Manufacturing

Milling cutters are sharp. Protect your hands with a cloth or _____ when handling them.

gloves

Drills are made from _____.

high-speed steel and carbon steel.

The _____ tooth pattern is also recommended for most nonferrous metallic materials.

hook

Face milling cutters over 6" (150 mm) in diameter are usually of the _____ type.

inserted tooth

The _____ is almost identical to the hand reamer except that the shank has been designed for machine use.

jobber's reamer

The process of forming horizontal or diamond-shaped serrations on the circumference of the work is called ______.

knurling

Stop the machine before making adjustments and _______.

measurements

The micrometer caliper is nicknamed ____

mike

The surface being machined is parallel with the periphery of the cutter in ______ milling.

peripheral

A(n) _____-type milling machine has a horizontal spindle and the worktable has three movements.

plain

The _______ punch has a sharper point than the center punch.

prick

The rate at which the work moves into the cutter is known as the _____.

rate of feed

The _____ type saw has a back-and-forth cutting action.

reciprocating

List the three basic types of metal-cutting saws.

reciprocating, continuous band-type, and circular-type

The pitch of a thread can be determined with a(n) _____________.

screw pitch gage

Straight layout lines are drawn with a(n) _________.

scriber

In general, use the _____ arbor possible that permits adequate clearance between the arbor support and the work.

shortest

The _____ tooth pattern is preferred for cutting aluminum, magnesium, copper, and soft brass.

skip

When sawing (slitting) thin stock, the _____ diameter cutter that provides adequate clearance should be used.

smallest

The device used to permit a drill with a taper shank too large to fit the spindle opening is called a(n) _____.

socket

A(n) _____ expansion reamer provides rigidity and accuracy not possible with conventional expansion reamers.

solid

The _____ tooth pattern is best suited for cutting most ferrous metals.

standard

____ shank drills are used with a chuck.

straight

Long flat surfaces can be checked for trueness with a(n) _______.

straightedge

A(n) __________ is the flat granite or cast iron surface used for layout and inspection work.

surface plate

_____ shank drills fit directly into the drill press spindle.

taper

The _____ is fitted to many lathe carriages. It meshes with the lead screw and is used to indicate when to engage the half-nuts to permit the thread cutting tool to follow exactly in the original cut.

thread dial

Internal and external grinding can be done on the lathe with a(n) _____.

tool post grinder

Large circles and arcs are drawn with a(n) _________.

trammel

Before removing a machine's guards or covers, be sure that all power to the machine is _____.

turned off

A(n) ______ end mill is used when the cutter must be fed into the work like a drill.

two-flute

Blind keyseats or slots are made with a(n) _____ end mill.

two-flute

The cutting speed for a high-speed reamer is approximately _____ that for a similar-sized drill.

two-thirds

A(n) _____-type milling machine is similar to the plain-type milling machine but a fourth movement has been added to the worktable to permit cutting helical shapes.

universal

The vernier-type tool for measuring angles is called a(n) ____________________?

universal vernier bevel protractor

A(n) _____ scale on the spindle head of a vertical milling machine ensures accurate angular settings.

vernier

A(n) _____-type milling machine has the spindle perpendicular or at right angles to the worktable.

vertical

On the table saw, how far above the work should the blade be when cutting?

1/8 of an inch.

____ teeth per inch for cutting on the majority of light-duty machines, where work is limited to small sections and moderate to light feed pressures.

10- and 14-

The included angle of a drill point sharpened for general drilling is _____ degrees.

118

What is the minimum number of people that must be in the shop for you to work?

2

The compound rest is set at ______ when cutting threads to permit the cutting tool to shear the material better than if it were fed straight into the work.

29 Degrees

_____ teeth per inch for cutting large sections or readily machined materials.

4

_____ teeth per inch for cutting harder alloys and miscellaneous cutting.

6

What number do you call in case of an emergency?

911

Fly cutter

A facing mill with a single-point cutting tool.

What is a blind hole?

A hole that does not go all the way through the work.

What is "three-tooth rule" for sawing?

A minimum of three teeth must be cutting at all times.

When using the table saw, what do you use to push the material by the blade?

A push stick.

What is a spur gear?

A spur gear is a toothed wheel that has teeth that run straight across the face and are perpendicular to the sides. The teeth are shaped so contact between the mating gears is continually maintained while in operation.

Where do you place your work on the belt and disk sander?

Against the rest

An air gage employs air pressure to measure deep internal openings and hard-to-reach shaft diameters. It operates on the principle of ____________.

Air pressure leakage between the plug and hole walls.

A groove is cut at the point where a thread is terminate. It is cut to the depth of the tread and serves to:

All of the above: Permits a nut to be run up to the end of the thread,...,...

Into which of the following categories do the various parts of the lathe fall?

