Review Questions

- For taper turning, milling, study match the photo

Machining
- Machined parts can be classified as Rotational or Non-Rotational
- Rotational parts are cylindric or disk like (using a lathe)
- Non- Rotational parts can be any shape
- The final shape is defined by the movement and shape of the cutting tool. This process is called
Generating.
- Forming is opposite to generating, when the shape of the cutting tool determines the shape of
the cut
- Forming & Generating can be combined.

Turning Operations
- Turning can be used for different cuts, these include Facing, Contour Turning, Chamfering,
Cutoff, Threading
- Facing is where the cutting tool is fed perpendicular to the lengthwise axis. This process is used
to leave a flat face on an object. When cutting, the tool will go a little past the radius
- Contour Turning is where the tool is fed in a ‘sin pattern’ to make a wavy cut
- Chamfering is ‘filleting’ the edges (get rid of sharp corners)
- Parting is cutting a piece in half on a lathe
- Threading uses a V-shaped tool to create a thread (remember machine shop demonstration)
- Drilling
- Boring is used to increase the diameter when the part has already been drilled. It uses a
stationary piece to cut rather than a rotating drill.
- Tapering makes a hole go from a large diameter to a smaller diameter. It works similarly to a
bore though moves in a diagonal direction.
- The Feed Rate is the distance that you move when cutting per minute. Expressed as: feed rate =
rpm* feed distance / minute.
- The Time Requirement uses the feed rate and the length of the cut. Expressed as: time =
length / feed rate. There is also a relationship
- RPM can be found by taking the velocity/(pi*diameter)
- Material Removal Rate for turning can be expressed as : velocity x feed x depth of cut
Lathes
- Bed holds the lathe
- Headstock holds the part
- Tailstock can be used to centre the part and to guide the part / cutting tool and support the
workpiece
- Carriage / Saddle & Cross Slide are used to let the cutter move in x y and z direction
- The important specifications of lathes are the Size (how big of a part can fit?), Max RPM and
Horsepower
- When holding a material Between Centres, the piece is clamped from each end while being
allowed to rotate. Generally used for parts with larger aspect ratios (longer parts)
- Chucks are used to hold a material between 3 or 4 jaws. Each jaw is adjustable allowing for off-
centre work pieces to be centred.
- Work holding collets use three slits to squeeze the material. They only work for specific
diameters (like the bore measurement material). Even though they are less versatile they are
faster to unload / load the piece with good accuracy.
- Face Plate is like the chuck though works for even more irregular shapes.
- Engine lathes are the typical lathe, good accuracy, works for small and larger parts
- Tool Room Lathe gives much better accuracy than an engine lathe but is much smaller in size.
This is usually used to cut tools
- Turret Lathes have a magazine of multiple tools without having to switch them out. They hold up
to 6 tools
- Automatic Chucking lathes are like turret (basically a CNC lathe)
- Bar Machine is very similar to the last two though automated for production
- Screw Machines is like the bar machine though makes screws
- Multiple Spindle Bar Machines can work on multiple parts at a time, greatly increasing
production speed. These machines have 4, 6, or 8 spindles (each containing a tool). These are
generally fed a long piece of metal and then
- Vertical Lathes are used for very large pieces
- CNC Lathes are computer controlled lathes

Drilling
- Drilling is a process mainly used to make holes.
- The drill bit and feed are always perpendicular to the workpiece
- The flute allows for material (chips) to flow out of the material when drilling and carry the
coolant fluid
- Drilling can be used to lessen material weight
- The Shank holds the drill bit in the machine
- The Drill geometry has a conventional angle of 118 degrees. Flattening the angle is better for
hard material, creates thicker chips though removes material at a slower rate
- Drill bits are generally held in Vises (two jaws), Fixture (custom designed) or Drill Jigs
- Thrust Force is the force when pushing the bit down (in the direction of the hole axis). It is
dependent on the drill bit design, rotational speed, feed and workplace material
- Power is the specific energy (energy required to remove a unit of material) x MRR (material
removal rate)
- Torque = Power / Angular velocity
- Cutting Speed = the velocity / pi x diameter
- Feed (in rpm x in/rev) = Cutting speed / Recommended Feed
- Through holes go all the way through the piece, Blind Holes do not
- Time to drill a through hole = thickness + Approach rate / feed rate
- Time to drill a blind hole = depth of the hole / feed rate
- Rate of material removal = pi x diameter^2 feedrate / 4
- Reaming is somewhat like boring, using a drill to finish a hole (more so for surface finish and
tolerance)
- Tapping creates an internal thread
- Countersinking is creating a tapered hole so screws can lay flat on the cut
- Counterboring is boring though just enlarging the top not the entire hole.
- Spot facing uses a small fillet to make sure the screw sits flat with the surface
- Drill presses come in two form factors, Upright and Radial. Radial is used for larger parts though
the drill press generally has better tolerance for holes
- Tapping Machines and Multi-Spindles are also used to make holes. Multi spindles are basically
drill presses put together

Milling
- Three things to remember: the cutting tool is rotating; mills have multiple cutting edges, and the
tool rotation is always perpendicular to the surface
- Peripheral Milling is the exception since the tool moves across the piece whereas the face mill
goes perpendicular to the surface
- Slab Milling means the cut width extends beyond the material (finish in one pass)
- Slotting runs parallel to the workpiece though is less thick than the piece creating a slot
- Straddle Milling and Gang Milling use two and 3 slot mills respectively
- Shape Milling is like slotting though produces a shape
- Face Milling is when the cutter is bigger than the workpiece
- Partial Facing is when the cut is only part of the piece
- End Milling is used to create a good surface finish on the edge of the piece or create a slot in the
piece
- Pocket Milling uses an end mill to create a pocket in the material
- Surface contouring uses a “ball nose mill” to create a contour (curved) shape, used to make
injection molds
- Conventional Milling has a tool rotating clockwise, since the chip thickness gradually increases,
the force gradually increases as well though this can pull the workpiece up
- Climb milling creates a thick chip at the start and thins out at the end. The workpiece is pushed
down in this process. This is generally used on thinner or harder to hold parts since it pushes the
material down.
- Knee and Column is a milling machine
- Horizontal milling machines uses the parallel (peripheral) milling tool
- Vertical milling machine uses the face milling tool
- Bed and CNC mills are generally automated
- Milling Speed = the cutting velocity / pi x the mill diameter
- Milling Feed = Milling speed x feed from the table x number of teeth on the cutter
- MMR = width x depth x feedrate