Machines for Metal Cutting 130 - Tooling U-SME

Machines for Metal Cutting 130
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Class Outline
Class Outline
Objectives
Machines for Metal Cutting
Saws
Lathes
Types of Lathes
Lathe Components
The Carriage and the Compound Rest
Cutting Tools for the Lathe
Milling Machines
Types of Milling Machines
Milling Machine Components
Moveable Components of the Milling Machine
Cutting Tools for the Milling Machine
Drill Presses
Broaching Machines
Summary
Lesson: 1/16
Objectives
l Describe machining.
l Describe common saws.
l Describe how lathes cut parts.
l Describe common lathes.
l Identify major lathe components.
l Define carriage and compound rest.
l Describe common lathe cutting tools.
l Describe how milling machines cut parts.
l Describe common milling machines.
l Identify major milling machine components.
l Define different moving components of the milling machine.
l Describe common milling machine cutting tools.
l Describe the role of the drill press.
l Identify components of the drill press.
l Describe a broaching machine.
Figure 1. A band saw is a metal cutting
machine that is instrumental in preparing stock
for machining.
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Lesson: 1/16
Objectives
l Describe machining.
l Describe common saws.
l Describe how lathes cut parts.
l Describe common lathes.
l Identify major lathe components.
l Define carriage and compound rest.
l Describe common lathe cutting tools.
l Describe how milling machines cut parts.
l Describe common milling machines.
l Identify major milling machine components.
l Define different moving components of the milling machine.
l Describe common milling machine cutting tools.
l Describe the role of the drill press.
l Identify components of the drill press.
l Describe a broaching machine.
Figure 1. A band saw is a metal cutting
machine that is instrumental in preparing stock
for machining.
Figure 2. Moveable components of the column and -knee mill can move a workpiece up-and down, in-and -out, and side -to-side.
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Figure 3. The teeth of this broach increase in
size gradually, from a rough circle shape at (A)
to a square shape at (B).
Figure 3. The teeth of this broach increase in
size gradually, from a rough circle shape at (A)
to a square shape at (B).
Lesson: 2/16
Machines for Metal Cutting
Machining produces parts by removing material from a workpiece. Cutting is a traditional
machining process that makes parts by creating chips. A closeup view of chips is shown in Figure
1.
Every metal cutting process involves the combination of a cutting tool and a machine tool. A single
machine tool can use a variety of cutting tools to machine a workpiece and remove material. Cutting
tools are commonly divided into single-point tools and multi-point tools and are carefully chosen
based on their shape. Figures 2 and 3 show a single- and multi-point cutting tool, respectively.
While the cutting tool determines the specific operation, different machine tools are best suited for
specific types of workpieces. The most common machines for metal cutting include the saw, lathe,
milling machine, drill press, and broaching machine. In this class, you will learn about these machine
tools and their components. You will also learn about the tools that each machine uses to cut
parts.
Figure 1. Metal chips are the by -products of
metal cutting.
Figure 2. Single-point tools have only one
cutting edge contacting the workpiece at any
time.
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Lesson: 2/16
Machines for Metal Cutting
Machining produces parts by removing material from a workpiece. Cutting is a traditional
machining process that makes parts by creating chips. A closeup view of chips is shown in Figure
1.
Every metal cutting process involves the combination of a cutting tool and a machine tool. A single
machine tool can use a variety of cutting tools to machine a workpiece and remove material. Cutting
tools are commonly divided into single-point tools and multi-point tools and are carefully chosen
based on their shape. Figures 2 and 3 show a single- and multi-point cutting tool, respectively.
While the cutting tool determines the specific operation, different machine tools are best suited for
specific types of workpieces. The most common machines for metal cutting include the saw, lathe,
milling machine, drill press, and broaching machine. In this class, you will learn about these machine
tools and their components. You will also learn about the tools that each machine uses to cut
parts.
Figure 1. Metal chips are the by -products of
metal cutting.
Figure 2. Single-point tools have only one
cutting edge contacting the workpiece at any
time.
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Figure 3. Multi-point tools have two or more
cutting edges contacting the workpiece at any
time.
Figure 3. Multi-point tools have two or more
cutting edges contacting the workpiece at any
time.
Lesson: 3/16
Saws
When stock arrives at a shop, manufacturers often use saws to cut the stock into smaller pieces
or into different shapes before it is machined further. This first step of the machining process
involves rough cutting long bar stock to length or cutting a part from flat plate stock.
There are three common types of saws used to cut stock:
l
l
l
Band saws are common machines that cut with an "endless" or continuously revolving thin
blade and are often used as cut-off machines. They can also cut shapes out of flat metal
because they are able to cut gradually curving lines. Figure 1 shows a band saw.
Circular saws, like the saw shown in Figure 2, can cut with either a rapidly revolving abrasive
wheel, a circular toothed wheel for very large stock, or a friction saw, which melts through the
metal.
Hacksaws are solid straight saws that use a reciprocating motion in which only one of the
two back-and-forth strokes actually makes a cut. This motion is illustrated in Figure 3.
Saws provide a vital first step by preparing stock for further machining.
Figure 1. A band saw cuts with a continuously
revolving blade.
Figure 2. This circular saw uses a circular
toothed wheel to separate very large stock.
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Figure 3. A reciprocating saw cuts on the
backstroke with a blade similar to a handheld
hacksaw.
Lesson: 3/16
Saws
When stock arrives at a shop, manufacturers often use saws to cut the stock into smaller pieces
or into different shapes before it is machined further. This first step of the machining process
involves rough cutting long bar stock to length or cutting a part from flat plate stock.
