Machining Operations on the Lathe

1. If a 0.050" depth of cut is taken on the diameter of a workpiece, by how much will the
diameter be reduced?

To calculate the reduction in diameter when a 0.050" depth of cut is taken, you would simply
double the depth of cut since it's taken off the diameter. Therefore, the reduction in diameter
would be 0.100".

2. A lathe cross slide uses a diameter-reading micrometer collar. If the cross slide is advanced by
0.150", what depth of cut would result?

If the lathe cross slide is advanced by 0.150", this advancement corresponds to the radius of the
cut. To find the depth of cut, you would multiply this by 2 to get the diameter of the cut. So, the
depth of cut would be 0.150" x 2 = 0.300".

3. In what units are feed rates measured for lathe operations?

Feed rates for lathe operations are typically measured in units of inches per revolution (IPR) or
millimeters per revolution (mm/rev). This indicates the distance the cutting tool advances along
the workpiece for each revolution of the workpiece.

4. Are deeper cuts used for roughing or finishing operations?

Deeper cuts are typically used for roughing operations. These cuts remove more material quickly
but may result in a rougher surface finish.

5. Calculate spindle RPM and machining time for cutting a 1.5" diameter 4" long at 225 SFPM
using a feed rate of 0.004".

To calculate spindle RPM:

SFM × 3.82
RPM=
Diameter
225× 3.82
RPM=
1.5
RPM=568.5

To calculate machining time:

Length
Machining Time=
FeedRate × RPM
4
Machining Time= 0.004 ×568.5
¿
¿
Machining Time= 17.6 minutes

6. List three safety precautions related to clothing that should be observed during lathe
operation.

Three safety precautions related to clothing during lathe operation:

 Avoid wearing loose clothing or jewelry that could get caught in moving parts.

 Wear proper safety attire such as closed-toe shoes, safety glasses, and, if necessary,
gloves.

 Tie back long hair and avoid wearing clothing with loose sleeves or hems.

7. What two materials are most commonly used for lathe cutting tools?

The two most commonly used materials for lathe cutting tools are high-speed steel (HSS) and
carbide.

8. What feature of a lathe cutting tool has a direct effect on surface finish?

The cutting edge geometry, including tool nose radius and edge sharpness, has a direct effect on
surface finish.

9. Is a left-hand or right-hand tool normally used for facing?

A right-hand tool is normally used for facing.

10. What part of the lathe is used to feed the tool during facing?

The cross slide is used to feed the tool during facing.

11. When facing, why should the tool not be fed past the center of the workpiece?

The tool should not be fed past the center of the workpiece during facing to avoid chatter and
poor surface finish.

12. Should a left-hand or right-hand tool be used when turning toward the headstock?

A right-hand tool is typically used when turning toward the headstock.

13. When and how should chips be removed from the work and cutting tool?

Chips should be removed from the work and cutting tool periodically during machining to prevent
chip buildup, which can affect cutting performance and surface finish.

14. What are two reasons for center drilling on the lathe?

Two reasons for center drilling on the lathe are to create a starting point for drilling operations
and to provide support for long workpieces.
15. When drilling and reaming on the lathe, how are the tools usually fed into the workpiece?

Tools are usually fed into the workpiece manually during drilling and reaming on the lathe.

16. How can hole depth be controlled during drilling operations?

Hole depth can be controlled during drilling operations by using a stop or depth gauge to ensure
consistent drilling depths.

17. What are two reasons boring may be selected to produce a hole instead of drilling and
reaming?

Boring may be selected over drilling and reaming for producing holes when precise diameter and
surface finish requirements are needed, or when working with materials that are difficult to drill.

18. Why must extra care be taken when performing boring operations?

Extra care must be taken during boring operations to ensure proper alignment, cutting tool
sharpness, and chip evacuation, as boring operations are more sensitive to misalignment and
deflection than drilling operations.

19. How can a tap be aligned when threading a hole on the lathe?

A tap can be aligned when threading a hole on the lathe by using a tap guide or aligning the
tailstock with the workpiece axis.

20. Briefly define form cutting.

Form cutting is a machining process where a cutting tool creates a specific shape or contour on a
workpiece surface.

