Manual Machining

Manual machining involves the machining of a part on the engine lathe or the manual mill. Both the engine lathe and the basic column-and-knee mill are essential machine tools used to change the size, shape, and finish of a workpiece with a variety of cutting tools. The engine lathe is operated manually and is often used for cylindrical workpieces. The manual mill is most often used for rectangular or flat workpieces. Operating a manual machine requires a skilled machinist with a "sense of feel."
These classes cover the basic components of the engine lathe and column-and-knee mill and address how these components are used during the various cutting processes. Intermediate-level classes focus on the setup of the engine lathe and mill and instruct on how to perform a variety of cutting operations on sample parts.


Class Functional Area Format Difficulty Version Department
1
Classes 1 to 10 of 10
Manual Mill Basics 201

Manual Mill Basics provides an introduction to the manual milling machine. Manual mills are generally either vertical or horizontal, depending on their spindle orientation. This class introduces the machine components, cutting tools and workholding devices commonly used on milling machines. ...

Related 1.0 Class:
Basics of the Manual Mill 110
Machining Online Intermediate 2.0 Manual Machining
Engine Lathe Basics 211

Engine Lathe Basics provides an introduction to the components and controls used on a manual lathe. The lathe creates cylindrical parts by producing a round diameter on a part by rotating a workpiece against a stationary single-point cutting tool. The ...

Related 1.0 Class:
Basics of the Engine Lathe 115
Machining Online Intermediate 2.0 Manual Machining
Manual Mill Setup 221

Manual Mill Setup details important considerations that a mill operator must make before starting any cutting process as well as the steps an operator must follow to ensure proper manual mill setup. Mill setup requires operators to know how to ...

Related 1.0 Class:
Overview of Manual Mill Setup 200
Machining Online Intermediate 2.0 Manual Machining
Engine Lathe Setup 231

Engine Lathe Setup details important considerations that a lathe operator must take before starting any cutting process as well as the steps to ensure proper engine lathe setup. Lathe setup requires operators to know how to select appropriate cutting variables ...

Related 1.0 Class:
Overview of Engine Lathe Setup 205
Machining Online Intermediate 2.0 Manual Machining
Benchwork and Layout Operations 241

Benchwork and Layout Operations provides a detailed overview of the various benchwork and layout processes that operators often need to perform during manual machining. Layout is the process of marking a workpiece prior to cutting in order to have a ...

Related 1.0 Class:
Benchwork and Layout Operations 210
Machining Online Intermediate 2.0 Manual Machining
Manual Mill Operation 251

Manual Mill Operation serves as a guide for manually machining various features onto a workpiece. The class takes the users through the steps of creating a part on the manual mill, including determining the order of operations, squaring the six ...

Related 1.0 Class:
Manual Mill Operation 220
Machining Online Intermediate 2.0 Manual Machining
Engine Lathe Operation 261

Engine Lathe Operation serves as a guide for manually machining various features onto a workpiece. The class establishes principles of basic lathe operation and takes users through procedures for common outer diameter operations, including turning, facing, taper turning, knurling, parting ...

Related 1.0 Class:
Engine Lathe Operation 225
Machining Online Intermediate 2.0 Manual Machining
Holemaking on the Manual Mill 271

Holemaking on the Manual Mill provides information on the principles and processes for various holemaking operations that the manual milling machine can perform. A manual mill is capable of a number of precise holemaking operations, including drilling, tapping, reaming, counterboring, ...

Related 1.0 Class:
Holemaking on the Mill 230
Machining Online Intermediate 2.0 Manual Machining
Threading on the Engine Lathe 301

The class Threading on the Engine Lathe explains threads and how to make them using a manual lathe. Engine lathes can create both external (OD) and internal (ID) threads classified according to either Unified or ISO metric standards. To manually ...

Related 1.0 Class:
Threading on the Engine Lathe 235
Machining Online Advanced 2.0 Manual Machining
Taper Turning on the Engine Lathe 311

Taper Turning on the Engine Lathe describes how to machine common types of tapers on an engine lathe. Cylindrical tapers are a uniform change in diameter on a cylindrical object and help to align and hold various tools and workholding ...