There are three common types of saws used to cut stock:
l
l
l
Band saws are common machines that cut with an "endless" or continuously revolving thin
blade and are often used as cut-off machines. They can also cut shapes out of flat metal
because they are able to cut gradually curving lines. Figure 1 shows a band saw.
Circular saws, like the saw shown in Figure 2, can cut with either a rapidly revolving abrasive
wheel, a circular toothed wheel for very large stock, or a friction saw, which melts through the
metal.
Hacksaws are solid straight saws that use a reciprocating motion in which only one of the
two back-and-forth strokes actually makes a cut. This motion is illustrated in Figure 3.
Saws provide a vital first step by preparing stock for further machining.
Figure 1. A band saw cuts with a continuously
revolving blade.
Figure 2. This circular saw uses a circular
toothed wheel to separate very large stock.
Figure 3. A reciprocating saw cuts on the
backstroke with a blade similar to a handheld
hacksaw.
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hacksaw.
Lesson: 4/16
Lathes
The lathe is one of the more versatile and common machine tools found in the shop today. Figure
1 shows a typical lathe. Lathes are used to cut cylindrical parts through turning. The turning
process can shape both internal and external surfaces of a workpiece.
The cutting principle behind the lathe is similar to the principle behind the potter’s wheel. On the
potter's wheel, a clay mass rotates while the potter forms it into a cylindrical shape. Similarly, a part
rotates on the lathe while the cutting tool removes chips.
A lathe commonly rotates a workpiece on a horizontal axis, as demonstrated in Figure 2. Very large
and heavy workpieces are sometimes rotated on a vertical axis, which uses gravity for better
stability.
There are many sizes and types of lathes available for manufacturing cylindrical parts. They range
from the small jeweler’s lathe, which can sit on a table top, to massive lathes that can turn parts
larger than the operator.
Figure 1. The lathe is the most versatile and
common machine tool used for machining
cylindrical workpieces.
Figure 2. A lathe commonly rotates a
workpiece on a horizontal axis.
Lesson: 5/16
Types of Lathes
All lathes are a variation of the basic engine lathe, which is shown in Figure 1. Basic engine lathes
are used today for sharpening tools or for making a small batch of parts.
The turret lathe, shown in Figure 2, includes various lathes equipped with a six-sided toolholding
component called the turret. This lathe can perform several operations on the same part, one after
another. Because the turret can hold several tools, a part may be completed in one setup.
Figure
3 shows
automatic
machine.
This machine is another type of lathe that improves
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U, LLC.bar
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Reserved.
upon the basic model of the engine lathe. Unlike the engine lathe, the automatic bar machine is
capable of continuously feeding bar stock into the cutting area to replenish the workpiece material.
Lesson: 4/16
Lathes
The lathe is one of the more versatile and common machine tools found in the shop today. Figure
1 shows a typical lathe. Lathes are used to cut cylindrical parts through turning. The turning
process can shape both internal and external surfaces of a workpiece.
The cutting principle behind the lathe is similar to the principle behind the potter’s wheel. On the
potter's wheel, a clay mass rotates while the potter forms it into a cylindrical shape. Similarly, a part
rotates on the lathe while the cutting tool removes chips.
A lathe commonly rotates a workpiece on a horizontal axis, as demonstrated in Figure 2. Very large
and heavy workpieces are sometimes rotated on a vertical axis, which uses gravity for better
stability.
There are many sizes and types of lathes available for manufacturing cylindrical parts. They range
from the small jeweler’s lathe, which can sit on a table top, to massive lathes that can turn parts
larger than the operator.
Figure 1. The lathe is the most versatile and
common machine tool used for machining
cylindrical workpieces.
Figure 2. A lathe commonly rotates a
workpiece on a horizontal axis.
Lesson: 5/16
Types of Lathes
All lathes are a variation of the basic engine lathe, which is shown in Figure 1. Basic engine lathes
are used today for sharpening tools or for making a small batch of parts.
The turret lathe, shown in Figure 2, includes various lathes equipped with a six-sided toolholding
component called the turret. This lathe can perform several operations on the same part, one after
another. Because the turret can hold several tools, a part may be completed in one setup.
Figure 3 shows an automatic bar machine. This machine is another type of lathe that improves
upon
the basic
model
of U,
the
engine
lathe.
Unlike the engine lathe, the automatic bar machine is
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Tooling
LLC.
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Reserved.
capable of continuously feeding bar stock into the cutting area to replenish the workpiece material.
After machining, workpieces are cut off, and another section of bar stock is fed into the machining
area.
Lesson: 5/16
Types of Lathes
All lathes are a variation of the basic engine lathe, which is shown in Figure 1. Basic engine lathes
are used today for sharpening tools or for making a small batch of parts.
The turret lathe, shown in Figure 2, includes various lathes equipped with a six-sided toolholding
component called the turret. This lathe can perform several operations on the same part, one after
another. Because the turret can hold several tools, a part may be completed in one setup.
Figure 3 shows an automatic bar machine. This machine is another type of lathe that improves
upon the basic model of the engine lathe. Unlike the engine lathe, the automatic bar machine is
capable of continuously feeding bar stock into the cutting area to replenish the workpiece material.
After machining, workpieces are cut off, and another section of bar stock is fed into the machining
area.
The most sophisticated lathe is the CNC turning center, which is shown in Figure 4. This machine
combines some features of turret lathes and automatic bar machines. Computers control the
motion of the tool and the workpiece. A CNC turning center can perform numerous operations to
achieve incredibly precise dimensions.
Figure 1. Today, an engine lathe is used for
sharpening tools or for making a small batch of
parts.
Figure 2. This lathe has a six -sided turret and
can perform several operations on the same
part, one after another.
