designed for cutting threads on the workpiece.
Thread Turning Tool: Specifically designed for turning threads.
Parting Tools:
Parting Tool Blade: A straight-edged tool used for parting or cutting off a workpiece.
Knurling Tools:
Knurling Tool: Used to create a knurled pattern on the workpiece for improved grip or aesthetics.
Chamfering and
Deburring Tools:
Chamfering Tool: Used to create chamfered edges on the workpiece.
Deburring Tool: Designed to remove burrs and sharp edges from the workpiece.
Taper Turning Tools:
Taper Turning Attachment: Used to achieve tapering on the workpiece.
Taper Turning Tool: Designed for manual taper turning operations.
Forming Tools:
Form Tools: Custom-shaped tools used for contouring and creating specific profiles on the workpiece.
Specialty Tools:
Diamond Tipped Tools: Used for machining hard materials like ceramics or carbide.
Radius Cutting Tools: Designed for creating curved or radiused features on the workpiece.
Profile Tools: Custom tools for creating intricate profiles and shapes.
Carbide Inserts:
Indexable carbide inserts are commonly used as cutting tools in modern lathes due to their durability and versatility. These inserts are available in various shapes and cutting geometries for different applications.
Tool Holders:
Various tool holders, such as turning tool holders, boring bar holders, and parting tool holders, are used to secure cutting tools in the tool post of the lathe.
Tool Bits:
High-speed steel (HSS) tool bits are traditional cutting tools used in lathes. These are available in different shapes and sizes and can be ground to the desired cutting geometry.
Describe various types of Milling Machines
Vertical Milling Machine:
Vertical Knee Mill: The most common type of vertical milling machine, it has a vertically oriented spindle that holds and rotates cutting tools. It is often used for face milling, end milling, and drilling operations.
Bed Mill: Similar to the knee mill, but the bed moves vertically and horizontally along the fixed spindle. This design allows for more versatile workpiece handling.
Horizontal Milling
Machine:
Horizontal Plain Mill: In this machine, the spindle is oriented horizontally, and the workpiece is mounted on the table. It’s suitable for producing flat surfaces and slots.
Horizontal Universal Mill: Similar to the plain mill but with additional swiveling motions of the worktable, allowing for more complex machining tasks.
Turret Milling Machine:
Turret mill or Bridgeport mill: This versatile milling machine has a rotating turret head that can hold multiple cutting tools. It’s highly adaptable for a wide range of operations, including face milling, slotting, and contouring.
Bed Milling Machine:
Gantry Milling Machine: A large, heavy-duty milling machine with a gantry frame above the worktable. It is suitable for machining large and heavy workpieces, often used in aerospace and shipbuilding.
Portal Milling Machine: Similar to a gantry mill, but with a stationary worktable and a movable bridge or portal for greater rigidity and precision.
Planer Milling Machine:
Double Column Milling Machine: These machines have a massive structure with two columns and a cross rail. They are used for heavy-duty milling operations on large workpieces.
CNC Milling Machine:
Vertical CNC Mill: A computer numerical control (CNC) milling machine with a vertically oriented spindle. CNC mills are highly automated and can produce complex parts with precision.
Horizontal CNC Mill: Similar to vertical CNC mills but with a horizontal spindle orientation. They are used for specialized applications, such as machining multiple sides of a workpiece in one setup.
5-Axis CNC Mill: These advanced machines can move the workpiece and cutting tool simultaneously in five axes, enabling complex machining of intricate parts from multiple angles.
High-Speed Milling
Machine:
High-Speed Machining Center: Designed for fast and precise machining, often used in the aerospace and automotive industries for producing complex components quickly.
Mini Milling Machine:
Mini Mill or Benchtop Mill: Compact milling machines suitable for hobbyists, small workshops, and educational settings. They are scaled-down versions of larger milling machines.
Drill Press with Milling
Capabilities:
Some drill presses can be equipped with milling attachments or accessories, allowing for limited milling operations.
Specialty Milling
Machines:
Thread Milling Machine: Designed specifically for creating threads on workpieces.
Copy Milling Machine: Used for replicating complex shapes and profiles.
Keyway Milling
Machine: Specialized for cutting keyways in shafts and other components.
Contrast Vertical and Horizontal Milling
Vertical milling and horizontal milling are two primary types of milling machines, each with distinct orientations and advantages. Here’s a contrast between vertical and horizontal milling:
Vertical Milling:
Spindle Orientation:
In a vertical milling machine, the spindle is oriented vertically, meaning it extends up and down from the machine’s worktable.
