Lesson 1 - Milling Operations


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


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


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


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


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.