Figure 3. An automatic bar machine is capable
of continuously feeding bar stock into the
cutting area to replenish the workpiece
material.
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material.
Figure 4. A CNC turning center can perform
numerous operations to achieve incredibly
precise dimensions.
Lesson: 6/16
Lathe Components
The two main ends of the engine lathe are the headstock and the tailstock, which are illustrated in
Figure 1. The headstock contains the main drive that turns the spindle. The tailstock contains a
center that holds the other end of the workpiece in place. Both the headstock and tailstock rest
upon the bed of the engine lathe.
Chucks and collets are attached to the spindle. A chuck is shown in Figure 2, and several collets of
various sizes are shown in Figure 3. These workholding components are used to clamp the
workpiece in the spindle. During operation, the spindle and the center hold the workpiece in place
firmly on both ends. The spindle also powers the rotation, but the center merely holds the part still.
Not all operations require a workpiece that is held on both ends. Some operations hold the
workpiece in the headstock on one end and use a cutting tool in the tailstock. Longer workpieces
are most often held on both ends.
Figure 1. The basic parts of the lathe include
the headstock, tailstock, bed, spindle, and
center.
Figure 2. The chuck is held on the spindle.
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Lesson: 6/16
Lathe Components
The two main ends of the engine lathe are the headstock and the tailstock, which are illustrated in
Figure 1. The headstock contains the main drive that turns the spindle. The tailstock contains a
center that holds the other end of the workpiece in place. Both the headstock and tailstock rest
upon the bed of the engine lathe.
Chucks and collets are attached to the spindle. A chuck is shown in Figure 2, and several collets of
various sizes are shown in Figure 3. These workholding components are used to clamp the
workpiece in the spindle. During operation, the spindle and the center hold the workpiece in place
firmly on both ends. The spindle also powers the rotation, but the center merely holds the part still.
Not all operations require a workpiece that is held on both ends. Some operations hold the
workpiece in the headstock on one end and use a cutting tool in the tailstock. Longer workpieces
are most often held on both ends.
Figure 1. The basic parts of the lathe include
the headstock, tailstock, bed, spindle, and
center.
Figure 2. The chuck is held on the spindle.
Figure 3. Collets offer more complete support
for smaller workpieces.
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Lesson: 7/16
Lesson: 7/16
The Carriage and the Compound Rest
A moveable section of the lathe called the carriage is capable of sliding from one end of the
machine to the other as the workpiece rotates. The carriage, shown in Figure 1, slides on the
ways, which are shown in Figure 2. The ways are precisely measured and embedded into the bed
of the lathe. The carriage contains the compound rest, which permits angular adjustment of the
cutting tool.
The carriage and the compound rest work together to control the type of cutting operation
performed by the tool. First, the compound rest moves to determine the angle of the cut. After the
tool is positioned, the carriage moves along the ways to begin the actual cutting.
The carriage is powered by a leadscrew, which is shown in Figure 3. The leadscrew rotates to time
the movement of the carriage with the rotation of the workpiece. On the lathe, there are controls
for the spindle speed, carriage movement, and tailstock movement.
Figure 1. The carriage supports the compound
rest, which holds the cutting tool.
Figure 2. The ways guide the motion of the
carriage.
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carriage.
Figure 3. The major components of the lathe.
Lesson: 8/16
Cutting Tools for the Lathe
During turning, a lathe uses a single-point cutting tool to remove material from the workpiece. The
most common tool is a carbide insert clamped onto a toolholder, as shown in Figure 1. More
traditional tools are made from high-speed steel (HSS). High-speed steel tools are inexpensive
and are relatively tough. However, carbide tools have better strength and hardness than HSS and
are better for high speeds and higher temperatures. Carbide inserts are common in shops today
because they are durable and inexpensive, have several cutting points, and are removable and
disposable.
Single-point tools provide both the sharp edge and the shape needed for a particular operation.
The machinist chooses a cutting tool based on the operation. Different cutting tool materials offer a
different hardness and withstand different temperatures, speeds, and feeds. The machinist may
choose a roughing tool to make deep cuts at high speed. A finishing tool provides smooth
finishes and close tolerances.
Figure 1. Carbide inserts are durable and
inexpensive, have several available cutting
points, and are easily replaced.
Lesson: 9/16
Milling Machines
Along with the lathe, the milling machine is one of the most useful and versatile machines in the
shop today. Milling machines are most often used to generate flat surfaces, but they can also cut
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U, LLC. All Unlike
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pockets
complex
the lathe, the tool on the mill rotates against a stationary
workpiece.
Lesson: 8/16
Cutting Tools for the Lathe
During turning, a lathe uses a single-point cutting tool to remove material from the workpiece. The
most common tool is a carbide insert clamped onto a toolholder, as shown in Figure 1. More
traditional tools are made from high-speed steel (HSS). High-speed steel tools are inexpensive
and are relatively tough. However, carbide tools have better strength and hardness than HSS and
are better for high speeds and higher temperatures. Carbide inserts are common in shops today
because they are durable and inexpensive, have several cutting points, and are removable and
disposable.
Single-point tools provide both the sharp edge and the shape needed for a particular operation.
The machinist chooses a cutting tool based on the operation. Different cutting tool materials offer a
different hardness and withstand different temperatures, speeds, and feeds. The machinist may
choose a roughing tool to make deep cuts at high speed. A finishing tool provides smooth
finishes and close tolerances.
Figure 1. Carbide inserts are durable and
inexpensive, have several available cutting
points, and are easily replaced.
