ESL Machining Student Manual PDF

STUDENT MANUAL
Carl Perkins Discretionary Grant Texas Higher Education Coordinating Board Texas State Leadership Consortium for Curriculum Development Houston, Texas 2006
TABLE OF CONTENTS
1 2 3 4 5 6 7 8 9 10 11 12 13 14 15
Introduction to Machining Technology Safety in the Machine Shop Measurement Gages Layout Tools and Procedures Hand Tools and Bench Work Metal Cutting Technology Metal Cutting Saws Drilling Machine The Lathe Vertical Milling Machines Horizontal Milling Machines Computer Age Machining Grinding Metallurgy Glossary
1 12 22 31 40 49 60 71 82 95 107 117 127 137 147 157
UNIT 1
Introduction to Machining Technology
Objectives: Given topics on introduction to machine tools and machine trade opportunities; texts that are varied and of a specialized and technical nature , which include information presented from other sources (e.g., photographs, drawings, reference text/ research information, diagrams), the participant will use English with 70% accuracy to: 1. 2. 3. 4. 5. Receive spoken messages in the workplace. Tell what a machinist does in his or her work. Identify and pronounce correctly vocabulary related to the standard types of machine tools used in shops. Talk about different types of jobs in the machine trade. Identify and use the illustration and list of items patterns of organization.
UNIT 1 Vocabulary Development
STUDENT HANDOUT
H 1:1
Study the following words and complete the sentences. 1. assembly
____________ is the process of joining together two or more parts to complete a unit or structure.
____________________ is a generic term for the representation of the work piece to be machined. It can be a pencil sketch or a CAD drawing or any of a number of other graphic options used to represent the design.
2. blueprint
3. cutting tools __________________ are any tools used to cut material. This usually refers to milling cutters, lathe bits, or drills.
4. drill A ___________ is a tool used to make holes in firm material. 5. lathe A ________________ is a turning machine capable of producing round diameters by rotating a work piece against a stationary singlepoint cutting tool. A ___________________________ is an apparatus consisting of inter-related parts with separate functions, used to remove material from a work piece. Examples are milling machines, lathes, drill presses, surface grinders, and hundreds more. The _____________________ is used to produce flat and angular surfaces, grooves, contours, gears, racks, sprockets, and helical grooves. A _______________ is a hollow form for giving a particular shape to something in a molten or plastic state.
6. machine tool
7. milling machine
8. mold
9. punch press
A ___________________ is a power driven machine used to cut, draw, or otherwise shape material, especially metal sheets, with dies, under pressure or by heavy blows. _____________ is the material being machined. It can be any material and any shape. In the machine shop it usually refers to round or flat pieces of metal ready to be machined.
10. stock
UNIT 1 Reading Comprehension
STUDENT HANDOUT
H 1:2
The Metalwoking Industry

A. Read the following paragraphs. A machinist is a craftsman. 2He makes things out of metal or other solid material. 3Machinists make precision metal parts. 4They utilize machine tools like lathes, milling machines, and machining centers. 5 Normally parts will be made in large volumes. 6But precision machinists also make small quantities of unique or special parts. 7Machinists must rely on their knowledge and understanding of the metals properties to make products that hold to strict specs. 8They must also utilize their skills and abilities in combination with machine tools. The first step in machining a part is planning and preparing for operation. 10Machinists look over blueprints and specifications. 11Then they plan out where they must cut or bore the metal they are working with. 12They also plan how quickly the metal needs to be fed in the machine, and how much metal needs to be removed. 13Next, they decide which tools and goods will be used for the job. 14 Finally, they map out the steps of cutting and finishing operations, and make marks on the metal to outline where they will make cuts. A machinist can then begin to perform the job after the process has been completely planned out. 16He must position metal stock on the machine tool properly. 17This could be a drill press, milling machine, or lathe. 18 He then sets the proper controls and begins cutting. 19Throughout this process machinists must ensure that the machine is being fed the metal stock at the proper rate. 20They must also make sure the machine is running at the desired speed. 21Since the machining process creates a lot of heat, machinists must also make sure that the piece is adequately lubricated and cooled. 22Metals tend to expand when hot. 23Consequently, the temperature of the metals is very important to the machinist. 24He must make adjustments to his cuts as changes in temperature occur. 25A machinist works with metals like titanium at very hot temperature levels. A machinist may qualify to work in a variety of shops. maintenance, production, and jobbing shops.
28 26 27 15 9 1
The three most common are
A maintenance shop is usually connected with a manufacturing plant, lumber mill, or foundry. 29A maintenance machinist generally makes and replaces parts for all types of setup and cutting tools and production machinery. 30The machinist must be able to operate all machine tools. 31He must also be familiar with bench operations such as layout, fitting and assembly. A production shop may be connected with a large factory or plant that makes many types of identical machined parts, such as pulleys, shafts, bushings, motors, and sheet-metal pieces. 33A person working in a production shop generally operates one type of machine tool and often produces identical parts. A jobbing shop is generally equipped with a variety of standard machine tools. 35It may also have a few production machines, such as a turret lathe and punch and shear presses. 36 A jobbing shop may be required to do a variety of tasks. 37This is usually under contract to other companies. 38This work may involve the production of jigs, fixtures, dies, molds, tools, or short runs of special parts. 39A person working in a jobbing shop generally is a qualified machinist, toolmaker, or mold maker. 40He is required to operate all types of machine tools and measuring equipment.
Source: Bureau of Labor Statistics, U.S. Department of Labor, Occupational Outlook Handbook, 2006-07 Edition, Machinists, on the Internet at http://www.bls.gov/oco/ocos223.htm
34 32
B. Read the questions and choose the correct answer. 1. The machinists main job is to: a. Make small quantities of unique or special parts. b. Make machine tools like lathes and milling machines. c. Make large quantities of unique parts.
d. Make accurate parts out of metal or other solid materials.
2. The first step in machining a part is to: a. Plan out where the metal must be cut. b. Look over blueprints and specs. c. Decide how much metal needs to be removed.
d. Map out the steps of cutting and finishing operations.
3. A drill press is an example of: a. A lathe. b. Metal stock. c. A machine tool.
d. A milling machine.
4. The temperature of the metals is very important to the machinist because: a. Metals tend to expand when hot. b. He must lubricate and cool the piece. c. He works with metals like titanium. d. He must make sure the machine is running at the desired speed.
5.
The topic of paragraph 1 is: a. A machinists job. b. Machine tools. c. Special parts. d. Machining centers.
6. Paragraph 2 is organized as a: a. b. List of items. Series of events or stages. C. Classification. D. Cause and effect.
7. Paragraph 4: a. Defines shops. b. Compares shops. c. Classifies shops. d. Contrasts shops.
8. Complete the following map of paragraphs 4 through 7.
There are three common types of shops.
Maintenance
_______________
_________________
Connected with manufacturing plant, __________________or ______________________
Connected with ______________ _________________________ or __________________________
Contracted to other ___________ __________________________
Makes and replaces parts for all types of ________________ and _____________ and __________
Makes many types ____________ _______________________ parts.
Produces jigs, ______________, dies, __________, or short runs of _____________________
Machinist operates __________ __________________________
Machinist operates ____________ ___________________________
Machinist operates ___________ ___________________________
9.
Which word from the following sentence indicates an example? A. Also b. Few c. Such as d. And
It may also have a few production machines, such as a turret lathe and punch and shear presses. 10. Which of the following statements are true? a. A maintenance shop machinist operates all machine tools. c. d. A jobbing shop machinist operates one type of machine tool. All of the statements.
b. A production shop machinist operates all types of measuring equipment.
UNIT 1
STUDENT HANDOUT
H 1:3
Read the following sentences. Identify what words signal that one or more examples are coming, what the examples are, and what they are examples of. 1. The machine tool industry is divided into several different categories, such as the general machine shop, the toolroom, and the production shop. Signal words: Examples: Examples of:
2. Operations including drilling, reaming, and tapping are commonly performed on a drill press. Signal words: Examples: Examples of:
3. The class A machine operator possesses more skill and knowledge than class B and C operators. For example, a class A operator should be able to operate the machine and read and use precision measuring tools. Signal words: Examples: Examples of:
4. A maintenance machinist may be required to move and install machinery, specifically production lines. Signal words: Examples: Examples of:
5. Some technicians may need knowledge beyond that of their specialty field. For instance, a machine tool technician should have a knowledge of industrial machines and manufacturing processes to know the best method of manufacturing a product. Signal words: Examples: Examples of:
STUDENT HANDOUT
H 1:4
Study the following words and complete the sentences.
1. die A __________ is a tool to make threads on the outside diameter of shafts. It is also used to form and blank sheet metal parts.
2. dismantling 3. feed
_________________ is taking apart, disassembling or tearing down. _____________ is the motion of moving the work piece and the cutting tool together so as to remove material. ____________ is a mechanical device used to attach two pieces of tubing/ piping together or to attach a piece of tubing/pipe to a component. A ________________ is a production work-holding device used for machining duplicate workpieces.
4. fitting
5. fixture
6. installing
___________________ is putting machinery or equipment into place and making it ready for use.
7. jig A ____________ is the part of a metalworking machine that holds the object to be worked on and guides the cutting or drilling tool. 8. measuring instruments
__________________________ are devices used to determine physical size of parts to verify compliance to requirements.
9. rigging _____________ are gates, risers, loose pieces, etc., needed on the pattern to produce a sound casting. ______________ refers to line preparation to cut new width size for customer specification.
10. setup
STUDENT HANDOUT
H 1:5
Careers in the Metalworking Industry
A. Read the following paragraphs. Many different careers are available in the metal-working industry. 2An individual can choose the right one depending on his skill, initiative, and qualifications. 3The person must also possess characteristics such as orderliness, accuracy, confidence, and safe work habits. Machine tool operators are classified as semiskilled tradespeople. 5They are usually rated and paid according to their job classification, skill, and knowledge. 6The class A operator possesses more skill and knowledge than class B and C operators. 7For example, a class A operator should be able to operate a machine and make necessary machine setups. 8Class A operators also adjust cutting tools and calculate cutting speeds and feeds. The maintenance machinist needs a combination of mechanical, rigging, and carpentry skills. 10A maintenance machinist may be required to move and/or install machinery, including production lines. 11 He needs to read drawings and calculate sizes, fits, and tolerances of machine parts. 12He may also have to repair machines by replacing and fitting new parts. 13Dismantling and installing equipment is another part of the job. Machinists are skilled workers. 15Thy can efficiently operate all standard machine tools. 16They must be able to read drawings and use precision measuring instruments and hand tools. 17They need the knowledge and sound judgment to perform any bench, layout, or machine tool operation. 18 In addition, they need to make mathematical calculations required for setting up and machining any part. 19Machinists should have a thorough knowledge of metallurgy and heat treating. A tool and diemaker is a highly skilled craftsperson. 21He makes different types of dies, molds, cutting tools, jigs, and fixtures. 22He must know what production method will be used to produce the part. 23This work also requires a broad knowledge of shop mathematics, print reading, machine drafting, principles of design, machining operations, metallurgy, heat treating, and computers. A CNC machine operator is skilled in computer numerical control. 25He is responsible for the setup and operation of the machine tool. 26He may also prepare the computer program. 27This individual must visualize a CNC program. 28He must also understand machining processes and the sequence of operations. 29The CNC machine operator makes machine setups, calculates speeds and feeds, and selects cutting tools.
30 24 20 14 9 4 1
Technicians work at a level between the professional engineer and the machinist. 31They may assist the engineer in making cost estimates of products, preparing technical reports on plant operation, or programming a numerical control machine.
A technologist works at a level between a graduate engineer and a technician. 33This individual may do many jobs normally performed by an engineer, such as design studies, production planning, laboratory experiments, and supervision of technicians.
32
B. Read the questions and choose the correct answer. 1. Choosing the right career depends on ones a. Skills. b. Initiatives. c. Knowledge. d. All of the above.
2. Which career requires the most skills and knowledge? a. Machinist. b. Technician. c. d. CNC machine operator. Technologist.
3. Having a sound knowledge of metallurgy and heat treating is important for which careers? a. Machine tool operators. b. Machinists. c. d. Tool and die makers. Technicians.
4. Which career is at a supervisory level? a. Maintenance machinist. b. CNC machine operator. c. d. Technician. Technologist
5. The topic of this reading is a. Different careers in the metal-working industry. b. Semiskilled trades. c. The setup and operation of machine tools. All of the above.
d.
6. Match the numbers with the letters. a. _____ technologist b. _____ tool and die maker c. _____ machine tool operator d. _____ machinist e. _____ CNC machine operator f. _____ technician [1] is classified as a semiskilled worker. [2] is classified as a skilled worker. [3] is classified as a highly skilled worker. [4] is skilled in computer numerical control. [5] works at a level between the professional engineer and the machinist. [6] works at a level between a graduate engineer and a technician.
Read pages 18-26 in your textbook and complete the following tasks. 7. Write down the job duties of a quality control inspector.
8. Describe the job of an instrument maker.
9. Name the two machine tool related organizations who are involved in the continual updating of programs for students, educators, tradespeople, and manufacturing personnel.
10. Complete the modular training system chart below.
Flexible Manufacturing
10
UNIT 1
STUDENT HANDOUT
H 1:6
A. Arrange the following sentences in a logical order. Put a 1 in front of the sentence that should come first, a 2 in front of the sentence that comes next, a 3 in front of the third sentence, a 4 in front of the fourth sentence, and a 5 in front of the sentence that should come last. The result will be a short paragraph. Use the addition words as a guide. Another is exploring your interests by talking to people who do the type of work that you are considering. Finally, submit the rsum with a cover letter to the personnel manager of the company you are interested in. There are several steps you need to take when looking for a job. A third is to prepare a rsum listing such things as name, address, education, special training, and previous employment. First of all, you should assess your abilities by asking yourself questions like, What skills have I acquired at school?
___ ___ ___ ___ ___
B. The paragraph below is organized as a list of items. Complete the outline of the list by first filling in the missing part of the main idea. Then add to the outline the three major details listed in the paragraph. A modular training system offers technical/vocational training. It covers the skills required for modern manufacturing in the metalworking trade. The training program consists of five main areas. First of all, it starts with the conventional machine tools and machining processes associated with each tool. Second, it progresses through the CNC machining and CAD/CAM techniques. Another module incorporates quality control skills that play a vital role in improving the competitive position of the manufacturer. Maintenance is the fourth module and covers the routine upkeep and repairs of conventional and CNC machine tools. The last module is automation, which provides training in automating the loading and unloading of workpieces for CNC machine tools. Main Idea: A modular training program consists of 1. 2. 3. 4. 5. .
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Unit 2
Safety in the Machine Shop
Objectives: Given topics on safety in the machine shop; texts that are varied and of a specialized and technical nature which include information presented from other sources (e.g., photographs, drawings, reference text/ research information, diagrams), the participant will use English with 70% accuracy to: Select and use appropriate reference materials. Read a safety maintenance bulletin. Identify factual details and specifications within a text. Identify and use chronological order: process. Identify and pronounce correctly vocabulary related to common shop hazards. Identify and pronounce correctly vocabulary related to common shop safety equipment. Identify key safety practices for the machine shop. Talk about shop safety hazards, shop safety equipment, and shop safety practices.
12
STUDENT HANDOUT
H 2:1
1. accident An _________________ is something going wrong unexpectedly such as falling on a slippery floor.
2. careless
________________ is not giving sufficient attention or thought to avoiding harm or mistakes. _____________________ is loss or harm resulting from injury to person, or property.
3. damage 4. grooming
_____________ is to care for one's appearance such as wearing approved safety clothes.
5. hazard 6. housekeeping
A ___________________ _____is a danger or harm. ______________________________________ is management and maintenance of the property and equipment of the shop. ____________________________ is damage or harm. ______________ is taking advance measures against something possible or probable such as measures taken to prevent leaks.
7. injury 8. prevention
9. protect 10. safety
_______________________ is to keep from injury. _________________ is the condition of being free from danger, injury, or damage.
13
UNIT 2
STUDENT HANDOUT
H 2:2
Reading Comprehension
Safety in the Machine Shop
A. Read the following paragraphs. All hand and machine tools are dangerous if used improperly or carelessly. 2One of the first things a student should learn is how to work safely. 3The safe way is usually the correct and most efficient way. 4A person must learn the safety regulations and precaution for each tool or machine he is learning to operate. 5Many accidents are caused by careless work habits. 6A shop worker must develop safe work habits to prevent the consequences of an accident. 7Safety is everyones business and responsibility. Accidents dont just happen. 9They are caused. 10Someones carelessness is usually the cause of an accident. 11Workers can avoid accidents. 12There are several steps a worker can take to develop safe work habits. 13First, a worker should be neat, tidy, and safely dressed for the job he or she is performing. 14 Another is to develop a responsibility for personal safety and the safety of fellow workers. 15Finally, a worker should think safely and work safely at all times. You can divide safety in a machine shop into two broad categories. 17The first includes those practices that prevent injury to workers. 18The second includes those practices that prevent damage to machines and equipment. 19When considering these categories, we must consider personal grooming, proper housekeeping including machine maintenance, safe work practices, and fire prevention. Personal grooming refers to wearing approved safety equipment and clothing in the machine shop. All employees and visitors should wear safety glasses or some other eye protection when entering a shop area. 22In addition, workers should never wear loose clothing when operating any machine. 23They should also remove wrist watches, rings, and bracelets. 24These can get caught in the machine and cause painful and often serious injury.
21 20 16 8 1
Good housekeeping never interferes with safety or efficiency. 26Workers should stop the machine before they attempt to clean it. 27Other good housekeeping habits include cleaning the machine and hand tools and sweeping up the metal chips on the floor. Safe work practices include keeping hands away from moving parts and getting first aid immediately for any injury. 29In addition, workers should follow safe lifting practices for heavy objects. Finally, you should be familiar with fire prevention factors before starting to work in a machine shop. Workers should always dispose of oily rags in proper metal containers. 32They should also know the location and operation of every fire extinguisher in the shop.
31 30 28
25
14
B. Read the questions and choose the correct answer. 1. The topic of the reading is Practices that prevent injury to workers. d. Practices that prevent damage to machines and equipment. 2. All hand and machine tools a. Are dangerous at all times. b. Are dangerous if used improperly. 3. Most accidents are caused by a. Hand and machine tools. b. Careless work habits. 4. Match the numbers with the letters. a. ___ personal grooming b. ___ proper housekeeping c. ___ safe work practices 1. stopping the machine before cleaning it 2. know the location of fire extinguishers 3. wearing safety glasses 4. keeping hands away from moving parts c. Lack of personal grooming. c. Are dangerous if used carelessly. c. e. Safety in the machine shop. f. Fire prevention factors.
d. Both [b] and [c].
d. Lack of good housekeeping.
d. ___ fire prevention 5. Paragraph 3 a. Defines safety in a machine shop. b. Classifies safety in a machine shop. 6. Accidents are prevented by a. Personal grooming. b. Safe work habits. 7. A list of items is given in paragraph. a. One. 2. Two.
c.
Describes safety in a machine shop.
d. Gives examples of safety in a machine shop.
c.
Fire prevention.
d. All of the above.
c.
Three.
d. Four.
15
Read pages 32 to 37 in your textbook and complete the following tasks. 8. State four precautions that must be observed with regard to clothing worn in a shop.
9. Describe the procedure to follow for lifting a heavy object.
10. What fire prevention factors should you become familiar with before starting to work in a machine shop?
16
UNIT 2
STUDENT HANDOUT
H 2:3
The following passage gives directions involving several steps that must be done in order. Complete the map by writing the main idea in the top of the box and filling in the steps. To help yourself identify each step, underline the time words.
Fire extinguishers come in many different types, but all of them operate in a similar manner. There are several steps to operating this device. First, pull the pin at the top of the extinguisher. The pin releases a locking mechanism and will allow you to discharge the extinguisher. Then, aim at the base of the fire, not the flames. This is important - in order to put out the fire, you must extinguish the fuel. Next, squeeze the lever slowly. This will release the extinguishing agent in the extinguisher. If the handle is released, the discharge will stop. Lastly, sweep from side to side. Using a sweeping motion, move the fire extinguisher back and forth until the fire is completely out. Operate the extinguisher from a safe distance, several feet away, and then move towards the fire once it starts to diminish.
17
STUDENT HANDOUT
H 2:4
1.
hard hat
2.
coveralls
3.
respirator
4.
welders gloves
5.
apron
6.
goggles
7.
face shield
8.
shoe covers
9.
ear plugs
10.
safety glasses
11.
ear muffs
12.
laynard
1. 2.
____________________ or ________________ prevent damage to your ears from loud noise. Wear a _______________ to protect you from falling.
3. Eye protection like ______________________, __________________, or a ____________________ is the primary piece of safety equipment in a machine shop. 4. Proper dress for the machine shop is ______________ or an ___________________. 5. You should wear a ________________ to keep from inhaling dust or toxic fumes.
6.
You should wear a ___________________________ in this area.
7. 8.
___________________________________ protect your hands. Your feet are protected by wearing ________________________.
18
UNIT 2 Reading Comprehension 1.
STUDENT HANDOUT
H 2:5
Read the following paragraphs. Answer the questions that follow.
Maintenance Safety Bulletin

All maintenance personnel. The Fluid Power Safety Institute.
1
TO: FROM:
SUBJECT: Maintenance worker fatally injured after having hydraulic oil injected into hand while attempting to bleed trapped air from a hydraulic cylinder. Description of the Accident: A machine operator was fatally injured while he was attempting to bleed trapped air from a hydraulic cylinder located on an automated forming machine. How The Accident Occurred: The injuries occurred when he opened a bleed-toatmosphere type air-bleed valve located on a hydraulic cylinder, causing high pressure hydraulic oil to be injected into his hand. Contributing Factors: The Fluid Power Safety Institutes unofficial accident analysis and opinions are based on discussions with the maintenance personnel, and an inspection of the machine. 1. Improper Procedure a. 4The operator attempted to bleed air from the system. 5This should have been a maintenance responsibility. b. 6No Job Safety Breakdown (JSA), or Job Safety Analysis (JSA) was written for this procedure. 2. Training a. 7The process for ensuring that employees have received proper training and reinforcement is inadequate because several key elements are missing in the training process. b. 8Training of supervisors does not include key safety issues for this procedure. c. 9Air-bleed training was not specific for this job. d. e.
10 11 3 3 2
Maintenance personnel have only on-the-job training in hydraulics. Operators, mechanics, and supervisors receive no training in hydraulic safety.
3. Unreported Incidents a.
12
Similar incidents have occurred while bleeding trapped air from a hydraulic system.
19
4. Inexperience a. The operator had no experience with hydraulics, or any knowledge of how to safely bleed trapped air from a hydraulic system. Production demands were so high that, to save time, basic service and repairs were left to the operator. Manual bleed-to-atmosphere air-bleed devices lend themselves to this kind of accident. 16Even a trained person is at risk. 17Alternative air-bleed devices, such as automatic air-bleed valves, closed-loop ball-valves, or Safe-T-Bleed should be specified.
15 14 13
5. Production Demands a.
6. Equipment Design a.
Suggestions On How To Prevent This Type Of Accident:

18
a. b. c. d. e.
Train everyone who works on and around your hydraulic systems- this includes operators, supervisors, and plant managers.
Only allow trained, authorized personnel to execute service and maintenance functions on your hydraulic systems.
20 21
19
Include safety in machine specifications, i.e. design for safety.
Have suitably qualified persons write Job Safety Breakdowns for all special skills tasks.
Install closed-circuit pressure verification and bleed-down devices in all areas where energy can be stored in your hydraulic systems.
Source: The Fluid Power Safety Institute, Maintenance Safety Bulletin (Ref. No. MSB-015), http://www.fluidpowersafety.com/fpsi_mntcsafety-15.html
1. Who is sending the bulletin?
2. Why was the safety bulletin written?
3. Match the description to the contributing factor. 1. __ improper procedure [a] Instruction in hydraulic safety was not provided. 2. __ training [b] The operator handled basic service and repairs to save time. 3. __ inexperience [c] There was no written documentation for job safety. 4. __ production demands [d] Alternative air-bleed devices were not specified. [e] The operator did not know how to bleed trapped air from 5. __ equipment design a hydraulic system. 4. Answer the following questions True or False. Write [T] or [F] in the blank. _____ a. Only plant managers need to be trained on hydraulic systems. _____ b. An expert needs to write job safety breakdowns for all special skills tasks. _____ c. Pressure verification devices should be installed in all areas of the hydraulic system.
20
UNIT 2
STUDENT HANDOUT
H 2:6
Look at the pictures for lifting a heavy object from ground level. Read the instructions below and match them to the correct picture.
1. _____
2. _____
3. ___
4. ____
5. ____
6. ____
a. Next pull the bag up the leg and get a firm, balanced grip on it. Use the palm of your hands and gloves if necessary. b. Immediately stand upright and lift by straightening your legs and slightly unbending your back. c. First raise bag upright, face the object and place one foot behind the object and one foot along its side. d. Then put one knee against the bag and bend at the knees. e. Finally carry the load with your back in upright position and proceed with caution through doors and around corners. f. Now rest the bag on the edge of the knee and keep it as close to your body as possible.
Now underline the transition words and indicate the pattern of organization. Pattern of Organization: _____________________________________
21
Unit 3
Measurement
Objectives: Given topics on measurement and measuring tools; texts that are varied and of a specialized and technical nature , which include information presented from other sources (e.g., photographs, drawings, reference text/ research information, diagrams), the participant will use English with 70% accuracy to: Say and write correctly some abbreviations and formulas used in the machine shop. Read and pronounce correctly the graduations shown on some common steel rules. Read and pronounce correctly the readings from an outside micrometer and a vernier caliper. Identify and pronounce correctly vocabulary related to common measuring instruments. Identify and write sentences that define a term and give an example.
22
UNIT 3
STUDENT HANDOUT
H3:1
Vocabulary Development
Study the following words and complete the sentences. 1. accuracy 2. angle An ___________________ is the space between two lines diverging from a common point and expressed in numerical form. 3. datum A __________________ is a reference point from which movements or measurements are made. A datum can lie anywhere on the surface of a work piece. _____________ is the ability to be precise and avoid errors.
4. divisor 5. fraction
A ____________ is a number divided into another number. For example, 7 is a divisor of 42 because 42/7 = 6. A ______________ is a number that is not a whole number, e.g. 1/2 simple fraction or 0.5 decimal fraction, formed by dividing one quantity into another.
6. ISO ________________ is the abbreviation for the International Organization for Standardization. 7. machining 8. multiplier _____________________ is to cut, shape, or finish a piece of work using a power-driven tool such as a lathe or drilling device. The ________________ is the number by which another number multiplicand is multiplied, e.g. the number 4 is the multiplier in the statement 2 4 = 8 Two lines or surfaces extending in the same direction, everywhere equidistant, and not meeting are ____________________. The __________________________is a document that describes the order of processing for the part(s) being manufactured (machined).
9. parallel
10. route sheet
23
STUDENT HANDOUT
H3:2
MEASUREMENT A. Read the following paragraphs. Measurement is the process by which physical size may be determined. 2For example, by measuring a piece of stock before machining, the machinist can determine if there is enough material for the machining process. 3He can also determine if there is too much material for the process. 4Measuring the part while machining or measuring between the machining processes helps verify the accuracy of the machining process by comparing it to a blueprint or route sheet. The most common type of measurement is linear measurement. 6It begins with establishing a line of length to be measured. 7That line of measure starts at a reference point and ends at the measured point. 8 Both the reference point and the measured point relate to a feature of the part being measured. 9A feature is a physical characteristic of the part but can sometimes be an unapparent datum. 10There is no direction component to linear measurement. 11This is because the distance from the edge of the part (shown right) to the center of the hole is the same as the distance from the center of the hole to the edge. 12Either the hole or the edge can be the measured point or the reference point. Another type of measurement is angular measurement. 14Angular measurement is the relationship between two features that share a common point or, explained differently, two surfaces that are not parallel. 14 The figure shown below has two surface features (a and b) whose line extensions pass through the same point (c). 15Angular measurement uses degrees as the standard of measure and there are 360 degrees in one complete rotation of arc. 16Each degree has 60 subdivisions called minutes and each minute has 60 subdivisions called seconds.
13 5 1
There are two systems of measurement used in machine shops today, the Metric system and the Inch system. 18The Metric system is based on the meter as the standard unit of reference. 19A meter (approximately 39.37 inches in length) is subdivided into 10 equal parts called decimeters. 20Each decimeter is divided into 10 parts called centimeters and each centimeter is divided into 10 parts called millimeters. 21The Metric system is a very coherent system because it is exclusively a decimal system and therefore has a common multiplier and divisor of 10. 22Regular fractions are not used in the metric system. 23Instead the metric system uses only decimal fractions. 24Other names for the Metric system include SI units and ISO units. 25The Metric system is the most commonly used system of measurement in the world. The Inch system is based on the foot as the standard unit of reference. 27A foot is divided into 12 equal parts called inches. 28Each inch is subdivided into a variety of fractions and decimals. 29The Inch System is a rather incoherent system because it lacks the decimal based advantage of the Metric System. 30Parts of a foot can not be easily expressed as decimal inches. 31For example, in the metric system 7 millimeters is 0.7 centimeters which is 0.07 decimeters which is 0.007 meters. 32But 7 inches is 0.583333 feet which is 0.19444 yards and so on. 33This is a clear advantage for the metric system. 34Another name for the Inch System is the English System. 35The Inch System is used in most English speaking countries but is being slowly replaced by the metric system. Source: Virtual Machine Shop, http://www.jjjtrain.com/vms/index.html
26
17
24
B. Read the questions and choose the correct answer. 1. The main pattern of organization in the reading is: a. Comparison and Contrast. b. Cause and Effect. c. Definition and Example. d. Time Order.
2. How can you check the accuracy of a machining process?
3. Name two types of measurement. a. b.
4. Which type of measurement is used more? a. linear measurement.
c. angular measurement.
5. Why is there no direction component to linear measurement?
6. Which figure below illustrates angular measurement?
[a] 7. Name the two systems of measurement machinists use. a. b.
[b]
8. Why is the metric system considered to be more accurate than the inch system?
9. When you refer to SI units and ISO units, you are talking about the: a. metric system b. inch system
10. Which system of measurement is more popular in the United States?
25
UNIT 3
STUDENT HANDOUT
H 3:3
A.
Arrange the following sentences in an order that makes sense. Put a 1 in front of the sentence that should come first, a 2 in front of the sentence that comes next, and a 3 in front of the sentence that should be last. The result will be a short paragraph.
____ ____ ____
A micrometer, for instance, is a widely used device in mechanical engineering for precisely measuring thickness of blocks, outer and inner diameters of shafts and depths of slots. A precision instrument is a tool or mechanical device, especially one used for precision work in science, medicine, or technology. Another example is the vernier caliper, which can be used to measure internal and external distances extremely accurately.
B. Read paragraph 1 below and answer the questions that follow. Measurement is the process by which physical size may be determined. For example, by measuring a piece of stock before machining, the machinist can determine if there is enough material for the machining process. He can also determine if there is too much material for the process. Measuring the part while machining or measuring between the machining processes helps verify the accuracy of the machining process by comparing it to a blueprint or route sheet. 1. What word is being defined? 2. What is the definition?
3. Which sentence explains more about the word?
26
UNIT 3
Vocabulary Development
STUDENT HANDOUT
H 3:4
Study the following words and write them next to the correct number.
12
11 10 BAR 9
7
5 VERNIER SCALE 6 ADJUSTING NUT
2 FIXED JAW 3
4 MOVABLE JAW 1 VERNIER CALIPER
1. ________________________________ 2. ________________________________ 3. ________________________________ 4. ________________________________ 5. ________________________________ 6. ________________________________
7. ________________________________ 8. ________________________________ 9. ________________________________ 10. ________________________________ 11. ________________________________ 12. ________________________________
27
UNIT 3
STUDENT HANDOUT
H3:5
Reading Comprehension VERNIER CALIPERS A. Read the following paragraphs. Vernier calipers are precision tools used to make accurate measurements to within .001 in. or 0.02 mm. They can measure the outside diameter or width of an object. 3They can measure the inside diameter or width of an object. 4They can also measure the depth of an object. 5Vernier calipers are available in inch and metric graduations. 6Some types have both inch and metric graduations on the same caliper.
2 1
The vernier caliper consists of an L-shaped frame and a movable jaw. 8The L-shaped frame consists of a bar and the fixed jaw. 9The bar shows the main scale graduations. 10The movable jaw slides along the bar and contains the vernier scale. 11An adjusting nut adjusts for size and the locking or clamp screws lock readings into place. Most bars are graduated on both sides or on both edges. 13One side takes outside measurements and the other takes inside measurements. 14The internal jaws measure inside spaces like holes. 15The external jaws measure things like the outside diameter of a piece of pipe. In figure 1, the vernier scale (below) is divided into 10 equal divisions and thus the least count of the instrument is 0.1 mm. 17Both the main scale and the vernier scale readings are taken into account while making a measurement. 18The main scale reading is the first reading on the main scale immediately to the left of the zero of the vernier scale (3 mm), while the vernier scale reading is the mark on the vernier scale which exactly coincides with a mark on the main scale (0.7 mm). 19The reading is therefore 3.7 mm.
16 12
Figure 1
28
B. Read the questions and choose the correct answer. 1. Vernier calipers measure A. Outside diameter. B. Inside width. 2. Vernier calipers are available A. Only in inch graduations. B. Only in metric graduations. 3. The L-shaped frame of a vernier caliper has A. A bar and the movable jaw. B. A bar and the fixed jaw. 4. Which statement is correct? A. Both sides take outside measurements. B. Both sides take inside measurements. 5. Paragraph 1 A. Defines vernier calipers. B. Contrasts vernier calipers. 6. A description of vernier calipers is found in A. Paragraph 1. B. Paragraph 2. 7. How to read a vernier caliper is found in A. Paragraph 1. B. Paragraph 2. C. Paragraph 3. D. Paragraph 4. C. Paragraph 3. D. Paragraph 4. C. Compares vernier calipers. D. Lists vernier calipers. C. One side takes both outside and inside measurements. D. One side takes only outside or inside measurements. C. The vernier scale. D. All of the above. C. In both inch and metric graduations on the same caliper. D. None of the above. C. Depth. D. All of the above.
8. Look at the two figures below and determine the readings.
This reads
This reads
29
UNIT 3
STUDENT HANDOUT THE MICROMETER
H3:6
Read the information below and answer the questions. The micrometer is a precision measuring instrument, used by machinists. Each revolution of the rachet moves the spindle face 0.5mm towards the anvil face. The object to be measured is placed between the anvil face and the spindle face. The rachet is turned clockwise until the object is trapped between these two surfaces and the rachet makes a clicking noise. This means that the rachet cannot be tightened any more and the measurement can be read.
To take a sample reading, use the first example seen below: 1. Read the scale on the sleeve. The example clearly shows12 mm divisions. 2. Still reading the scale on the sleeve, a further mm (0.5) measurement can be seen on the bottom half of the scale. The measurement now reads 12.5mm. 3. Finally, the thimble scale shows 16 full divisions (these are hundredths of a mm). The final measurement is 12.5mm + 0.16mm = 12.66
SLEEVE READS FULL mm = SLEEVE READS MM = THIMBLE READS = TOTAL MEASUREMENT =
_________ _________ _________ _________
SLEEVE READS FULL mm = SLEEVE READS MM = THIMBLE READS = TOTAL MEASUREMENT =
_________ _________ _________ _________
Source: V. Ryan 2004 http://www.technologystudent.com/equip1/microm1.htm
30
Unit 4
Gauges
Objectives: Given topics on gages; texts that are varied and of a specialized and technical nature which include information presented from other sources (e.g., photographs, drawings, reference text/ research information, diagrams), the participant will use English with 70% accuracy to: 1. 2. 3. 4. Define and pronounce correctly vocabulary related to gauges. Identify and use the comparison-contrast patterns of organization. Recognize and describe the uses of three basic types of plugs and ring gauges. Identify the main idea and supporting detail in a reading.
31
STUDENT HANDOUT
H4:1
1. accountability
_______________________ is an obligation or willingness to accept responsibility to somebody or for something.
2. brightness _________________ is the intensity of light reflected or emitted by something.
3. CMM A __________________ is a Coordinate Measuring Machine. It is a mechanical system designed to move a measuring probe to determine coordinates of points on a work piece surface.
4. density
_________________________ is the mass per unit volume of a substance, usually expressed in grams per cubic centimeter or in pounds per cubic foot. A ______________________ are the goods or services produced and completed by a company.
5. finished product
6. gauge ______________ is any one of a large variety of devices for measuring or checking the dimensions of objects.
7. impedance
_______________ is a measure of resistance to electrical current flow when a voltage is moved across something, such as a resistor. A _____________________________ is either one of a pair of things that belong together.
8. mating part
9 . standard
A _____________ is the level of quality or excellence that is accepted as the norm or by which actual attainments are judged. ____________________ is a range by which a product's gauge can deviate from those ordered and still meet the order's requirements.
10. tolerance
32
UNIT 4
STUDENT HANDOUT
H4:2
Reading Comprehension Measuring vs. Gauging A. Read the following paragraphs. Virtually every manufactured product must be measured in some way. 2Indeed, it is inevitable that some characteristic of size, volume, density, pressure, heat, impedance, brightness, etc. must be evaluated numerically at some point during the manufacturing process, as well as on the finished product.
3 1
For a measurement to have meaning, an accepted standard unit must exist. 4The inspector measuring parts on the shop floor must know that his or her millimeter or ounce is the same as that being used on a mating part across the plant, or across the ocean. 5A chain of accountability, or traceability, connects the individual gauge back to a national or international standards body to ensure this.
Once the unit of measurement is accepted, some means of comparing the process or product against that unit must be applied. 7When the characteristic to be evaluated is dimensional such as size or location, there are two basic approaches. Measuring is the first approach. 9It involves the use of direct-reading instruments that count all units and decimal places, from zero up to the dimension at hand. 10Direct-reading instruments commonly used in manufacturing include steel rules or scales, vernier calipers, micrometers and some digital height stands. Gauging, on the other hand, uses indirect-reading instruments to compare the work piece against a standard or master. 12This is a precision object that represents a known multiple of the measurement unit. 13 Gauges typically start not at zero but at the specified dimension, and they indicate the size of the work piece as deviation from the specification. 14A result of zero on a gauge thus indicates that the part is precisely the right size. Both kinds of equipment have their roles. 16The strength of measuring devices is their flexibility. 17You can measure virtually anything with a vernier caliper or a CMM over a fairly broad range of sizes. 18Gauges tend to be quicker and easier to use because they are designed for more specific tasks. 19The gauge user generally needs to observe only the last digit or two of a dimension to know whether a part is within tolerances. 20And because gauges are designed for use over a shorter range of dimensions, they tend to be capable of generating results of higher accuracy. 21Therefore, gauges are usually the practical choice for high-volume parts inspection, particularly where high precision is needed.
15 11 8
Source: George Schuetz, Gauges: The Hand Tools of Quality, http://www.qualitydigest.com/apr/gauges.html
33
B. Read the questions and choose the correct answer. 1. The word Indeed in sentence 2 introduces: A. A contrast. B. A comparison. c. An emphasis. d. A result.
2. What insures that a millimeter or ounce is the same as that being used on a mating part anywhere in the world? A. An accepted standard unit. B. The individual gauge. c. The inspector. d. All of the above.
3. When measuring the size of a process or product, what approach can be used? A. Measuring. B. Gauging. c. Both [a] and [b]. d. Neither [a] nor [b].
4. Steel rules, scales, vernier calipers, and micrometers a. Are indirect-reading measurements. b. Do not start at zero but at the specified dimension. 5. Gauges a. Count all units and decimal places from zero up to the dimension at hand. B. Indicate the size of the work piece as deviation from the specification. 6. Paragraph 5 a. Compares measuring. b. Contrasts measuring and gauging. 7. Which sentence is true. a. Measuring is better than gauging. b. Gauging is better than measuring. C. Measuring is as effective as gauging. d. None of the above. c. Presents a list of items. d. Illustrates paragraph 4. c. Both [a] and [b]. d. Neither [a] nor [b]. c. Count all units and decimal places from zero up to the dimension at hand. d. None of the above.
8. When using a gauge to determine whether a part is within tolerance, you need to observe A. All units and decimal places. B. Only the last digit or two of the dimension. c. Both [a] and [b]. d. Neither [a] nor [b].
9. Because gauges are designed for more specific tasks, they are A. Quicker. B. Easier to use. c. More flexible. d. Both [a] and [b].
10. The sentence, And because gauges are designed for use over a shorter range of dimensions, they tend to be capable of generating results of higher accuracy, is presenting a. A comparison and contrast. b. A cause and effect. c. A definition and example. d. A list of items.
34
UNIT 4
STUDENT HANDOUT
H4:3
A. Complete each sentence with a suitable comparison word or phrase from the box below. (just) as (just) like alike likewise in like manner similar (ly) in a similar manner in the same way resemble
1. Plug gauges are used to compare hole and slot dimensions or locations to specific tolerances. , pin gauges effectively ensure that a part being measured is within its designed tolerance limits. 2. Machine operators use gauges to keep a check on wearing tools and other machine problems which prevent absolute uniformity in their work. , the subcontractors inspection department carefully spot-checks the parts before being shipped, and again at the assembly plant when received. 3. A plain cylindrical plug gauge is used for the dimensional control of the diameter of a specified hole. A taper cylindrical plug gauge functions . 4. For a taper ring gauge, the precautions and procedures are taper plug gauge. 5. Both snap gauges and ring gauges external dimensions. to those of a are used for the control of specified
B. Read the passage and then answer the questions and complete the outline that follows. There are several similarities between plug and pin gauges. Plug and pin gauges alike are used to compare hole and slot dimensions or locations to specific tolerances. In addition, both use similar gauging technologies. The first are pneumatic systems that measure the changes in flow or pressure in air nozzles located inside air plugs, rings, or snaps. Next, electronic gauges use electronic probes to sense the distance of displacement of a contact or stylus. Finally, mechanical gauges use comparison or the physical movement and displacement of a gauging element (e.g., spindle, slide, stem) to determine the dimensions of a part or feature. 1. Check () the pattern used in this passage: a. ___ comparison 2. Complete the following map of the paragraph: There are several similarities between and b. ___ contrast
1.
Compare
2. Use
a.
b.
c.
35
STUDENT HANDOUT
H4:4
Study the following words and complete the sentences. 1. air gauging ____________________is a technology that employs the use of air flow volumes and air pressure to determine the size of measured part dimensions.
2. amplifier An _________________ is the readout of an air gauge system. It contains the necessary restrictions to change the pneumatic pressure or flow and then displays readings on a scale as dimensional values. 3. balance _______________ is the resultant non-movement on the display of an air amplifier that occurs when one nozzle of a two nozzle tool is closed toward the workpiece and the other nozzle equally compensates for that movement. A ___________ is an air-electronic amplifier or a flow system amplifier featuring a vertical bar graph display or flowmeter tube. __________ refers to air tooling designed to measure close to shoulder.
4. column 5. CTS
6. flowmeter tube A ________________ is a graduated glass tube of a precise size with a floating cork that displays the reading on a flow air gauge system. 7. full scale value (FSV) ____________________________ is the numeric equivalent of the graduated display. It is usually 1 to 2 times greater than the tolerance being measured to show approach or oversize conditions.
8. lobe A ______________ is a rounded projection that is part of a larger structure.
9. magnification 10. nozzle
_________________ is the visual increase of size that is created by an air amplifier. A __________________ is the orifice in the air gauge tooling that emits the air that blows against the part being measured.
36
UNIT 4
STUDENT HANDOUT Air Gauging Applications
H4:5
A. Read the following paragraphs.

Inside and Outside Diameters Air gauges are most commonly used for measuring the size and form of inside diameters 2 (IDs) and outside diameters (ODs). Two-nozzle air plugs, with nozzles diametrically opposed, are often used for internal measuring, and two-nozzle air rings are used for external dimensions.
1
Averaging 3 Multiple nozzles are equally located about the circumference of the air tool to allow for average size 4 measurement. Commonly used for thin-walled or out-of-round parts four, six, or more nozzles are used, depending on the tool size.
Out-of-Round 5 6 Air tools can gauge a part for roundness. For two-point out-of-round conditions, a 7 standard two-nozzle air tool can be used. If lobing exists in the part, an odd number of nozzles must be used, depending on the number of lobes.
Straightness 8 A common application of air gauging is to dynamically measure the straightness or "bow" of an 9 ID. In this case, a custom-designed air plug makes verifying a part's straightness simple and fast. (A straightness air plug cannot measure diameter). Squareness To determine squareness of a part, for example a bore to face, air nozzles configured as a "z" are used with dynamic measurement to change the back pressure from square to out-of-square conditions.
10
Taper Angle variation of tapered surfaces is commonly checked with air gauging as the difference of two diameters.
11
12
Flatness 13 To measure flatness, an air nozzle is mounted within a stationary platen. The part is then 14 moved across the nozzle. This process provides a convenient, quick method to accurately gauge flatness.
Groove Width 16 The measurement of grooves is conveniently achieved with flat, blade-type air tools. Air gauging not only determines groove size, but with exploration around the workpiece, parallelism of the groove faces can also be determined.
15
Matching
17
A specified clearance between two mating parts is often required to assure proper part 18 operation. An amplifier allows for the individual display of the bore size, the shaft size, and 19 the clearance between the two parts. Operators need only observe the clearance display to determine if the two components have the required match dimension. Source: Robert Edmunds III, Putting Air Gauges to Work
http://www.metrologyworld.com/content/news/article.asp?DocID={9317C89F-2984-11D4-8C3C009027DE0829}&VNETCOOKIE=NO
37
B. Read the questions and choose the correct answer.

1.
Air gauges measure A. The size and form of inside diameters. B. The size and form of outside diameters. C. Both (a) and (b). D. Neither (a) nor (b).
2. When multiple nozzles are equally located about the circumference of the air tool, the air gauging application used is A. Averaging. B. Groove width. C. Out-of-round. D. Matching.
3. To measure the bow of an inside diameter you would use the air gauging application of A. Out-of-round. B. Squareness. C. Straightness. D. Flatness.
4. In order to determine if two mating parts have the required match dimension, the operators need to observe A. The bore size display. B. The shaft size display. 5. Air gauging A. Only determines groove size. B. Only determines parallelism of the groove faces. 6. Air plugs are used for measuring A. Internal dimensions. B. External dimensions. 7. Air rings are used for A. Internal dimensions. B. External dimensions. C. Both (a) and (b). D. Neither (a) nor (b). C. Both (a) and (b). D. Neither (a) nor (b). C. Both (a) and (b). d. Neither (a) nor (b). C. The clearance display. D. All of the above.
8. When an air nozzle is mounted within a stationary platen and the part is moved across the nozzle, you are gauging A. Squareness. B. Flatness. 9. Which of the following statements are true? A. Diameter can not be measured by a straightness air plug. B. Roundness cannot be gauged by air tools. c. To determine squareness of a part, you can use a taper air gauging application. D. All of the above. C. Inside and outside diameters. D. Groove width.
10. What air gauging application can be used to gauge a part for roundness? A. Inside and outside diameters. B. Averaging. C. Out-of-round. D. Matching.
38
UNIT 4
STUDENT HANDOUT
H4:6
A. Complete each sentence with a suitable contrast word or phrase from the box below. but however in contrast on the other hand on the contrary different (ly) differ from difference(s) unlike although even though while
1. Go gauge dimensions are based on the minimum inside diameter (ID) tolerance of the inspected part. ________________, no-go gauge dimensions are based on the minimum outside diameter (OD) tolerance of the inspected part. 2. Double-ended go/no-go gauges include a go gauge pin on one end of a handle and a no-go gauge pin on the opposite end. _____________________, progressive or step go/no-go gauges have stepped pins with the go gauge surface and the no-go gauge surface on the same side of the handle. 3. The ______________________ between plug gauges and ring gauges is that plug gauges check internal dimensions and geometries and ring gauges check external dimensions and geometries. 4. Measuring involves the use of direct-reading instruments that count all units and decimal places, from zero up to the dimension at hand. ________________, gauging uses indirect-reading instruments to compare the work piece against a standard or master. 5. Snap gauges measure diameters, lengths, and thickness. _______________, surface gauges measure flatness, parallelism and heights. B. Read the passage and then answer the questions and complete the outline that follows. There are several differences between fixed variable gauges and adjustable variable gauges. Fixed variable gauges measure manufacturing variation for a specific-size part. On the contrary, the adjustable varieties can be set for use across a wide range of part sizes. Fixed variable gauges differ from adjustable variable gauges in that they can measure tighter tolerances and are somewhat quicker and simpler to use. A separate fixed gauge is usually required for every different dimension that must be inspected. In contrast, adjustable variable gauges have greater flexibility of use. For high-volume jobs, where many thousands of identical parts must be inspected rapidly, or for production runs that are likely to last for months or years, the additional investment in fixed gauging may pay off. However, where production runs are short or where inspection speed is not an issue, adjustable gauging may be more economical because the investment can be spread over a greater number of jobs. 1. Check () the pattern used in this passage: a. ___ comparison 2. Complete the following map of the paragraph:
There are several differences between ___________ variable gauges and ____________ variable gauges.
b. ___ contrast
fixed variable gauges 1. measure for a specific-size part 2. 3. 4. 5.
adjustable variable gauges set for use across a wide range of part sizes
39
Unit 5
Layout Tools and Procedures
Objectives: Given topics on layout tools and procedures; texts that are varied and of a specialized and technical nature which include information presented from other sources (e.g., photographs, drawings, reference text/ research information, diagrams), the participant will use English with 70% accuracy to: Distinguish between semi-precision and precision layout. Identify and pronounce correctly vocabulary related to layout tools. Identify and state the purposes of some layout tools. Identify the steps for laying out a casting having a cored hole. Read two or more column charts to obtain information. Distinguish between comparison and contrast. Read a description and interpret picture labels.
40
STUDENT HANDOUT
H5:1
Study the following words and complete the sentences. 1. bevel protractor A is an instrument in the form of a half circle used for measuring and making angles other than a 900 angle.
2. combination set A is a set of tools used extensively in layout work. It consists of a steel rule, square head, bevel protractor, and center head, 3. height gauge A is an instrument used to scribe accurately dimensioned lines on a workpiece which has been prepared by brushing it with layout dye. 4. hermaphrodite caliper A is a tool for marking lines parallel to square edges and shoulders on a workpiece. 5. layout 6. layout die is a fast-drying colored liquid, usually a very deep blue, that is brushed onto a workpiece to prepare it for laying out guide lines. is the process of measuring and marking a workpiece with finely scribed lines that guide you during the cutting process.
7. reference 8. scriber
is a surface of known flatness or a point from which other lines and locations can be measured. A is a sharp instrument used to mark and lay out a pattern of work to be followed in subsequent machining operations.
9. surface gauge A is a tool for scribing layout lines on a workpiece, or for transferring measurements from a rule to a workpiece.
10. surface plate
A provides a precision reference surface for layout, checking, machining and gauging work.
41
STUDENT HANDOUT
H5:2
Layout A. Read the following paragraphs. Lay out is the planning of the work on the surface of the material that is to be made into the finished part. It is the scribing of lines which indicates cuts to be made, the centerlines of holes to be drilled, and other details that guide the worker in completing the job. 3The precision of the finished part depends largely on the care the worker takes in making the layout. 4The type of part determines the tools to be used.
2 1
Layouts may be of two types basic (or semiprecision) and precision. 6Semi-precision layout is generally used on work that does not require an accuracy of less than 1/64 in. (0.38 mm). 7The tools used for semiprecision layout include a rule, dividers, adjustable square, center head, bevel protractor, and surface gauge. 8On the other hand, precision layout is generally used on work that requires an accuracy of less than 1/64 in. (0.38 mm). 9Vernier, dial, or digital height gauges and calipers that can be set to an accuracy of .001 in. (0.02 mm) are used for precision layout. In layout work, a base or reference surface is selected from which to begin making the measurements. On a flat layout, this is commonly the smoothest, straightest edge on the piece. 12On some layouts, base lines instead of surfaces are used as reference points for measurements. 13Before the layout is begun, the workpiece is coated with a "bluing" or purple layout dye. 14This makes the scribed lines highly visible, thus contributing to the accuracy of the work. 15Other tools used to do layout work include precision steel rules, layout rules, squares, bevel protractors, surface gauges, height gauges, scribers, hermaphrodite calipers, and dividers. 16In order to ensure the accuracy of the work and to reduce the chance of errors, the various types of lines making up a layout must be laid out in a definite sequence as outlined below.
11 10
Figure 1. Part to be laid out.
1. Locate and scribe base lines.
2. Locate all circle and arc centerlines.
3. Scribe in all circles and arcs.
4. Locate and scribe in angular lines.
5. Complete all other object lines.
Source: Fox Valley Technical College. http://its.fvtc.edu/MachShop1/Layout/LayoutPced.htm
42
B. Read the questions and choose the correct answer. 1. Laying out is a. The finished part. b. The planning of the work. 2. The word it in sentence 2 refers to a. Laying out. b. Centerlines of holes. 3. If the worker is not careful in making the layout, a. The finished part wont be accurate.
C. The surface of the material. D. None of the above. C. Cuts to be made. D. Other details. B. The finished part will be precise.
4. In planning a layout, what determines the tools to be use?
5. If you need an accuracy of .001 in., you would use: a. Semi-precision layout. b. Precision layout. 6. On a flat layout, what reference surface is selected to begin making the measurements?
7. Surfaces are always used as reference points for measurements. a. True. B. False. 8. Before you begin the layout, what do you need to do?
9. How can you ensure the accuracy of the work and reduce the chance of error in layout?
10. Match the instruction to the illustration. a. b. Locate and scribe in angular lines.
[ ]
Scribe in all circles and arcs.