21. How do grooving and cutoff speeds compare to turning speeds?

Grooving and cutoff speeds are typically higher than turning speeds because these operations
involve more rapid material removal.

22. How can tool binding be overcome when cutting deep grooves or cutting off large diameters?

Tool binding when cutting deep grooves or cutting off large diameters can be overcome by using
proper tool geometry, coolant/lubrication, and appropriate cutting parameters.

23. List the two basic knurl patterns.

The two basic knurl patterns are diamond and straight.

24. How is knurling different from other lathe operations?

Knurling is different from other lathe operations because it doesn't involve material removal but
rather deformation of the workpiece surface to create a textured pattern.
25. List and briefly describe the two different types of knurling tools.

The two different types of knurling tools are:

 Single-point knurling tool: Features a single wheel or roller that impresses the knurl
pattern onto the workpiece.

 Two-point knurling tool: Utilizes two wheels or rollers arranged symmetrically to produce
a more uniform knurl pattern.
Vertical Milling Machine Operations
1. List five safety guidelines to observe when operating the vertical milling machine.

Five safety guidelines to observe when operating a vertical milling machine are:

a. Wear appropriate personal protective equipment (PPE) such as safety glasses, hearing
protection, and steel-toed shoes.

b. Ensure the machine is properly secured to the floor and all safety guards are in place before
operating.

c. Familiarize yourself with emergency stop procedures and the location of safety switches.

d. Keep work area clean and organized to avoid tripping hazards and ensure proper machine
operation.

e. Do not wear loose clothing or jewelry that could get caught in moving parts, and tie back long
hair.

2. Briefly describe the process of aligning a milling vise with the table movement using a dial
indicator.

The process of aligning a milling vise with table movement using a dial indicator involves:

a. Mounting the dial indicator on the machine spindle or a suitable holder.

b. Bringing the indicator into contact with the fixed jaw of the vise.

c. Moving the table longitudinally (X-axis) while observing the indicator to ensure minimal
deviation from zero.

d. Locking the table in place once alignment is achieved.

3. What is chip load?

Chip load refers to the thickness of the material removed by each cutting edge during a single
revolution of the cutting tool. It is typically measured in inches per tooth (IPT) or inches per
revolution (IPR).

4. Define IPM.

IPM stands for Inches Per Minute and represents the rate at which the cutting tool or workpiece
moves in linear distance during machining operations.

5. Calculate spindle speed and feed for the two following situations:
a. Use an HSS 1/2"-diameter three-flute endmill to mill 6061 aluminum 350 SFPM using a
0.0015" chip load.

a. Spindle speed calculation:

Cutting Speed (SFM )×12

Spindle Speed (RPM)=
pi× Diameter
350× 12
Spindle Speed (RPM)¿
pi× 0.5
= 2675 RPM

Feed calculation:

Feed (IPM)=Chip Load×Number of Flutes×Spindle Speed (RPM)

Feed (IPM)=0.0015×3×2675≈12.04 IPM

b. Use a carbide 3"-diameter eight-tooth shell mill to machine H13 tool steel at 200 SFPM using a
0.003" chip load.

b. Spindle speed calculation:

Cutting Speed ×12

Spindle Speed (RPM)=
pi × Diameter
200× 12
Spindle Speed (RPM)=
pi× 3
=254.65 RPM

Feed calculation:

Feed (IPM)=Chip Load×Number of Teeth×Spindle Speed (RPM)Feed (IPM)=Chip Load×Number of

Teeth×Spindle Speed (RPM)

Feed (IPM)=0.003×8×254.65≈6.12 IPM

6. Briefly describe the process of locating the center of an existing hole on a vertical milling
machine.

The process of locating the center of an existing hole on a vertical milling machine involves:

a. Placing a center finder or edge finder in the spindle.

b. Positioning the workpiece on the milling machine table.

c. Bringing the center finder into contact with the hole's edge while moving the table.
d. When the center finder no longer moves, the spindle is aligned with the hole's center.

7. What are two benefits of boring over other holemaking operations?

Two benefits of boring over other holemaking operations are:

a. Boring allows for greater precision and control over hole diameter and surface finish.

b. Boring can be used to enlarge existing holes accurately, achieving tight tolerances.