Lesson: 9/16
Milling Machines
Along with the lathe, the milling machine is one of the most useful and versatile machines in the
shop today. Milling machines are most often used to generate flat surfaces, but they can also cut
pockets and complex contours. Unlike the lathe, the tool on the mill rotates against a stationary
workpiece.
Mills use multi-point tools. Keep in mind that the term "mill" can refer to either the machine or the
cutting tool. Each time one of the milling cutter edges engages the metal, it removes a small
individual chip of material. The equally spaced teeth of the milling cutter rapidly enter the workpiece,
one after another. Workholders, such as the vise in Figure 1, hold the workpiece on the machine
table during the milling operation.
Milling machines are classified as either vertical or horizontal milling machines, depending on the
orientation of the spindle. The vertical mill has a spindle that is perpendicular to the shop floor, as
shown in Figure 2. The horizontal mill has a spindle that is parallel to the shop floor, as shown in
Figure 3.
Figure 1. A vise can be used to hold the
workpiece firmly in place during machining on a
mill.
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Lesson: 9/16
Milling Machines
Along with the lathe, the milling machine is one of the most useful and versatile machines in the
shop today. Milling machines are most often used to generate flat surfaces, but they can also cut
pockets and complex contours. Unlike the lathe, the tool on the mill rotates against a stationary
workpiece.
Mills use multi-point tools. Keep in mind that the term "mill" can refer to either the machine or the
cutting tool. Each time one of the milling cutter edges engages the metal, it removes a small
individual chip of material. The equally spaced teeth of the milling cutter rapidly enter the workpiece,
one after another. Workholders, such as the vise in Figure 1, hold the workpiece on the machine
table during the milling operation.
Milling machines are classified as either vertical or horizontal milling machines, depending on the
orientation of the spindle. The vertical mill has a spindle that is perpendicular to the shop floor, as
shown in Figure 2. The horizontal mill has a spindle that is parallel to the shop floor, as shown in
Figure 3.
Figure 1. A vise can be used to hold the
workpiece firmly in place during machining on a
mill.
Figure 2. The spindle on a vertical mill has an
axis that is perpendicular to the shop floor.
Figure 3. The spindle on a horizontal mill has
an axis that is parallel to the shop floor.
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Figure 3. The spindle on a horizontal mill has
an axis that is parallel to the shop floor.
Lesson: 10/16
Types of Milling Machines
A common type of milling machine used for general operations is the column-and-knee milling
machine. As shown in Figure 1, the column refers to the main vertical support of the machine.
The knee refers to the support underneath the worktable.
The bed-type milling machine and planer-type milling machine, shown in Figure 2, are easily
distinguished by their large worktables. They are designed to handle large flat parts. These
machines have greater stiffness but less motion in the table. Each machine may have several
different cutters in both the vertical and horizontal orientation.
Improvements in computer technology have led to the development of versatile and powerful milling
machines called CNC machining centers. Figure 3 shows two examples of these powerful
machines. These multi-purpose machines are able to accurately perform many machining operations
besides milling. They can execute a wide range of holemaking operations and can machine very
complex contours.
Figure 1. On the column-and -knee milling
machine, the column is the main vertical
support, while the knee is the support
underneath the worktable.
Figure 2. The planer-type milling machine has
a very large worktable.
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Figure 3. These two examples of CNC
machining centers are run by a computer.
Lesson: 10/16
Types of Milling Machines
A common type of milling machine used for general operations is the column-and-knee milling
machine. As shown in Figure 1, the column refers to the main vertical support of the machine.
The knee refers to the support underneath the worktable.
The bed-type milling machine and planer-type milling machine, shown in Figure 2, are easily
distinguished by their large worktables. They are designed to handle large flat parts. These
machines have greater stiffness but less motion in the table. Each machine may have several
different cutters in both the vertical and horizontal orientation.
Improvements in computer technology have led to the development of versatile and powerful milling
machines called CNC machining centers. Figure 3 shows two examples of these powerful
machines. These multi-purpose machines are able to accurately perform many machining operations
besides milling. They can execute a wide range of holemaking operations and can machine very
complex contours.
Figure 1. On the column-and -knee milling
machine, the column is the main vertical
support, while the knee is the support
underneath the worktable.
Figure 2. The planer-type milling machine has
a very large worktable.
Figure 3. These two examples of CNC
machining centers are run by a computer.
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Figure 3. These two examples of CNC
machining centers are run by a computer.
Lesson: 11/16
Milling Machine Components
On the vertical spindle column-and-knee machine illustrated in Figure 1, a head located at the top
of the column extends over the workpiece. The head contains the spindle. As with the lathe, the
spindle is the machine component that rotates. However, on the milling machine, the spindle
rotates the cutting tool instead of the workpiece. Figure 2 shows the location of the spindle on a
vertical mill.
The horizontal spindle column-and-knee milling machine, illustrated in Figure 3, has an overarm
that extends over the workpiece. The overarm supports the arbor, which holds the milling cutter.
On the horizontal mill, the arbor is the component that rotates the milling cutter. Whether the mill
is vertical or horizontal, a base provides support and rigidity to the machine.
Figure 1. A head located at the top of the
column extends over the workpiece on the
vertical spindle column-and -knee machine.
Figure 2. On a mill, the spindle rotates the
cutting tool.
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Lesson: 11/16
Milling Machine Components
On the vertical spindle column-and-knee machine illustrated in Figure 1, a head located at the top
of the column extends over the workpiece. The head contains the spindle. As with the lathe, the
spindle is the machine component that rotates. However, on the milling machine, the spindle
rotates the cutting tool instead of the workpiece. Figure 2 shows the location of the spindle on a
vertical mill.