All: Driving the lathe, Holding and rotating the work, Holding, moving, and guiding the cutting tool

Which of the following actions are considered dangerous when operating a lathe?

All: Wearing loose clothing and jewelry, Measuring with work rotating, Operating lathe with most guards in place

Treat all small cuts and skin punctures as potential sources of infection. Which of the following should be done?

All: clean them thoroughly, apply antiseptic and cover with a bandage, promptly report the injury to your instructor

Cutting fluids are used to _____.

All: cool the drill, improve the finish of a drilled hole, aid in the removal of chips

A(n) ______ can be used to locate the first hole of a series to be drilled on a vertical milling machine.

All: edge finder, wiggler, centering scope

The spiral grooves in a drill body are used to ____.

All: help form the cutting edge of the drill point, curl chips for easier removal, form channels through which the chips can escape from the hole

Knurling is commonly done to _____.

All: provide a gripping surface, change the appearance of the work, increase the work's diameter

What do you use to push a piece through the bandsaw?

Always use a push piece.

Where should the guards be set on the bandsaw?

As close to the workpiece as possible.

Some lathes come equipped with a(n) ______ allowing for slower speeds with greater power.

Back Gear

Accumulated metal chips and dirt are cleaned from the lathe with a(n) _____, never with your hands.

Brush

Two-flute end mill.

Can be fed into work like a drill

Flanged vise

Can only be mounted parallel to or at right angles on worktable

Magnetic chuck

Can only be used with ferrous metals

Cutting speeds can be increased 300% to 400% by using _____ cutting tools.

Carbide

The tip of a cutting tool to cut a Sharp V thread is sharpened using a(n) _____ to check that it is the correct shape.

Center Gauge

Before work can be mounted between centers, a(n) ______ must be drilled at each end of the stock.

Center Hole

What should you do before starting a machine?

Check to see if it is clear by operating it manually.

What tasks do you need to complete after you are done working?

Clean up your area, wipe down the machines, and put all your tools away.

Permits angular tool movement.

Compound Rest

What is the name of the operation used to cut a chamfer in a hole to receive a flat-head screw?

Countersinking

____ is the operation that machines a circular spot on a rough surface for the head of a bolt or nut.

Countersinking

Polishing is an operation used to produce a(n) _____ on the work.

Cover the bed and moving parts with a heavy duty cloth.

Permits transverse tool movement

Cross-Slide

Internal thread

Cut on inside surface of piece.

External thread

Cut on outside surface of piece.

Slab cutter

Cutter with helical teeth designed to cut with a shearing action

Plain milling Cutter

Cutter with teeth located around the circumference.

Pitch diameter

Diameter of imaginary cylinder that would pass through threads at such points as to makewidth of thread and width of space at these points equal.

Lead

Distance a nut will travel in one complete revolution of screw.

Pitch

Distance from one point on a thread to a corresponding point on next thread.

____ mills are the cutters normally used on a vertical milling machine.

Face and End

A mcron is one-thousandth part of a meter. T/F

False

The two basic types of a dial indicator are as follows: discrete and unbalanced. T/F

False

_____ is used to indicate the distance that the cutter moves in one revolution of the work.

Feed

Staggered-tooth side cutter

Has alternate right-hand and left-hand helical teeth

Swivel vise

Has circular base graduated in degrees

Side milling cutter

Has cutting teeth on the circumference and on one or both sides

In most lathe operations, you will be using a single-point cutting tool made of ______.

High-Speed Steel (HSS)

After tightening the collet on the milling machine, what do you do with the wrench?

Immediately remove it.

Face milling cutter

Intended for machining large flat surfaces parallel to the cutter face.

Boring is a(n) ______.

Internal machining operation in which a single-point cutting tool is used to enlarge a hole.

Gage blocks are often referred to as _______________ blocks.

Jo

Vise lug

Keys vise to a slot in worktable

Major diameter

Largest diameter of thread.

What should you wear on your hands when using solvents?

Latex gloves.

What is wrong with using a pencil to make layout lines on metal?

Lines will rub off and would be too wide

Shell end mill

Mounts on a stub arbor

Rotary table

Needed when cutting segments of circles, circular slots, and irregular shaped slots

Can you use compressed air to clean up the machines?

No

Do you ever use the cord to move the hand power saw?

No

When using the drill press, do you ever hold the work with your hands?

No, always use a vise.

Do you ever use a taper shank tool in a drill chuck?

No.

When using the parting tool, the spindle speed of the machine is about _____ the speed used for conventional turning.

One-third

What do you do for 5 minutes after you are done in the shop?

Perform general cleaning around the shop.

Universal vise

Permits compound angles (angles on two planes) to be machined without complex or multiple setups

Indexing table

Permits rapid positioning of circular work in 15° increments and can be locked at any angular setting.