[ ]
c.
Complete all other object lines.

[ ]
d.
Locate and scribe base lines.

[ ]
e.
Locate all circle and arc centerlines.

[ ]
43
UNIT 5
STUDENT HANDOUT
H5:3
A. Read pages 151 to 152 in your textbook for laying out a casting having a cored hole. Number the six given layout steps below in the correct order. Use words from the box. first 1. ____ 2. ____ 3. ____ 4. ____ 5. ____ 6. ____ next then finally after that
Using the intersection of these arcs as a center, scribe a circle of the required diameter on the casting. Tap a tightly fitting wooden piece into the cast hole. Prick-punch the layout line. Coat the surface to be laid out with a solution of layout die. Grind the scale off the surface to be laid out. With the hermaphrodite calipers, scribe four arcs using the outside diameter of the shoulder as the reference surface.
B. Read the advertisement below for bevel protractors and complete the sentences with same or different.
Universal Bevel Protractors
Hardened stainless steel, rust and wear resistant Flush-reading, no parallax error Dial: 1 Vernier: 1min Magnifier glass for easier and faster reading
Order No. 187-903 187-904 187-906
Model ABC DEF XYZ
Description 6" & 12" blade and acute angle attachment 6" blade and clamp box for inch height gages 12" blade and clamp box for inch height gages
Price $165.00 $269.79 $282.29
1. 2. 3. 4. 5.
The ABC and XYZ models have the _________________ size blade. The DEF and XYZ models have _______________________ size blades. The ABC and DEF models have the _________________ size blade. All three models have _____________________________ prices. The DEF and XYZ have the _________________ box for inch height gages. 44
STUDENT HANDOUT
H5:4
Study the following words and complete the sentences. 1. adjust ___________ is to bring the components of a part into a more effective or efficient calibration or state. 2. center head A is a part of the combination square set that is used to find the center of or to bisect a round or square workpiece. 3. depth micrometer A___________________ is an instrument used to measure the depth of slots, steps, and other features. 4. dividers ______________ are used for scribing arcs and circles on a layout and for transferring measurements.
5. prick punch The ______________ is used to permanently mark the location of layout lines.
6. squares
______________ are used to lay out lines at right angles to a machined edge to test the accuracy of surfaces that must be square, and to set up work for machining.
7. square head The ________________ is used to check 450 and 900 angles and measure depths.
8. steel rule The ___________ is a scale used for measuring and layout.
9. trammel A ____________ is used to scribe large arcs and circles.
45
UNIT 5
STUDENT HANDOUT
H5:5
Reading Comprehension Layout Tools
The combination set is one of the most versatile and useful measuring tools for basic layout. 2It consists of a steel rule, square head, bevel protractor, and center head. 3You can fit the steel rule to the other three parts of the combination set for various layout, setup, and checking operations. The square head is mounted on the steel rule and is used to measure right angles and 450 angles. 5It can also be used as a depth gage. 6When the center head is used, the edge of the steel rule passes through the center of the head. 7This allows the machinist to use the center head to find the center of a piece of round stock by drawing two intersecting lines on the end of the workpiece. 8When mounted on a rule, the bevel protractor is used to lay out or measure angles from 00 to 1800 with accuracy to within + 30. A vernier height gauge, in contrast, is used for precision layout. 10It is a height gauge with the additional refinement of a vernier scale for greater accuracy in reading or setting the tool. 11The image shows two height gauges, the left height gauge has the vernier scale, the right one has a digital readout making it an electronic height gauge. 12These measuring tools are used in metalworking or metrology to either set or measure vertical distances. 13The pointer is sharpened to allow it to act as a scriber and assist in marking out workpieces. 14They may also be used to measure the height of an object by using the underside of the scriber as the datum. 15The datum may be permanently fixed or the height gauge may have provision to adjust the scale. 16This is done by sliding the scale vertically along the body of the height gauge by turning a fine feed screw at the top of the gauge; then with the scriber set to the same level as the base, the scale can be matched to it. 17This adjustment allows different scribers or probes to be used, as well as adjusting for any errors in a damaged or resharpened probe.
9 4
46
B. Read the questions and choose the correct answer. 1. Which of the tools below does not form part of the combination set? A. Square head. B. Steel rule. c. Bevel protractor. d. Vernier height gauge.
2. Name three operations where you can use the combination set. A. B. C. 3. You can use the center head to: a. Measure 900 angles. b. Measure 450 angles. 4. Which of the following is used for precision layout? A. Square head. B. Steel rule. c. Bevel protractor. d. Vernier height gauge. c. Find the center of a piece of round stock. d. Measure angles from 00 to 1800.
5. What gives the vernier height gauge greater accuracy in reading or setting the tool?
6. What converts the vernier height gauge into an electronic height gauge?
7. Vernier height gauges are used to: a. Set vertical distances. b. Measure vertical distances. c. Measure the height of an object. d. All of the above.
8. By using the underside of the scriber as the datum, the vernier height gauge measures a. Vertical distances. b. The height of an object. 9. A vernier height gauge a. Has a permanently fixed datum. b. Has a provision to adjust the scale. c. Both (a) and (b). d. Neither (a) nor (b). c. Both (a) and (b). d. Neither (a) nor (b).
10. When the scale is adjusted on the vernier height gauge a. Different scribers can be used. b. Different probes can be used. c. Adjustments for errors in a damaged probe can be made. d. All of the above.
47
UNIT 5
STUDENT HANDOUT
H5:6
Read the descriptions below and complete the sentences with the name of the tool or part. 1.
A [1] _________gauge is very useful when finding the center of a piece of round section material. It is normally used to scribe parallel lines. Its base is heavy and this means it is stable when in used. Surface gauges sometimes have magnetic bases and this means they can be locked onto metal surfaces making it easier to use.
The diagram above shows the round section steel held in a [2] _____________ block. The surface [3] _________ is then moved across the surface of the steel, scribing a line. The steel is then rotated through 90 degrees and another line is scribed. This is repeated until a square is produced in the center. Diagonal lines are then drawn from each corner of the square to locate the exact center of the circle. 2. The depth gauge micrometer is a precision measuring instrument, used by engineers to measure depths. Each revolution of the [4] _____________ moves the [5] _________ face 0.5mm towards the bottom of the blind hole. The diagram below shows how the depth gauge is used. The ratchet is turned clockwise until the spindle face touches the bottom of the blind hole.
Source: V. Ryan, Technology Student.com http://www.technologystudent.com/index.htm
48
Unit 6
Hand Tools and Bench Work
Objectives: Given topics on hand tools and bench work; texts that are varied and of a specialized and technical nature which include information presented from other sources (e.g., photographs, drawings, reference text/ research information, diagrams), the participant will use English with 70% accuracy to: Read labels and instructions for holding, assembling and dismantling work pieces. Record essential information that involves more than one sentence. Identify and pronounce correctly vocabulary related to hand tools and bench work. Identify the purpose and correct use of hand tools. Scan a reading for needed information. Identify the main idea and supporting details of a reading.
49
STUDENT HANDOUT
H6:1
Study the following words and complete the sentences. 1. bench vise A __________________ is a device for holding small work securely for sawing, chipping, filing, polishing, drilling, reaming, and tapping operations.
2. file
A __________ is a hand cutting tool made of high-carbon steel. It has a series of teeth cut on its body by parallel chisel cuts.
3. file card A _____________is a wire brush mounted on a block of wood to clean the file. 4. hammer A _________ is a hand tool consisting of a shaft with a metal head at right angles to it, used mainly for driving in nails and beating metal. 5. hand hacksaw A __________________ consists of a frame and a saw blade and is generally used for cutting metal into pieces.
6. pliers
____________ are a hand tool with two hinged arms ending in jaws that are closed by hand pressure to grip something.
7. scraper A ___________ is a hand tool used to move something hard, sharp, or rough across a surface, especially in order to clean it.
8. screwdriver
A _______________________ is a hand tool for fastening screws.
9. taps _______________are cutting tools used to cut internal threads.
10. wrench
A _________________ is a hand tool with fixed or movable jaws, used to seize, turn, or twist objects such as nuts and bolts.
50
STUDENT HANDOUT
H6:2
Hand Tools

1
"Man without tools is nothing; with tools he is all." - 2This sentence as defined by Thomas Carlyle has well elaborated the importance of tooling to a man.
The term 'Tooling' as applied to the machining discipline refers to any equipment or instrument that gives help in the production of a product or any related activities. 4Simply speaking, it ranges from the most fundamental type of hand tools such as a file to the very complex machine tools such as a CNC Machining Center.
Thus, one may ask the question - Why do we still have to use hand tools in this modern age of technology? 6It is reasonable to say that the efficiency of any hand process is low and the outcome quality depends highly upon the skill of individuals. 7Perhaps it is fair to consider the following points before a definite answer is given to the above question: 1. Accuracy The CNC machine can give a higher degree of dimensional accuracy when compared with the inconsistent outcome of hand fitting. 9However, the extreme high degree of flatness required for a surface table is usually obtained by hand scraping only. 2. Flexibility Hand processes are very flexible and can be carried out at any place where necessary while machining processes are not. 11In addition, machining usually requires a rigid setting up, while fitting is simple. 3. Quantity For large batch size, advanced production machines are commonly employed in order to maintain accuracy as well as efficiency. 13But for "jobbing type" works, such as the manufacture of a prototype or the repairing of a single component, it would not be economical to use these advanced machine tools. 14 Instead, "jobbing type" works are usually produced by conventional machining and followed by hand fitting where necessary. 4. Final Assembly
15 12 10 8
In the assembly of precise component parts, no matter how accurately they are produced, a skilled fitter is often required to give the necessary "finishing touch" to ensure that everything goes together correctly.
Source: Hong Kong Polytechnic University, http://www.mmu.ic.polyu.edu.hk/handout/0101/0101.htm#1
51
B. Read the questions and choose the correct answer. 1. The saying, Man without tools is nothing; with tools he is all. means a. Men need tools. b. Men like tools. 2. Which would refer to tooling? a. b. 3. Pliers. Hammers. c. Both (a) and (b). d. Neither (a) nor (b). c. Both (a) and (b). d. Neither (a) nor (b).
The word it in sentence 4 refers to: a. Tooling. b. A CNC Machine Center. c. A file. d. A product.
4.
The words following points in sentence 7 refer to a. Accuracy. b. Final Assembly. c. Flexibility. d. All of the above.
5.
Hand fitting a. b. c. d. Can give as high degree of dimensional accuracy as the CNC machine. Is never as accurate as the CNC machine. Can be more accurate than the CNC machine on certain occasions. None of the above.
6.
Machining processes are a. More flexible than hand processes. b. Less flexible than hand processes. c. As flexible as hand processes. d. As simple as hand processes.
7.
When you are repairing a single component a. b. c. d. Advanced production machines are more economical than conventional machining. Conventional machining is as economical as advanced production machines. Conventional machining is more economical than advanced production machines. None of the above.
8.
Putting the finishing touch to precise component parts is best done through a. Hand processes. b. Advanced production machines. c. Both (a) and (b). d. Neither (a) nor (b).
9.
The pattern of organization in sentence 9 is one of a. Addition. b. Contrast. c. List of items. d. Cause and effect.
10.
The main pattern of organization in paragraph 5 is one of a. Addition. b. Contrast. c. Time. d. Cause and effect.
52
UNIT 6
STUDENT HANDOUT
H6:3
Read pages 162 to 179 in your textbook and choose the correct answer. 1. What tool is used to hold small work securely for sawing, chipping, filing, polishing, drilling, reaming, and tapping operations? a. Bench vise. b. Hand hacksaw. 2. c. Machinist file. d. Scraper.
Which tool is made from high quality tool steel, hardened and ground? A. Wrenches. B. Hand taps. c. Pliers. d. Screwdrivers.
3.
Which of these are used solely for cutting wire and small pieces of soft metal?
a.
b.
c.
4.
Label the parts of the bench vise.
1 3
2 5. Write the name of the type of screwdriver in the blanks.
53
6.
Which of these tools would you use on the circumference of a round nut?
a. 7. Label the parts of a hand hacksaw. 1
b.
c.
2 3 4
8. What is used to turn the die onto the workpiece? a. A solid die nut. b. A screw plate die. 9. Label the main parts of a file. 5 1 4 c. A split die. d. A die stock.
10.
Which is a T-handle tap wrench?
a.
b.
c.
54
STUDENT HANDOUT
H6:4
Study the following words and complete the sentences. 1. broaching ______________ is a process in which a special tapered multitoothed cutter is forced through an opening or along the outside of a piece of work to enlarge or change the shape of the hole or to form the outside to a desired shape. 2. burnishing _____________ is developing a smooth finish on a metal by tumbling or rubbing with a polished hand tool. 3. electropolishing
_________________ is a process that involves passage of electric current through a workpiece, while it is submerged in a speciallydesigned acid solution.
4. finish
_________ refers to the surface appearance of steel after final treatment.
5. hand reamer A _________ is a tool used to finish drilled holes accurately and provide a good finish. 6. honing 7. keyway ________________ is a mechanical locking device located on the slitter head spindle shaft that holds the knives and spacers in place. 8. lapping 9. reaming _______________ is a machining process using a reamer to smooth and accurately size a previously cored, drilled, or bored hole. __________ is an abrading process used to remove minute amounts of metal from a surface that must be flat, accurate to size, and smooth. ___________ is removing stock generally on the internal cylindrical surface of a workpiece with an abrasive stick mounted in a holder.
10. tumbling
__________________ is a production process that is used for cleaning, polishing, and removing sharp corners and burrs from metal parts. 55
STUDENT HANDOUT
H6:5
Honing
A. Read the following paragraphs. There are many variables to consider when trying to optimize a metalworking process. 2In the simplest terms, you have to squeeze as much productivity as possible out of every aspect of the process. 3That includes the reconditioning of cutting tools. When it comes to tools and optimizing a process, one question must be answered: Are the tools being fully utilized? 5If hand honing isnt part of your tool-reconditioning program, the answer is no. 6Tool life, which is intimately tied to part quality and productivity, can be increased through the proper selection and application of hones. The first step in tool honing is stone selection. 8Matching the stone to the job is of paramount importance. 9A compatible match is as essential as selecting the correct wheel for a tool-grinding operation. 10In fact, the forethought required for both honing and tool grinding is similar. 11Consideration must be given to tool geometry and material and to the degree of abrasiveness needed for the job. Hones are available in a multitude of shapes, sizes and abrasive types. The vast assortment can seem overwhelming to the beginner. 14But once the selection process is understood, the best choice soon becomes obvious.
13 12 7 4 1
Cutting tools also come in many shapes and sizes. 16A tools basic geometry usually consists of either planar or curved surfaces. 17Even special shapes are a combination of these two geometries. 18Stone shapes for planar surfaces include square, rectangle, triangle, diamond or any combination of these shapes. 19Curved surfaces require stones that are round, half-round or concave. The geometry of the tools cutting edge will determine the best stone for the job. 21A good stone for the 1/4"-radius form tool shown in Figure 1a, for example, would be round, have a 1/2" diameter and be made of a medium-grit aluminum oxide. 22(Other recommended shapes and sizes are depicted in Figures 1b, 1c and 1d.) 23Generally, if the surface area of the cutting edge is large, select a large stone. Choosing the appropriate abrasive is the next task. 25The most common hone materials are Al2O3, silicon carbide, diamond and Arkansas (hard quartzite). 26Most cutting tools are manufactured from either HSS or carbide. 27 The old school of thought reserved diamond hones for carbide tools, but the real determining factor in abrasive selection is the required rate of material removal. 28Expect a rapid rate of material removal when using a diamond hone on HSS cutting tools.
Source: Tory Gallier. Home Improvement, June 1999/Volume 51/Number 4 http://www.ctemag.com/article/viewArticle.asp?ARTICLE_ID=36
24 20
15
Figure 1: A tools cutting-edge geometry determines the best hone for the job. (a) A 1/4"-radius form tool is reconditioned by a round, 1/2"-dia. stone made of medium-grit Al2O3. (b) A large formmilling cutter is deburred with a rectangular, mediumgrit, SiC stone. (c) A 400-grit diamond hone reconditions a carbide turning tool. (d) A small form-milling cutter is reconditioned with a diamond-shaped, medium-grit, Al2O3 stone.
56
1. The central point of the reading is a. Stone selection. b. Honing. 2. The reconditioning of cutting tools is one way to a. Make the metalworking process most effective. b. Consider variables. 3. Hand honing a. Should be part of a tool-reconditioning program. b. Can extend the life of tools. 4. The topic of paragraph [3] is a. Tool grinding. b. Abrasiveness. c. Stone selection. d. Tool geometry. c. Both (a) and (b). d. Neither (a) nor (b). c. Both (a) and (b). d. Neither (a) nor (b). c. Tool grinding. d. Curved surfaces.
5. In selecting a stone for honing, consideration must be given to a. Tool geometry. b. Tool material. 6. The main idea of paragraph 5 is a. b. c. d. Cutting tools come in many shapes and sizes. A tools basic geometry consists of either planar or curved surfaces. Even special shapes are a combination of these two geometries. Curved surfaces require stones that are round, half-round or concave. c. Degree of abrasiveness. d. All of the above.
7. Read paragraph 5 and complete the following map about cutting tools.
Cutting Tools
surfaces surfaces
Square
Round
57
8. The best stone for the job is determined by a. The radius. B. The diameter. 9. A carbide turning tool is best reconditioned by a. A square-shaped stone. b. A diamond-shaped stone. 10. The following are examples of hone materials: a. Silicon carbide. b. Hard quartzite. c. Ai203. d. All of the above. c. A triangle-shaped stone. d. A round-shaped stone. c. The aluminum oxide. d. The geometry of the tools cutting edge.
58
UNIT 6
STUDENT HANDOUT
H6:6
Read pages 162-192 in your text book and match the picture to the name of the hand tool.
10
11
12
13
14
15
16
17
18
19
20
21 [ ] hacksaw [ ] hand taps [ ] hex key [ ] pliers [ ] broaches
22 [ ] bench vise [ ] hammer [ ] arbor press [ ] external lap [ ] socket wrench
23 [ ] file card
24
25
[ ] scraper [ ] adjustable wrench [ ] hand reamer [ ] Phillips screwdriver [ ] die stock
[ ] die [ ] tap extractor [ ] screwdriver [ ] open-end wrench [ ] file
[ ] burnishing tool [ ] T-handle tap wrench [ ] rotary files [ ] tumbling machine
59
Unit 7
Metal Cutting Technology
Objectives: Given topics on metal cutting technology; texts that are varied and of a specialized and technical nature which include information presented from other sources (e.g., photographs, drawings, reference text/ research information, diagrams), the participant will use English with 70% accuracy to: Define and pronounce correctly vocabulary related to metal cutting. Use the nomenclature of a cutting-tool point. Identify and use the cause and effect pattern of organization. Classify chip types.
60
STUDENT HANDOUT
H7:1
Study the following words and complete the sentences. 1. built-up edge
____________________________ is a layer of compressed metal from the material being cut which adheres to and piles up on the face of the cutting tool edge during a machining operation.
2. chip-tool interface The ________________________ is that portion of the face of a cutting tool on which the chip slides as it is cut from the metal.
3. crystal elongation 4. deformed zone
_____________________ is the distortion of the crystal structure of the work material that occurs during a machining operation. The ______________________ is the area in which the work material is deformed during cutting.
5. plastic deformation _________________________ is the change in shape of the work material that occurs in the shear zone during a cutting action. 6. plastic flow _________________ is the flow of metal that occurs on the shear plane, which extends from the cutting-tool edge to the corner between the chip and the work surface.
7. rupture A ____________ is the tear that occurs when brittle materials, such as cast iron, are cut and the chip breaks away from the work surface. 8. shear angle The ______________ is the angle of the area of the material where plastic deformation occurs. 9. shear zone The _________________ is the area where plastic deformation of the metal occurs.
61
STUDENT HANDOUT
H7:2
Basic Metal Cutting Theory