The horizontal spindle column-and-knee milling machine, illustrated in Figure 3, has an overarm
that extends over the workpiece. The overarm supports the arbor, which holds the milling cutter.
On the horizontal mill, the arbor is the component that rotates the milling cutter. Whether the mill
is vertical or horizontal, a base provides support and rigidity to the machine.
Figure 1. A head located at the top of the
column extends over the workpiece on the
vertical spindle column-and -knee machine.
Figure 2. On a mill, the spindle rotates the
cutting tool.
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Figure 3. An overarm supports the arbor,
where the milling cutter is held on the
horizontal spindle column-and -knee milling
machine.
cutting tool.
Figure 3. An overarm supports the arbor,
where the milling cutter is held on the
horizontal spindle column-and -knee milling
machine.
Lesson: 12/16
Moveable Components of the Milling Machine
Different components of the milling machine are capable of movement during operations. As you
can see in Figure 1, the moveable components of the column-and-knee mill can move a workpiece
up-and-down, in-and-out, and side-to-side. The knee supports the worktable from underneath,
and it can be adjusted vertically. The worktable, located on top of the knee, can be adjusted back
and forth. The table supports the workholder and the workpiece.
The saddle provides movement in and out with respect to the machine. The column, which is the
backbone of the machine, supports and guides the vertical travel of the knee. The knee, worktable,
and saddle work together to allow the machine operator to perform a variety of milling cuts. Figures
2 and 3 show the moveable components of the vertical and horizontal column-and-knee milling
machine, respectively.
Figure 1. Moveable components of the column and -knee mill can move a workpiece up-and down, in-and -out, and side -to-side.
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Figure 2. The knee, table, and saddle allow for
movement on the vertical column -and -knee
Lesson: 12/16
Moveable Components of the Milling Machine
Different components of the milling machine are capable of movement during operations. As you
can see in Figure 1, the moveable components of the column-and-knee mill can move a workpiece
up-and-down, in-and-out, and side-to-side. The knee supports the worktable from underneath,
and it can be adjusted vertically. The worktable, located on top of the knee, can be adjusted back
and forth. The table supports the workholder and the workpiece.
The saddle provides movement in and out with respect to the machine. The column, which is the
backbone of the machine, supports and guides the vertical travel of the knee. The knee, worktable,
and saddle work together to allow the machine operator to perform a variety of milling cuts. Figures
2 and 3 show the moveable components of the vertical and horizontal column-and-knee milling
machine, respectively.
Figure 1. Moveable components of the column and -knee mill can move a workpiece up-and down, in-and -out, and side -to-side.
Figure 2. The knee, table, and saddle allow for
movement on the vertical column -and -knee
mill.
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Figure 3. The knee, table, and saddle allow for
movement on the horizontal column -and -knee
mill.
Figure 3. The knee, table, and saddle allow for
movement on the horizontal column -and -knee
mill.
Lesson: 13/16
Cutting Tools for the Milling Machine
Milling cutters, or mills, are multi-point tools that have two or more cutting edges. Like single-point
tools, mills are cutting tools that use removable carbide inserts.
On a vertical milling machine, mills are mounted directly in the spindle or in a collet. Different types
of milling cutters have their own specific applications:
l
l
l
A face mill, like the tool shown in Figure 1, can machine large flat surfaces.
An end mill, shown in Figure 2, cuts slots and internal pockets or recesses.
A shell mill, which is a variety of an end mill, is used for machining large surfaces.
On a horizontal milling machine, mills are held in an arbor. The different orientation of the cutter
axis leads to a different set of milling cutters:
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l
l
A plain mill, or slab mill, uses a wide cylinder for generating flat surfaces. Figure 3 illustrates
some slab mills.
A side mill is a narrow cylinder for cutting slots. The T-slot cutter is another variation.
A form mill is shaped to match the desired dimensions of the part.
Figure 1. This large face mill is used to machine
wide, flat surfaces.
Figure 2. An end mill is used to cut slots and
concave or convex shapes.
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Lesson: 13/16
Cutting Tools for the Milling Machine
Milling cutters, or mills, are multi-point tools that have two or more cutting edges. Like single-point
tools, mills are cutting tools that use removable carbide inserts.
On a vertical milling machine, mills are mounted directly in the spindle or in a collet. Different types
of milling cutters have their own specific applications:
l
l
l
A face mill, like the tool shown in Figure 1, can machine large flat surfaces.
An end mill, shown in Figure 2, cuts slots and internal pockets or recesses.
A shell mill, which is a variety of an end mill, is used for machining large surfaces.
On a horizontal milling machine, mills are held in an arbor. The different orientation of the cutter
axis leads to a different set of milling cutters:
l
l
l
A plain mill, or slab mill, uses a wide cylinder for generating flat surfaces. Figure 3 illustrates
some slab mills.
A side mill is a narrow cylinder for cutting slots. The T-slot cutter is another variation.
A form mill is shaped to match the desired dimensions of the part.
Figure 1. This large face mill is used to machine
wide, flat surfaces.
Figure 2. An end mill is used to cut slots and
concave or convex shapes.
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Figure 3. A plain mill, or slab mill, uses a wide
cylinder for generating flat surfaces.
Figure 3. A plain mill, or slab mill, uses a wide
cylinder for generating flat surfaces.
Lesson: 14/16
Drill Presses
A drill press, shown in Figure 1, is used to make and finish holes. These operations include drilling,
reaming, countersinking, and tapping, among others. Besides the common upright drill press,
you may see a radial drill. This drill can accommodate large workpieces that are hard to move.
Multiple spindle drills are useful in high-production environments. As with most CNC machines,
the CNC drill has several tools available to perform any number of the operations mentioned above,
all in one place.