Workpiece Positioning:
The workpiece is typically mounted on the machine’s worktable, which moves in the X and Y axes, while the spindle moves in the Z-axis (up and down). This allows for easy setup and positioning of the workpiece.
Tool Access:
Vertical mills are well-suited for tasks where the cutting tool needs to extend vertically into the workpiece. This orientation is ideal for tasks like drilling holes, slotting, and contouring.
Gravity-Assisted Chip Removal:
Gravity naturally helps remove chips and debris from the cutting area, making chip evacuation relatively straightforward.
Common Applications:
Vertical milling machines are commonly used for tasks such as face milling, end milling, drilling, and pocketing. They are versatile and suitable for a wide range of operations.
Horizontal Milling:
Spindle Orientation:
In a horizontal milling machine, the spindle is oriented horizontally, meaning it extends parallel to the worktable.
Workpiece Positioning:
The workpiece is usually mounted on the machine’s worktable, which moves primarily in the X and Y axes. The spindle moves vertically in the Z-axis. This arrangement allows for machining features on multiple sides of the workpiece in a single setup.
Tool Access:
Horizontal mills excel at tasks where the cutting tool needs to approach the workpiece from the side, making them suitable for tasks like facing large surfaces, slotting, and contouring.
Complex Machining:
Horizontal milling is particularly useful for complex parts that require machining on multiple faces or require features at various angles. The horizontal spindle can reach all sides of the workpiece without repositioning.
Coolant and Chip Management:
Horizontal mills typically require more extensive coolant and chip management systems to handle chips and coolant effectively.
Common Applications:
Horizontal milling machines are often used for producing parts with multiple features on different faces, such as engine blocks, gearboxes, and complex machine components
Identify the adjustable parts on the milling machine
Table (Worktable): The worktable is usually adjustable in three main directions:
X-Axis: The worktable can move left and right along the machine’s bed.
Y-Axis: The worktable can move forward and backward along the saddle.
Z-Axis: The worktable can move up and down vertically to control the depth of the cut. This adjustment is achieved by raising or lowering the knee.
Knee: The knee is an adjustable vertical component that supports the table. It can be raised or lowered along the machine’s column to adjust the workpiece’s vertical position relative to the cutting tool.
Saddle: The saddle is mounted on the knee and can be moved horizontally along the ways on the machine’s column to control the workpiece’s lateral positioning.
Headstock: The headstock houses the spindle and cutting tool. It can often be adjusted in several ways:
Headstock Inclination: The headstock can be tilted or swiveled to set the cutting tool at various angles for taper milling and other angled cuts.
Spindle Height: The spindle can be raised or lowered vertically to adjust the tool’s height relative to the workpiece.
Spindle Speed: Some milling machines have adjustable spindle speeds to control cutting tool rotation speed for different materials and machining operations.
Tool Holder or Tool Post: The tool holder or tool post on the milling machine’s headstock can be adjusted:
Tool Height: The tool height can be adjusted vertically to align the cutting tool precisely with the workpiece.
Tool Angular Orientation: Depending on the tool holder design, it may allow for angular adjustments to set the tool at specific angles relative to the workpiece.
Feed Controls: Milling machines have controls for adjusting the feed rate of the worktable or spindle. These controls allow operators to set the desired rate at which the cutting tool moves across or into the workpiece.
Coolant and Lubrication Systems: Some milling machines have adjustable coolant and lubrication systems that allow for controlling the flow and distribution of cutting fluid to ensure efficient machining and tool cooling.
Digital Readouts (DRO): DRO systems provide digital readouts of the machine’s position, allowing operators to precisely track the movement of adjustable parts like the worktable, saddle, and knee.
Clamps and Fixtures: While not part of the machine itself, clamps and fixtures are essential for securing the workpiece to the table. These can be adjusted to hold the workpiece securely in place during machining.
Identify different types of milling cutting tools
End Mill:
End mills have cutting edges on both the end face and the periphery. They are versatile and can be used for a wide range of milling operations, including face milling, slotting, contouring, and profiling.
Types of end mills include square end mills, ball nose end mills, corner radius end mills, and roughing end mills.
Face Mill:
Face mills have multiple cutting inserts arranged on their face. They are primarily used for facing large flat surfaces, but they can also be used for contouring and pocketing.