A. Read the following paragraphs. The usual conception of cutting suggests clearing the substance apart with a thin knife or wedge. 2When metal is cut the action is rather different and although the tool will always be wedge shaped in the cutting area and the cutting edge should always be sharp the wedge angle will be far too great for it to be considered knife shaped. 3 Consequently a shearing action takes place when the work moves against the tool.
1
Figure 1. Basic Metal Cutting Theory
Figure 1 shows a tool being moved against a fixed work piece. 5When the cut is in progress the chip presses heavily on the top face of the tool and continuous shearing takes place across the shear plane A. 6 Although the Figure shows a tool working in the horizontal plane with the work piece stationary, the same action takes place with the work piece revolving and the tool stationary. The type of chip produced depends on the material being machined and the cutting conditions at the time. 8These conditions include the type of tool used, rate of cutting condition of the machine, and the use or absence of a cutting fluid.
Continuous Chip
7
This leaves the tool as a long ribbon and is common when cutting most ductile materials such as mild steel, copper and aluminum. 10It is associated with good tool angles, correct speeds and feeds, and the use of cutting fluid.
Figure 2. Continuous Chip
Discontinuous Chip The chip leaves the tool as small segments of metal resulting from cutting brittle metals such as cast iron and cast brass with tools having small rake angles. 12There is nothing wrong with this type of chip in these circumstances.
Figure 3. Discontinuous Chip
11
Continuous Chip with Built-up Edge This is a chip to be avoided and is caused by small particles from the work piece becoming welded to the tool face under high pressure and heat. 14The phenomenon results in a poor finish and damage to the tool. 15 It can be minimized or prevented by using light cuts at higher speeds with an appropriate cutting lubricant.
Source: Hong Kong Polytechnic University, http://mmu.ic.polyu.edu.hk/handout/0102/0102.htm
13
Figure 4. Continuous Chip with Buildup Edge
62
B. Read the questions and choose the correct answer. 1. Cutting metal a. b. c. d. Is the same as the usual conception of cutting. Is different than the usual conception of cutting. Does not use a wedge-shaped tool in the cutting area. Produces a knife-shaped wedge angle.
2.
The word it in sentence 2 refers to a. Tool. b. Cutting edge. c. Cutting area. d. Wedge angle.
3.
A shearing action takes place when the work moves against the tool is a. b. c. d. An addition to the wedge angle being far too great for it to be considered knife shaped. A comparison of the wedge angle being far too great for it to be considered knife shaped. The result of the wedge angle being far too great for it to be considered knife shaped. None of the above.
4.
Continuous shearing takes place in Figure 1 a. b. c. d. When the tool is working in the horizontal plane with the work piece stationary. With the work piece revolving and the tool stationary. Both (a) and (b). Neither (a) nor (b).
5.
The type of chip produced is determined by a. The material being machined. b. The use or absence of a cutting fluid. c. The type of tool used. d. All of the above.
6.
Complete the following diagram on Chip Types.
Chip Types
63
7.
Write the type of chip under the corresponding figure.
1.
2.
3.
8.
Match the chip type to how the tool is left. a. continuous chip b. discontinuous chip c. continuous chip with built-up edge [ ] as small particles welded to the tool face [ ] as a long ribbon [ ] as small segments of metal
9.
Which type of chip results in better surface finishes. a. A continuous chip. b. A continuous chip with built-up edge. c. A discontinuous chip. d. None of the above.
10.
A continuous chip is associated with a. b. Good tool angles. Correct speeds and feed. c. Use of cutting fluid. d. All of the above.
64
UNIT 7
STUDENT HANDOUT
H7:3
A. Complete each sentence with a suitable cause and effect word or phrase from the box below. because as a result since causes resulted
1. New cutting tools, speeds and feeds, and cutting tool angles and clearances have been developed of research in the area of metal cutting. 2. Many new terms from the research conducted on metal cutting.
3. ______________ of the forces exerted by the cutting tool, compression occurs in the work material. 4. This concentration of stresses flow along the chip-tool interface. 5. the chip to shear from the material and
most metals are ductile to some degree, a plastic flow generally occurs.
B. Read the paragraph below, looking for one cause and three main effects. Then complete the diagram that follows. The continuous chip with the built-up edge is the main cause of surface roughness. In addition, this type of chip affects cutting-tool life in two ways. First, the fragments of the built-up edge abrade the tool flank as they escape with the work piece and chip. Second. a cratering effect is caused a short distance back from the cutting edge where the chip contacts the tool face. As this cratering continues, it eventually extends closer to the cutting edge until fracture or breakdown occurs.
Effect
Cause Effect
Effect
65
UNIT 7
STUDENT HANDOUT
H7:4
Vocabulary Development Study the following words and complete the sentences.
face
point nose cutting edge shank
base flank 1. base 2. cutting edge The __________________ is the bottom surface of the tool shank. The __________________ is the leading edge of the toolbit that does the cutting. The ______________ is the surface against which the chip bears as it is separated from the work. The __________________ is the surface of the tool adjacent to and below the cutting edge. The ____________ is the tip of the cutting tool formed by the junction of the cutting edge and the front face. The ______________________ is the radius to which the nose is ground. The __________________ is the end of the tool that has been ground for cutting purposes. The ___________________ is the body of the toolbit or the part held in the tool holder.
3. face
4. flank
5. nose
6. nose radius 7. point
8. shank
66
angle of keenness
1. angle of keenness
The _____________________________ is the included angle produced by grinding side rake and side clearance on a toolbit. The ______________________________ is the backward slope of the tool face away from the nose. The _____________________________________ is the angle formed by the end cutting edge and a line at right angles to the centerline of the toolbit. The __________________ is the angle ground below the nose of the toolbit which permits the cutting tool to be fed into the work. The ______________________ is the angle the cutting edge forms with the side of the tool shank. The _____________________ is the angle at which the face is ground away from the cutting edge. The ____________________________ is the angle ground on the flank of the tool below the cutting edge.
2. back rake angle
3. end cutting edge angle
4. end relief angle
5. side cutting edge angle
6. side rake angle
7. side relief angle
67
STUDENT HANDOUT
H7:5
Tool Angles
1
There are three important angles in the construction of a cutting tool - rake angle, clearance angle, and plan approach angle.
Figure 1. Main Features of a Single Point Cutting Tool Rake angle is the angle between the top face of the tool and the normal work surface at the cutting edge. In general, the larger the rake angle, the smaller the cutting force on the tool. 4The reason for this is that for a given depth of cut the shear plane, shown in Figure 1, decreases as rake angle increases. 5A large rake angle will improve cutting action, but would lead to early tool failure, since the tool wedge angle is relatively weak. 6A compromise must therefore be made between adequate strength and good cutting action.
3 2
Clearance angle is the angle between the flank or front face of the tool and a tangent to the work surface originating at the cutting edge. 8All cutting tools must have clearance to allow cutting to take place. 9 Clearance should be kept to a minimum, as excessive clearance angle will not improve cutting efficiency and will merely weaken the tool. 10Typical value for front clearance angle is 6 in external turning. The plan shape of the tool is often dictated by the shape of the work, but it also has an effect on the tool life and the cutting process. 12Figure 2 shows two tools, one where a square edge is desired and the other where the steps in the work end with a chamfer or angle. 13The diagram shows that, for the same depth of cut, the angled tool has a much greater length of cutting edge in contact with the work. 14Thus the load per unit length of the edge is reduced. 15The angle at which the edge approaches the work should in theory be as large as possible, but if too large, chatter may occur. 16This angle, known as the Plan Approach Angle, should therefore be as large as possible without causing chatter.
17 11
Figure 2. Plan Approach Angle
The trailing edge of the tool is ground backwards to give clearance and prevent rubbing and a good general guide is to grind the trailing edge at 90 to the cutting edge. 18Thus the Trail Angle or Relief Angle will depend upon the approach angle. 19A small nose radius on the tool improves the cutting and reduces tool wear. 20If a sharp point is used it gives poor finish and wears rapidly.
Source: Hong Kong Polytechnic University, http://mmu.ic.polyu.edu.hk/handout/0102/0102.htm
68
B. Read the questions and choose the correct answer. 1. The central point of the reading is a. Tool angles. b. Clearance angles.
c. Rake angles. d. Plan approach angles.
2.
The angle at which the edge approaches the work is the a. Clearance angle. c. Rake angle. b. Plan approach angle. d. None of the above. The main pattern of organization in paragraph 2 is a. Comparison. c. Addition. b. Contrast. d. Cause and effect. The effect of a larger rake angle is a. The cutting force on the tool is greater. b. The cutting force on the tool is smaller. A large rake angle a. Improves cutting action. b. Leads to early tool failure.
3.
4.
c. The cutting action is weaker. d. There is no noticeable effect.
5.
c. Both (a) and (b). d. Neither (a) nor (b).
6.
What is the reason a large rake angle leads to early tool failure?
7.
The sentence, A compromise must therefore be made between adequate strength and good cutting action, is a. The cause of the previous sentence. b. A comparison with the previous sentence. C. The effect of the previous sentence. D. A contrast to the previous sentence.
8.
The topic of paragraph 3 is a. Clearance angle. b. Front face of the tool.
c. Cutting tools. d. Cutting efficiency.
9.
The angle at which the edge approaches the work [paragraph 4] is the a. Rake angle. c. Plan Approach angle. b. Clearance angle. d. Trail angle. Another name for the Trail Angle is a. Approach angle. b. Plan angle.
10.
c. Relief angle. d. Cutting angle.
69
UNIT 7
STUDENT HANDOUT
H7:6
Read the paragraph below looking for the causes and effects of heat treating processes. Then complete the diagram. There are five basic heat-treating processes that result in a desired change in the physical properties of a metal: hardening, case hardening, annealing, normalizing, and tempering. Each of these processes brings about different results in metal. The hardening process leads to an increase in the hardness and strength of metal, but it also increases its brittleness. During the casehardening process, low-carbon steel is heated to a specific temperature in the presence of a material (solid, liquid, or gas) which decomposes and deposits more carbon into the surface of steel. Then, when the part is cooled rapidly, the outer surface becomes hard, leaving the inside of the piece soft but very tough. The annealing process consists of heating the metal to a specific temperature, soaking, and cooling to room temperature. Annealing is often accomplished after various cold working operations because many nonferrous metals become hard and brittle after cold working. Also, annealing is used to remove the effects of solution heat treatment so that machining or working qualities can be improved. Normalizing is achieved by heating the metal to a specified temperature (which is higher than either the hardening or annealing temperatures), soaking the metal until it is uniformly heated, and cooling it in still air. Ferrous metals are normalized leading to relief in the internal stresses produced by machining, forging, or welding. Consequently, normalized steels are harder and stronger than annealed steels. Steel is tempered after being hardened to relieve the internal stresses and reduce its brittleness. Tempering consists of heating the metal to a specified temperature and then permitting the metal to cool.
Effect
Change in physical property of metals
Cause
Cause
Cause
Cause
Cause
Effect
Effect
Effect
Effect
Effect
Effect
Effect
Effect
Effect
Effect
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Unit 8
Metal Cutting Saws
Objectives: Given topics on metal cutting saws; texts that are varied and of a specialized and technical nature which include information presented from other sources (e.g., photographs, drawings, reference text/ research information, diagrams), the participant will use English with 70% accuracy to: Identify several different types of saws and their uses. Locate chart information at intersections of rows and columns. Identify and pronounce correctly vocabulary related to sawing machines. Complete an outline on types of metal saws. Name the main operative parts of a contour-cutting bandsaw and state the purpose of each. Identify sawing problems and possible causes. Identify the main idea and supporting details of a reading.
71
STUDENT HANDOUT
H8:1
Study the following words and complete the sentences. 1. abrasive cut-off saw The _______________________________ is a cutting-off machine used to cut material by means of a thin, abrasive wheel revolving at high speed.
2. blade tension handle 3. cold circular cutoff saw
The __________________________ is a part of the horizontal band saw used to adjust the tension on the saw blade.
The ____________________________ is a cutting-off machine used to cut soft or unhardened metals.
4. frame
The ______________ is a part of the horizontal band saw, hinged at the motor end, that has two pulley wheels mounted on it, over which the continuous blade passes. ______________________________ is a burning process by which a saw band, with or without saw teeth, is run at high speeds to burn or melt its way through the metal. A _____________________________ is a cutting-off machine that has a flexible, belt-like one-way blade that cuts continuously in one direction.
5. friction sawing
6. horizontal band saw
7. power hacksaw A _______________________ is a cutting-off machine utilized to cut material of various shapes and sizes up to six inches across.
8. roller guide brackets
________________________ are a part of the horizontal band saw that provide rigidity for a section of the blade and can be adjusted to accommodate various widths of material. _____________ are a part of the horizontal band saw used to vary the speed of the continuous blade to fit the type of material cut. The ___________ is a part of the horizontal band saw that can be adjusted to hold various sizes of work pieces. 72
9. step pulleys 10. vise
STUDENT HANDOUT
H8:2
The Horizontal Band Saw A. Read the following paragraphs. The horizontal band saw is an important machine found in almost every shop. 2Although simple in appearance, this machine requires that the operator pay strict attention to setup and operation. 3This is because the slightest change in cutting conditions could result in any number of errors, from angular cuts to broken saw blades. The machine most operators will use is illustrated here. 5It is a simple machine with fundamental operation procedures. 6The upper part of the machine is the saw blade itself. 7It has blade guards, (the covers that hide the majority of the blade), the saw machine controls, and blade tension handles used to keep the blade taunt and allow the blade to be changed. 8Some of the more expensive saws have a shock absorber type hydraulic system, which allows for the controlled descent of the saw blade. 9The material is placed on the saw on the table of the machine, and is held securely in place by a vise. 10 There is usually a length stop attached to the table, so that each piece is cut exactly the same. Development of high carbon steel strip in the 1920s paved the way for band saws to be used in metal cutting. 12 By selectively flame hardening the toothed edge of the saw, the combination of hard tooth and flexible body could be obtained from the same material. 13High speed steel strip, available 30 years later, was similarly selectively hardened. 14This new alternative - a composite material - was not commercially available until the 1960s. Manufacturers of saw blades are researching areas featuring powder metallurgy, high speed steels, laser welded strip, shot peening (to improve fatigue resistance), and saw blades with exotic metal coatings. 16The type of saw blade is determined by the type of material being cut. 17Generally, the harder the material, the more teeth per inch of saw blade needed. 18 For example, a good blade to use while cutting aluminum is one with 4-6 teeth per inch. 19Mild steel is cut with a saw blade having anywhere from 18-24 teeth per inch of blade.
15 11 4 1
Source: Virtual Machine Shop, http://www.jjjtrain.com/vms/other_horiz_band_saw.html
73
B. Read the questions and choose the correct answer. 1. The topic of the reading is: a. Setup and operation of the horizontal band saw. b. The horizontal band saw. c. High carbon steel. d. Flame hardening.
2. Setup and operation for the horizontal band saw are of: a. Little importance. 3. Label the parts of the horizontal band saw below. 1 9 2 b. Great importance.
7 3 6 5 4
4. Broken saw blades on the horizontal band saw is the result of a. Poor setup and operation. b. Strict setup and operation. c. Simple appearance. d. None of the above.
5. The saw blade has a. Blade guards. b. Blade tension handles. c. Saw machine controls. d. All of the above.
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6. The blade is kept taunt by the a. Blade guards. b. Saw machine controls. c. Blade tension handles. d. Vise.
7. Band saws are used in metal cutting as a result of a. High carbon steel strip. b. High speed steel strip. c. Flame hardening. d. A composite material.
8. Flame hardening is the cause of a. b. c. d. Hard tooth being obtained from the material. Flexible body being obtained from the material. The combination of hard tooth and flexible body being obtained form the material. The toothed edge of the saw.
9. This new alternative in sentence 14 refers to a. b. High speed strip steel. Hard tooth. c. High carbon steel strip. d. Band saws.
10. Since mild steel is cut with a saw blade having anywhere from 18-24 teeth per inch of blade, a. b. Mild steel is harder than aluminum. Aluminum is softer than mild steel. c. Mild steel is softer than aluminum. d. Both [a] and [b].
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UNIT 8 1. What is the topic of Unit 35?
STUDENT HANDOUT
H8:3
2. Read the passage on Methods of Cutting Off Material and complete the outline below by filling in the main idea and major details, including a brief explanation of each. Main idea: There are 1. 2. Bandsawing 3. 4. 5. - cuts most metals and materials such as glass and ceramics. common methods of cutting off material.
cuts only on the forward stroke, resulting in considerable wasted material .
3. Complete the map of Horizontal Bandsaw parts. Then match the part to the description.
Horizontal Bandsaw Parts
____ step pulleys ____ vise ____ frame ____ blade tension handle ____ roller guide brackets
a. Can be adjusted to hold various sizes of workpieces. b. Used to adjust the tension on the saw blade. c. Used to vary the speed of the continuous blade to fit the type of material cut. d. Provide rigidity for a section of the blade and can be adjusted to accommodate various widths of material. e. Has two pulley wheels mounted on it over which the continuous blade passes.
4. Identify the name of the item to complete the sentences. a. b. c. d. e. A An A A A is used for cutting soft or hardened metals. . saw will cut hardened metals, glass and ceramics. is used to support long pieces while they are cut. is used to clamp a short workpiece in a vise. is used when many pieces of the same length must be cut. 76
UNIT 8
STUDENT HANDOUT
H8:4
Vocabulary Development A. Study the following words and complete the sentences.
1. angular cutting
___________________ is a bandsaw operation where the work may be clamped at any angle and fed through the saw. The _______________ is the thickness of the saw blade that has been standardized according to blade width. _____________ is a bandsaw application where sections of metal can be removed in one piece rather than in chips. The __________________of bandsaw blades is expressed as the number of teeth per linear inch of the blade. __________________________ is a bandsaw operation where internal or external contours may be cut easily. The __________ of a blade is the amount that the teeth are offset on either side of the center to produce clearance for the back of the band or blade. _____________________ is a bandsaw operation where the saw makes a slit in the material. _____________________ is a bandsaw operation where the saw divides the material into usually two pieces, especially lengthways. _________________________________ is a bandsaw operation where complicated shapes may be cut. A _____________________ is a machine tool that provides a fast and economical method of cutting metal and other materials.
2. gage
3. notching
4. pitch
5. radius cutting
6. set
7. slotting
8. splitting
9. three-dimensional shaping
10. vertical bandsaw
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B. Look at page 280 in your text and label the parts of the contour-cutting bandsaw (vertical bandsaw). 6
7 8 3
2 9
1. ____________________ 2. ____________________ 3. ____________________ 4. ____________________ 5. ____________________
6. ____________________ 7. ____________________ 8. ____________________ 9. ____________________
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STUDENT HANDOUT
H8:5
Straight-Line Sawing A. Read the following paragraphs. Straight-line sawing is performed on the vertical band saw machine by using one or a combination of several mechanisms or attachments: the miter guide attachment, with or without power feed, with or without the work-holding jaw device- and the work-holding jaw device with power feed and angular blade guide attachment. The miter guide attachment (figure 1) on some machines can be connected to the power feed mechanism and on others must be fed by hand. 3The workpiece is clamped or hand-held against the miter guide attachment and the workpiece and attachment are moved on a track parallel to the blade, thereby assuring a straight-line cut. The work-holding jaw device on some machines can be connected to the power feed to produce straight-line cuts. The angular blade guide attachment is used for straight-line sawing when the workpiece cannot be cut in the usual manner because it is too large or too long to clear the column of the bar, sawing machine frame.
5 4 2 1
Figure 1
6
A typical example of straight-line sawing is outlined below :

7
First, select a band saw blade of the desired pitch for the nature of material to be cut. 8The blade should be as wide as possible for straight-line sawing. Then, set the desired speed on the bandsawing machine.
Next, position the workpiece at the desired angle in one of the machine attachments and connect the cable to the power feed mechanism if power feed is to be used. Finally, start the bandsawing machine and feed the workpiece lightly into the blade to start the cut. 12Once the cut is started, the feed can be increased. 13If feeding is by hand, the pressure applied to the workpiece by the operator can be varied to find the best cutting conditions.
11
10
Source: Fundamentals of Machine Tool, Scarlet Oaks Career Development Campus, http://www.constructionmaintenance.org/id680.htm#top
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B. Read the questions and choose the correct answer. 1. The topic of the reading is a. Straight-line sawing. b. The work-holding jaw device.
c. The miter guide attachment. d. The angular blade guide attachment.
2. Which of the flowing mechanisms or attachments are used on the vertical band saw machine for straight-line sawing? a. The miter guide attachment with power feed. c. The miter guide attachment without power feed. b. The miter guide attachment with the d. All of the above. work-holding jaw device. 3. Complete the map of paragraph 3 by filling in the main idea and missing major supporting details.
Straight--line sawing on the vertical band saw machine uses__________ __________ _________________.
4. The cause of assuring a straight-line cut when using the miter guide attachment is a. The miter guide attachment is connected to the power feed mechanism. b. The miter guide attachment is fed by hand. c. The workpiece is clamped against the miter guide attachment and both are moved on a track parallel to the blade. d. The workpiece is on a track parallel to the blade. 5. If the workpiece is too large or too long to clear the column of the bar sawing machine frame, a. The workpiece cannot be cut in the usual manner. c. Both [a] and [b]. b. The angular blade guide attachment is used. d. Neither [a] nor [b]. 6. It in sentence 5 refers to a. The angular blade guide attachment. b. The workpiece. 7. The main pattern of organization in paragraph 3 is a. Cause and effect. b. A series of events. 8. For straight-line sawing a. The width of the blade should be wide. b. The width of the blade should be narrow.
c. Straight-line sawing. d. The column of the bar.
c. A list of items. d. Comparison and contrast.
c. The width of the blade is not important. d. None of the above.
9. What is the effect of varying the pressure applied to the workpiece when feeding by hand?
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UNIT 8
STUDENT HANDOUT
H8:6
Read pages 279 to 295 and answer the questions.
1. Read the passage on Bandsaw Applications and complete the outline below by filling in the main idea and major details, including a brief explanation of each. Main idea: There are 1. 2. Slotting 3. 4. 5. 6. - cuts complicated shapes. common operations that can be performed on a sections of metal removed in one piece. .
2. Complete the map of common set patterns of blades. Then match the set pattern to the description.
Set Patterns of Blades
Has one tooth offset to the right and the next to the left. Has a group of teeth offset to the right and the next group to the left. Has one tooth offset to the right, one offset to the left, and the third tooth straight.
3. Read Table 37.1 and identify the sawing problems or the possible causes. Problem Blade dulls quickly ________________ Saw teeth clogging ________________ Blade not cutting Possible Causes _________________________________________________________________ Too heavy feed; Pitch too coarse; Wrong type of blade. __________________________________________________________________ Too heavy feed; Improper feed tracking; Improper blade tension; Saw guides to far apart; Blade dull on one side. ___________________________________________________________________
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Unit 9
Drilling Machines
Objectives: Given topics on drilling machines; texts that are varied and of a specialized and technical nature which include information presented from other sources (e.g., photographs, drawings, reference text/ research information, diagrams), the participant will use English with 70% accuracy to: Identify six standard operations that may be performed on a drill press. Read two-or more column charts to obtain information. Identify and pronounce correctly vocabulary related to the sensitive drill press. Identify the names of some major drilling operations and the tools used. Identify and pronounce correctly the major parts of the twist drill. Interpret tables, photographs, and illustrations. Label the parts of a reamer.
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STUDENT HANDOUT
H9:1
A. Study the following words and complete the sentences. 1. body 2. boring ___________ is the operation of truing and enlarging a hole by means of a single-point cutting tool. 3. counterboring ___________ is the operation of enlarging the top of a previously drilled hole to a given depth to provide a square shoulder for the head of a bolt or capscrew. 4. countersinking ______________ is the operation of producing a tapered or cone-shaped enlargement to the end of a hole. The _________ is the portion of the drill between the shank and the point.
5. drilling
______________ is the operation of producing a hole by removing metal from a solid mass using a cutting tool called a twist drill. The ________ is the part of a twist drill that consists of the chisel edge, lips, lip clearance, and heel. _______________is the operation of sizing and producing a smooth, round hole from a previously drilled or bored hole with the use of a cutting tool having several cutting edges. The _________ is the part of the drill that fits into the holding device, whether it is a straight shank or a tapered shank.
6. point
7. reaming
8. shank
9. spot facing ______________________ is the operation of smoothing and squaring the surface around a hole to provide a seat for the head of a cap screw or a nut.
10. tapping is the operation of cutting internal threads in a hole with a cutting tool called a tap.
83
B. Look at page 302 in your text and label the parts of the drilling machine.
8 7 6
2 3 4
1. _______________________________________ 2. _______________________________________ 3. _______________________________________ 4. _______________________________________ 5. _______________________________________ 6. _______________________________________ 7. _______________________________________ 8. _______________________________________
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STUDENT HANDOUT
H9:2
Twist Drills A. Read the following paragraphs. Twist drills (figure 1) are end-cutting tools used to produce holes in most types of material. 2On standard drills, two helical grooves, or flutes, are cut lengthwise around the body of the drill. 3They provide cutting edges and space for the cuttings to escape during the drilling process. 4The twist drill is made from high speed steel, tempered to give maximum hardness throughout the parallel cutting portion. The principal parts of a twist drill are the body, the shank, and the point (fig. 1). 6The body is the portion of the drill between the shank and the point. 7It consists of a number of parts important to the efficiency of the cutting action. 8The flutes are two or more helical grooves cut around the body. 9They form the cutting edges, admit cutting fluid, and allow the chips to escape from the hole. 10The margin is the narrow, raised section immediately next to the flutes and extends along the entire length of the flutes. 11Its purpose is to provide a full size to the drill body and cutting edges. 12The body clearance is the undercut portion of the body between the margin and the flutes. 13It is made smaller to reduce friction between the drill and the hole during drilling operation. The dead center of a drill is the sharp edge at the extreme tip end of the drill. 15It is formed by the intersection of the cone-shaped surfaces of the point and should always be the exact center of the axis of the drill. 16The point of the drill should not be confused with the dead center. 17The point is the entire cone-shaped surface at the end of the drill. 18It consists of the chisel edge, lips, lip clearance, and heel. 19The lip or cutting edge of a drill is that part of the point that actually cuts away the metal when drilling a hole. 20It is ordinarily as sharp as the edge of a knife. 21There is a cutting edge for each flute of the drill. The shank is the part of the drill that fits into the socket, spindle, or chuck of the drill press. 23Generally drills up to in. in diameter usually have tapered shanks. 24 Straight-shank drills are held in a drill chuck while taperedshank drills fit into the internal taper of the drill press spindle. 25 Types of drill shanks can be seen in fig. 2. Figure 1. Parts of a twist drill
22 14 5 1
CHISEL EDGE
HEEL
Figure 2. Types of drill shanks 85
1.
The topic of the reading is a. Twist drills. b. Flutes. c. End-cutting tools. d. Cutting-edges.
2.
Another name for helical grooves is a. Standard drills. b. Twist drills. c. Flutes. d. None of the above.
3.
Complete the map below with the main parts of a twist drill.
TWIST DRILL
4. The flutes a. Allow the chips to escape from the hole. b. Admit cutting fluid. c. Form the cutting edges. d. All of the above.
5. The narrow raised section immediately next to the flutes is the a. Flutes. b. Margin. c. Drill body. d. Cutting edges.
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6. It in sentence 7 refers to the a. Body. b. Point. 7. The main pattern of organization in paragraph 2 is a. Comparison and Contrast. b. Definition and Description. 8. The topic of paragraph 3 is the a. Tip end of the drill. b. Sharp edge. c. Point of the drill. d. Dead center. c. Cause and Effect. d. List of Items. c. Shank. d. Number of parts.
9. Tapered-shank drills a. Are used with drills up to in. in diameter. b. Fit into the internal taper of the drill press spindle. c. Are held in a drill chuck. d. Both (a) and (b).
10. Identify the type of drill shank by writing the name under the picture.
a. ____________________
b. ____________________
c. ____________________
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UNIT 9
STUDENT HANDOUT
H9:3
Read pages 311-331 in your textbook and answer the questions below.
A.
Complete the table below with the type of drill or its purpose.
TYPE OF DRILL 1. 2. low-helix drill 3. 4. core drill 5. 6. straight-fluted drill 7. 8. saw -type hole cutter 9. 10. step drill Drills hardened steel.
PURPOSE Performs well on a wide variety of materials, equipment, and job conditions by varying the point angle and the speeds and feeds used. Drills deep holes in aluminum, copper, die-cast material, and other metals where the chips have a tendency to jam in a hole. Used on turret lathes and screw machines.
Produces holes from approximately to 3 in. in diameter and as deep as 20 ft.
B.
Write the type of drill from the box below under the correct picture. high-helix drill spade drill core drill step drill gun drill low-helix drill oil hole drill straight-fluted drill
1. ________________
2. ________________
3. _______________
4. _________________
5. ________________
6. ________________
7. ______________
8. _______________
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C. Look at Table 41.1 on page 321 and answer the questions. 1. How many steel drills are being compared? Name them.
2. What is the cutting speed in feet per minute for a steel casting drill with a in. drill size?
3. What is the drill size for a machine steel drill with a speed of 3,055 feet per minute?
D. Mark the statement true [T] or false [F]. 1. ____ The larger the drill size the faster the cutting speeds per minute. 2. ____ Cutting speeds for brass and aluminum steel drills are faster than machine steel drills. 3. ____ Cutting speeds of 490 ft/min with a in. drill is used for steel casting drills. 4. ____ All of the cutting speeds are different for high-speed drills using the same drill size. 5. ____ The slower the cutting speed the larger the drill size.
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STUDENT HANDOUT
H9:4
Study the following words and read a description of reamer parts on page 332 of your text. Then complete the sentences below.
Reamers generally consist of three main parts: [1] and angle of chamfer. The shank, which may be [3] is used to drive the [5] helical grooves, or [6] A [8] end of the flute. The body [10] and [7] (the top of each tooth) runs from the angle of [9]
, [2] or [4] (the portion between the flutes). to the angle is the angle formed by
. The body of the reamer contains several straight or
angle is a relief or clearance behind the margin that
reduces friction while the reamer is cutting. The [11] reamer. The [12]
the face of the tooth when a line is drawn from a point on the front marginal end through the center of the is the part of the reamer that actually does the cutting.
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STUDENT HANDOUT
H9:5
Reaming A. Read the following paragraphs.