Many drill components have names and functions similar to those of other machine tools. As you
can see in Figure 2, the drill press may resemble the vertical milling machine. Like the milling
machine, the drill press also has a base, column, spindle, and worktable. The base supports the
vertical column. The head, which reaches out over the worktable area, contains the spindle. The
spindle commonly uses a chuck to hold the drill bit. A feed handle moves the spindle up and
down.
Figure 1.
A drill press is used to make and
finish holes.
Figure 2. A drill press has components that are
similar to the components of a vertical mill.
Lesson: 15/16
Broaching Machines
The broaching machine, shown in Figure 1, uses a broach to remove large amounts of metal
from a workpiece. The broach is a tapered multi-toothed cutter that has the roughing, semifinishing, and finishing teeth built into the tool, as shown in Figure 2. It rapidly cuts away the metal
because the teeth progressively increase in size, and it performs its work with a single stroke.
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The broach can remove metal from both internal and external surfaces by being pulled or pushed
through a drilled or bored hole. For example, a broach can create a keyway or a hexagonal shape
Lesson: 14/16
Drill Presses
A drill press, shown in Figure 1, is used to make and finish holes. These operations include drilling,
reaming, countersinking, and tapping, among others. Besides the common upright drill press,
you may see a radial drill. This drill can accommodate large workpieces that are hard to move.
Multiple spindle drills are useful in high-production environments. As with most CNC machines,
the CNC drill has several tools available to perform any number of the operations mentioned above,
all in one place.
Many drill components have names and functions similar to those of other machine tools. As you
can see in Figure 2, the drill press may resemble the vertical milling machine. Like the milling
machine, the drill press also has a base, column, spindle, and worktable. The base supports the
vertical column. The head, which reaches out over the worktable area, contains the spindle. The
spindle commonly uses a chuck to hold the drill bit. A feed handle moves the spindle up and
down.
Figure 1.
A drill press is used to make and
finish holes.
Figure 2. A drill press has components that are
similar to the components of a vertical mill.
Lesson: 15/16
Broaching Machines
The broaching machine, shown in Figure 1, uses a broach to remove large amounts of metal
from a workpiece. The broach is a tapered multi-toothed cutter that has the roughing, semifinishing, and finishing teeth built into the tool, as shown in Figure 2. It rapidly cuts away the metal
because the teeth progressively increase in size, and it performs its work with a single stroke.
The broach can remove metal from both internal and external surfaces by being pulled or pushed
through a drilled or bored hole. For example, a broach can create a keyway or a hexagonal shape
in a round hole with the broaches shown in Figure 3. A slab broach is pulled across the workpiece
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2015 Tooling
U, LLC.
All Rights
Reserved. machines using very expensive broaches can
to
form its©outside
surface.
Large
high-production
efficiently and precisely produce many parts.
Lesson: 15/16
Broaching Machines
The broaching machine, shown in Figure 1, uses a broach to remove large amounts of metal
from a workpiece. The broach is a tapered multi-toothed cutter that has the roughing, semifinishing, and finishing teeth built into the tool, as shown in Figure 2. It rapidly cuts away the metal
because the teeth progressively increase in size, and it performs its work with a single stroke.
The broach can remove metal from both internal and external surfaces by being pulled or pushed
through a drilled or bored hole. For example, a broach can create a keyway or a hexagonal shape
in a round hole with the broaches shown in Figure 3. A slab broach is pulled across the workpiece
to form its outside surface. Large high-production machines using very expensive broaches can
efficiently and precisely produce many parts.
Figure 1. A broaching machine is capable of
removing a large amount of metal in one
motion.
Figure 2. Used to make a square shape in a
round hole, the teeth of this broach increase in
size gradually, from a rough circle shape at (A)
to a square shape at (B).
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Figure 3. These broaches can be used to
create a key way (A) or a hexagonal shape in a
round hole (B).
Figure 3. These broaches can be used to
create a key way (A) or a hexagonal shape in a
round hole (B).
Lesson: 16/16
Summary
Machining produces parts by removing material from a workpiece. Cutting is a machining process
that makes parts by creating chips. Metal cutting machines use various cutting tools to separate
the pieces of metal.
Saws cut stock and parts. Some common saws in the machine shop include the bandsaw, circular
saw, and reciprocating saw. Saw blades are multi-point cutting tools.
Lathes are machines used to turn cylindrical parts. The turning process can shape both internal and
external surfaces of the workpiece. A workpiece rotates on the lathe while the single-point cutting
tool removes chips. Common lathes include the engine, turret, and CNC lathes.
Milling machines are most often used to generate flat surfaces. The milling cutter’s equally spaced
teeth rapidly enter the workpiece and create chips. Mills are available in horizontal or vertical
orientations. CNC machining centers are versatile, powerful machines that can perform a wide range
of milling operations.
Besides the lathe and the mill, other common machine tools are used in the shop. Drill presses are
used to make and finish holes. The broaching machine uses a broach to cut and finish a part with a
single pass.
Figure 1. Metal chips are the by -products of
metal cutting.
Figure 2. On a lathe, the workpiece is rotated
in the spindle.
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Lesson: 16/16
Summary
Machining produces parts by removing material from a workpiece. Cutting is a machining process
that makes parts by creating chips. Metal cutting machines use various cutting tools to separate
the pieces of metal.
Saws cut stock and parts. Some common saws in the machine shop include the bandsaw, circular
saw, and reciprocating saw. Saw blades are multi-point cutting tools.