Related 1.0 Class:
Taper Turning on the Engine Lathe 240
Machining Online Advanced 2.0 Manual Machining
FormatFunctional AreaDepartment IDDepartmentClass IDClass NameDescriptionDifficultyVersionLanguageRelated Classes
OnlineMachining150Manual Machining280110 Manual Mill Basics 201 Manual Mill Basics provides an introduction to the manual milling machine. Manual mills are generally either vertical or horizontal, depending on their spindle orientation. This class introduces the machine components, cutting tools and workholding devices commonly used on milling machines. The class also provides an overview of the various controls on the mill that are used to adjust spindle rotation, speed, feed, and depth.Before learning to operate a manual mill, it is necessary to have a basic understanding of the machine tool components as well as the cutting tools and workholding devices that may be used on the machine. The manual mill is a complex machine with many controls and variables, and familiarity is key to becoming a successful operator.Intermediate2.0English(150110) Basics of the Manual Mill 110
OnlineMachining150Manual Machining280115 Engine Lathe Basics 211 Engine Lathe Basics provides an introduction to the components and controls used on a manual lathe. The lathe creates cylindrical parts by producing a round diameter on a part by rotating a workpiece against a stationary single-point cutting tool. The engine lathe, operated manually, is composed of a bed, ways, headstock, spindle, tailstock, carriage assembly, and leadscrew. Workholding devices are attached to the spindle to hold the workpiece as the carriage moves the cutting tool parallel or perpendicular to the workpiece. Cutting operations performed on the lathe include outer diameter (OD) operations and inner diameter (ID) operations.To produce parts on a manual lathe, the operator must first understand the lathe’s basic components and functions. After the class users should be able to describe the general machine components and controls of a manual engine lathe and their basic function.Intermediate2.0English(150115) Basics of the Engine Lathe 115
OnlineMachining150Manual Machining280120 Manual Mill Setup 221 Manual Mill Setup details important considerations that a mill operator must make before starting any cutting process as well as the steps an operator must follow to ensure proper manual mill setup. Mill setup requires operators to know how to select appropriate cutting variables and tools, align various mill components and a workpiece, use an edge finder and readout, and determine part zero. Correct setup is critical for cutting precisely and accurately dimensioned parts.Performing cutting operations on a mill with incorrect setup up results in reduced part quality and increased scrap production and manufacturing costs. After taking this class, a user should be able to accurately select process variables as well as correctly perform manual mill setup.Intermediate2.0English(150200) Overview of Manual Mill Setup 200
OnlineMachining150Manual Machining280125 Engine Lathe Setup 231 Engine Lathe Setup details important considerations that a lathe operator must take before starting any cutting process as well as the steps to ensure proper engine lathe setup. Lathe setup requires operators to know how to select appropriate cutting variables and tools, align various lathe components and a workpiece, and zero the tool. Correct setup is critical for cutting precisely to create parts with accurate dimensions.Performing turning operations on a lathe with incorrect or inadequate setup results in reduced part quality and increased scrap production and manufacturing costs. After taking this class, a user should be able to accurately select process variables as well as correctly perform engine lathe setup.Intermediate2.0English(150205) Overview of Engine Lathe Setup 205
OnlineMachining150Manual Machining280130 Benchwork and Layout Operations 241 Benchwork and Layout Operations provides a detailed overview of the various benchwork and layout processes that operators often need to perform during manual machining. Layout is the process of marking a workpiece prior to cutting in order to have a visual guideline during cutting operations. Benchwork includes various cutting processes that machinists complete by hand rather than on a machine when creating part features that require less power and force. Common benchwork operations include hand tapping, hand reaming, hand filing, and engraving.Manually machined workpieces often require benchwork and layout operations. As a result, benchwork and layout are essential skills to have for any manual mill operator. A knowledge of not just how, but also when and why to perform benchwork and layout operations is key to becoming a skilled manual machinist and producing precise, accurate manually cut parts.Intermediate2.0English(150210) Benchwork and Layout Operations 210