1
A reamer or ream is a tool for enlarging holes and is used in metalworking. 2It may be used as a hand tool or may have a specialized drive end. 3For production machine tools the drive will usually be a standard taper. 4For hand tools the drive will usually be a square drive, intended for use with the same type of wrench used to turn a tap for the cutting of threads.
5
A typical reamer consists of a set of parallel straight or helical cutting edges along the length of a cylindrical body. 6Each cutting edge is ground at a slight angle and with a slight undercut below the cutting edge. 7Reamers must combine both hardness in the cutting edges, for long life, and toughness, so that the tool does not fail under the normal forces of use. 8They should only be used to remove small amounts of material. 9This ensures a long life for the reamer and a superior finish to the hole. 10Because of the delicate nature of the operation and since little material is removed, reaming can be done by hand. 11 Reaming is most accurate for axially symmetric parts produced and reamed on a lathe.
12 13
Reaming is a process which slightly enlarges a pre-existing hole to a tightly toleranced diameter. A reamer is similar to a mill bit in that it has several cutting edges arranged around a central shaft, as shown in Figure 1.
Figure 1
14
Reamed holes should not intersect with drilled holes, so the configuration in Figure 2 should NOT be implemented:
Figure 2
Reaming should not be relied upon to correct the location or alignment of a hole. 16Its primary purpose is to fine-tune the diameter of the hole. 17As with a drilled hole, clearance for chips is needed at the bottom of a reamed hole. 18This is illustrated in Figure 3:
15
Figure 3 Source: efunda, Engineering Fundamentals, http://www.efunda.com/processes/machining/drill_ream.cfm
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B. Read the questions and choose the correct answer. 1. It in sentence 2 refers to a. Tool. b. Metalworking. 2. A reamer is a. Only used as a hand tool. b. Only used as a machine tool. 3. A standard taper drive is used for a. A machine tool. b. A hand tool. 4. The drive for a hand tool reamer is a a. A wrench. b. A tap. 5. c. A square drive. d. Threads. c. Both [a] and [b]. d. Neither [a] nor [b]. c. Used as both a hand and machine tool. d. None of the above. c. Drive end. d. Reamer.
A wrench used to turn a tap for the cutting of threads a. b. c. d. Cannot be used with a square drive reamer. Is the same type as that used with a square drive reamer. Is a machine tool. None of the above.
6.
Paragraph 2 a. Compares reamers. b. Contrasts reamers. c. Describes reamers. d. Classifies reamers.
7.
The pattern of organization in the sentence, Reamers must combine both hardness in the cutting edges, for long life, and toughness, so that the tool does not fail under the normal forces of use. is a. Classification. b. Time Order. c. Comparison and contrast. d. Cause and effect.
8.
This in sentence 9 refers to a. b. c. d. Ensuring a long life for the reamer and a superior finish to the hole. Reamers only being used to remove small amounts of material. Reamers combining hardness in the cutting edges. Reamers not failing under the normal forces of use.
9.
Reaming can be done by hand because a. The nature of the operation is delicate. b. Little material is removed. C. Both [a] and [b]. D. Neither [a] not [b].
10.
The primary purpose of reaming is a. To correct the location of a hole. b. To correct the alignment of a hole. c. To fine-tune the diameter of the hole. d. All of the above.
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UNIT 9
STUDENT HANDOUT
H9:6
Read pages 332 to 344 in your textbook and answer the questions below. A. Label the parts of a reamer.
1 4 3
B. Identify the reamer by writing the type under the picture.
1. _________________
2. ______________________
3. ____________________
4. __________________
5. _________________________
6. _____________________
C. What is the topic of Unit 44?
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D.
Match the drill press operation descriptions to the pictures.
1. [
2. [
3. [
4. [
a. Spot Facing - Allows the head of a bolt to be sunk beneath the surface. b. Tapping can be used to add threads to holes c. Counterboring - Allows the head of cap screws to be sunk beneath a surface d. Countersinking - Allows counter sunk head screws to be sunk beneath a surface.
E.
Identify the taps below by writing the name next to the picture.
1. 2.
3.
4.
5.
6.
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Unit 10
The Lathe
Objectives: Given topics on the lathe; texts that are varied and of a specialized and technical nature which include information presented from other sources (e.g., photographs, drawings, reference text/ research information, diagrams), the participant will use English with 70% accuracy to: Identify factual details and specifications within text. Follow sequential directions to complete a task. Identify and pronounce correctly the major parts of the engine lathe. Identify the names of a variety of lathe cutting tools and name the parts of a toolbit. Identify and pronounce correctly the names of some important work-holding devices for the lathe. Identify and describe some common lathe operations. Label the parts of a screw thread.
95
STUDENT HANDOUT
H10:1
Study the diagram and parts of a lathe and complete the sentences.
1. 2. 3.
apron bed carriage
The ___________________ is fastened to the saddle and houses the gears and mechanism required to move the carriage and cross-slide automatically. The _____________________ is usually made of cast iron. It provides a heavy rigid frame on which all the main components are mounted. The ______________ consists of three main parts: the saddle, cross-slide, and apron. It is used for mounting and moving most of the cutting tools along the lathe bed.. The _______________________ is a 3-jaw (self centering) or 4-jaw (independent) device used to clamp the part being machined. The _______________________ is mounted to the cross slide. It is used to support the cutting tool. The _________________________ is mounted on the traverse slide of the carriage, and uses a handwheel to feed tools into the workpiece.
4. 5. 6.
chuck compound rest cross slide
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7. 8. 9.
feed reverse lever feed rod follow rest
The _______________________ is mounted on the headstock and reverses the rotation of the feed rod and lead screw. The ____________________ advances the carriage for turning operations when the automatic feed lever is engaged. The __________________ is bolted to the lathe carriage. It uses adjustable fingers to bear against the workpiece opposite the cutting tool to prevent deflection. The ______________________ is inside the headstock, providing multiple speeds with a geometric ratio by moving levers. The ________________________ is mounted in a fixed position on the inner ways, usually at the left end. Using a chuck, it rotates the work. The ___________________________ is used for cutting threads. The _________________________________ contains a number of different-size gears and provides the feed rod and lead screw with various speeds for turning and thread cutting operations. The _____________ is an H-shaped casting mounted on the top of the lathe ways and provides a means of mounting the cross-slide and the apron. The ______________________ is the hole through the headstock to which bar stock can be fed. The _______________________ is when closed around the lead screw, the carriage is driven along by direct drive without using a clutch. The _______________ is clamped to the lathe ways. It uses adjustable fingers to contact the workpiece and align it. It can be used in place of tailstock to support long or unstable parts being machined. The ________________fits on the inner ways of the bed and can slide towards any position on the headstock to fit the length of the work piece. An optional taper turning attachment would be mounted to it. The ________________ has a Morse taper to hold a lathe center, drill bit or other tool. The _________ is used to mount tool holders in which the cutting bits are clamped. The are inner and outer guide rails that are precision machined parallel to assure accuracy of movement.
10. gearbox 11. headstock 12. lead screw 13. quick change gearbox 14. saddle
15. spindle 16. split nut 17. steady rest
18. tailstock
19. tailstock quill 20. tool post 21. ways
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STUDENT HANDOUT
H10:2
The Engine Lathe A. Read the following paragraphs. The lathe is a machine tool used principally for shaping round metal (or other materials). 2It causes the workpiece to be held and rotated by the lathe while a carbide tool bit is advanced into the work causing a cutting action. 3The basic parts of an engine lathe are; the headstock, spindle, tail stock, quill, ways, bed, carriage, apron, saddle, cross slide, compound slide, tool post, feed rod, and lead screw. The spindle rotates in both directions. 5The tail stock can be positioned along the ways and the quill moves within the tail stock. 6The carriage also moves along the ways. 7The cross slide moves perpendicular to the ways. 8The compound slide moves at any preset angle over the saddle. 9The lead screw and feed rod also rotate and are reserved for certain automatic functions. To keep some of the mechanisms moving longitudinally straight and true, ways are machined on the top surface of the bed. 11Ways are ground and often hardened . 12They can be shaped like an inverted "V", flat, or other shapes that the manufacturer decides to use. 13The carriage and tail stock mechanisms are aligned on the ways.
14 10 4 1
Modern machines are called gear-head lathes because the entire system of speed and feed adjustments are gears just like the transmission of an automobile. 15The headstock contains the heart of the lathe and includes the motor and gear train. 16The motor is normally below the headstock and connected by a belt or gears to the spindle and lead screws. 17The spindle of the lathe has many attachments which facilitate turning, boring, facing, etc.
The carriage is a combination of five main parts; the saddle, the cross-slide, the apron, the compound rest and the tool rest. 19The purpose of this combination is to hold a cutting tool securely while at the same time moving it (feeding) to whatever position is necessary to machine the work piece. 20The apron is the front vertical face of the carriage. 21It is a covering plate or a casting that houses gears, clutches and levers. 22The apron has an autofeed knob, a shift-feed knob, and a threading nut engagement handle. The tail stock and the headstock are opposite one another and in normal conditions are aligned on the same center. 24For cutting a taper the tail stock can be adjusted off center. 25The tail stock is positioned behind the carriage and mounted on the same ways as the saddle. 26It can be locked in any position on the ways (figure 1). 27There are two units to a tail stock; the base and the head (figure 2). 28To set the tail stock on or off center, there are offsetting adjusting screws on the base. 29The head consists of the quill (ram or spindle are also names used), quill lock, hand wheel, and a clamp lever or nut. 30A clamp lever or nut is used to tighten the tail stock in position on the ways (the longer handle in figure 1 is the clamp lever that pulls upward against the clamp barely visible below the tail stock in figure 3.). 31The quill has a standard Morse internal taper for holding a center, Jacobs chuck or any other tool that has a standard external Morse taper (figure 4).
23
18
Figure 1
Figure 2
Figure 3
Figure 4
Source: Virtual Machine Shop, http://www.jjjtrain.com/vms/lathe_functions.html
98
B. Read the questions and choose the correct answer. 1. It in sentence 2 refers to: a. Lathe. b. Metal. 2. The pattern of organization in sentences 1 and 2 is: a. Comparison and contrast. b. Classification. 3. The pattern of organization in sentence 3 is: a. Comparison and contrast. b. Classification. 4. The following parts move along the ways: a. The tail stock. b. The carriage. c. The cross slide. d. Both (a) and (b). c. Cause and effect. d. List of items. c. Cause and effect. d. List of items. c. Workpiece. d. Tool bit.
5. The effect of machining ways on the top surface of the bed is: a. To keep some of the mechanisms moving longitudinally straight. b. To ground and harden ways. c. Both (a) and (b). d. Neither (a) nor (b).
6. Modern lathe machines are compared to an automobile in sentence 14 because a. They are called gear-head lathes. b. Their system of speed and feed adjustments are gears. 7. The topic of paragraph 5 is the: a. Carriage. b. Cross-slide. 8. This combination in sentence 19 refers to a. Holding a cutting tool securely. b. The five main parts of the carriage. 9. Which of the following statements are true? a. b. c. d. The tail stock and headstock are mounted on the same ways. The tail stock and the saddle are aligned on the same center. The tail stock is composed of a base and a head. All of the above. c. Feeding the cutting tool. d. Machining the wokpiece. c. Saddle. d. Apron. c. They have transmissions. d. They have speed.
10. Ram is another name for a. Quill. b. Spindle. c. Head. d. Both (a) and (b).
99
UNIT 10
STUDENT HANDOUT
H10:3
Read pages 347-396 in your textbook and answer the questions below. A. Look at Figure 45-2 on page 352 and label the parts of the lathe. 13 14 1
11 10
12
2 3
4 9 8 7 6 5
1. 2. 3. 4. 5. 6. 7. 8. 9. 10. 11. 12. 13. 14.
100
B. Match the picture to the name of the lathe accessory. a. four-jaw chuck b. steadyrest c. lathe center d. revolving tailstock center e. lathe dog f. boring tools g. cam-lock spindle nose h. tool holders i. three-jaw chuck j. mandrel k. follower rest l. toolpost
1. [
2. [
3. [
4. [
5. [
6. [
7. [
8. [
9. [ ]
10. [
] 11. [ ]
12. [
101
STUDENT HANDOUT
H10:4
A. Study the following words and complete the sentences. 1. crest The ________________ is the top surface joining two sides of a thread. 2. depth The _________ is the distance between the crest and root measured perpendicular to the axis.
3. form turning 4. grooving
_________________ is a lathe operation that forms irregular shapes or contours on a workpiece. ______________ is a lathe operation done at the end of a thread to permit full travel of the nut up to a shoulder or at the edge of a shoulder to ensure a proper fit of mating parts. ______________ is a lathe operation that impresses a diamondshaped or straight-line pattern into the surface of the workpiece to improve its appearance or to provide a better gripping surface. The ________ is the distance a screw thread advances axially in one revolution.
5. knurling
6. lead 7. pitch
The __________ is the distance from a point on one thread to a corresponding point on the next thread, measured parallel to the axis. 8. root The ______________ is the bottom surface joining the sides of two adjacent threads.
9. taper A ____________ is a uniform change in the diameter of a workpiece measured along its axis.
10. thread
A _________ is a helical ridge of uniform section formed on the inside or outside of a cylinder or cone.
102
STUDENT HANDOUT
H10:5
Knurling and Grooving A. Read the following paragraphs.
Knurling Knurling is a manufacturing process that is typically conducted on a lathe. 2In this process, a visuallyattractive diamond-shaped pattern is cut or rolled into metal. 3This pattern allows human hands or fingers to get a better grip on the knurled object than would be provided by the originally-smooth metal surface. 4 Occasionally, the knurled pattern is a series of straight ridges or a helix of "straight" ridges rather than the more-usual diamond-shaped pattern. 5The two-wheel inserts shown on the tool below (figure 1) contact the work piece, and with pressure, cold-form a pattern into the surface of the part.
1
Knurling may also be used as a repair method. 7Because a rolled-in knurled surface has raised-up areas surrounding the depressed areas, these raised areas can make up for wear on the part. 8Knurling can also be used when a high precision component will be assembled into a low precision component. 9For example, when a metal pin is assembled into a plastic molding.
10
Figure 1
On the lathe, knurl cutting is usually accomplished using the same automatic-feed mechanisms that are used to cut screw threads. 11Knurling can be thought of as simply a series of threads cut at extremely coarse pitch and in both the left-hand and right-hand directions. Grooving
12
Grooving and other form cutting is one of the more complicated operations performed on the engine lathe. 13The cutting of grooves often requires high levels of precision, and a "feel" for the machine. 14 Although theory dictates a method of selection of the correct speed and feed, sometimes practice and experience will make the job much easier. A groove is the location of an indentation in the part. 16This indentation can be square, round or angular in the shape (figure 2). 17 The function of a groove is usually to allow room for a fitting part, such as a rubber O-ring.18It could also be the place where another part fits into this part. 19Grooves also provide a relief in the back side of a thread where the thread finishes. Grooving is most often a precision operation, requiring a high degree of accuracy with low tolerances. 21To guarantee this level of accuracy, a procedure will be developed using a rough out, semi-finish, and finish. 22A tool should be selected based on the lathe, material, and precision of the groove.
20 15
Figure 2
Sources: Wikipedia, the free encyclopedia http://en.wikipedia.org/wiki/Knurling Virtual Machine Shop http://www.jjjtrain.com/vms/lathe_grooving.html
103
B. Read the questions and choose the correct answer. 1. Knurling and grooving are a. Lathes. b. Diamond-shaped patterns. 2. Knurling is used a. To get a better grip on the object. b. To assemble a metal pin into a plastic molding. 3. This pattern in sentence 3 refers to a. Human hands and fingers. b. Diamond-shaped pattern. 4. A knurled pattern is a. Diamond-shaped. b. A helix of straight ridges. 5. The topic of paragraphs 4-6 is a. Form cutting. b. Functions of groves. 6. The main pattern of organization in paragraph 2 is a. Classification. b. Comparison and contrast. 7. The function of a groove is to a. Allow room for a fitting part. b. Allow another part to fit into it. 8. The pattern of organization in sentence 7 is a. Cause and effect. b. Definition and example. c. Comparison and contrast. d. Time order. c. Provide a relief in the back side of a thread. d. All of the above. c. Addition. d. Time order. c. Precision operations. d. Grooving. c. A series of straight-ridges. d. All of the above. c. Knurled object. d. Metal Surface. c. As a repair method. d. All of the above. c. Engine lathe operations. d. Screw threads.
9. The method of selection of the correct speed and feed for cutting grooves is determined by a. Theory. b. Practice. 10. Grooving a. Is not a complicated operation. b. Is a repair method. c. Is not a precision operation. d. Requires a high degree of accuracy. 104 c. Experience. d. All of the above.
UNIT 10
STUDENT HANDOUT
H10:6
Read pages 397-460 in your textbook and answer the questions below. A. Read Table 54.1 on page 406 and answer the following questions. 1. Classify self-holding tapers
Self-Holding Tapers
2.
Look at the diagram below and label the parts.
A D P 3. What is the diameter at gage line for a number 4 Morse taper? 4. What is the taper per foot for a number 2 Brown and Sharpe taper? 5. What is the diameter at small end for a number 350 in. tpf taper? 6. What is the length of a number 1 Morse taper? 7. What is the taper number and series for a taper with the following dimensions: .502 taper per foot, .3752 diameter at gage line, .3125 diameter at small end, and 1 length? Taper number: Taper series:
105
B.
Read page 418 and label the parts of a screw thread.
1 2 7 6 4 3
1. 2. 3. 4. 5. 6. 7.
C.
The pattern of organization on page 441 for the section To Turn Work on a Mandrel is a. Time order: process. b. Time order: dates and events. c. Comparison and contrast. d. Cause and effect.
D.
Identify the types of spindle noses below. Write the name under the picture.
1.
2.
3. 106
Unit 11
Vertical Milling Machines
Objectives: Given topics on vertical milling machines; texts that are varied and of a specialized and technical nature which include information presented from other sources (e.g., photographs, drawings, reference text/ research information, diagrams), the participant will use English with 70% accuracy to: Identify and pronounce correctly the parts of the vertical milling machine. Identify and pronounce correctly the parts of the rotary table. Recognize task-related words with technical meanings. Classify the most common vertical milling machining operations. Match the tool and accessory to the picture.
107
STUDENT HANDOUT
H11:1
A. Study the diagram of a vertical milling machine and complete the sentences.
1. base 2. column 3. cross traverse hand wheel 4. head 5. knee 6. longitudinal traverse hand wheel 7. motor 8. overarm 9. quill 10. quill feed hand wheel 11. spindle 12. turret 13. vertical movement crank
The ________________is the part of a vertical mill that is made of ribbed cast iron. It may contain a coolant reservoir. The ______________ is the part of a vertical mill that holds the turret. The ___________________moves the work table in and out The __________, or drive, is that part of the drive system that transforms electrical power from a motor to mechanical power in the spindle. The ___________ moves up and down by sliding on ways that are parallel to the column and supports the saddle and table. The _______________________________________________ moves the worktable to the left and right. The ___________ is mounted on top of the head and provides drive to the spindle, usually through V-belts. The __________, or ram, slides on the turret and allows the milling head to be repositioned over the table. The ______________moves vertically in the head and contains the spindle. The ______________________________ moves the quill up and down within the head as does the quill feed lever. The ______________ is that part of the mill in which cutting tools are installed. The __________________ allows the milling head to be rotated around the columns center. The __________________________________moves the knee, saddle, and worktable up and down in unison. 108
STUDENT HANDOUT
H11:2
Parts of the Vertical Mill Head A. Read the following paragraphs. The vertical mill head has various parts. 2The motor reversing switch is a three position forward-reverse-off switch for the motor. 3There will be many cases when you will have to change the rotational direction of the spindle, so it is imperative that you know which position is forward, reverse and off. 5Off is almost always straight up. Not all machines have a main power switch like the one shown in the photo. 6With the main power off the motor reversing switch has no function. 7The brake is used to halt rotation of the spindle after powering off. 8Make sure the brake is properly adjusted so it does not apply braking friction during normal operation. 9The quill feed selector allows the operator to select (typically) between three feeds that will give the quill a controlled upward or downward movement. 10The values of these three feeds are usually found on a nameplate located next to the quill feed selector. The micrometer adjusting nut sets the maximum depth for quill feed. 12The feed reversing knob sets the direction of the feed. 13If it is pulled out, it usually sets a down feed. 14If it is pushed in, it usually sets an up feed. 15A neutral position in between is no feed. 16When not in use this knob should be in the middle position where no movement will occur. 17The feed control lever is a pressure sensitive clutch which engages the feed operation. 18The quill stop travels with the quill and when it reaches the hard stop of the micrometer adjusting nut the pressure kicks the feed control lever out, thus stopping the feed. 19 The quill lock clamps the quill in position and eliminates some vibration. 20The draw bar is used to attach tooling to the spindle. The transmission engagement crank is the primary shift lever for this mechanical operation. 22This lever must be engaged or quill feed will not be possible. 23It is a good idea to return this crank to its neutral position once the job is completed to avoid unnecessary wear on the internal mechanism. The quill feed handle is used to manually adjust the depth of the quill. 25It can not be used during automatic quill feed. 26 The back gear (speed range lever) adjusts the range of the spindle speed between high RPM and low RPM. 27 In effect, the use of the back gear doubles the number of available spindle speeds. 28It is often necessary to rotate the spindle a few degrees by hand to get the back gear to lock into position. Caution: changing the back gear position reverses the rotation of the spindle! 30Use your motor reversing switch accordingly.
29 24 21 11 1
Source: Virtual Machine Shop, http://www.jjjtrain.com/vms/mill_vert_head.html#top
109
B. Read the questions and choose the correct answer. 1. The topic sentence of the reading is: a. Parts of the vertical mill head. b. The motor reversing switch. 2. The main pattern of organization in the reading is: a. Comparison and contrast. b. Definition and explanation. 3. Match the part to the definition or explanation. 1. 2. 3. 4. 5. 6. 7. 8. 9. 10. 11. 12. Brake Motor reversing switch Quill feed handle Transmission engagement crank Quill lock Feed reversing knob Draw Bar Quill feed selector Back gear Feed control lever Quill stop Micrometer adjusting nut [ [ [ [ [ [ [ [ [ [ [ [ ] ] ] ] ] ] ] ] ] ] ] ] A pressure sensitive clutch which engages the feed operation. Sets the direction of the feed. Used to attach tolling to the spindle. Used to halt rotation of the spindle after powering off. Stops the feed. Clamps the quill in position. Used to manually adjust the depth of the quill. Adjusts the range of the spindle speed between high RPM and low RPM. Sets the maximum depth for quill feed. The primary shift lever. A three position forward-reverse-off switch for the motor. Allows the operator to select between three feeds that gives the quill a controlled upward or downward movement. c. Cause and effect. d. Time order: process. c. The vertical mill head has various parts. d. All of the above.
4. The pattern of organization in sentence 3 is a. Definition. b. Cause and effect. 5. It in sentence 13 refers to a. The direction. b. The feed. 6. The effect of pulling out the feed reversing knob is a. A down feed is set. b. No feed is set. 7. The cause of setting an up feed is a. The feed reversing knob is pulled out. b. The feed reversing knob is pushed in. c. The feed reversing knob is neutral. d. The feed position knob is in the position. c. An up feed is set. d. No movement will occur. c. The feed reversing knob. d. None of the above. c. Classification. d. Time order: process.
8. Why is it a good idea to return the transmission engagement crank to its neutral position once the job is completed? 9. What is another name for the back gear? 10. Which sentences give a warning? 110
UNIT 11
STUDENT HANDOUT
H11:3
A. Label the parts of the vertical milling machine.
13 2 3 12 4
11 10 9
7 6
1. 2. 3. 4. 5. 6. 7. 8. 9. 10. 11. 12. 13. 111
B. Read Parts of the Ram-Type Vertical Mill on pages 465-466 in your textbook and the vocabulary list above to complete the sentences. The [1] (drive) is that part of the drive system that transforms electrical power from a [2] to mechanical power in the [3] . The drive system also allows the machinist to change the speed of the spindle (RPM) and therefore the cutting tool. The [4] moves vertically in the head and contains the spindle in which cutting tools are installed. The [5] moves the quill up and down within the head as does the [6] . The [7] moves up and down by sliding on ways that are parallel to the [8] . The [9] _______________sits on the knee and allows translation of the [10] _____________. Sitting on the base is the column whose main function is to hold the [11] . The turret allows the milling head to be rotated around the column's center. The [12] (ram) slides on the turret and allows the milling head to be repositioned over the table. The [13] moves the worktable to the left and right, the [14] moves the work table in and out, the [15] moves the knee, saddle, and worktable up and down in unison. C. Read Table 60.1 Milling Machine Cutting Speeds on page 468 and answer the questions. 1. Using a high-speed steel cutter, what is the cutting speed range in feet per minute for aluminum? 2. If you are using a carbide cutter that cuts within a range of 100-300 feet per minute, what metal are you cutting?
D. Classify the most common vertical milling machining operations.
Vertical Milling Operations
112
STUDENT HANDOUT
H11:4
A. Study the following words and complete the sentences. 1. boring head A __________________ is a cutting tool placed in a cutter head to dress round holes. 2. collet A ______________ is a cone-shaped sleeve used for holding circular or rod-like pieces in a lathe or other machine.
3. drill chuck
A _______________ is a holding device used to hold and drive straightshank cutting tools.
4. end mill An ________________ is a milling cutter with straight or tapered shanks that can cut both on the sides and on the end.
5. fly cutter A _______________________ is a unit holding two or more replaceable cutting tools that is used for milling large, flat surfaces.
6. keyseat A ________________ is a cutter that makes a recessed groove or slot machined into a shaft or part going on the shaft, usually a wheel or gear.
7. PCBN 8. shell mill
__________________ is an acronym for Polycrystalline Cubic Boron Nitride. It is a crystalline body of many small crystals randomly oriented to form a material for cutting hard ferrous metals. A ____________________ is a type of milling cutter that has cutting edges around its periphery and can be mounted on an arbor.
9. T-slot cutter A _____________________ is a cutting tool used to machine T-slot grooves in worktables, fixtures, and other holding devices. 10. Woodruff key A ____________ key is a semi-circular or half-round piece, resting in a circular groove cut in a shaft. These cutters are used for milling semicylindrical keyways in shafts.
113
STUDENT HANDOUT
H11:5
So You Got a Mill, Now What?