Lathes are machines used to turn cylindrical parts. The turning process can shape both internal and
external surfaces of the workpiece. A workpiece rotates on the lathe while the single-point cutting
tool removes chips. Common lathes include the engine, turret, and CNC lathes.
Milling machines are most often used to generate flat surfaces. The milling cutter’s equally spaced
teeth rapidly enter the workpiece and create chips. Mills are available in horizontal or vertical
orientations. CNC machining centers are versatile, powerful machines that can perform a wide range
of milling operations.
Besides the lathe and the mill, other common machine tools are used in the shop. Drill presses are
used to make and finish holes. The broaching machine uses a broach to cut and finish a part with a
single pass.
Figure 1. Metal chips are the by -products of
metal cutting.
Figure 2. On a lathe, the workpiece is rotated
in the spindle.
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Figure 3. On a mill, the spindle rotates the
cutting tool.
in the spindle.
Figure 3. On a mill, the spindle rotates the
cutting tool.
Class Vocabulary
Term
Definition
Arbor
Automatic Bar Machine
Axis
Backstroke
The bar attached to the spindle in a horizontal milling machine. The arbor holds the milling cutter.
A turning machine that continuously cuts a number of parts from a piece of bar stock, one after
another. The bar stock advances through the spindle and is held by the collet during the operation.
An imaginary straight line that passes through the center of an object.
The return motion of a saw blade that cuts with a back-and-forth movement.
Band Saw
A long, continuous cutting blade with serrated teeth that is looped around two or more wheels.
Bar Stock
Raw material purchased from metal manufacturers in the form of long bars.
Base
Bed
Bed-Type Milling Machine
Broach
Broaching Machine
Carbide Insert
The foundation of a machine that supports all the other machine components.
The main supporting structure upon which the operating parts of the machine are mounted and
guided.
A type of milling machine used to mill flat surfaces that has a large bed, which only moves along a
horizontal axis.
A multi-point cutting tool made of a series of progressively smaller teeth that can both remove metal
and finish the surface of a workpiece with one pass of the cutting tool.
A machine that uses a multi-point cutting tool to shape and finish either the interior of a hole or the
surface of a workpiece.
A cutting bit made of hard material that has multiple cutting edges. Once a cutting edge is
excessively worn, it can be indexed to another edge, or the insert can be replaced.
Carriage
The section of the lathe that slides back and forth along the ways and supports the cross-slide and
cutting tool.
Center
The device located in the tailstock that holds in place the end of the workpiece opposite the spindle.
Chip
An unwanted piece of metal that is removed from a workpiece. Chips are formed when a tool cuts or
grinds metal.
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Chuck
A device that holds a workpiece in place as it rotates. The chuck commonly has three or four jaws
that can be adjusted to fit various sizes.
Class Vocabulary
Term
Definition
Arbor
Automatic Bar Machine
Axis
Backstroke
The bar attached to the spindle in a horizontal milling machine. The arbor holds the milling cutter.
A turning machine that continuously cuts a number of parts from a piece of bar stock, one after
another. The bar stock advances through the spindle and is held by the collet during the operation.
An imaginary straight line that passes through the center of an object.
The return motion of a saw blade that cuts with a back-and-forth movement.
Band Saw
A long, continuous cutting blade with serrated teeth that is looped around two or more wheels.
Bar Stock
Raw material purchased from metal manufacturers in the form of long bars.
Base
Bed
Bed-Type Milling Machine
Broach
Broaching Machine
Carbide Insert
The foundation of a machine that supports all the other machine components.
The main supporting structure upon which the operating parts of the machine are mounted and
guided.
A type of milling machine used to mill flat surfaces that has a large bed, which only moves along a
horizontal axis.
A multi-point cutting tool made of a series of progressively smaller teeth that can both remove metal
and finish the surface of a workpiece with one pass of the cutting tool.
A machine that uses a multi-point cutting tool to shape and finish either the interior of a hole or the
surface of a workpiece.
A cutting bit made of hard material that has multiple cutting edges. Once a cutting edge is
excessively worn, it can be indexed to another edge, or the insert can be replaced.
Carriage
The section of the lathe that slides back and forth along the ways and supports the cross-slide and
cutting tool.
Center
The device located in the tailstock that holds in place the end of the workpiece opposite the spindle.
Chip
Chuck
Circular Saw
An unwanted piece of metal that is removed from a workpiece. Chips are formed when a tool cuts or
grinds metal.
A device that holds a workpiece in place as it rotates. The chuck commonly has three or four jaws
that can be adjusted to fit various sizes.
A power saw that cuts with a toothed or abrasive disk rotating at high speed.
CNC Machining Center
A sophisticated CNC machine that can perform multiple machining operations in the same setup with
a variety of tools.
CNC Turning Center
A sophisticated CNC machine that specializes in turning, boring, drilling, and threading operations, all
at the same location.
Collet
Column
Column-And-Knee Milling Machine
Compound Rest
A slitted device that holds a workpiece in place as it rotates. A collet has a hole through which the
workpiece passes, and it is designed to hold specific dimensions. Collets can also be used to hold
cutting tools.
The vertical support, or backbone, of a machine.
A milling machine with a spindle that is mounted in the column and a worktable that rests on an
adjustable knee.
The part of the lathe on the carriage that allows for angular adjustment of the cutting tool.
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A cutting process that creates a curved, non-linear dimension.
Countersinking
The cutting of a beveled edge at the end of a hole so that the head of a screw can rest flush with the
Compound Rest
Contour
Countersinking
The part of the lathe on the carriage that allows for angular adjustment of the cutting tool.
A cutting process that creates a curved, non-linear dimension.
The cutting of a beveled edge at the end of a hole so that the head of a screw can rest flush with the
workpiece surface.