OnlineMachining150Manual Machining280140 Manual Mill Operation 251 Manual Mill Operation serves as a guide for manually machining various features onto a workpiece. The class takes the users through the steps of creating a part on the manual mill, including determining the order of operations, squaring the six sides, creating a step, grooving, center drilling, and drilling. It focuses on step-by-step instructions on how to perform each operation to result in a part that is symmetrical and within tolerance. These steps can be applied to various face milling, end milling, and holemaking operations, allowing students to create precise parts through manual milling.A broad knowledge of not only how to operate a manual milling machine, but why each step in the operations process is used, is key for any machinist. This class will speed up the time it takes for new operators to learn manual milling and reduce user errors.Intermediate2.0English(150220) Manual Mill Operation 220
OnlineMachining150Manual Machining280145 Engine Lathe Operation 261 Engine Lathe Operation serves as a guide for manually machining various features onto a workpiece. The class establishes principles of basic lathe operation and takes users through procedures for common outer diameter operations, including turning, facing, taper turning, knurling, parting off, grooving, and threading, and inner diameter operations, such as drilling, boring, reaming, and tapping. It focuses on step-by-step instructions on how to perform each operation, allowing students to create precise parts on the engine lathe.A broad knowledge of not only how to operate an engine lathe, but also the importance of each step in an operation, is key for any machinist. This class will speed up the time it takes for students to learn to operate an engine lathe and also reduce operator errors.Intermediate2.0English(150225) Engine Lathe Operation 225
OnlineMachining150Manual Machining280150 Holemaking on the Manual Mill 271 Holemaking on the Manual Mill provides information on the principles and processes for various holemaking operations that the manual milling machine can perform. A manual mill is capable of a number of precise holemaking operations, including drilling, tapping, reaming, counterboring, countersinking, and boring. Each holemaking operation requires different tools, preparation, and operation.Machinists commonly perform holemaking operations on the manual mill and must perform them accurately to produce parts that are within tolerance. If holemaking operations are not precise and accurate, assembly of the part will be impossible, leading to increased scrap. Manual machinists must understand how to carry out the various holemaking operations in order to reduce costs and increase quality.Intermediate2.0English(150230) Holemaking on the Mill 230
OnlineMachining150Manual Machining280220 Threading on the Engine Lathe 301 The class Threading on the Engine Lathe explains threads and how to make them using a manual lathe. Engine lathes can create both external (OD) and internal (ID) threads classified according to either Unified or ISO metric standards. To manually machine a thread a machinist must know how to set up and use a threading tool, compound rest, and quick-change gearbox before engaging the threading feed by moving the half-nut lever to the proper line on the threading dial. Machinists should also know how to perform initial operations such as chamfering and making an undercut. In order to cut threads successfully on the lathe, an operator must understand the various lathe components and processes used for threading. After taking this class, users should be able to describe best practices for external and internal threading on an engine lathe.Advanced2.0English(150235) Threading on the Engine Lathe 235
OnlineMachining150Manual Machining280225 Taper Turning on the Engine Lathe 311 Taper Turning on the Engine Lathe describes how to machine common types of tapers on an engine lathe. Cylindrical tapers are a uniform change in diameter on a cylindrical object and help to align and hold various tools and workholding devices. A taper's angle is commonly expressed by taper per inch or foot, and the class covers these measurement types. It also describes the most common taper turning methods performed on the engine lathe: using a taper attachment, using the compound rest, and offsetting the tailstock. Each method has advantages and disadvantages.Taper turning is a common but advanced machining process. If a machine operator does not select the appropriate method for turning a specific taper or fails to execute the turning operation correctly, it will lead to scrapped parts and wasted labor. After taking the course, users will understand the processes to create external and internal tapers on the engine lathe.Advanced2.0English(150240) Taper Turning on the Engine Lathe 240