A. Read the following paragraphs. One of the problems beginners have when they get a new mill is learning about what accessories are needed and how they are used. 2This article is meant to be an introduction to the use of a vertical mill and what tooling the beginner should start out with. The primary piece of tooling every mill ought to have is a good milling vise. 4The vise of choice today is the "Kurt" type. 5Import vises purchased from local dealers such as Rutland and J&L are good deals. 6 Another handy item is a Clamping Kit. 7This is an assortment of "T" nuts, studs, nuts, step blocks, and step clamps. 8 Be sure to measure the "T" slot in your milling table before buying the kit. 9Most mill drills can use the Bridgeport size, but the "T" nuts must be ground a little thinner to get them to slide in the slots. As for any other metal working operation, calipers and micrometers are indispensable. 11For the mill, you should also have two or three dial indicators with at least 1" travel. 12These can be used for precise movements on the X or Y, and precise depth control. 13Another device, that is very useful for center indicating and setting the vise true, is the test indicator. 14Edge finders are used to quickly find the edge of the work-piece. 15I use an edge finder with a diameter of .200". 16The shank is .375" in diameter and can be held in a chuck or collet. The ideal situation is to have three drill chucks. 18One very small chuck, 0 to 0.187", for fine work; a high precision chuck from 0 to 3/8" for general work; and a large, maybe 1/8" to 5/8", for the bigger work. 19 Good chucks use a Jacobs taper on the back of the chuck. 20This is used with an adapter for conversion to a straight shank, Morse taper, or R8 taper. I use collets for holding end-mills. 22There is quite a bit of controversy on this matter. 23The problem has been with end-mills being "pulled" from the collet because of the lift forces of the flutes of the end-mill. 24 This can cause you to damage the work-piece, vise, end-mill, table, or all of the above. 25I have found that if you use a good quality collet, and tighten it properly, you will not have a problem. 26This allows you to keep the head closer to the work, and speeds up tool changing quite a bit. 27Buy high quality collets in the following sizes: 3/16", 1/4", 3/8", 1/2", 5/8", and 3/4". 28These are the sizes used by standard endmills. 29Collets can also be used to hold drill bits. 30The drill bit should be within 1/64" of the collet you plan to use. End-mills come in single and double ended, two or four flute, and center cutting or not center cutting. For aluminum, and milling slots in steel, use a two flute end-mill. 33For general milling of steel, and finish cuts on aluminum, four flute end-mills are best. 34Two flute end-mills are generally center cutting. 35This means that they can be plunged into the work. 36 Four flute end-mills can be purchased either way. 37Ballnose end-mills are also available, buy these as requirements arise. 38The same can be said for the Woodruff keyway cutters. 39Buy them as you run across the need.
32 31 21 17 10 3 1
Fly cutters can be used to mill large areas very flat. 42Make sure your mill is "Trammed-In" properly. The fly cutters will really show-off a mill where the spindle is not dead-on perpendicular to the table. 44 With a boring head you can make any size hole (within the confines of the boring head and cutter) you desire. 45Boring heads can also be used to trepan (fly cut) large holes in panels. 46To cut slots you can use saw-blade type cutters in the mill. 47There are two basic types: Jewelers saws, which use a small diameter arbor and have fine teeth, and Slitting saws that have course teeth and larger diameters.
43
41
I hope this little article has helped you sort out what tooling you may need for your new machine. 49Much of your needs will be defined by the type of work you plan to do. 50Tooling a lathe or mill is an ongoing process.
Source: George Carlson, Journal of the Home Metal Shop Club of Houston, Texas, http://www.homemetalshopclub.org/news/may98/may98.html#Mill,
48
114
1. The topic sentence of this paragraph is a. The title. b. Sentence 1. c. Sentence 2. d. Sentence 3.
2. According to the author, the most important tool for milling is a. A vertical mill. b. Studs. 3. Handy in sentence 6 means a. Using the hands. b. Clamping kit. 4. Indispensable in sentence 10 means a. Crucial. b. Necessary. 5. The topic of paragraph 5 is a. Collets. b. End-mills. 6. The pattern of organization in paragraph 5 is a. A list of items. b. Time order: process. c. Time order: dates and events. d. Cause and effect. c. Flutes. d. Lift forces. c. Essential. d. All of the above. c. At hand. d. Useful. c. T-nuts. d. A milling vise.
7. According to the author, what tools should be bought as needed? a. Woodruff keyway cutters. b. Ball-nose end-mills. c. Four-flute end-mills. d. Both (a) and (b).
8. The main pattern of organization in this reading is a. A list of items. b. Time order: process. c. Time order: dates and events. d. Cause and effect.
9.. The authors purpose in writing this article is to a. b. c. d. Inform the reader what tools you need when you first start to use a vertical mill. Persuade the reader to buy a vertical mill. Entertain the reader about buying tools for a metal working operation. None of the above.
10. On this matter in sentence 22 refers to a. Quite a bit of controversy. b. Using collets for holding end mills. c. Both (a) and (b). d. Neither (a) nor (b).
115
UNIT 11
STUDENT HANDOUT
H11:6
Read pages 482-505 in your textbook and answer the questions below. A. Match the tool and accessory to the picture. 1. fly cutter 2. end mills 3. Woodruff key 4. boring head 5. vise 6. shell mill 7. keyseats 8. boring chuck 9. collet 10. slitting saw 11. drill chuck 12. T-slot cutters
[ ]
[ ]
[ ]
[ ]
[ ]
[ ]
[ ]
[ ]
[ ]
[ ]
[ ]
[ ]
B.
Read the description of the rotary table on page 498 and label the parts.
1 2
7 6 5 1. 2. 3. 4. 5. 6. 7.
116
Unit 12
Horizontal Milling Machines
Objectives: Given topics on horizontal milling machines, the indexing head, gears, and the jig borer and jig grinder; texts that are varied and of a specialized and technical nature which include information presented from other sources (e.g., photographs, drawings, reference text/ research information, diagrams), the participant will use English with 70% accuracy to: Identify and pronounce correctly the important parts of the horizontal milling machine. Identify and pronounce correctly the index head parts. Identify and pronounce correctly the main parts of a jig borer. Identify the main idea and supporting details by outlining a reading.
117
STUDENT HANDOUT
H12:1
A. Study the following words and complete the sentences.
1. arbor support
The __________________ is the part of the milling machine that aligns and supports various arbors and attachments. The _________________ is the part of the milling machine that gives support and rigidity to the machine and acts as a reservoir for the cutting fluids. The ___________________ is a precision-machined and scraped section used to support and guide the knee when it is moved vertically. The ______________________________________ is the part of the machine used to move the table toward or away from the column. The ____________________________ is the part of the machine that gives an upward or downward movement to the knee and the table. The _______________________ is the part of the machine used to regulate the table feeds. The _____________________ is the part of the machine that houses the feed mechanism. The __________________ is the part of the machine that provides for correct alignment and support of the arbor and various attachments. The ________________is the part of the machine that is fitted on top of the knee and may be moved in or out either manually or automatically. The ________________ is the part of the machine that provides the drive for arbors, cutters, and attachments used on the milling machine. The __________________ is the part of the machine that is set by a crank that is turned to regulate the spindle needle. The ___________________________ is the part of the machine that enables the table to be swiveled 450 to either side of the centerline. The _______________ is the part of the machine that supports the vise and the work. The ____________________ is the part of the machine used to move the table toward or away from the column.
2. base
3. column face 4. crossfeed handwheel 5. elevating screw 6. feed dial 7. knee 8. overarm 9. saddle 10. spindle 11. spindle feed dial 12. swivel table housing 13. table 14. table handwheel
118
STUDENT HANDOUT
H12:2
Parts of the Horizontal Milling Machine A. Read the following paragraphs. The primary difference between the vertical milling machine and the horizontal milling machine is the location of the spindle. 2On a vertical milling machine the spindle is located at 90although the drill work is done on the same plane as the table. Although drill work is performed on horizontal mills, as a rule horizontal milling machines do not have a quill that extends from the spindle for drilling, boring, etc. 4Horizontal mills are able to utilize cutters and attachments that normally would not be practical to use on vertical machines. 5The milling machine with only three table motions is called the Plain Milling Machine. 6In this reading we will examine the main operating parts of this machine.
3 1
The frame and base give support and rigidity to the horizontal milling machine and consist of the reservoir in the base for the cutting fluids. 8The knee is attached to the column and houses the feed mechanisms. 9The column is a precision-finished section that supports and guides the knee when it is moved vertically. 10The saddle is mounted on the knee and is able to be cross fed either manually or under power. 11The table is supported on the saddle and travels on the longitudinally and horizontal plane. 12On some machines the table can be swiveled 45.13The table traverse hand wheel is used to move the table horizontally left and right in front of the column. 14The table cross feed hand wheel is used to move the table toward or away from the column. 15The spindle holds and drives tools such as arbors, cutters, and attachments used on a milling machine. 16The ram overarm holds the arbor support. 17The arbor support holds the arbor in alignment and steady during the machining. 18Revolutions per minute are controlled by the spindle-speed dial.
Source: Virtual Machine Shop, http://www.jjjtrain.com/vms/mill_horizontal.html
119
B. Read the questions and choose the correct answer. 1. The topic of this reading is a. Milling machines. b. Comparing milling machines. 2. The main pattern of organization in the reading is a. Comparison and contrast. b. Description and explanation. 3. The horizontal and the vertical milling machines a. Have spindles. b. Perform drill work. c. Have quills. d. Both (a) and (b). c. Cause and effect. d. Classification. c. Parts of milling machines. d. Horizontal milling machine parts.
4. Match the part of the horizontal milling machine to its use.
PART 1. cross-feed hand wheel 2. overarm 3. column 4. spindle-fee dial 5. spindle 6. reservoir 7. base 8. arbor support 9. traverse hand wheel 10. knee
USE [ ] a. Holds and drives tools and attachments. [ ] b. Moves the table horizontally left and right in front of the column. [ ] c. Gives support and rigidity to the machine. [ ] d. Holds the arbor in alignment and steady during machining. [ ] e. Supports and guides the knee vertically. [ ] f. Houses the feed mechanism. [ ] g. Moves the table toward or away from the column. [ ] h. Controls revolutions per minute. [ ] i. Holds the cutting fluids. [ ] j. Holds the arbor support.
5. What is the source for this reading?
120
UNIT 12
STUDENT HANDOUT
H12:3
Read pages 506-536 in your textbook and answer the questions below. A. Label the parts of the horizontal milling machine. 1 2 3
4 5 6 7 13
12
11 10 1. 2. 3. 4. 5. 6. 7. 9 8. 9. 10. 11. 12. 13.
B. Complete the following outline of Horizontal Milling Operations. Main idea: The wide variety of horizontal milling operations that can be performed depends on the type of machine used, the cutter used, and the attachments and accessories available for the milling machine. 1. Milling a Flat Surface - Machined on a workpiece with a helical milling cutter. 2. Face Milling 3. 4. 5. -
121
STUDENT HANDOUT
H12:4
A. Study the following words and complete the sentences. 1. adjustable center rest The ______________________ is part of the universal dividing head set that prevents long, slender work held between centers from bending. The _______________________ is an attachment for the milling machine that divides the workpiece circumference accurately into any number of divisions.
2.
dividing head
3. 4. 5. 6.
indexing index crank index plates quadrant
______________________ is the process of providing discrete spaces, parts, or angles in a workpiece by using a dividing head. The _______________ is a device consisting of an arm or handle that is connected to an index head used to turn the spindle. ___________________ are plates with circular graduations or holes arranged in circles, each circle with different spacing used for indexing on machines. A __________________ is a machine part that is shaped like a quarter circle.
7. 8.
swiveling block tailstock
_________ is an attachment that enables the headstock to be tilted from 5o below the horizontal position to 10o beyond the vertical position. The ________________ is part of the universal dividing head set used in conjunction with the headstock to support work held between centers or the end of work held in a chuck.
9.
universal chuck A ____________________ is a chuck having jaws which can be moved simultaneously so as to grasp objects of various sizes.
10. worm wheel A ________________ is a type of gear that engages with a worm to greatly reduce rotational speed or to allow higher torque to be transmitted.
122
STUDENT HANDOUT
H12:5
The Indexing Head
A. Read the following paragraphs. Indexing, or dividing, heads have many parts, work holding accessories, and capabilities. 2Many machining situations can be accommodated by the indexing head because of its ability to swivel from horizontal to vertical in angular increments. 3The scale provides the ability to set the desired angle. 4This along with the ability to attach a 4-jaw chuck, 3-jaw chuck, or center with drive dog gives the indexing head the capability to hold objects with a variety of shapes. 5In fact, it is very similar to the engine lathe when you consider the work holding capabilities. Contrasting the Rotary Table with the Indexing Head In may ways the rotary table and indexing head are similar and in others they are quite different. 7Both rotate the part but 1. The rotary table uses angular moves to rotate the part while the indexing head uses turns and holes on an index plate. 9Yes, the indexing head move can be converted to angles or angles can be converted to turns and holes, but turns and holes are the primary method of rotating the part.
10 8 6 1
2.
The rotary table can divide a circle into equal parts but can just as easily make each angular move at a different angle. 11The indexing head is primarily designed to divide a circle into equal parts. 12 Making unequal moves is possible to an extent but is much more difficult. The rotary table uses the built in scales for rotating the part. 14Most include degrees and minutes, while some also include seconds giving the device the ability to make very precise and almost unlimited angular moves. 15The indexing head relies on the index plate for rotating the part. 16With an assortment or index plate or a wide range divider (divides circle into approximately 400,000 divisions) the index plate is also almost unlimited in dividing a circle and also extremely accurate.
13
3.
The primary purpose of the indexing head is to divide a circle into equal number of parts (divisions). Yet, as you index to the next position the choice to make a cut at that location is up to you. 19 If necessary, that location could be left blank (no cut). 20This choice is available at any location. 21In other words, if you did the calculations to divide a circle into 56 equal parts (divisions) say for the purpose of cutting gear teeth, you could cut a tooth at each of the 56 locations, cut a tooth at every other location, cut the first 10 teeth then skip the next 20 teeth and then cut the remaining teeth. 22The possibilities are too numerous to mention. 23The one constant is that the spacing between indexes will remain equal (even when skipping locations).
18
17
Source: Indexing Heads http://instruction.blackhawk.tec.wi.us/CNC/CNC%20Milling%20Applications/learning_plans.htm
123
B. Read the questions and choose the correct answer. 1. The topic of the reading is a. Machining situations. b. The rotary table. 2. This in sentence 4 refers to a. The ability of the scale to set the desired angle. b. The capability to hold objects with a variety of shapes.
c. The indexing head. d. The engine lathe.
c. The ability to attach a center with drive dog. d. All of the above.
3. The capability of the indexing head to hold objects with a variety of shapes is due to a. The ability of the scale to set the desired angle. c. The ability of the indexing head to attach b. The capability of the indexing head to attach a center with the drive dog. a 4-jaw chuck with the drive dog. d. All of the above. 4. Sentence 5 a. Describes the engine lathe. b Contrasts the indexing head and the engine lathe. 5. It in sentence 5 refers to a. Engine lathe. b. The work.
c. Emphasizes the work holding capabilities of the indexing head. d. None of the above.
c. Drive dog. d. Indexing head.
6. The pattern of organization in sentences 6 through 15 is a. Cause and effect. c. Classification. b. Time order: process. d. Comparison and contrast. 7. Both the rotary table and the indexing head a. Make each angular move at a different angle. b. Divide a circle into equal parts. 8. What is the primary purpose of the indexing head?
c. Use angular moves to rotate the part. d. Use the built-in scales for rotating the part.
9. When dividing a circle into equal number of parts, as you index to the next position a. A cut must be made at that location. b. A tooth must be cut at every other location. 10. The pattern of organization in sentence 20 is a. Classification. b. Definition. c. That location must be left blank. d. You can choose to make a cut at that location. c. Illustration. d. Contrast. 124
UNIT 12
STUDENT HANDOUT
H12:6
Read pages 537-593 in your textbook and answer the questions below. A. Label the parts of the universal dividing head set. 8 7 9 10 1 2
6 5 4 6. 7. 8. 9. 10. 3
1. 2. 3. 4. 5. B. Match the term to the description. 1. graduated downfeed dial 2. quill housing 3. graduated dials 4. variable pitch pulley drive 5. rapid feed handwheel 6. spindle 7. friction clutch 8. reference scales 9. adjustable stop for hole depths 10. brake lever
[ ] a. Allow the table to be positioned quickly and accurately. [ ] b. Revolves inside the quill and supplies drive for the cutting tools. [ ] c. Engages or disengages the handfeed of the quill. [ ] d. Allows the spindle to move to a predetermined depth for drilling or boring a hole. [ ] e. Determine the position of the starting or reference point of the job [ ] f. Reads the distance of vertical spindle travel by means of a vernier. [ ] g. Provides the spindle with a variable speed range. [ ] h. Stops the rotation of the spindle. [ ] i. Can be raised or lower to accommodate various sizes of work. [ ] j. Allows the spindle to be raised or lowered rapidly by hand.
125
C.
Label the parts of the jig borer. 1 2 3
4 18 17 16 7 15 14 13 6 5
12
11 9 10
1. 2. 3. 4. 5. 6. 7. 8. 9.
10. 11. 12. 13. 14. 15. 16. 17. 18.
126
Unit 13
Computer Age Machining
Objectives: Given topics on computer-age machining; texts that are varied and of a specialized and technical nature which include information presented from other sources (e.g., photographs, drawings, reference text/ research information, diagrams), the participant will use English with 70% accuracy to: Identify the names and functions of some common parts of a computer. Identify and pronounce correctly vocabulary related to CNC machining. Define CAD and CAM. Fill out a chart with information that a supervisor gives to a new employee. Analyze information from a line graph. Identify the main idea and supporting details by outlining and mapping a reading. Label the parts of a CNC machining center.
127
UNIT 13
STUDENT HANDOUT
H13:1
Vocabulary Development A. Study the following words and complete the sentences. 1. absolute system __________________ is a numerical control system in which all positional dimensions, both input and feedback, are given with reference to a common datum point. ______________contains a program of instructions and commands, which consists of numbers, letters, and other symbols.
2. CNC code
3. Computer Numerical Control [CNC] __________________________________________ is a form of programmable automation in which the machine tool is controlled by a program in computer memory. 4. continuous path positioning ____________________ is a CNC programming method that has the ability to control motions on two or more machine axes simultaneously to keep a constant cutter-work relationship.
5. G-codes
______________ refer to some action occurring on the X, Y, and/or Z axis of a machine tool that cause some movement of the machine table or head. ______________________ is a CNC programming mode in which program dimensions or positions are given from the current point. _______________ are used to turn either ON or OFF different functions that control certain machine tool operations.
6. incremental system
7. M-codes 8. Machining Center
A ________________ is a CNC machine which at one setup is capable of executing such operations as milling, drilling, boring, tapping, reaming and so forth, on one or more faces of the part.
9. Numerical Control [NC]
_____________________ is a form of programmable automation in which the machine tool is controlled by punched tape. ____________________ is a CNC programming method in which any number of programmed points are joined together by straight lines. 128
10. Point-to-point positioning
STUDENT HANDOUT Computer Numerical Control (CNC)
H13:2
A. Read the following paragraphs. Computer Numerical Control (CNC) is the process of having a computer control the operation of a machine. 2This would include the table motions, the spindle speed, and various other machining functions. 3Having the computer control the machine is accomplished by a program that is written using NC code. 4These coded instructions are carefully arranged by using letters (A,B,C,....Z), numbers (1,2,3...9) and symbols(+,-,/...etc.) to create a program. 5These instructions can range from a few lines for a simple part to many thousand of lines for a complex part. 6If the cumulative instructions (program) are written correctly it will provide specific guidance on exactly what functions you want the machine to perform, resulting in the production of a quality part. 7On the other hand, a poorly written program can have disastrous results... scraping parts, destroying tools, and possibly damaging the machine. 8In extreme cases the operator's own personal safety may be in jeopardy. The NC codes are the "language" that is recognized and understood by the computer controlling the machine. 10This language, like any language, has a specific structure to insure accurate communication. 11 The NC code structure consists of characters, words, blocks, and programs. There are 9 character types used in CNC programming: 1] letters A thru Z; 2] a number or combination of numbers 0 thru 9; 3] + plus sign; 4] - minus sign; 5] . decimal or period; 6] : colon; 7] ; semi-colon; 8] / slash; 9] % percent Word - is a series of characters arranged in a specified order that provides a specific command to the machine. 14A word consists of an address followed by numbers and/or symbols. 15For example, F as in F12.0 is Feed rate (as in 12.0 inches per minute)
16 13 12 9 1
A block is a series of words that defines a single instruction. 17A block can be a single word or a combination of words. 18A block is terminated by an "end of block" character. 19An example of blocks is N89 M30 (two word block).
A program is a series of blocks and normally contains a complete set of coded instructions required to completely machine a part or a predetermined portion of a part. 21A program can be as short as a few blocks or as long as many thousand blocks for complex parts. 22The program contains all the instructions and information necessary for the computer to command the machine to perform specified functions, ultimately resulting in the complete machining of a part.
23
20
A program and all of its parts can be equated to the English language as follows: English Language Equiv
Character Word
CNC Code Language

Character Word
Comment
24
The characters are the same for both languages. (1,2,3...;,+,=,%....)

