MACHINE SHOP THEORY AND PRACTICE REVIEWER:

BASIC MACHINE TOOLS: (ENUMERATION)

 DRILLING AND BORING (including REAMING, TAPPING, TURNING, MILLING)

Drilling is a basic machine shop operation dating back to primitive humans. It consists of cutting a round hole by
means of a rotating drill.

Boring involves the finishing of a hole already drilled or cored. This is accomplished by means of a rotating,
offset, single-point tool that somewhat resembles the tool used in a lathe or a planer. The tool is stationary and the work
revolves on some boring machines. On other types of boring machines, the reverse is true.

Reaming consists of finishing an already drilled hole. This is done to very close tolerances.

Tapping is the process of cutting a thread inside a hole so that a screw may be used in it.

Turning is done on a lathe. The lathe, as the turning machine is commonly called, is the father of all machine
tools. The principle of turning has been known since the dawn of civilization, probably originating as the potter's wheel.
In the turning operation, the piece of metal to be machined is rotated and the cutting tool is advanced against it.

Turret lathe is a lathe equipped with a multisided toolholder called a turret, to which a number of different
cutting tools are attached. This device makes it possible to bring several different cutting tools into successive use and to
repeat the sequence of machining operations without the need to reset the tools.

Single- and multiple-spindle automatics are used when the number of identical parts to be turned is increased
from a few to hundreds, or even thousands. These machines perform as many as six or eight different operations at one
time on a number of different parts.

Milling consists of machining a piece of metal by bringing it into contact with a rotating cutting tool with multiple
cutting edges. A narrow milling cutter resembles a circular saw blade familiar to most people. Other milling cutters may
have spiral edges, which give the cutter the appearance of a huge screw.

Machines that use the milling principle but are built especially to make gears are called bobbing machines.

Planing or shaping metal with a machine tool is a process somewhat similar to planing wood with a carpenter's
hand plane. The essential difference lies in the large size of the machine tool and the fact that it is not portable. The
cutting tool remains in a fixed position, while the work is moved back and forth beneath it. On a shaper, the process is
reversed. The workpiece is held stationary, while the cutting tool travels back and forth.

Broaches may be classified as planing machines. The broach has a number of cutting teeth. Each cutting edge is a
little higher than the previous one, and it is graduated to the final size required.

Grinding consists of shaping a piece of work by bringing it into contact with a revolving abrasive wheel. The
process is often used for the final finishing to close dimensions of a part that has been heat-treated to make it very hard.

Lapping involves the use of abrasive pastes and compounds. It is limited in its use to extremely small amounts of
stock removal and to situations where there is a high degree of precision and surface finish needed.

The honing technique, in contrast, is widely accepted as a process separate from that of lapping. For example,
there are honing machines with rotating heads that carry abrasive inserts for the extremely accurate finishing of holes.

Shear - This tool is used to cut metal into the required shapes.

Punch press - This tool is used to punch holes in metal sheet and plate.

Mechanical press - This tool is used to blank out the desired shape from a metal sheet and squeeze it into the
final shape in a die under tremendous pressure.

Hydraulic press - This tool does the same work as the mechanical press by the application of hydraulic power.

Drop hammer - This tool is operated by steam or air. It is used to forge or hammer white-hot metal on an anvil.
 Forging machine - This tool squeezes a piece of white-hot metal under great pressure in a die. During the
process, the metal flows into every part of the die cavity where it assumes the shape of the cavity.

SAFETY MAP:

TOPIC 3:
HEAD:

SPINDLE:

TABLE:
BASE:

TWIST DRILLS:

The operation in which a cone-shaped enlargement is formed at the end of a hole is called countersinking.

The operation in which a hole is enlarged cylindrically partway along its length is called counterboring.

CHUCKS:
TOOL OR CUTTING HOLDER:

A tapered drill sleeve is used to hold taper-shank twist drill that are too small for the tapered hole in the spindle
of the drill

A drill socket is used to hold twist drills with shanks too large to fit into either the drill press spindle or a sleeve

A tapered key or drill drift is used to remove twist drills sleeves, and sockets from the drill press spindle

A drill press vise is used to hold and support the work on the drill press table.

Parallels are used to raise the work above the drill press table so that the part can be drilled completely through
without damage to either the vise or the table.

The angle plate is useful when it is desirable to drill a hole parallel to another surface.

A step block is used to support the end of a clamp or strap opposite the work.

TOPIC 4:

Grinding consists of shaping a piece of work by bringing it into contact with a revolving abrasive wheel.

Nonprecision grinding is also called offhand grinding. Metal is removed by this method when there is no great
need for accuracy.

In precision grinding, metal can be removed with great accuracy. There are a number of different precision
grinding machines available that can grind metal parts to different shapes and sizes with very accurate dimensions.

An abrasive is any material that can wear away a substance softer than itself. Sand and sandstone are perhaps
the oldest abrasives known to mankind. Emery and corundum are two natural abrasives commonly used in industry to
sharpen tool edges. The first man-made abrasives are silicon carbide and aluminum oxide.
GRINDING WHEELS:

TYPES OF BONDS:

 VITRIFIED BONDS - has the strength and porosity to enable it to remove a considerable amount of stock from a
job for each inch of wheel wear. It is not affected by water, acids, or ordinary temperature changes, and it is free
from hard or soft spots.
 SILICATE BONDS - is made from sodium silicate. The hardness of a silicate-bond wheel is governed by the
amount of bond material used, and by the amount of tamping or pressing. This kind of bond produces a wheel
that is milder acting than the vitrified wheel.
 RUBBER BONDS - Rubber wheels are made of a mixture of abrasive, rubber, and Sulphur. The mass is then
pressed into shape and given a mild vulcanizing treatment. Wheels of this bond are used for highspeed grinding
operations.
 SHELLAC BONDS - Shellac-bonded wheels are made by mixing the abrasive and the bond in a heated machine,
which completely coats the abrasive with the bonding material. After the wheels are formed, they are placed in
an oven, covered with sand, and baked for a short time at approximately 300 F.
 RESINIOD BONDS - Resinoid-bonded wheels are made by mixing powdered resinoid with the abrasive. particles
and adding a plastic substance so that the wheels can be molded. The mold is then placed in an electric oven and
heated to approximately 300°F for a period ranging from a few hours to three or four days depending on the size
of the wheel.

The term wheel structure refers to the spacing of the abrasive grains.
 Dressing is the operation of cleaning, or fracturing, the cutting surface of a wheel to expose new cutting particles.

Truing is the operation of removing material from the cutting face so that the resulting surface runs concentric with
the wheel-spindle axis.

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