Lesson 1 - Machining Cylindrical Shapes

Topics:

Turning; Shoulder facing; Machining fillets; Turning profiles; Knurling; Filing; Facing; Boring; Counterboring; Thread cutting

Learning Objectives:
– Explain the procedures for turning single and multiple diameters, including shoulders, fillets, and relief notches.
– Compute tapers, including the use of the setover method, compound rest method, and taper attachment method.
– Show how to use the cutting tools and machines for knurling, filing, and polishing.
– List the procedures for facing chucked work and work mounted between centers on the lathe.
– Describe the procedures for boring and counterboring in a lathe and boring mill.


Lesson 2 - Drilling, Reaming, and Honing

Topics:

Workpiece stationary, drill rotating; Workpiece rotating, drill stationary; Drill press jobs; Radial drill presses; Spot facing tools; Boring bars; Drill bushings and jigs; Reaming; Honing

Learning Objectives:
– Describe the basic drilling process.
– List drilling procedures for work mounted in a lathe.
– List drilling procedures for work mounted in a drill press.
– Explain the use of reaming in a lathe and a drill press.
– Explain the use of honing and the type of equipment used.


Lesson 3 - Machining Flat Surfaces

Topics:

Plain, side, straddle, profile, and face milling; Irregular shapes; Slotting; Shaping; Broaching; Surface grinding

Learning Objectives:
– Describe the basic milling process, cutter types, and their application.
– List slotting procedures in a milling machine.
   and milling.
– Define broaching, its application, and the machines used.
– Define surface grinding, its application, and the machines used.


Lesson 4 - Determining Tolerances and Finishes

Topics:

Linear dimensions; Tolerances; Limits; Tolerance stackup; Rough cuts; Allowances for finishing; Finish cuts; Surface texture and finish

Learning Objectives:
– Define dimensional factors, including linear and angular dimensions.
– Compute tolerances and tolerance stackup.
– Describe allowance for finishing, including procedures for finish cuts.
– Compute surface texture in terms of an average used for final machining.
– Analyze surface finish requirements as specified for the job.


Lesson 5 - Variables Affecting Job Efficiency

Topics:

Machinability; Chip formation; Selection and application of cutting fluids; Solid lubricants; Machining efficiency; Selecting tooling/fixtures

Learning Objectives:
– Define machinability of workpiece stock, including machining variables, and workpiece variables.
– Explain machinability ratings.
– Select cutting fluids, cutting lubricants, and solid lubricants.
– Describe machining efficiency, including minimal workpiece setups and standard versus special tooling and fixtures.
– Identify the correct machine and cutting tool for a given job.