8. What are face milling and peripheral milling?

Face milling and peripheral milling are both types of milling operations:

 Face milling involves cutting with the end of the cutter perpendicular to the workpiece
surface, resulting in flat surfaces.

 Peripheral milling involves cutting with the side of the cutter, producing contours or
profiles along the edge of the workpiece.

9. When squaring a block on the vertical mill, what surface of the block should be machined first,
and why?

When squaring a block on the vertical mill, the surface that should be machined first is one of the
larger faces of the block. This ensures that subsequent machining operations will be performed on
a stable, flat surface.

10. What are the three basic methods used to mill angular surfaces?

The three basic methods used to mill angular surfaces are: a. Tilting the milling head or the milling
table to the desired angle. b. Using a specially designed angle milling cutter. c. Employing an
indexing head or rotary table for precise angular positioning.

11. What must first be done before milling with either a T-slot cutter or dovetail cutter?

Before milling with either a T-slot cutter or dovetail cutter, the workpiece must be securely
clamped to the milling machine table and properly aligned to ensure accurate and safe machining.

12. What are the two basic types of keys?

The two basic types of keys are:

a. Square keys, which have a square cross-section and fit into square keyways.

b. Woodruff keys, which have a half-moon shape and fit into semicircular keyways.

13. What diameter cutter should be used to create 3/16" radii in the corners of a pocket?
To create 3/16" radii in the corners of a pocket, a cutter with a diameter equal to the desired
radius plus the desired width of the pocket should be used. Therefore, a cutter with a diameter of
3/16" (0.1875 inches) should be used.

14. When roughing a pocket, should you machine in a clockwise or counterclockwise direction,
and why?

When roughing a pocket, it's generally advisable to machine in a counterclockwise direction. This
direction of cutting helps to prevent climb milling, reduces cutter deflection, and improves tool
life.
Indexing and Rotary Table Operations
1. What is a rotary axis?

A rotary axis is a rotational axis in a machining setup, typically used in CNC machining, that allows
the workpiece or tool to rotate around an axis perpendicular to the primary machining axes (X, Y,
Z).

2. Define the term indexing.

Indexing refers to the process of accurately rotating a workpiece or tool to a specific angular
position in order to perform machining operations at precise intervals or angles.

3. Describe the primary differences between the rotary table and the indexing head.

The primary differences between a rotary table and an indexing head are:

 Rotary Table: A rotary table is primarily used for rotating workpieces around a vertical or
horizontal axis to perform machining operations at various angles. It provides continuous
rotation and can support larger and heavier workpieces.

 Indexing Head: An indexing head is designed specifically for precise angular positioning of
workpieces or tools. It typically allows for incremental rotation at precise intervals using
indexing plates or mechanisms.

4. Name three types of workpiece features that are well suited to using a rotary positioning
device.

Three types of workpiece features well suited to using a rotary positioning device are:

 Radial slots or grooves

 Circular pockets or holes

 Gear teeth or splines

5. Briefly describe the two alignment steps that need to be performed when setting up the
rotary table on the milling machine.

The two alignment steps when setting up a rotary table on a milling machine are:
a. Centering the rotary table with the milling machine spindle: This involves aligning the center of
the rotary table with the centerline of the milling machine spindle to ensure concentricity and
accurate rotation.

b. Squaring the rotary table with the milling machine axes: This involves aligning the axis of
rotation of the rotary table perpendicular to the X and Y axes of the milling machine to ensure
squareness and accurate angular positioning.

6. If the outside of a 6"-diameter disk is to be milled using a rotary table and a 3/4" diameter
endmill, what is the total amount the milling machine axis must be offset from the center of the
rotary table?

To mill the outside of a 6"-diameter disk using a rotary table and a 3/4" diameter endmill, the total
amount the milling machine axis must be offset from the center of the rotary table is equal to the
radius of the disk plus half the diameter of the endmill. Therefore, the offset would be
6/2+3/8=3+3/8=3.375"6/2+3/8=3+3/8=3.375".

7. What is the gear ratio found in the gear train of most indexing heads?

The gear ratio found in the gear train of most indexing heads is typically a multiple of 40. For
example, a common gear ratio might be 40:1 or 72:1.

