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MACH 1124 17F
Machining fundamenta
| Question | Answer |
|---|---|
| Oily rags should be placed in safety container to prevent _____? | Spontaneous combustion |
| One-millionth part of a standard inch is known as______? | Microinch |
| One-millionth part of a meter is called _______? | micrometer |
| Name four parts of twist drill | Point, Shank, body. |
| A micrometer caliper is nicknamed ________ | "Mike" |
| List 4 ways to care for calipers | Keep clean, wipe with lightly oiled rag to prevent rust,oil screw thread to keep operating smoothly Avoid "springing by putting too much pressure when making measurements Clean before use Check accuracy regularly Avoid placing where it can fall |
| Micomerter is capable of measuring 0.0001" or 0.0025mm when fitted with ________? | Vernier scale |
| Vernier type tool used for measuring angles? | Universal vernier bevel protractor |
| Gage blocks are often refered to as ______blocks | Jo- |
| What are the two basic types of dial indicators? | Balanced and continuos |
| What is the purpose of the point on a Twist drill | The point is the cone-shaped end what does the cutting |
| What parts does the point of a Twist drill consist of | The dead centre The lips The heel Lip clearance |
| What is the dead centre of a drill | The sharp edge at the extreme tip of the drill |
| What are the lips on the twist drill | Are the cutting edges of the drill |
| What is the heel of the drill | Portion of the point back from the lips |
| What does lip clearance refer to on a drill | The amount the surface of the point is relieved back from the lips |
| What is the portion of the drill between the point and the shank called? | The body |
| What are the purposes of the flutes on a drill? | Help form cutting edges Curl chip tightly Form channels for chip to escape as hole drilled Allow for coolant and lubrication to flow to cutting edges |
| What is the shank of a drill | The portion that mounts into Chuck or spindle |
| Four ways Drill sizes are expressed | Numbers-#80-#1 Letters A-Z Inches and Fractions1/16"-3 1/2" Metric 0.15mm-76.0mm |
| When measuring diameter of drill with calipers where do you measure | Across drill margins unless worn, then across shank at the end if the flutes |
| When using a drill gauge where do you measure? | New drills at point Worked drills at end of flutes. |
| What is the most common material for Surface Plates? | Granite |
| Why is Granite a better choice for surface plates than cast iron? | Cast iron is more affected by temperature changes |
| what are V-blocks used for? | to hold round stock for layout and measurement |
| How is the size of a vise determined? | The width of the jaws |
| when should you use copper, brass or aluminum vise caps? | when clamping work that could be marred by the serrations in the jaws of the vise |
| What type of hammer is used for setting work tightly on parallels | soft -faced |
| what materials are soft faced hammers made of? | copper, brass, lead, rawhide, and plastic. |
| what is a dead blow hammer? | The head of the dead blow hammer contains tiny steel shot encased in plastic. |
| what is the benefit of a dead blow hammer? | a hammer that has striking power but will not rebound (bounce back) as will other mallets and soft-face hammers. |
| Parts of a hacksaw | Frame with handle and replaceable blade |
| which stroke, forward or backward, does a hacksaw cut on? | forward (push) |
| What is the most common Drill point angle? | 118 degrees |
| Why must a new blade be re-tightened on a hacksaw after a few strokes? | the blade stretches due to the heat produced while cutting. |
| why notch the work before cutting with hacksaw? | easier to start the cut |
| how many strokes per minute should be made when using a hacksaw? Why? | about 40 to 50 strokes per minute. More strokes per minute may generate enough heat to draw the blade temper and dull the teeth. |
| What is a Reamer? | a tool that will produce smoothness and accuracy. used for final sizing of a hole. |
| How does a drill work? | rotating against material with sufficient pressure to cause penetration. |
| What are drills made from? | High-speed steel (HSS) carbon steel |
| what are two types of drill shanks? | Straight shank and Taper shank |
| ____ shank drills are used with a chuck. | Straight |
| ______ shank drills fit directly into the dill press spindle. | Taper |
| The lathe operates on the principle of _________ | the work rotating against the cutting tool, which is controllable. |
| The size of the lathe is determined by ________ | the swing and the length of the bed. |
| The largest piece that can be turned between centres is equal to ________ | the length of the bed minus the space taken up by the headstock and the tailstock. |
| What are the categories that various parts of the lathe fall into? | Driving the lathe Holding and rotating the work Holding, moving , and guiding the cutting tool |
| Some lathes are equipped with a ______ ______ allowing for slower speeds with greater power. | back gear |
| When drilling on a lathe, drills larger than 1/2" (12.5mm) in diameter usually have______ shanks. | taper |
| When drilling with drills ½” in diameter or smaller, a starting point made with a ____________ is adequate. | countersink (center drill) |
