MFG 260 - Mill Operations Theory

1. Evaluate shop safety as it applies to the milling machines
   1. Wear safety clothing appropriate for work with milling machine
   2. Wear eye protection in the lab.
   3. Explain what routine maintenance on the machine must be performed
2. Explain tools used on the milling machines
   1. Identify what kinds of cutters are mounted directly on the spindle nose
   2. List the two types of tapers found on milling machines
   3. Summarize the two basic kinds of milling cutters with reference to their tooth shape.
   4. Show the difference between climb and conventional milling
   5. Describe the setup and operation of an offset boring head in common boring operations
3. Examine the Vertical Milling Machines
   1. Name the six major components of the vertical milling machine
   2. Describe which parts are used to move the table longitudinally
   3. Explain which parts are used to move the saddle
   4. Identify the purpose of the table clamp
   5. Explain the purpose of the spindle brake
   6. Describe how a loose table movement is adjusted
   7. Discuss the purpose of the quill clamp 
4. Examine how to set up and how to use the milling machines
   1. Identify the important components and controls on the Vertical Milling Machines
   2. Describe the functions of machine parts and controls
   3. Perform routine maintenance on the machine
   4. Describe how work pieces are aligned when they are clamped to the table
   5. Show how a vise is aligned on a machine table
   6. Describe how to check tool-head alignment
   7. Provide an explanation of why it is important that the knee clamping bolts are tight before aligning a tool-head
   8. Explain why the tool-head alignment needs to be checked again after all the clamping bolts are tightened
5. Examine Milling cutters
   1. Identify common cutters for the vertical mill
   2. Select a proper cutter for a given machining task
   3. Explain how a right-hand cut end mill is identified
   4. Describe what characteristic of end mills allows them to be used for plunge cutting
   5. Explain the main difference between a general purpose end mill and one designed to cut aluminum
   6. Describe when carbide-tipped end mills are chosen over high-speed steel end mills
   7. Identify what kind of end mill would be used to remove a considerable amount of metal
   8. Explain what tapered end mills are used for
6. Calculate speeds and feeds
   1. Compute the rpm for a given size high speed mill cutter
   2. Calculate the feed for a given type cutter and a given type steel
   3. Explain when lower cutting speeds are recommended
   4. Describe when cutting fluids are used
   5. Discuss how the tool is affected by the chip thickness
   6. Describe what the maximum depth of an end mill is