8. When using the indexing head, a _____________ can be used to support long workpieces
during machining.

When using the indexing head, a tailstock can be used to support long workpieces during
machining, providing additional stability and reducing vibration.

9. A workpiece requires 9 divisions. Calculate the correct direct indexing plate and number of
notches to advance the plate. Plates with 24, 30, and 36 notches are available.

To calculate the correct direct indexing plate and number of notches to advance the plate for 9
divisions, you would use the formula:

Number of Notches=(Total Number of Divisions)/(Number of Indexing Plate Notches)

For a total of 9 divisions and indexing plates with 24, 30, and 36 notches:

 For a 24-notch plate: 9/24=0.375249=0.375 divisions per notch.

 For a 30-notch plate: 9/30=0.3309=0.3 divisions per notch.

 For a 36-notch plate: 9/36=0.25369=0.25 divisions per notch.

Since you cannot achieve fractional divisions, you would select the plate that comes closest to the
desired division accuracy, which would be the 24-notch plate.
10. In the formula 40 D 5 T, what do T and D represent?

In the formula 40D÷5T, T represents the number of divisions desired on the workpiece, and D
represents the number of divisions on the indexing plate. This formula is used for direct indexing
on an indexing head.

Grinding
1. What are three benefits of precision grinding?

Three benefits of precision grinding are:

a. High dimensional accuracy: Precision grinding can achieve tight tolerances and precise
dimensions, ensuring that parts meet exact specifications.

b. Superior surface finish: Grinding produces smooth surface finishes with minimal surface
roughness, which is crucial for parts requiring fine surface texture or aesthetics.

c. Improved part quality and consistency: Grinding removes material uniformly, resulting in
consistent part dimensions and quality, reducing the need for additional finishing operations.

2. What is the major use of the surface grinder?

The major use of the surface grinder is to produce flat, smooth, and parallel surfaces on
workpieces. This includes grinding surfaces to achieve precise dimensions, surface finish, and
flatness, as well as squaring and truing up workpieces.

3. What are the two spindle types used for surface grinders?

The two spindle types used for surface grinders are:

a. Horizontal spindle: The grinding wheel is mounted on a horizontal spindle, typically used for
surface grinding operations.

b. Vertical spindle: The grinding wheel is mounted on a vertical spindle, which allows for grinding
operations such as face grinding and cylindrical grinding.

4. What are the two types of table movements used for surface grinders?

The two types of table movements used for surface grinders are:

a. Longitudinal table movement: This movement occurs along the length of the grinding wheel,
allowing for grinding operations along the length of the workpiece.

b. Crossfeed table movement: This movement occurs perpendicular to the longitudinal movement,
allowing for grinding operations across the width of the workpiece.
5. Label the parts of the surface grinder.

1. Parts of the surface grinder:

a. Grinding wheel: The abrasive wheel used for grinding operations.

b. Workpiece: The material being ground.

c. Table: The flat surface on which the workpiece is mounted and moved during grinding.

d. Crossfeed handwheel: Controls the crossfeed movement of the table.

e. Longitudinal handwheel: Controls the longitudinal movement of the table.

f. Wheel guard: Encloses the grinding wheel for safety.

g. Spindle: Holds and rotates the grinding wheel.

h. Column: Supports the spindle and wheel head.

i. Wheel dresser: Used to dress the grinding wheel to the desired shape or profile.

j. Wheel guard adjustment: Adjusts the position of the wheel guard relative to the grinding wheel.

6. What are three types of cylindrical grinders?

Three types of cylindrical grinders are:

a. Plain cylindrical grinder: This type of grinder is used for cylindrical surfaces without any form of
traverse or crossfeed movement.

b. Universal cylindrical grinder: A versatile grinder capable of grinding cylindrical, conical, and
contoured surfaces. It typically includes a swiveling wheelhead and a workhead that can be
adjusted to various angles.

c. Centerless cylindrical grinder: In this grinder, the workpiece is supported by a workrest blade
and driven by a regulating wheel while being ground between the grinding wheel and regulating
wheel. This type of grinder is primarily used for high-production grinding of cylindrical components
with consistent diameter.

7. Tool and cutter grinders can be used to________ existing cutting tools or to create new,
customized

sharpen existing cutting tools