| Holes over ½” in diameter require a pilot hole, which should have a diameter equal to the width of the larger drills ______ ____ | dead center. |
| The vernier caliper has several advantages over the micrometer. List two of them. | very accurate, can be used on wide range of sizes, makes both inside and outside measurements |
| what is a Screw Thread? | Measures pitch diameter of thread A set of thread micrometers is necessary to measure the full range of thread pitches |
| what is the purpose of the Tailstock on a lathe? | Outer end of work is supported by the tailstock Can be adjusted along the ways to accommodate different lengths of work Used to mount the lathe center Can be fitted with tools for drilling, reaming, and threading Can be offset for taper turning |
| what is the Largest diameter that can be turned over the ways on a lathe called? | Swing |
| What is the Entire length of the ways on a lathe called? | Bed lenght |
| what is the internal machining operation in which a single pointed cutting tool is used to enlarge a hole? | Boring |
| what is Knurling? | the process of forming horizontal or diamond shaped serrations on the circumference of the work. |
| two purposes of Knurling | Provide gripping surface, increase diameter of work |
| purpose of filing? | to remove burrs, round off sharp edges, blend in form cut lines |
| precautions for filing on lathe | Move carriage out of way, remove tool post Use left-hand method of filing |
| purpose of Steady and follower rests? | Needed to provide additional support when the work piece is long and thin Keeps work from springing or bending away from the cutting tool Needed to reduce chattering |
| Purpose of Mandrel | Used to machine the outside diameter of a piece concentric with a hole that has been previously bored or reamed |
| Types of Mandrels | Solid, Expansion, and Gang |
| Procedure for filing on a lathe | Operate lathe at high spindle speed Apply long, even strokes Release pressure on return stroke Uneven pressure results in out-of-round work Clean the file often |
| Solid mandrel | Made from hardened steel with slight taper Made in standard sizes |
| Expansion mandrel | Permits work with openings that vary from standard size to be turned Shaft and sleeve have corresponding tapers Sleeve slotted to expand when forced onto the tapered shaft |
| Gang mandrel | Helpful when many pieces of the same configuration must be turned Pieces mounted on the mandrel and separated with spacing collars Locked in place by tightening a nut |
| Two types of milling machines? | Horizontal and Vertical |
| describe the horizontal milling machine | the cutter is fitted onto an arbor mounted in the machine on an axis parallel with the worktable. Multiple cutters maybe mounted on the spindle for some operations. |
| describe vertical milling machine | is normally perpendicular (at a right angle) to the worktable. However, on many vertical milling machines the spindle can be tilted to perform angular cutting operations. |
| describe Plain Milling Machine | , the cutter spindle projects horizontally from the column. The worktable has three movements: vertical, cross, and longitudinal |
| describe Universal Milling Machine | A universal milling machine, Figure 18-9, is similar to the plain milling machine, but the table has a fourth axis of movement. table can be swiveled on the saddle through an angle of 45' or more |
| how does a vertical milling machine differ from a plain or universal milling machine? | by having the cutter spindle in a vertical position, at a right angle to the top of the worktable. |
| what type of cutter is the vertical milling machine best suited for? | This type of milling machine is best suited for use with an end mill or face mill cutter |
| 3 types of heads found on vertical milling machines? | swivel-head, sliding-head, and rotary-head types. |
| explain A swivel-head milling machine | often found in training programs. The spindle can be swiveled for angular cuts |
| what direction can the head be moved on a sliding head type milling machine? | the spindle head is fixed in a vertical position. The head can be moved in a vertical direction by hand or under power, |
| what is the benefit of a rotary head on a vertical milling machine? | The spindle can be moved vertically and in circular arcs of adjustable radii about a vertical center line |
| 4 Control methods for milling machines are- | Manual. All movements are made by hand lever control. Semi-automatic. Movements can be controlled by either hand or power feed. Fully automatic. Computerized (CNC) |
| how can you be sure a drill point is sharpened at proper angle? | |
| After sharpening a drill how can it be tested | drill a hole in soft metal. chips should come out of flutes in curled spirals of equal size and length |
| What operations can be performed on a vertical milling machine? | milling, drilling, boring and reaming |
| Why must the spindle of a vertical milling machine be perpendicular to the work table? | if it's not the surface will not be flat, but dished and irregular |
| What is the most accurate way to check for milling head perpendicularity? | a dial indicator aligned in a solid vise jaw |