25
The word is merely a combination of characters in 26 both languages. It's just that the combination of characters in the NC Code Language is a little different than we are used to seeing, but still words none-theless.
27
Block
Sentence
The block is equivalent to a sentence in the English 28 language. They both convey specific thoughts or commands and have punctuation that ends them.
29
Program
Memo or Letter
The program is equivalent to a complete memo or 30 letter in the English language. They both are a combination of sentences/blocks that convey complete ideas (English) or completed parts (NC Code).
Source: Virtual Machine Shop, http://www.jjjtrain.com/vms/cnc_intro_code.html
129
B. Read the questions and choose the correct answer. 1. What is the central point of the reading?
2. How does the computer control the operation of the machine?
3. These coded instructions in sentence 4 refers to: a. Letters. b. Symbols. c. Numbers. d. NC code.
4. What is the result of writing the CNC program correctly?
5. The effect of not writing the CNC program correctly is a. Damaging the machine. b. Destroying the tool. 6. The pattern of organization in sentence 7 is a. Cause and effect. b. Comparison. 7. The pattern of organization in sentence 11 is a. Cause and effect. b. Comparison. c. Contrast. d. Classification. c. Contrast. d. Classification. c. Scraping parts. d. All of the above.
8. Match the NC code language to the corresponding CNC code structure. a. N11 T01 M06 b. % F as in F12.0 N89 M30 % c. S as in S1250 d. % [ ] character [ ] word [ ] block [ ] program
9. Which NC code structure contains a complete set of coded instructions required to completely machine a part?
10. A block in CNC code language is the English language equivalent of a. A character. b. A sentence. c. A word. d. A letter.
130
UNIT 13
STUDENT HANDOUT
H13:3
A. Complete the following outline of Interpolation. Main idea: There are programming applications. of interpolation used in CNC
1. Linear 2. 3. 4. 5.
- Used for straight-line machining between two points. -
B. Complete the map on the types of turning centers.
TURNING CENTERS
131
STUDENT HANDOUT
H13:4
A. Study the following words and complete the sentences. 1. automatic tool change (ATC) 2. computer-aided design (CAD) ____________________________________is the use of a wide range of computer-based tools that assist engineers, architects, and other design professionals in their design activities. 3. computer-aided manufacturing (CAM) ___________________refers to the software used to generate the instruction codes for a CNC machine in order for it to cut out a shape designed in a computer-aided design (CAD) system. A _____________ is an instruction or series of instructions that is to be executed repeatedly to produce a desired operation. The ___________________________ is one of the CNC components of a machining center.
4. loop
5. machine control unit (MCU) The ___________________________ is one of the CNC components of a machining center.
6. reset 7. servo system
______________ is returning a storage location in the MCU to zero or to a specified initial value.
A _______________ is an automatic system for maintaining the read/write head on track. It can be either "open loop", "quasi-closed loop", or "closed loop".
8. tool function
___________________is a command that identifies a tool and calls for its selection. _________________________________ is the distance between the bottom of the fully retracted tool and the part Z0.
9. tool length offset
10. tool offset _______________ is a correction entered for a tool's position parallel to a tool movement axis.
132
STUDENT HANDOUT
H13:5
Comparison of CNC and Traditional Machines A. Read the following paragraphs. CNC Computer Numerical Control machines are widely used in the manufacturing industry. 2Traditional machines such as vertical millers, center lathes, shaping machines, routers etc.... operated by a trained engineer have, in many cases, been replaced by computer control machines.
1
COMPUTER NUMERICAL CONTROL - MACHINE ADVANTAGES 1. 3CNC machines can be used continuously 24 hours a day, 365 days a year and only need to be switched off for occasional maintenance. 2. 4CNC machines are programmed with a design which can then be manufactured hundreds or even thousands of times. 5Each manufactured product will be exactly the same. 3. 6Fewer skilled and trained people can operate CNCs unlike manual lathes or milling machines etc., which need skilled engineers. 4. 7Training in the use of CNCs is available through the use of virtual software. 8This is software that allows the operator to practice using the CNC machine on the screen of a computer. 9The software is similar to a computer game. 5. 10CNC machines can be programmed by advanced design software such as Pro/ DESKTOP, enabling the manufacture of products that cannot be made by manual machines. 6. 11Modern design software allows the designer to simulate the manufacture of his/her idea. 12There is no need to make a prototype or a model. 13This saves time and money. 7. 14One person can supervise many CNC machines as once they are programmed they can usually be left to work by themselves.
MANUALLY OPERATED CENTER LATHE DISADVANTAGES 1. 15CNC machines are more expensive than manually operated machines, although costs are slowly coming down. 2. 16The CNC machine operator only needs basic training and skills, enough to supervise several machines. 17In years gone by, engineers needed years of training to operate center lathes, milling machines and other manually operated machines. 18This means many of the old skills have been lost. 3. 19Fewer workers are required to operate CNC machines compared to manually operated machines. 20Investment in CNC machines can lead to unemployment. 4. 21Many countries no longer teach students how to use manually operated lathes and milling machines etc. 22Students no longer develop the detailed skills required by engineers of the past. 23These include mathematical and engineering skills.
Source: V. Ryan, Technologystudent.com http://www.technologystudent.com/cam/camex.htm
133
B. Read the questions and answer them true [T] or false [F].
1. _____ 2. _____ 3. _____ 4. _____ 5. _____ 6. _____
The pattern of organization of the reading is comparison and contrast. More computer control machines are used in industry today than traditional machines. More workers are needed to operate CNC machines than manually operated ones. It takes a more skilled machinist to operate a CNC machine than a traditional one. Traditional machines can be used as often as CNC machines. Products manufactured on a manually operated machine will be less uniform than those manufactured on a CNC machine.
7. _____
People who operate a CNC machine will probably have better mathematical and engineering skills than those who operate a traditional machine.
8. _____
Making a prototype or model is less costly and time effective than simulating the manufacture of the designers idea.
9. _____
CNC machines need less supervision than manually operated ones.
10. _____ Traditional machines can manufacture as many products as CNC machines. 11. _____ Training on the CNC machine can only be done in the machine shop. 12. _____ There is less maintenance on CNC machines than on manually operated ones. 13. _____ Pro/DESTOP is a type of training software. 14. _____ It is more expensive to operate a CNC machine than a manual lathe. 15. _____ It takes longer to train a CNC operator than one who operates a traditional machine.
134
UNIT 13
STUDENT HANDOUT
H13:6
Read pages 642-668 in your textbook and answer the questions below. A. Label the parts of a CNC machining center.
2 3
5 6
1. 2. 3. 4. 5. 6. 7. 135
B.
Identify the following machining center accessories by writing their names under the picture. automatic tool changer rose reamer oil-hole drill face milling cutter two-flute end mills spiral flute tap single-point boring tool precision machine vise
1. ______________
2. _______________
3. ______________
4. _____________
5. ______________
6. ________________
7. ______________
8. _________________
C.
Complete this map of Toolpaths and their purposes.
TOOLPATHS
Pocket
Remove material from a cavity in the stock
136
Unit 14
Grinding
Objectives: Given topics on grinding; texts that are varied and of a specialized and technical nature which include information presented from other sources (e.g., photographs, drawings, reference text/ research information, diagrams), the participant will use English with 70% accuracy to: Identify and pronounce correctly the important parts of three common grinding machines. Identify surface grinding problems, causes, and remedies. Identify and pronounce correctly the main parts of a cutter and tool grinder. Identify the main idea and supporting details by outlining and mapping a reading. Interpret tables and label illustrations. Classify types of grinders. Label the parts of a hydraulic surface grinder.
137
STUDENT HANDOUT
H14:1
A. Study the following words and complete the sentences. 1. abrasive ________________ is the material used in making grinding wheels or abrasive cloth.
2. bond 3. bushing
____________ is the media or glue that holds abrasive grains together in the form of a wheel.
______________ is an operation in the manufacture of vitrified grinding wheels in which the arbor hole is fitted with a lead or plastic-type liner to fit a specific spindle size. 4. firing ___________ ___is an operation in the manufacture of vitrified grinding wheels which causes the bond to melt and form a glassy case around each grain producing a hard wheel. A solid is______________ when it is easily crumbled into powder or small particles. The ___________________ of a grinding wheel is the degree of strength with which the bond holds the abrasive particles in the bond setting. A _________________ is an expendable wheel composed of abrasive material held together with a suitable bond and used in grinding machines.
5. friable 6. grade 7. grinding wheel
8. molding
______________________ is an operation in the manufacture of vitrified grinding wheels in which a proper amount of the mixture is placed in a steel mold of the desired wheel shape and compressed in a hydraulic press. __________________ is an operation in the manufacture of vitrified grinding wheels in which special wheel shapes and recesses are shaped or shaved to size in the green, or unburned, state on a shaving machine, which resembles a potters wheel.
9. shaving
10. truing
__________________ is an operation in the manufacture of vitrified grinding wheels in which the cured wheels are mounted in a special lathe and turned to the required size and shape by hardened-steel conical cutters, diamond tools, or special grinding wheels. 138
STUDENT HANDOUT Grinding
H14:2
A. Read the following paragraphs. Grinding is generally considered to be a finishing operation. 2Possibilities include re-sharpening cutting tools, surface grinding of work fixtures and mold sections, inside and outside diameter grinding of valve bodies, and many other potential applications. 3Grinding has many different applications in the machine tool industry. 4The grinding operation can be performed on a variety of machines such as the lathe and the mill - with the appropriate add-on accessories. To be successful with grinding, it is necessary to understand some basic principles. 6Grinding uses a method of material removal called abrasion. 7Rather than cutting like a lathe bit, the material is slowly worn away because the abrasive is harder than the material being ground. 8In truth the grinding wheel acts like many thousands of very small lathe bits, each cutting off some metal. 9The abrasive must also be strong enough to withstand the forces acting upon it while grinding. 10Usually some sort of impact shock occurs when the abrasive comes in contact with the material. Heat while grinding is of major concern, with effects seen at every phase of the operation. 12Also the abrasive needs to be able to withstand high temperatures caused by the friction during the grinding. 13 Sometimes, these high temperatures will cause damage to the bonding agents found in the wheel causing the wheel to break down. 14In general coolant must be directed at the grinding wheel, not the material being ground, as heat causes more damage to the wheel than the work piece. Most abrasive wheels need to be able to be resurfaced (dressed), as the old surface will become impregnated with material during the grinding operation. 16Dressing is accomplished with a diamond tipped tool. The grinder is a machine that is used for fine surface finishing and the amount of material removed rarely exceeds a few thousands of an inch. 18These machines have been developed over the years to satisfy specific needs of the industry it serves, so grinding has become specialized, as has turning and milling. 19 The most common types of grinders are the surface grinder, the universal tool and cutter grinder, and the cylindrical grinder.
17 15 11 5 1
Source: Virtual Machine Shop, http://www.jjjtrain.com/vms/other_grinding.html
139
B. Read the questions and choose the correct answer. 1. An example of a finishing operation is: a. Re-sharpening cutting tools. b. Diameter grinding of valve bodies. 2. The pattern of organization in sentence 4 is a. Definition. b. Classification. 3. The topic of paragraph 2 is a. Success with grinding. b. Abrasion. 4. Abrasion a. Cuts like a lathe bit. b. Grinds the material. 5. c. Wears away the material. d. Is not influenced by grinding forces. c. Basic principles. d. The lathe bit. c. Illustration. d. Time order: process. c. Surface grinding of fixtures. d. All of the above.
What is the effect of the abrasive coming in contact with the material in sentence 10?
6. Identify the basic principles needed to be successful with grinding. a. Abrasion. b. Heat. 7. The main pattern of organization in paragraph 3 is a. Comparison and contrast. b. Time order: process. 8. What is another name for dressing? c. Classification. d. Cause and effect. c. Dressing. d. All of the above.
9. Grinders a. Remove a large amount of material. b. Are common machines. c. Remove a small amount of material. d. None of the above.
10. Classify the types of grinders by completing the map below.
Types of Grinders
140
UNIT 14
STUDENT HANDOUT
H14:3
Read pages 671-703 in your textbook and answer the questions below. A. Complete the following outline on manufactured abrasives. Main Idea: There are several types of manufactured abrasives. Used for high-tensile-strength materials, including all ferrous metals except cast iron.
1. Aluminum oxide -
2.
3.
4.
5.
6.
7.
B.
Complete the following map on bond types.
BOND TYPES
Vitrified
rapid removal of metals
141
C. Look at the following grinding wheel grades and match the description to the grade.
a. [
b. [
c. [
1. Medium Grade Synthetic Diamonds having strong, blocky & uniform cubo-octahedral shaped crystals. Extremely good thermal stability with very high toughness & wear resistance. Work piece material: Fragile & Brittle Materials like Glass & some types of stones. 2. Premium Grade Synthetic Diamonds having extremely strong, very blocky, highly uniform cubooctahedral shaped crystals. Extremely high toughness, thermal stability & wear resistance. Work-piece Material: Ceramics, Glass, Hard Stones, etc. 3. Economy Grade Synthetic Diamonds having friable & angular shaped diamonds having sharp-edged, rough fractured grains. Low toughness, wear resistance & thermal stability. Work-piece Material: Very soft materials.
D. Label the parts of a Hydraulic Surface Grinder.
9 1 2 8 3 4 7 6 5
1. 2. 3. 4. 5.
6. 7. 8. 9. 142
STUDENT HANDOUT
H14:4
Study the diagram of a universal cutter and tool grinder and complete the sentences.
WHEELHEAD
HEADSTOCK
FOOTSTOCK UPPER TABLE
STOP DOGS LOWER TABLE
TABLE TRAVERSE KNOB TABLE TRAVERSE CRANK
SADDLE WHEELHEAD HANDWHEEL CROSSFEED HANDWHEEL
BASE
The [1]
is of a heavy, cast-iron boxlike construction that provides rigidity. The top of the . The [3] is
base is machined to provide the ways for the [2] located on either side of the base.
mounted on a column located at the back of the base. It may be raised or lowered by the [4]
The saddle is mounted on the ways of the base and is moved in and out by the [5] located at the front and back of the machine. The table is composed of two units, the [6] and [7] means of the slow [9] longitudinally with locking screws. [10] table, control the length of the table traverse. table. The table unit may be moved longitudinally by three [8] , one located at the front and two at the back. The table may also be traversed slowly by . The table may be locked in place laterally and , mounted in a T-slot on the front of the
143
STUDENT HANDOUT Cylindrical Grinders
H14:5
A. Read the following paragraphs. The diameter of a workpiece can be ground accurately to size and to a high surface finish on a cylindrical grinder. 2There are two types of machines suitable for cylindrical grinding the center type and the centerless type each with its special applications. Work which is to be finished on a cylindrical grinder is generally held between centers but may also be held in a chuck. 4Grinding for surfaces of rotation (axially symmetric surfaces) can be either centered or centerless. 5Centered grinding involves fixturing the part on a spindle axis as it is ground, figure 1. 6This configuration can be compared to fixturing a part on a lathe with or without a tail stock. 7 The abrasive material is on a grinding wheel that rotates in a direction such that rolling or sliding contact occurs where the wheel and work piece touch. 8Centered grinding is accurate and stable, but set-up takes time and throughput suffers.
9 3 1
Figure 1
Centerless grinding is similar to centered grinding except that there is no spindle. 10This allows high through-put since parts can be quickly inserted and removed from the process. 11There are three main types of centerless grinding: Through-Feed Grinding, In-feed grinding, and End-feed grinding. In through-feed grinding, the part rotates between the grinding wheel and a regulating wheel. 13One or both wheels of the centerless grinding machine are canted out of the horizontal plane, figure 2. 14This imparts a horizontal velocity component to the work piece, so that outside feed mechanisms are not necessary. In-feed grinding differs from through-feed grinding in that the part is not fed axially so that the ground surface does not need to be a right circular cylinder. 16The grinding wheel can be dressed to accommodate the part. 17 Once the work piece part is in place, the grinding wheel is fed in radially.
Figure 2
15 12
Because of the set up time involved for each part, in-feed grinding does not have the high throughput of through-feed grinding, figure 3.
18
Figure 3
In end-feed grinding, the part moves in axially between the grinding wheels, stops for grinding, and then moves out again. 20 The wheel can be dressed to form more complex shapes, but the part can only get progressively smaller in diameter, figure 4.
Figure 4
19
Source: efunda, http://www.efunda.com/processes/machining/grind_centerless.cfm 144
B. Read the questions and choose the correct answer. 1. A cylindrical grinder. a. b. c. d. Can grind the angle of a workpiece accurately to size. Can grind the diameter of a workpiece to a high surface finish. Both (a) and (b). Neither (a) nor (b).
2. A cylindrical grinder a. Holds work between centers. b. Holds work in a chuck. 3. Another name for axially symmetric surfaces is a. Surfaces of rotation. b. Centered. 4. In Figure 1 a. b. c. d. The part is fixtured on a spindle axis while being ground. The part is fixtured on a lathe with a tail stock. The part is fixtured on a lathe without a tail stock. All of the above. c. Centerless. d. None of the above. c. Both (a) and (b). d. Neither (a) nor (b).
5. This configuration in sentence 6 refers to a. b. c. d. Fixturing a part on a lathe with or without a tail stock. Fixturing the part on a spindle axis as it is ground. Both (a) and (b). Neither (a) nor (b).
6. The pattern of organization in sentence 11 is a. Comparison. b. Contrast. 7. This in sentence 14 refers to a. b. c. d. Imparting a horizontal velocity component to the work piece. Making outside feed mechanisms unnecessary. Rotating the part between the grinding wheel and a regulating wheel. Having one or both wheels of the centerless grinding machine canted out of the horizontal plane. c. Definition. d. Classification.
8. The pattern of organization in sentence 15 is a. Cause and effect. b. Contrast. 9. The part is fed axially in a. Through-feed grinding. b. End-feed grinding. 10. A disadvantage of end-feed grinding is a. b. c. d. The wheel can be dressed to form more complex shapes. The part can only get progressively smaller in diameter. Both (a) and (b). Neither (a) nor (b). 145 c. In-feed grinding. d. All of the above. c. Both (a) and (b). d. Neither (a) nor (b).
UNIT 14
STUDENT HANDOUT
H14:6
Read pages 705-742 in your textbook and answer the questions below. A. Look at Tables 82.1 and 83.1 and complete the sentences. 1. 2. 3. 4. 5. 6. 7. 8. 9. 10. The cause of burning or discoloration is A glazed wheel causes A remedy for chatter is Scratches on the work surface are caused by When the spindle bearing is too loose, The cause of a barber-pole finish is Vibrations in the machine cause A remedy for intermittent cutting action is The causes of long, wavy marks are A remedy for a rough finish is . . . . will occur. . . . . .
B. Label the parts of the universal cylindrical grinder. 1 11
2 3
10
9 4 8 5 6 7
1. 2. 3. 4. 5. 6.
7. 8. 9. 10. 11.
146
Unit 15
Metallurgy
Objectives: Given topics on metallurgy; texts that are varied and of a specialized and technical nature which include information presented from other sources (e.g., photographs, drawings, reference text/ research information, diagrams), the participant will use English with 70% accuracy to: Create a flowchart describing the production of steel. Identify and pronounce correctly heat-treatment terms. Interpret tables and illustrations. Identify the main idea and supporting details of a reading. Classify nonferrous metals.
147
STUDENT HANDOUT
H15:1
Study the following words and complete the sentences. 1. brittleness __________ is the property of the metal that permits no permanent distortion before breaking. 2. ductility ____________ is the ability of the material to be permanently deformed without breaking.
3. elasticity
________________ is ability of the material to return to its original shape.
4. hardness
________________ is the ability of the material to resist penetration.
5. malleability
______________ is the ability of the material to be rolled into shapes.
6. prereduction _____________ is the process used to preheat and prereduce the iron ore fed to the smelter, using the offgases from the smelter. 7. refining ________________ is a process that produces liquid steel, suitable for ladle metallurgy treatment. 8. smelting ________________ is the process by which iron is removed from iron ore.
9. tensile strength
________________ is the maximum amount of pull that a material will withstand before breaking.
10. toughness
______________ is the property of the metal to withstand shock or impact.
148
STUDENT HANDOUT
H15:2
The Making of Steel A. Read the following paragraphs. Steel, in its most basic form, is a combination of iron and carbon. 2Iron is a mineral mined from large deposits in the earth's crust and carbon is one of the most common of earth's elements. 3To produce steel, the first step is to make what is called pig iron. 4Alternating layers of iron ore, limestone (a mineral used to purify the mixture), and coke (coal that has been prepared specially for this process) are poured into a blast furnace. 5Hot air at 1200 degrees F is then blasted through the exhaust vent to create the combustion process. 6The coke then burns the mixture at 3000 degrees F and two reactions occur. 7 The first reaction is when the carbon from coke and the oxygen from the air combine to liberate the metallic iron and make it liquid, directing it to the bottom of the furnace. 8The second reaction is when the limestone attracts the impurities. 9These impurities float to the top of the melted pig iron and is siphoned off as slag. 10Every few hours, the melted pig iron is removed from the bottom of the furnace and further processed.
11 1
Pig iron contains 4 to 5% carbon which makes it much too brittle to be used as is. 12Reducing the extra carbon in the pig iron will convert it to steel. 13This process is called "refining". 14Just as crude oil is refined into gasoline kerosene pig iron is refined into steel.
There are two methods of refining this iron into steel. 16The first way to reduce the carbon is the basic oxygen furnace steel making process. 17In this process, the amount of carbon is decreased by regulating the amount of oxygen that is injected into the pig iron. 18The oxygen removes the unwanted carbon by oxidation. 19This unwanted carbon, together with a mixture of other impurities constitutes the slag and is removed from the furnace. The second way to refine the pig iron into steel is called the electric arc furnace steel making process. 21 In this process, the amount of carbon is regulated by exposing the pig iron to an electric arc. 22The arc is generated by electrodes in the oven which are placed on opposite sides of the molten steel. With the early iron making process molten metal was tapped from the bottom of the furnace and allowed to flow down a narrow stream and into sand molds. 24These molds were called "piglets" because the arrangement looked something like suckling pigs. 25Thus the name "pig iron" even today.
23 20
15
Source: Virtual Machine Shop, http://www.jjjtrain.com/vms/engineering_metallurgy.html#1
149
B. Read the questions and choose the correct answer. 1. When you combine iron and carbon, you get a. A mineral. b. An element. c. Steel. d. All of the above. c. Coke d. All of the above. c. Contrast. d. Classification.
2. Pig iron is made with a. Iron ore. b. Limestone. 3. The main pattern of organization in paragraph 1 is a. Time order: process. b. Comparison. 4. What is the cause of brittleness in pig iron?
5. How can you convert the pig iron to steel?
6. This process in sentence 13 refers to a. Reducing the extra carbon in the pig iron. b. Refining the pig iron.
c. Both (a) and (b). d. Neither (a) nor (b).
7. Name the two methods for refining pig iron into steel. a. b. 8. The main pattern of organization in paragraph 5 is a. Definition. b. Classification. 9. How did the term pig iron get its name? c. Cause and effect. d. Contrast.
10. Complete the flowchart below on the production of steel. Use the following words: basic oxygen furnace, blast furnace, coal, coke, coke ovens, iron ore, limestone, molten iron, molten steel
150
UNIT 15
STUDENT HANDOUT
H15:3
Read pages 745-759 in your textbook and answer the questions below. A. Complete the map on the chemical composition of steel.
Chemical Composition of Steel
Carbon
Hardening agent
B. Look at Table 85.1 and answer the questions true (T) or false (F). 1. _____ 2. _____ 3. _____ 4. _____ 5. _____ Nickel increases hardenability. Only one alloying element increases toughness. Lead acts as a deoxidizer. Cold-shortness is caused by phosphorous. Vanadium decreases fatigue resistance.
C. Identify the different steel shapes produced by rolling by writing the name under the picture.
1.
2.
3.
4.
5.
6.
7.
8.
9.
10.
151
STUDENT HANDOUT
H15:4
Study the following words and complete the sentences. 1. alpha iron _______________ is the state in which iron exists below the lower critical temperature. In this state, the atoms forma bodycentered cube. 2. annealing 3. ____________ is a solid solution of carbon in iron, which exists between the lower and upper critical temperatures. __________________ is a heat-treating operation used to soften metal and to improve its machinability.
4. ______________ is a carbide of iron, which is the hardener of steel.
5. gamma iron 6. hardening
___________ is the state in which iron exists in the critical range. ____________________ is the process of heating steel above its lower critical temperature and quenching in the proper medium of water, oil, or air to produce martensite. ___________________ is the process of heating and subsequent cooling of metals to produce the desired mechanical properties.
7. heat treatment 8.
______________ is the structure of fully hardened steel obtained when austenite is quenched.
9. normalizing 10.
________________ is the process of heating metal to just above its upper critical temperature and cooling it in still air to remove internal stresses and strains and to improve machinability.
_________________ is a laminated structure of ferrite, usually the condition of steel before heat treatment.
11. tempering
__________________ is the process of heating a hardened carbon or alloy steel below its critical temperature and cooling it by quenching in a liquid or in air. 152
STUDENT HANDOUT
H15:5
Metal Standards A. Read the following paragraphs. Metal standards are industry wide agreements as to how metals are defined. 2In this definition there may be information about the chemical composition, process of manufacture, heat treatment and many other pieces of hidden knowledge. 3The standard usually attempts to codify all of the various attributes into a simple to read letter/number designation. 4The ultimate utility of these standards is communication. 5 Engineers, machinists, purchasing agents, and suppliers can all speak the same language of steel, aluminum, and copper and be assured of a consistent product. Just as there are many different languages spoken on our planet, there are many different standards used around the globe. 7But even then foreign standards borrow heavily from or rely completely on United States standards. The American Iron and Steel Institute (AISI) has a standard that is widely accepted in the United States and other countries. 9However it does not cover all metals and, in many instances, it does not convey enough information to speak to all of the attributes of some metals. 10Therefore two United States standards organizations, ASTM (American Society for Testing and Metals) and SAE (Society of Automotive Engineers), have developed a standard for classification of metals that is independent of AISI standards. 11It is called the Unified Numbering System (UNS) and is composed of seventeen letters that represent seventeen metal types. 12Each letter is followed by five digits that signify the specific makeup of each of these metal types. 13The first three or four digits are derived from different standards.
14 15 8 6 1
Following are two examples of UNS designators and how they relate to AISE/SAE designations. Notice how the older standard numbers have been incorporated into the UNS. 1. 2. A resulfurized carbon steel containing 0.21% carbon would be UNS G11210 or AISI/ASE 1121. A steel alloyed with 20% chromium and vanadium and containing 0.75% carbon would be UNS G62750 or AISI/SAE 6275
18 17
Since the AISE/SAE standards have only three or four digits the last unused digit(s) in the UNS system can be used for added information such as tempering or manufacturing methods. 20At this writing all of these digits are not fully utilized but will surely be used in the near future. Note that the UNS standard is not yet widely used in the machine shop. 22However, since it is gaining acceptance with engineers and purchasing agents it will soon become the standard on the shop floor. 23 In the interim UNS can be easily translated from AISI and SAE designators and visa versa.
24 21
19

