Machine Shop Shaping Operations

Course Number: 820

This course covers types of milling machines and milling operations. It discusses spindles, arbors, feed rates, and safety precautions, as well as shaper and planer operations - setup, maintenance, and safety procedures. It also introduces grinding, power sawing, and gear cutting operations.

Recommended Contact Hours - 8

Chapter 1: Milling Operations

Topics: Milling machines; Spindles; Arbors; End mill holders and collets; Locating the cutter; Spindle speed, feed, and direction; Indexing; Safety

Learning Objectives:

• Explain the difference between peripheral milling and face milling.
• List the four types of knee-and-column milling machines.
• Explain how each of the knee-and-column machines works.
• Explain how a workpiece is held on a milling machine.
• Name and describe the three basic styles of arbor.
• Explain how the speed of a milling cutter is measured.
• Define indexing.

Chapter 2: Shaping and Planing

Topics: Shaper tooling; Cutting fluids; Cutting speeds; Setup procedures; Angular, internal shaping; Planer construction and tools; Safety

Learning Objectives:

• Compare and contrast shapers and planers.
• Explain the processes of shaping and planing.
• Explain how to select a shaper cutting fluid.
• Explain how shaper cutting speed is expressed.
• Explain how to check alignment of the shaper vise and ram.
• Explain how cutting fluids are applied to planer work

Chapter 3: Grinding Operations

Topics: Grinding machines; Manual grinding; Grinding wheels; Mounting, dressing, and truing a grinding wheel; Cutting fluids; Grinding faults; Safety

Learning Objectives:

• Define grinding.
• Name the five categories of grinding.
• Explain how to read the marking code on a grinding wheel.
• Explain how to mount a grinding wheel.
• Define the terms dressing and truing as related to grinding wheels.
• Explain how cutting fluids id grinding operations.
• List the steps involved in surface grinding.

Chapter 4: Gear Cutting

Topics: Gear types, terms, and definitions; Diametral pitch; Tooth calculations; Cutting spur, bevel gear teeth; Repairing a gear; Cutting other gears

Learning Objectives:

• Name the most common and easiest-to-make gear.
• Name the most widely used types of gears in plant machinery.
• Define the following terms: pitch diameter, circular pitch, diametrial pitch, working depth, and face width.
• Explain how to check the first full tooth of a spur gear after cutting.
• Describe the pitch line of an involute rack.
• Explain how the teeth of straight bevel gears are cut.

Chapter 5: Power Sawing

Topics: Power hacksaws; Blade selection, inspection, and installation; Band saws and blades; Cutting fluids; Straight, contour, and friction sawing; Safety

Learning Objectives:

• Explain when and why cutting fluid is required when using a power hacksaw.
• Explain how to select a power hacksaw blade.
• List at least three rules for good hacksawing.
• Contrast the operation of a hacksaw and a band saw.
• List the three factors involved in selecting the right band saw blade.
• Explain the important points of power sawing safety.