MFG 273 - Mill Operations II

1. Demonstrate shop safety as it applies to the milling machines.
   1. Wear safety clothing appropriate for operating a milling machine
   2. Wear eye protection
   3. Explain what routine maintenance on the milling machine must be performed
2. Identify tools used on the milling machines.
   1. Describe the setup and operation of the offset boring head
   2. Demonstrate knowledge of a rotary table
3. Demonstrate knowledge of the parts of the Horizontal Milling Machine.
   1. Name the six major components of the 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
4. Demonstrate how to set up the milling machine.
   1. Describe two methods of checking tool-head alignment
   2. Explain the procedure for positioning spindle with indicator
   3. Explain how a face-milling cutter is setup
5. Demonstrate knowledge of the proper care of milling cutters.
   1. Identify common cutters for the vertical mill
   2. Select a proper cutter for a given machining task
   3. Demonstrate knowledge of 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/indexable 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. Explain different methods of indexing.
   1. Identify the major parts of indexing heads and rotary tables
   2. Explain when indexing devices are used
   3. Describe the difference between simple and direct indexing
   4. Discuss how to index for a given number division
   5. Identify how to index for a given angular indexing
7. Calculate speeds and feeds.
   1. Compute the rpm for a given size carbide 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 cut for a roughing end mill is