AXXXXX Aluminum CXXXXX Copper and copper alloys FXXXXX Cast iron GXXXXX Carbon steel NXXXXX Nickel and nickel alloys SXXXXX Stainless steel TXXXXX Tool Steel WXXXXX Welding filler materials ZXXXXX Zinc and zinc alloys Figure 1
Figure 1 presents a list of UNS metal designations important to machinists.
Source: Virtual Machine Shop, http://www.jjjtrain.com/vms/engineering_metal_stds.html#3
153
B. Read the questions and choose the correct answer. 1. Metal standards deals with information about a. Chemical composition. b. Heat Treatment. 2. What is the purpose of having metal standards? c. Process of manufacture. d. All of the above.
3. The pattern of organization in sentence 9 is a. Cause and effect. b. Definition. 4. The AISI standards. a. Are not widely accepted in the United States. b. Speaks to all of the attributes of some metals. c. Covers all metals. d. None of the above. c. Contrast. d. Comparison.
5. The Unified Numbering System has been developed by the a. Society of Automotive Engineers. b. American Society for Testing and Metals. c. American Iron and Steel Institute. d. Both (a) and (b)
6. The letters in the Unified Numbering System represent a. Metal types. b. The specific makeup of the metal types. 7. G10300 is a designator under what system? c. Different standards. d. All of the above.
8. What are the last unused digits in the UNS system used for?
9. These digits in sentence 20 refers to a. The three or four digits in the AISE/SAE system. b. The last unused digits in the UNS system. 10. The Unified Numbering System a. Cannot be easily translated from AISI/SAE designators. b. Is the standard in machine shops. c. Is becoming popular with engineers and purchasing agents. d. Is widely used around the world. 154 c. Both (a) and (b) d. Neither (a) nor (b).
UNIT 15
STUDENT HANDOUT
H15:6
Read pages 760-786 in your textbook and answer the questions below. A. Match the description to the picture.
a. [
b. [
c. [
d. [
1. A carbide of iron, which is the hardener in steel. 2. The structure of fully hardened steel obtained when austenite is quenched. It is characterized by its needlelike pattern. 3. A solid solution of carbon in iron, which exists between the lower and upper critical temperatures. 4. A grain structure with globular-shaped particles (spheroids).
B. Determine the types of steel indicated by the following numbers: 1. 5160 2. E2145 -
C. Identify the instrument by writing the name under the picture.
1.
2.
3.
155
D. Label the parts of a Rockwell Hardness tester.
1 2 3 4 6
1. 2. 3.
4. 5. 6.
E. Classify Nonferrous Metal by completing the map.
NONFERROUS METALS
156
GLOSSARY
absolute system A numerical control system in which all positional dimensions, both input and feedback, are given with reference to a common datum point. The material used in making grinding wheels or abrasive cloth. A cutting-off machine used to cut material by means of a thin, abrasive wheel revolving at high speed. Something going wrong unexpectedly such as falling on a slippery floor. An obligation or willingness to accept responsibility to somebody or for something. The ability to be precise and avoid errors. To bring the components of a part into a more effective or efficient calibration or state. Part of the universal dividing head set that prevents long, slender work held between centers from bending. A technology that employs the use of air flow volumes and air pressure to determine the size of measured part dimensions. The state in which iron exists below the lower critical temperature. In this state, the atoms forma body-centered cube. The readout of an air gauge system. It contains the necessary restrictions to change the pneumatic pressure or flow and then displays readings on a scale as dimensional values. The space between two lines diverging from a common point and expressed in numerical form. The included angle produced by grinding side rake and side clearance on a toolbit. A bandsaw operation where the work may be clamped at any angle and fed through the saw. A heat-treating operation used to soften metal and to improve its machinability. Part of the lathe that is fastened to the saddle and houses the gears and mechanism required to move the carriage and cross-slide automatically. The part of the milling machine that aligns and supports various arbors and attachments. The process of joining together two or more parts to complete a unit or structure.
abrasive abrasive cut-off saw accident accountability
accuracy adjust adjustable center rest air gauging alpha iron amplifier
angle angle of keenness angular cutting annealing apron
arbor support assembly
157
austenite automatic tool change (ATC) back rake angle balance
A solid solution of carbon in iron, which exists between the lower and upper critical temperatures. One of the CNC components of a machining center.
The backward slope of the tool face away from the nose. The resultant non-movement on the display of an air amplifier that occurs when one nozzle of a two nozzle tool is closed toward the workpiece and the other nozzle equally compensates for that movement. 1) The bottom surface of the tool shank. 2) The part of a vertical mill that is made of ribbed cast iron and may contain a coolant reservoir. Part of the lathe usually made of cast iron that provides a heavy rigid frame on which all the main components are mounted. A device for holding small work securely for sawing, chipping, filing, polishing, drilling, reaming, and tapping operations. An instrument in the form of a half circle used for measuring and making angles other than a 900 angle. The part of the horizontal band saw used to adjust the tension on the saw blade. A generic term for the representation of the work piece to be machined. It can be a pencil sketch or a CAD drawing or any of a number of other graphic options used to represent the design. the portion of the drill between the shank and the point. The media or glue that holds abrasive grains together in the form of a wheel. The operation of truing and enlarging a hole by means of a singlepoint cutting tool. A cutting tool placed in a cutter head to dress round holes. The intensity of light reflected or emitted by something. The property of the metal that permits no permanent distortion before breaking. A process in which a special tapered multi-toothed cutter is forced through an opening or along the outside of a piece of work to enlarge or change the shape of the hole or to form the outside to a desired shape.
base
bed bench vise bevel protractor
blade tension handle blueprint
body bond boring boring head brightness brittleness
broaching
158
built-up edge
A layer of compressed metal from the material being cut which adheres to and piles up on the face of the cutting tool edge during a machining operation. A process that develops a smooth finish on a metal by tumbling or rubbing with a polished hand tool. An operation in the manufacture of vitrified grinding wheels in which the arbor hole is fitted with a lead or plastic-type liner to fit a specific spindle size. Not giving sufficient attention or thought to avoiding harm or mistakes. Part of the lathe that consists of three main parts: the saddle, crossslide, and apron. It is used for mounting and moving most of the cutting tools along the lathe bed. A carbide of iron, which is the hardener of steel. A part of the combination square set that is used to find the center of or to bisect a round or square workpiece. That portion of the face of a cutting tool on which the chip slides as it is cut from the metal. A 3-jaw (self centering) or 4-jaw (independent) device used to clamp the part being machined on a lathe. A Coordinate Measuring Machine. It is a mechanical system designed to move a measuring probe to determine coordinates of points on a work piece surface. Contains a program of instructions and commands, which consists of numbers, letters, and other symbols. The use of a wide range of computer-based tools that assist engineers, architects, and other design professionals in their design activities. Refers to the software used to generate the instruction codes for a CNC machine in order for it to cut out a shape designed in a computer-aided design (CAD) system. A form of programmable automation in which the machine tool is controlled by a program in computer memory. A cutting-off machine used to cut soft or unhardened metals. A cone-shaped sleeve used for holding circular or rod-like pieces in a lathe or other machine. 1) An air-electronic amplifier or a flow system amplifier featuring a vertical bar graph display or flowmeter tube. 2) The part of a vertical mill that holds the turret. 159
burnishing bushing
careless carriage
cementite center head chip-tool interface
chuck CMM
CNC code computer-aided design (CAD) computer-aided manufacturing (CAM) Computer Numerical Control [CNC] cold circular cutoff saw collet column
column face
A precision-machined and scraped section of the horizontal milling machine used to support and guide the knee when it is moved vertically. A set of tools used extensively in layout work. It consists of a steel rule, square head, bevel protractor, and center head, Part of the lathe that is mounted to the cross slide and used to support the cutting tool. A CNC programming method that has the ability to control motions on two or more machine axes simultaneously to keep a constant cutter-work relationship. The operation of enlarging the top of a previously drilled hole to a given depth to provide a square shoulder for the head of a bolt or capscrew. The operation of producing a tapered or cone-shaped enlargement to the end of a hole. The top surface joining two sides of a thread. Part of the lathe mounted on the traverse slide of the carriage, and uses a handwheel to feed tools into the workpiece. Part of the horizontal milling machine used to move the table toward or away from the column. Part of the vertical milling machine that moves the work table in and out. The distortion of the crystal structure of the work material that occurs during a machining operation. Refers to air tooling designed to measure close to shoulder. The leading edge of the toolbit that does the cutting. Any tools used to cut material. This usually refers to milling cutters, lathe bits, or drills. Loss or harm resulting from injury to person, or property. A reference point from which movements or measurements are made. A datum can lie anywhere on the surface of a work piece. The area in which the work material is deformed during cutting. The mass per unit volume of a substance, usually expressed in grams per cubic centimeter or in pounds per cubic foot. The distance between the crest and root of a thread measured perpendicular to the axis. An instrument used to measure the depth of slots, steps, and other 160
combination set
compound rest continuous path positioning counterboring
countersinking crest cross slide
crossfeed handwheel cross traverse hand wheel
crystal elongation CTS cutting edge cutting tools damage datum deformed zone density depth depth micrometer
features. die dismantling dividers dividing head divisor drill drill chuck drilling ductility elasticity electropolishing A tool to make threads on the outside diameter of shafts. It is also used to form and blank sheet metal parts. Taking apart, disassembling or tearing down. Instruments used for scribing arcs and circles on a layout and for transferring measurements. An attachment for the milling machine that divides the workpiece circumference accurately into any number of divisions. A number divided into another number. For example, 7 is a divisor of 42 because 42/7 = 6. A tool used to make holes in firm material. A holding device used to hold and drive straight-shank cutting tools. The operation of producing a hole by removing metal from a solid mass using a cutting tool called a twist drill. The ability of the material to be permanently deformed without breaking. The ability of the material to return to its original shape. A process that involves passage of electric current through a workpiece, while it is submerged in a specially-designed acid solution. The part of the horizontal milling machine that gives an upward or downward movement to the knee and the table. The angle formed by the end cutting edge and a line at right angles to the centerline of the toolbit. A milling cutter with straight or tapered shanks that can cut both on the sides and on the end. The angle ground below the nose of the toolbit which permits the cutting tool to be fed into the work. The surface against which the chip bears as it is separated from the work. The motion of moving the work piece and the cutting tool together so as to remove material. The part of the horizontal milling machine used to regulate the table feeds. Part of the lathe mounted on the headstock that reverses the rotation of the feed rod and lead screw. 161
elevating screw end cutting edge angle
end mill end relief angle
face
feed
feed dial feed reverse lever
feed rod file file card finish finished product firing
Part of the lathe that advances the carriage for turning operations when the automatic feed lever is engaged. A hand cutting tool made of high-carbon steel. It has a series of teeth cut on its body by parallel chisel cuts. A wire brush mounted on a block of wood to clean the file. Refers to the surface appearance of steel after final treatment. The goods or services produced and completed by a company. An operation in the manufacture of vitrified grinding wheels which causes the bond to melt and form a glassy case around each grain producing a hard wheel. A mechanical device used to attach two pieces of tubing/piping together or to attach a piece of tubing/pipe to a component. A production work-holding device used for machining duplicate workpieces. The surface of the tool adjacent to and below the cutting edge. A graduated glass tube of a precise size with a floating cork that displays the reading on a flow air gauge system. A unit holding two or more replaceable cutting tools that is used for milling large, flat surfaces. Part of the lathe bolted to the carriage that uses adjustable fingers to bear against the workpiece opposite the cutting tool to prevent deflection. A lathe operation that forms irregular shapes or contours on a workpiece. A number that is not a whole number, e.g. 1/2 simple fraction or 0.5 decimal fraction, formed by dividing one quantity into another. A part of the horizontal band saw, hinged at the motor end, which has two pulley wheels mounted on it, over which the continuous blade passes. Easily crumbling a solid into powder or small particles. A burning process by which a saw band, with or without saw teeth, is run at high speeds to burn or melt its way through the metal. The numeric equivalent of the graduated display. It is usually 1 to 2 times greater than the tolerance being measured to show approach or oversize conditions. refer to some action occurring on the X, Y, and/or Z axis of a machine tool that cause some movement of the machine table or head. 162
fitting fixture flank flowmeter tube fly cutter follow rest
form turning fraction frame
friable friction sawing full scale value (FSV)
G-codes
gage
The thickness of the saw blade that has been standardized according to blade width. The state in which iron exists in the critical range. Any one of a large variety of devices for measuring or checking the dimensions of objects. Part of the lathe inside the headstock, providing multiple speeds with a geometric ratio by moving levers. The degree of strength with which the bond holds the abrasive particles in the bond setting on a grinding wheel. An expendable wheel composed of abrasive material held together with a suitable bond and used in grinding machines. To care for one's appearance such as wearing approved safety clothes. A lathe operation done at the end of a thread to permit full travel of the nut up to a shoulder or at the edge of a shoulder to ensure a proper fit of mating parts. A hand tool consisting of a shaft with a metal head at right angles to it, used mainly for driving in nails and beating metal. A tool consisting of a frame and a saw blade generally used for cutting metal into pieces. A tool used to finish drilled holes accurately and provide a good finish. The process of heating steel above its lower critical temperature and quenching in the proper medium of water, oil, or air to produce martensite. The ability of the material to resist penetration. A danger or harm. That part of the drive system on the vertical milling machine that transforms electrical power from a motor to mechanical power in the spindle. Part of the lathe mounted in a fixed position on the inner ways, usually at the left end. Using a chuck, it rotates the work. The process of heating and subsequent cooling of metals to produce the desired mechanical properties. An instrument used to scribe accurately dimensioned lines on a workpiece which has been prepared by brushing it with layout dye. A tool for marking lines parallel to square edges and shoulders on a 163
gamma iron gauge
gearbox grade
grinding wheel grooming grooving
hammer hand hacksaw hand reamer hardening
hardness hazard head
headstock heat treatment height gauge hermaphrodite caliper
workpiece. honing horizontal band saw The process of removing stock generally on the internal cylindrical surface of a workpiece with an abrasive stick mounted in a holder. A cutting-off machine that has a flexible, belt-like one-way blade that cuts continuously in one direction. Management and maintenance of the property and equipment of the shop. A measure of resistance to electrical current flow when a voltage is moved across something, such as a resistor. A CNC programming mode in which program dimensions or positions are given from the current point. A device consisting of an arm or handle that is connected to an index head used to turn the spindle. Plates with circular graduations or holes arranged in circles, each circle with different spacing used for indexing on machines. The process of providing discrete spaces, parts, or angles in a workpiece by using a dividing head. Putting machinery or equipment into place and making it ready for use. The abbreviation for the International Organization for Standardization. Damage or harm. The part of a metalworking machine that holds the object to be worked on and guides the cutting or drilling tool. A cutter that makes a recessed groove or slot machined into a shaft or part going on the shaft, usually a wheel or gear. A mechanical locking device located on the slitter head spindle shaft that holds the knives and spacers in place. 1) 2) knurling The part of the vertical milling machine that moves up and down by sliding on ways that are parallel to the column and supports the saddle and table. The part of the horizontal milling machine that houses the feed mechanism.
housekeeping impedance incremental system index crank index plates indexing installing ISO injury jig keyseat keyway knee
A late operation that impresses a diamond-shaped or straight-line pattern into the surface of the workpiece to improve its appearance or to provide a better gripping surface. An abrading process used to remove minute amounts of metal from a surface that must be flat, accurate to size, and smooth. A turning machine capable of producing round diameters by rotating 164
lapping lathe
a work piece against a stationary single-point cutting tool. layout layout die lead lead screw lobe longitudinal traverse hand wheel loop M-codes machine tool The process of measuring and marking a workpiece with finely scribed lines that guide you during the cutting process. A fast-drying colored liquid, usually a very deep blue, that is brushed onto a workpiece to prepare it for laying out guide lines. The distance a screw thread advances axially in one revolution. Part of the lathe used for cutting threads. A rounded projection that is part of a larger structure. Part of the vertical milling machine that moves the worktable to the left and right. An instruction or series of instructions that is to be executed repeatedly to produce a desired operation. Used to turn either ON or OFF different functions that control certain machine tool operations. An apparatus consisting of inter-related parts with separate functions, used to remove material from a work piece. Examples are milling machines, lathes, drill presses, surface grinders, and hundreds more. To cut, shape, or finish a piece of work using a power-driven tool such as a lathe or drilling device. A CNC machine which at one setup is capable of executing such operations as milling, drilling, boring, tapping, reaming and so forth, on one or more faces of the part. One of the CNC components of a machining center. The visual increase of size that is created by an air amplifier. The ability of the material to be rolled into shapes. The structure of fully hardened steel obtained when austenite is quenched. Either one of a pair of things that belong together. Devices used to determine physical size of parts to verify compliance to requirements. A precision measuring instrument, used by machinists. Each revolution of the rachet moves the spindle face 0.5mm towards the anvil face. Used to produce flat and angular surfaces, grooves, contours, gears, racks, sprockets, and helical grooves.
machining machining center
machine control unit (MCU) magnification malleability martensite mating part measuring instruments micrometer
milling machine
165
mold molding
A hollow form for giving a particular shape to something in a molten or plastic state. An operation in the manufacture of vitrified grinding wheels in which a proper amount of the mixture is placed in a steel mold of the desired wheel shape and compressed in a hydraulic press. The part of the vertical milling machine mounted on top of the head and providing drive to the spindle, usually through V-belts. The number by which another number multiplicand is multiplied, e.g. the number 4 is the multiplier in the statement 2 4 = 8 The process of heating metal to just above its upper critical temperature and cooling it in still air to remove internal stresses and strains and to improve machinability. The tip of the cutting tool formed by the junction of the cutting edge and the front face. The radius to which the nose is ground. A bandsaw application where sections of metal can be removed in one piece rather than in chips. The orifice in the air gauge tooling that emits the air that blows against the part being measured. A form of programmable automation in which the machine tool is controlled by punched tape. 1) Part of the vertical milling machine that slides on the turret and allows the milling head to be repositioned over the table. 2) part of the horizontal milling machine that provides for correct alignment and support of the arbor and various attachments. Two lines or surfaces extending in the same direction, everywhere equidistant, and not meeting. An acronym for Polycrystalline Cubic Boron Nitride, which is a crystalline body of many small crystals randomly oriented to form a material for cutting hard ferrous metals. A laminated structure of ferrite, usually the condition of steel before heat treatment. 1) The number of teeth per linear inch of the bandsaw blade. 2) The distance from a point on one thread to a corresponding point on the next thread, measured parallel to the axis. The change in shape of the work material that occurs in the shear zone during a cutting action.
motor
multiplier normalizing
nose nose radius notching nozzle Numerical Control [NC] overarm (ram)
parallel PCBN
pearlite fine pitch
plastic deformation
166
plastic flow
The flow of metal that occurs on the shear plane, which extends from the cutting-tool edge to the corner between the chip and the work surface. A hand tool with two hinged arms ending in jaws that are closed by hand pressure to grip something. 1) The end of the tool that has been ground for cutting purposes. 2) The part of a twist drill that consists of the chisel edge, lips, lip clearance, and heel. A CNC programming method in which any number of programmed points are joined together by straight lines. A cutting-off machine utilized to cut material of various shapes and sizes up to six inches across. Taking advance measures against something possible or probable such as measures taken to prevent leaks. The process used to preheat and pre-reduce the iron ore fed to the smelter, using the offgases from the smelter. Instrument used to permanently mark the location of layout lines. To keep from injury. A power driven machine used to cut, draw, or otherwise shape material, especially metal sheets, with dies, under pressure or by heavy blows. A machine part that is shaped like a quarter circle. Part of the lathe that contains a number of different-size gears and provides the feed rod and lead screw with various speeds for turning and thread cutting operations. Part of the vertical milling machine that moves vertically in the head and contains the spindle. Part of the vertical milling machine that moves the quill up and down within the head as does the quill feed lever. A bandsaw operation where internal or external contours may be cut easily. The operation of sizing and producing a smooth, round hole from a previously drilled or bored hole with the use of a cutting tool having several cutting edges. A surface of known flatness or a point from which other lines and locations can be measured. A process that produces liquid steel, suitable for ladle metallurgy treatment. Returning a storage location in the MCU to zero or to a specified initial value. 167
pliers point
point-to-point positioning power hacksaw prevention prereduction prick punch protect punch press
quadrant quick change gearbox
quill quill feed hand wheel radius cutting reaming
reference refining reset
rigging roller guide brackets
Gates, risers, loose pieces, etc., needed on the pattern to produce a sound casting. A part of the horizontal band saw that provide rigidity for a section of the blade and can be adjusted to accommodate various widths of material. The bottom surface joining the sides of two adjacent threads. A document that describes the order of processing for the part(s) being manufactured (machined). The tear that occurs when brittle materials, such as cast iron, are cut and the chip breaks away from the work surface. 1) 2) An H-shaped casting mounted on the top of the lathe ways and provides a means of mounting the cross-slide and the apron. The part of the horizontal milling machine that is fitted on top of the knee and may be moved in or out either manually or automatically.
root route sheet rupture saddle
safety scraper screwdriver scriber servo system
The condition of being free from danger, injury, or damage. A hand tool used to move something hard, sharp, or rough across a surface, especially in order to clean it. A hand tool for fastening screws. A sharp instrument used to mark and lay out a pattern of work to be followed in subsequent machining operations. An automatic system for maintaining the read/write head on track. It can be either "open loop", "quasi-closed loop", or "closed loop". The amount that the teeth are offset on either side of the center to produce clearance for the back of the band or blade. Refers to line preparation to cut new width size for customer specification. 1) The body of the toolbit or the part held in the tool holder. 2) The part of the drill that fits into the holding device, whether it is a straight shank or a tapered shank. An operation in the manufacture of vitrified grinding wheels in which special wheel shapes and recesses are shaped or shaved to size in the green, or unburned, state on a shaving machine, which resembles a potters wheel. The angle of the area of the material where plastic deformation occurs. The area where plastic deformation of the metal occurs. A type of milling cutter that has cutting edges around its periphery 168
set setup shank
shaving
shear angle shear zone shell mill
and can be mounted on an arbor. side cutting edge angle side rake angle side relief angle slotting smelting spindle The angle the cutting edge forms with the side of the tool shank. The angle at which the face is ground away from the cutting edge. The angle ground on the flank of the tool below the cutting edge. A bandsaw operation where the saw makes a slit in the material. The process by which iron is removed from iron ore. 1) The hole through the headstock to which bar stock can be fed on a lathe. 2) Part of the vertical milling machine in which cutting tools are installed. 3) Part of the horizontal milling machine that provides the drive for arbors, cutters, and attachments used on the milling machine. The part of the horizontal milling machine that is set by a crank that is turned to regulate the spindle needle. Part of the lathe that when closed around the lead screw drives the carriage along by direct drive without using a clutch. A bandsaw operation where the saw divides the material into usually two pieces, especially lengthways. The operation of smoothing and squaring the surface around a hole to provide a seat for the head of a cap screw or a nut. Instruments used to lay out lines at right angles to a machined edge to test the accuracy of surfaces that must be square, and to set up work for machining. Device used to check 450 and 900 angles and measure depths. The level of quality or excellence that is accepted as the norm or by which actual attainments are judged. Part of the lathe clamped to the ways that uses adjustable fingers to contact the workpiece and align it. It can be used in place of tailstock to support long or unstable parts being machined. A scale used for measuring and layout. A part of the horizontal band saw used to vary the speed of the continuous blade to fit the type of material cut. The material being machined. It can be any material and any shape. In the machine shop it usually refers to round or flat pieces of metal ready to be machined. A tool for scribing layout lines on a workpiece, or for transferring measurements from a rule to a workpiece.
spindle feed dial split nut splitting spot facing squares
square head standard
steady rest
steel rule step pulleys stock
surface gauge
169
surface plate
Provides a precision reference surface for layout, checking, machining and gauging work. An attachment that enables the headstock to be tilted from 5o below the horizontal position to 10o beyond the vertical position. The part of the horizontal milling machine that enables the table to be swiveled 450 to either side of the centerline. The part of the horizontal milling machine that supports the vise and the work. The part of the horizontal milling machine used to move the table toward or away from the column. 1) Part of the lathe that fits on the inner ways of the bed and can slide towards any position on the headstock to fit the length of the work piece. 2) Part of the universal dividing head set used in conjunction with the headstock to support work held between centers or the end of work held in a chuck.
swiveling block swivel table housing table table handwheel tailstock
tailstock quill taper tapping taps tensile strength thread three-dimensional shaping tolerance tool function tool length offset tool offset tool post toughness
Has a Morse taper to hold a lathe center, drill bit, or other tool. A uniform change in the diameter of a workpiece measured along its axis. The operation of cutting internal threads in a hole with a cutting tool called a tap. Cutting tools used to cut internal threads. The maximum amount of pull that a material will withstand before breaking. A helical ridge of uniform section formed on the inside or outside of a cylinder or cone. A bandsaw operation where complicated shapes may be cut. A range by which a product's gauge can deviate from those ordered and still meet the order's requirements. A command that identifies a tool and calls for its selection. The distance between the bottom of the fully retracted tool and the part Z0. A correction entered for a tool's position parallel to a tool movement axis. Part of the lathe used to mount tool holders in which the cutting bits are clamped. The property of the metal to withstand shock or impact. 170
trammel
Instrument used to scribe large arcs and circles.
truing
An operation in the manufacture of vitrified grinding wheels in which the cured wheels are mounted in a special lathe and turned to the required size and shape by hardened-steel conical cutters, diamond tools, or special grinding wheels. A cutting tool used to machine T-slot grooves in worktables, fixtures, and other holding devices. A production process that is used for cleaning, polishing, and removing sharp corners and burrs from metal parts. Part of the vertical milling machine that allows the milling head to be rotated around the columns center. A chuck having jaws which can be moved simultaneously so as to grasp objects of various sizes. Precision tools used to make accurate measurements to within .001 in. or 0.02 mm. A machine tool that provides a fast and economical method of cutting metal and other materials. Part of the vertical milling machine that moves the knee, saddle, and worktable up and down in unison. A part of the horizontal band saw that can be adjusted to hold various sizes of work pieces. The inner and outer guide rails on a lathe that are precision machined parallel to assure accuracy of movement. A semi-circular or half-round piece, resting in a circular groove cut in a shaft used for milling semi-cylindrical keyways in shafts. A type of gear that engages with a worm to greatly reduce rotational speed or to allow higher torque to be transmitted. A hand tool with fixed or movable jaws, used to seize, turn, or twist objects such as nuts and bolts.
T-slot cutter tumbling turret universal chuck Vernier caliper vertical bandsaw vertical movement crank vise ways Woodruff key worm wheel wrench
171

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STUDENT MANUAL

1 12 22 31 40 49 60 71 82 95 107 117 127 137 147 157

Introduction to Machining Technology

UNIT 1 Vocabulary Development

Study the following words and complete the sentences. 1. assembly

UNIT 1 Reading Comprehension

The Metalwoking Industry

The three most common are

d. Make accurate parts out of metal or other solid materials.

d. Map out the steps of cutting and finishing operations.

3. A drill press is an example of: a. A lathe. b. Metal stock. c. A machine tool.

7. Paragraph 4: a. Defines shops. b. Compares shops. c. Classifies shops. d. Contrasts shops.

8. Complete the following map of paragraphs 4 through 7.

There are three common types of shops.

Connected with manufacturing plant, __________________or ______________________

Connected with ______________ _________________________ or __________________________

Contracted to other ___________ __________________________

Makes many types ____________ _______________________ parts.

Produces jigs, ______________, dies, __________, or short runs of _____________________

Machinist operates __________ __________________________

Machinist operates ____________ ___________________________

Machinist operates ___________ ___________________________

b. A production shop machinist operates all types of measuring equipment.

UNIT 1 Vocabulary Development

Study the following words and complete the sentences.

UNIT 1 Reading Comprehension

Careers in the Metalworking Industry

8. Describe the job of an instrument maker.

10. Complete the modular training system chart below.

___ ___ ___ ___ ___

Safety in the Machine Shop

UNIT 2 Vocabulary Development

Study the following words and complete the sentences.

9. protect 10. safety

Safety in the Machine Shop

d. Both [b] and [c].

d. Lack of good housekeeping.

Describes safety in a machine shop.

d. Gives examples of safety in a machine shop.

d. All of the above.

9. Describe the procedure to follow for lifting a heavy object.

UNIT 2 Vocabulary Development

Study the following words and complete the sentences.

You should wear a ___________________________ in this area.

UNIT 2 Reading Comprehension 1.

Read the following paragraphs. Answer the questions that follow.

Maintenance Safety Bulletin

Suggestions On How To Prevent This Type Of Accident:

Include safety in machine specifications, i.e. design for safety.

1. Who is sending the bulletin?

2. Why was the safety bulletin written?

10. route sheet

UNIT 3 Reading Comprehension

2. How can you check the accuracy of a machining process?

3. Name two types of measurement. a. b.

4. Which type of measurement is used more? a. linear measurement.

5. Why is there no direction component to linear measurement?

6. Which figure below illustrates angular measurement?

[a] 7. Name the two systems of measurement machinists use. a. b.

10. Which system of measurement is more popular in the United States?

____ ____ ____

3. Which sentence explains more about the word?

4 MOVABLE JAW 1 VERNIER CALIPER

Connected with manufacturing plant, or ____

Connected with __ _ or ______________

Contracted to other _ ________________

Makes many types ___________ parts.

Produces jigs, , dies, , or short runs of _________

Machinist operates ________________

Machinist operates _______________

Machinist operates _ _________________

_ _ _ _ ___

1. 2. 3. 4. 5. 6.

7. 8. 9. 10. 11. 12.

_____ _ _ _____

_____ _ _ _____