Series 320: Machine Shop Practices

Course 317: Machine Shop Shaping Operations

Covers types of milling machines and milling operations. Covers spindles, arbors, feed rates, and safety precautions. Discusses shaper and planer operations-setup, maintenance, and safety procedures. Also

Introduces grinding, power sawing, and gear cutting operations.

Available Media: Interactive, Self-Study Textbook, Videos, Pre- and Post- Tests, Spanish Textbook

Lesson 1 - Milling Operations

Topics:

Milling machines; Spindles; Arbors; End mill holders and collets; Locating the cutter; Spindle speed, feed, and direction; Indexing; Safety

Learning Objectives:

• Explain the difference between peripheral milling and face milling.
• List the four types of knee-and-column milling machines.
• Explain how each of the knee-and-column machines works.
• Explain how a workpiece is held on a milling machine.
• Name and describe the three basic styles of arbor.
• Explain how the speed of a milling cutter is measured.
• Define indexing.

Lesson 2 - Shaping and Planing

Topics:

Shaper tooling; Cutting fluids; Cutting speeds; Setup procedures; Angular, internal shaping; Planer construction and tools; Safety

Learning Objectives:

• Compare and contrast shapers and planers.
• Explain the processes of shaping and planing.
• Explain how to select a shaper cutting fluid.
• Explain how shaper cutting speed is expressed.
• Explain how to check alignment of the shaper vise and ram.
• Explain how cutting fluids are applied to planer work

Lesson 3 - Grinding Operations

Topics:

Grinding machines; Manual grinding; Grinding wheels; Mounting, dressing, and truing a grinding wheel; Cutting fluids; Grinding faults; Safety

Learning Objectives:

• Define grinding.
• Name the five categories of grinding.
• Explain how to read the marking code on a grinding wheel.
• Explain how to mount a grinding wheel.
• Define the terms dressing and truing as related to grinding wheels.
• Explain how cutting fluids id grinding operations.
• List the steps involved in surface grinding.

Lesson 4 - Gear Cutting

Topics:

Gear types, terms, and definitions; Diametral pitch; Tooth calculations; Cutting spur, bevel gear teeth; Repairing a gear; Cutting other gears

Learning Objectives:

• Name the most common and easiest-to-make gear.
• Name the most widely used types of gears in plant machinery.
• Define the following terms: pitch diameter, circular pitch, diametrial pitch, working depth, and face width.
• Explain how to check the first full tooth of a spur gear after cutting.
• Describe the pitch line of an involute rack.
• Explain how the teeth of straight bevel gears are cut.

Lesson 5 - Power Sawing

Topics:

Power hacksaws; Blade selection, inspection, and installation; Band saws and blades; Cutting fluids; Straight, contour, and friction sawing; Safety

Learning Objectives:

• Explain when and why cutting fluid is required when using a power hacksaw.
• Explain how to select a power hacksaw blade.
• List at least three rules for good hacksawing.
• Contrast the operation of a hacksaw and a band saw.
• List the three factors involved in selecting the right band saw blade.
• Explain the important points of power sawing safety.