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Manual Mill Operation 220

Manual Machining Training

Class Information

Tooling U classes are offered at the beginner, intermediate, and advanced levels. The typical class consists of 12 to 25 lessons and typically requires at least two hours of instruction time.

Class Name:	Manual Mill Operation 220
Description:	This class guides you through the machining of a common part on the mill as well as explains common milling operations performed on the mill.
Prerequisites:	150205
Difficulty:	Intermediate
Number of Lessons:	18

Class Outline

Objectives
Overview of Manual Mill Operations
Sample Part: Specifications
Order of Operations
Sample Part: Mill Preparation
Face Milling Principles
Sample Part: Squaring Surface #1
Sample Part: Squaring Surface #2
Sample Part: Squaring Surface #3
Sample Part: Squaring Surface #4
End Milling Principles
Sample Part: Squaring the Ends
Layout for the Mill
Sample Part: Milling the Step
Sample Part: Milling the Groove
Drilling Principles
Sample Part: Drilling
Summary

Class Objectives

List common manual mill operations.
Describe how a sample blueprint impacts the necessary machining steps.
Describe the operations performed on a sample part.
Describe common setup procedures required for a mill operation.
Describe common principles for face milling.
List the steps necessary to square the first surface on the sample part.
List the steps necessary to square the second surface on the sample part.
List the steps necessary to square the third surface on the sample part.
List the steps necessary to square the fourth surface on the sample part.
Describe common principles for end milling.
List the steps necessary for squaring the ends of the sample part.
Describe common layout methods used on the mill.
List the steps necessary to mill the step on the sample part.
List the steps necessary to mill the groove on the sample part.
Describe common principles for drilling.
List the steps necessary for drilling holes in the sample part.

Class Vocabulary
boring	The process of enlarging an existing hole with a single-point tool.
caliper	A measuring instrument with two pairs of jaws on one end and a long beam containing a marked scale of unit divisions. One pair of jaws measures external features; the other pair measures internal features.
center drill	A type of drill with a wide shank and a 60 degree angle tip.
center drilled	Using a center drill to make a tapered hole in the end of a part to be supported by a center.
conventional milling	A type of milling that feeds the cutter against the cutter rotation. Conventional milling is typically used for roughing the part to size.
dead blow hammer	A type of hammer that gives a solid blow to different materials without damaging their surfaces.
drill press	A machining tool that uses a drill to penetrate the surface of a workpiece and make a round hole. Drill presses can be used for a variety of hole-making operations.
drilling	The process of using a multi-point tool to penetrate the surface of a workpiece and make a round hole.
edge finder	A device used on a mill to locate the exact position of a part edge along the X-axis or Y-axis.
end mill	A narrow cutting tool that can be used to machine grooves, slots, circular slots, etc. into workpieces.
end milling	A milling operation that uses a narrower mill to create pockets and contours in a workpiece.
face mill	A type of mill cutter that contains multiple cutting teeth and is often used to remove large amounts of material.
face milling	A milling operation that produces a flat surface by guiding a wider mill across the surface of the workpiece.
flute	A groove on the periphery of a cutter that allows for chip flow away from the cut.
form milling	A milling operation that uses a mill with a unique shape to create that shape into the workpiece.
layout	The marking of lines, centers, or circles on metal workpieces. Layout work shows size, shape, hole locations, or areas to be machined.
layout dye	A fluid that is brushed on a metal workpiece before layout that allows the lines to be seen more clearly.
micrometer	A handheld measuring device used to inspect the dimensions of parts. The typical micrometer is accurate within 0.001 in. or 0.02 mm.
milling machine	A machine that uses a multi-point tool to remove metal from the surface of a workpiece.
parallels	Two metal supports that are used to position the workpiece to the desired working height in the vise.
plunging	A process that consists of quick movements of the quill and Y-axis to remove larger amounts of material in a short time.
reaming	The process of using a multi-point tool to smooth the interior surface of a hole.
slab milling	A milling operation that uses a cylindrical mill on an axis parallel to the worktable to create a flat surface.
slotting	A milling operation that cuts a narrow ridge into the surface of a workpiece
squaring	The process of making the sides of a part even and parallel using a rough face milling operation.
symmetrical	A part that can be divided by a line into two equal halves, with identical features that are equal distances from the dividing line. Both sides appear as mirror images of each other.
tapping	The process of cutting internal threads in a round hole with a multi-point tool.