Cutting
The use of single- or multi- point tools to separate metal from a workpiece in the form of chips.
Drilling
The use of a rotating drill in order to cut a round hole into a workpiece.
Drive
End Mill
Engine Lathe
Face Mill
Feed Handle
Finishing Tool
The main device that powers the rotation of the spindle.
A thin, tall mill cutter with cutting edges that wind up the sides. Both the bottom and side of the end
mill are used during milling operations. End mills resemble drills.
The original and most basic type of lathe.
A flat mill cutter with multiple cutting teeth surrounding the tool. The bottom of the face mill is
primarily used during milling operations.
A handle attached to a machine that controls the movement of the cutting tool.
A single-point cutting tool used to make a very light cut for final touches to achieve precise
tolerances or improved finishes.
Form Mill
A type of milling cutter that is designed in an irregular shape in order to mill contours.
Hacksaw
A saw that contains a blade made of high-speed steel, molybdenum, or tungsten alloy steel that cuts
in one direction.
Head
Headstock
High-Speed Steel
Keyway
The part of a drill press that contains the spindle and the motor.
The end of a lathe that holds the spindle and the drive that rotates the workpiece.
A material used in cutting tools to machine metals at high cutting speeds. High-speed steel stays
hard at high temperatures, has great hardness, and is resistant to abrasion.
A rectangular slot or groove that is machined down the length of a hole.
Knee
The device supported by an elevating screw that raises and lowers and guides the back and forth
motion of the saddle.
Lathe
A machine tool that holds a cylindrical workpiece at one or both ends and rotates it while various
cutting tools remove material. Turning is a common operation performed on the lathe.
Leadscrew
Machine Tool
Machining
Mill
Milling Cutter
Milling Machine
Multiple Spindle Drill
Multi-Point Tool
The long, threaded device that controls the precise movement of the carriage on a lathe.
A power-driven machine that holds a variety of tools. These tools include cutting tools, workholding
devices, punches, and other manufacturing tools.
The process of removing metal to form or finish a part, either with traditional methods like turning,
drilling, milling, and grinding, or with less traditional methods that use electricity, heat, or chemical
reaction.
A multi-point cutting tool that is used to remove metal from the surface of a workpiece.
A rotary cutting tool with teeth around its periphery that is used on milling machines.
A machine that uses a multi-point tool to remove metal from the surface of a workpiece.
A drilling machine that contains two or more spindles, which perform multiple cutting operations at
the same time.
A cutting tool that has two or more cutting edges.
Overarm
The device on a horizontal milling machine that reaches over the workpiece and supports the spindle
or arbor.
Plain Mill
A cutting tool for the milling machine with cutting surfaces on the periphery. It is used to mill flat
surfaces.
Milling
A very large type of milling machine that often contains numerous milling heads.
CopyrightPlaner-Type
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Plate Stock
A flat piece of raw material that is used to make manufactured parts.
Plain Mill
Planer-Type Milling Machine
Plate Stock
Pocket
Radial Drill
Reaming
Reciprocating
A cutting tool for the milling machine with cutting surfaces on the periphery. It is used to mill flat
surfaces.
A very large type of milling machine that often contains numerous milling heads.
A flat piece of raw material that is used to make manufactured parts.
An interior recess that is cut into the surface of a workpiece.
A drilling machine that can accommodate large workpieces by maneuvering an overarm in place over
the workpiece.
The use of a multi-point cutting tool to smooth or enlarge a previously drilled hole.
The back-and-forth motion of a hacksaw in which only one motion actually contacts and cuts the
workpiece.
Rough Cutting
The quick removal of metal from a workpiece without regard to tolerances or finish.
Roughing Tool
A single-point cutting tool used to make very heavy cuts and remove metal as quickly as possible.
Saddle
Saw
The device supported by the knee that slides back and forth on the knee and guides the left and
right motion of the worktable.
A multi-point cutting device that is used to rough cut a part to a certain length.
Shell Mill
A type of milling cutter that has cutting edges around its periphery and can be mounted on an arbor.
Side Mill
A narrow type of milling cutter that has cutting edges on both its end and periphery.
Single-Point Tool
Slab Broach
Spindle
Stock
Tailstock
Tapping
Tolerance
T-Slot Cutter
Turning
Turret
Turret Lathe
Vise
Ways
A cutting tool that has a single cutting edge.
A flat-shaped broach that is used to remove metal from the workpiece surface.
The part of the machine tool that spins. On the mill, the spindle holds a cutting tool. On the lathe,
the spindle holds the workpiece.
The raw material out of which manufactured parts are made.
The part located at the end of a lathe opposite the headstock that supports the end of longer
workpieces.
The process of cutting internal threads in a workpiece with a multi-point tool.
The unwanted but acceptable deviation from the desired dimension.
A type of milling cutter that is used to machine a portion of a T-shaped slot into a workpiece.
A machining operation used to make cylindrical parts. A single-point cutting tool passes along the
outer surface of a cylindrical workpiece as it rotates, and gradually removes a layer of material.
The component of a lathe that holds a number of cutting tools. The turret rotates to place tools in
the cutting position.
A lathe with a mounted device that holds multiple cutting tools. The turret rotates to position a
specific cutting tool in place.
A workholding device with one fixed jaw and one moveable jaw. Vises are often used to hold simple
rectangular or cubic workpieces on a mill or machining center.
Two precisely measured, parallel tracks that support and guide the movement of the carriage and
cross slide.
Workpiece
A part that is being worked on. It may be subject to cutting, welding, forming or other operations.
Worktable
The part of a machine tool that supports the workpiece and any workholding devices.
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