Lesson 1 - Power Sawing


Power hacksaw; Vertical and horizontal bandsaw; Band installation; Setup; Making the cut; Safety; Filing; Internal cutting; Welding the band

Learning Objectives:
– List the three main types of power saws commonly used in maintenance machine shops and describe their appropriate uses.
– Explain the primary difference between a hacksaw and a bandsaw.
– Demonstrate how to install the band on a horizontal bandsaw.
– Demonstrate how to set up a workpiece and make a cut on a horzontal bandsaw.
– Describe the safety precautions to be taken when working with a vertical bandsaw.
– Explain how to make an internal cut using the vertical bandsaw.
– Demonstrate how to reweld the band of a vertical bandsaw.

Lesson 2 - Drilling Operations


Drill press types and components; Sample drill press project-preparation, drilling corner, mounting, dowel holes, sawing out the center

Learning Objectives:
– Name three types of drilling machines in common machine shop use.
– List the main features of a sensitive drill press.
– Describe the factors used to select the best drill for a given job.
– Describe correct, safe practices for changing drill bits.
– Explain how to achieve the most efficient order of drill press operations.
– Demonstrate how to set a workpiece perfectly level on a drill press table.
– Demonstrate how to select the correct speeds and feed rates for a drill press.

Lesson 3 - Operating a Horizontal Shaper


Shaping machines; Shaper tables; Tool head and clapper box; Cutting tools; Work-holding devices; Sample project; Shaping slants and slots

Learning Objectives:
– List four specific uses for a horizontal shaper.
– Describe the safety precautions to be taken when working with or around a shaper.
– Demonstrate how to mount a block-shaped workpiece in a shaper vise.
– Explain how to calculate and set the proper stroke rate on a shaper.
– Demonstrate how to set length of stroke and correctly position the ram over the workpiece.
– Demonstrate how to indicate-in on a horizontal shaper.

Lesson 4 - Grinding Operations


Surface grinder; Preparation; Grinding basic flat, parallel surfaces; Cylindrical grinder; Grinding parallel diameters and square shoulders

Learning Objectives:
– Explain the purpose of a surface grinder
– Demonstrate how to dress and true a grinding wheel.
– Demonstrate how to set up a workpiece on a surface grinder, and grind its surfaces to specified dimensions.
– Explain the purpose of a cylindrical grinder.
– Demonstrate how to set up a workpiece between centers on a cylindrical grinder.
– Describe the processes of traverse grinding, plunge grinding, and bumping the shoulder.
– Calculate the rpm settings for the wheel of a cylindrical grinder and for the workpiece, given the sfpm.
– Describe safety procedures for both types of grinders.

Lesson 5 - Boring Mill Operations


Horizontal boring mill types; Boring tools and cutters; Setup and alignment; Holding the workpiece; Trial cut; Mill operations

Learning Objectives:
– Describe three different types of horizontal boring mills.
– Explain the purpose of a rotary table, a line boring bar, slot blocks, a drawbolt, and a continuous-feed (cross-slide) head.
– Explain how a boring bar is aligned on center of an existing hole in the workpiece.
– Describe how a facing operation works on a horizontal boring mill.