These tools are available in various sizes and configurations.
Slotting Cutter:
Slotting cutters have teeth on the periphery and are designed for cutting slots and keyways. They can also be used for general profiling.
Keyseat cutters are a type of slotting cutter specifically used for creating keyways.
Ball Nose Cutter:
Ball nose cutters have a rounded end, making them suitable for contouring and 3D machining. They can create smooth, curved surfaces and intricate details.
These cutters are often used for mold making and die-casting applications.
Roughing End Mill:
Roughing end mills are designed for high material removal rates and are used for quickly removing material in the early stages of machining. They leave a rough surface finish.
They have multiple flutes and coarse teeth.
T-Slot Cutter:
T-slot cutters are used for creating T-shaped slots in workpieces, commonly used for securing parts with T-nuts in machine tool tables.
Dovetail Cutter:
Dovetail cutters have a unique shape with a dovetail profile. They are used for creating dovetail grooves or slots for joining parts, often found in tooling and fixtures.
Chamfer Cutter:
Chamfer cutters have angled cutting edges and are used for creating chamfers or beveled edges on workpieces. They can also be used for deburring.
Chamfer cutters are available in various angles.
Shell Mill Cutter:
Shell mill cutters have multiple cutting inserts arranged on the periphery of a cylindrical shell. They are used for heavy-duty face milling and contouring.
They come in various sizes and styles.
Fly Cutter:
Fly cutters have a single cutting tool mounted on a rotating spindle. They are used for creating flat surfaces by making a single pass across the workpiece.
Thread Milling Cutter:
Thread milling cutters are used for creating threads in workpieces. They can produce internal and external threads of various sizes and pitches.
Woodruff Cutter:
Woodruff cutters are specifically designed for creating keyseats in workpieces, often used in keyway milling operations.
Profile Milling Cutter:
Profile milling cutters have custom-shaped cutting edges and are used for creating specific profiles and contours on workpieces.
Form Milling Cutter:
Form milling cutters are used for machining workpieces with complex shapes or profiles. They are designed to match the desired contour precisely.
Inserted Tooth Milling Cutter:
Inserted tooth milling cutters have replaceable cutting inserts, making them cost-effective and adaptable for various materials and machining conditions.
Describe Drill Presses
Key Components:
Base: The base is the sturdy foundation of the drill press, providing stability and support for the entire machine.
Column: The column is a vertical pillar that rises from the base and houses the internal components of the drill press. It provides rigidity and vertical guidance for the drill head and worktable.
Table: The table is a flat, adjustable work surface located directly beneath the drill head. It can be raised, lowered, tilted, or rotated to accommodate different workpieces and drilling angles.
Drill Head: The drill head contains the motor, spindle, and quill assembly. It can be moved vertically along the column to adjust the drilling depth.
Spindle: The spindle is the rotating component responsible for holding and driving the drill bit. It can typically accommodate various sizes of drill bits through a chuck or collet.
Quill: The quill is a vertically movable assembly that surrounds the spindle. It allows the drill bit to move up and down as the user operates the drill press handle or lever.
Chuck: The chuck is the component at the end of the spindle that holds and secures the drill bit. Keyed chucks require a chuck key to tighten or loosen the jaws, while keyless chucks can be tightened by hand.
Depth Stop: A depth stop is a feature that allows users to set and control the drilling depth accurately. It prevents the drill bit from going too deep into the workpiece.
Speed Control: Drill presses often feature multiple speed settings that can be adjusted to match the material being drilled and the size of the drill bit. Speed changes are typically achieved by adjusting belts or changing pulley positions.
Table Support and T-slots: Some drill press tables have T-slots or other features to secure workpieces and accessories, such as vises or clamps, for more precise drilling.
Features and Functions:
Drilling: The primary function of a drill press is to create holes in various materials with precision and accuracy.
Variable Speed: Many drill presses offer variable speed settings, allowing operators to choose the appropriate speed for the material and drill bit size.
Tilting Table: Some drill press tables can be tilted to accommodate angled drilling.
Depth Control: Depth stops and depth gauges enable precise control over drilling depth.
Safety Features: Drill presses often include safety features like safety switches, guards, and emergency stop buttons to protect the user.
Magnetic Base: Some models may have a magnetic base for holding metal workpieces securely.
Laser Guides: Advanced drill presses may have laser guides to assist with precise hole placement.
