Lesson 1 - Using the Horizontal Milling Machine

Topics:

Milling machine parts and functions; Vertical milling attachments; Speed and feed; Depth of cut; Lubricants; coolants

Learning Objectives:
– Identify the major parts of a universal horizontal milling machine and their functions.
– Define the use of a vertical milling attachment.
– Compute the milling spindle speed and the machine table feed rate.
– Install and align a workpiece in a V-block.
– Install and align a workpiece in a milling machine vise.


Lesson 2 - Slab Milling Procedures

Topics:

Slab milling cutters; Installing the arbor and cutter; Speed and feed selection; Depth of cut; Alignment; Trial cut; Rough milling; Finish milling cut

Learning Objectives:
– Select and install a slab milling cutter on a Style B arbor.
– Install a Style B arbor with cutter, spacers, key, and bearing sleeve into a horizontal milling machine.
– Complete a rough slab milling cut on a workpiece.
– Complete a finish slab milling cut on a workpiece.


Lesson 3 - Milling Slots and Angles

Topics:

Aligning cutter and workpiece; Milling a slot; Angle milling; Angular milling with a vertical milling attachment; Milling a dovetail

Learning Objectives:
– Mill a slot with the cutter in a horizontal and a vertical spindle position.
– Use a T-slot cutter in both a horizontal and vertical spindle position.
– Angle mill a bevel from both a horizontal and vertical spindle position.
– Use adapters for shank-type cutters.
– Cut a female dovetail in a workpiece using a dovetail cutter.


Lesson 4 - Straddle, Side, and Face Milling

Topics:

Selecting, mounting, and aligning the cutters; Machine setup; Making the first cut; Using trig functions for the final cut; Face milling

Learning Objectives:
– Select, set up, and align straddle milling cutters on a Style B arbor.
– Straddle mill a workpiece.
– Cut an angular step using a side milling cutter.
– Face the side of a workpiece with a shell end mill.
– Face a broad workpiece surface using a face mill.


Lesson 5 - Milling Keyseats, Squares, and Flats

Topics:

Keyseats for square and woodruff keys; Selecting and installing the cutter; Depth of cut; Speeds and feeds; Using automatic feed controls; Milling squares on round work; Milling tangs and flats

Learning Objectives:
– Select and install a standard Woodruff keyseat cutter.
– Mill a keyseat with rounded ends (for a square key) and a Woodruff keyseat (for a Woodruff key) in a workpiece.
– Make a plunge cut with a two-fluted end mill.
– Mill a square on the end of a shaft.
– Mill a tang and a flat on a cylindrical workpiece.