| How should a vise be prepared for mounting to the worktable and holding work? | wipe the vise base and worktable clean, inspect for burrs and nicks, bolt firmly to the machine |
| RPM? | revolutions per minute |
| IPM? | inches per minute |
| SFM? | surface feet per min |
| IPR | inches per revolution |
| IPT? | inches per tooth |
| how do you use an edge finder? | 1.With tip of tool below surface depth of work slowly feed work against tip. 2.tip gradually centres with shank 3. when 100% centred tip will jump sideways. STOP feeding work. zero out axis, move additional amt.= half diameter of tip. zero axis again. |
| Why is layout dye used | to make scribed lines stand out from metal by providing contrast between the scribed line and surrounding metal |
| What is a scriber | tool with harden steel point kept needle sharp by frequent honing used to scratch lines into metal |
| what is a divider? | divider is used to draw circles and arcs in the same way a scriber is used |
| What is a Trammel | made of a thin rod called a beam and two steel points. on with an adjustable screw. its used to mark arcs and circles too large for a divider. |
| describe a hermaphrodite caliper | has a blunt end for the sliding surface and a point for scribing. marks lines that are parallel to the edge of the material. |
| Exhaust system | Quiets the noise produced by engine operation Routes engine exhaust gases to the rear of the vehicle body |
| Clutch | Allows the driver to engage or disengage the engine and manual transmission or transaxle |
| When Clutch pedal released- | clutch locks the flywheel and the transmission together power flows to the transmission |
| when Clutch pedal depressed | clutch disengages power flow |
| what does the transmission system do? | Uses various gear combinations (ratios), to multiply engine speed and torque to accommodate driving conditions |
| Low gear ratios allow the vehicle to | accelerate quickly |
| High gear ratios permit | lower engine speed, providing good fuel economy |
| Automatic Transmission | Does not have to be shifted by the driver Uses an internal hydraulic system and, in most cases, electronic controls to shift gears Internal clutches or bands control gearsets to provide various gear ratios |
| how is the Input shaft is connected to the engine crankshaft? | Input shaft is connected to the engine crankshaft through a torque converter |
| Drive Shaft | Transfers power from the transmission to the rear axle assembly Universal joints allow the rear suspension to move up and down without damaging the drive shaft |
| rear Axel assembly | Contains a differential and two axles |
| Differential | set of gears and shafts that transmits power from the drive shaft to the axles |
| Axels | steel shafts that connect the differential and drive wheels |
| Transaxel | Used with front-wheel-drive vehicles Both manual and automatic transaxles are available |
| constant-velocity joints allow | allow the front wheels to be turned to the left or right and to move up and down |
| Front Drive Axles | Connect the transaxle differential to the hubs and wheels of the vehicle |
| Brake System | Produces friction to slow or stop the vehicle.Mechanisms force friction material against metal discs or drums to slow wheel rotation |
| When the driver presses the brake pedal....... | Fluid pressure actuates a brake mechanism at each wheel |
| Safety Systems | Common safety systems include: seat belts air bags security systems |
| Accessory Systems | Common accessory systems include: air conditioner sound system power seats power windows rear window defogger |
| Power tools | tools driven by compressed air, electricity, or pressurized liquid |
| Shop equipment | large shop tools such as floor jacks, parts cleaning tanks, and steam cleaners |
| Compressed-Air System | Components include: air compressor air hoses and lines pressure regulator filter and lubricator Air tools are driven by the compressed-air system |
| Air Compressor | Source of compressed air for an automotive service facility Turns on and off automatically to maintain a preset pressure in the system Metal air lines feed compressed air to several locations in the shop |
| Quick-disconnect couplings allow a technician to--- | connect or disconnect hoses or tools without using a wrench |
| Air Hoses | Made of flexible, high-pressure hose Connected to the metal lines from the air compressor. They Allow the technician to take a source of air pressure to the vehicle being serviced |
| Air Ratchet | Impact wrench designed to work in a limited space NEVER use to install spark plug in |
| Impact tools are always ________ _______ | flat black |
| Conventional tools are always _______ | Chrome |
| Impact Sockets and Extensions | Must be used with air wrenches Case hardened, thicker, and much stronger than conventional sockets and extensions |
| Blowgun | Commonly used to dry and clean parts washed in solvent |
| safety precautions for a blowgun are : | wear eye protection direct the blast of air away from yourself and others do not blow brake and clutch parts clean, as the dust from these parts may contain asbestos |
| Air Drill | Used to drill, grind, polish, and clean parts Power and rotating speed can be set to match the job at hand |
Created by:
Neeneral