Large drills require a considerable amount of power and pressure to get started. They also have a tendency to drift off center. These conditions can by minimized by first drilling a(n) _____ hole.

Pilot

Multiflute end mill

Recommended for conventional milling where plunge cutting (going into work like a drill) is not required.

Review Reading Micrometer

Review Reading Ruler

What should you remove or secure before you work on the machinery?

Rings, necklaces, long hair, and loose clothing.

A drill works by_____.

Rotating against material with sufficient pressure to cause penetration

Fitted to the ways and slides along them.

Saddle

What does "gang milling" mean?

Several cutters being used at the same time to machine a job

What do you have to do to the cylinder valves when the welding job is done?

Shut them off.

Before changing a blade or making an adjustment on the hand saw, what do you do?

Shut-off the power.

What do you do to a machine before cleaning?

Shut-off the power.

What is the procedure if you need to remove tools from the laboratory?

Sign the check-out sheet near the door.

Minor diameter

Smallest diameter of thread.

What do you do if the drill binds in a hole on the drill press?

Stop the machine and turn the spindle backwards by hand.

Drills that are used on the lathe are fitted with ______ shanks.

Straight and Taper

The size of a lathe is determined by the ______ and the length of the bed.

Swing

Automatic turning centers, also known as ______ machines can produce tiny precision parts in quantity.

Swiss-type

On the milling machine, what do you check in relation to the cutter before cutting metal?

The direction of rotation.

The largest piece that can be turned between centers is equal to ______.

The length of the bed minus the space taken up by the headstock and the tailstock

What type of protection do people within the welding area have to wear for their eyes?

The recommended shades.

Who do you have to get approval from before using welding equipment?

The shop staff.

On the lathe, how far do you let the toolbit overhang the toolholder?

The shortest amount possible to avoid chatter.

In or up-convectional milling, _____.

The work is fed into the rotation of the cutter

In climb or down-milling, ______.

The work moves in the same direction as the rotation of the cutter

The lathe operates on the principle of ______.

The work rotating against the cutting tool, which is controllable

What will happen to your laboratory privileges if you do not clean up after yourself?

They will be suspended and you will not pass the class.

Metal Slitting Saw

Thin milling cutter designed for machining narrow slots and for cutoff operations

Used to mount the cutting tool.

Tool Post

A dial indicator can be used to check for eccentricity. T/F

True

A ring gage is used to check whether diameters are within the specified tolerance range. T/F

True

One-millionth part of a standard inch is known as a "microinch". T/F

True

Optical flats employ light waves as a measuring standard. T/F

True

Dividing head

Used to divide circumference of round work into equally spaced divisions

Round stock is usually supported on _________ for layout and inspection.

V-blocks

Angular lines that must be very accurate should be laid out with a(n) _________.

Vernier protractor

When possible, what should you use instead of solvents?

Water based cleaners.

When do you need to wear safety glasses in the shop?

Whenever you are in the laboratory.

Should you remove flammable liquids from the welding area prior to welding?

Yes

What happens if you do not listen to the laboratory technician?

You lose your laboratory privileges and fail the course.

After you turn the power off on the drill press, how do you stop the spindle from turning?

You never use your hand and let it stop on its own.

After tightening the chuck on the lathe, what do you do with the chuck key?

You remove it immediately.

When chips or strings form on the lathe during an operation, how do you remove them?

You use a brush or tool and never try to remove them with your hand.

How do you remove chips from the work area?

You use a brush so you do not cut yourself.

A mandrel is usually pressed into the work with a(n) ______.

arbor press

If you are not sure about something in the laboratory, what should you do?

ask

The power hacksaw only cuts on the _____ stroke.

back

Work that is too large or too heavy to be turned in the horizontal position is turned on huge machines called vertical lathes or _____.

boring mills

There are times when a shaft is unsuitable as a bearing surface and connot be used with a steady rest. When this occurs, a(n) _____ can be used so the shaft can be supported with the steady rest.

cat head

The center of round stock can be found quickly with the ______ and rule of a combination set.

center head

The two broad classifications of milling machines are fixed-bed and _____ milling machines.

column and knee

The operation used to prepare a hole for a fillister or socket head screw is called _____.

counterboring

The distance, measured in feet or meters, that a point (tooth) on the circumference of a cutter moves in one minute, is known as the _____.

cutting speed

The most accurate way to align a vise on a milling machine is with a(n) _____.

dial indicator

Circles and arcs are drawn on work with a(n) _________.

divider

The _____ should be used frequently when sharpening to ensure a correctly sharpened drill.

drill point gage

The surface being machined is parallel with the cutter face in _____ milling.

face

When drilling a pilot hole, the hole should be as large as or slightly larger than, the width of the _____ of the drill point.

flute

The spiral grooves that run the length of the drill body are called _____.

flutes