Machine Shop Job Analysis

Table of Contents

Chapter 1: Machining Cylindrical Shapes

Topics: Turning; Shoulder facing; Machining fillets; Turning profiles; Knurling; Filing; Facing; Boring; Counterboring; Thread cutting

Learning Objectives:

• Explain the procedures for turning single and multiple diameters, including shoulders, fillets, and relief notches.
• Compute tapers, including the use of the setover method, compound rest method, and taper attachment method.
• Show how to use the cutting tools and machines for knurling, filing, and polishing.
• List the procedures for facing chucked work and work mounted between centers on the lathe.
• Describe the procedures for boring and counterboring in a lathe and boring mill.

Chapter 2: Drilling, Reaming, and Honing

Topics: Workpiece stationary, drill rotating; Workpiece rotating, drill stationary; Drill press jobs; Radial drill presses; Spot facing tools; Boring bars; Drill bushings and jigs; Reaming; Honing

Learning Objectives:

• Describe the basic drilling process.
• List drilling procedures for work mounted in a lathe.
• List drilling procedures for work mounted in a drill press.
• Explain the use of reaming in a lathe and a drill press.
• Explain the use of honing and the type of equipment used.

Chapter 3: Machining Flat Surfaces

Topics: Plain, side, straddle, profile, and face milling; Irregular shapes; Slotting; Shaping; Broaching; Surface grinding

Learning Objectives:

• Describe the basic milling process, cutter types, and their application.
• List slotting procedures in a milling machine.
• and milling.
• Define broaching, its application, and the machines used.
• Define surface grinding, its application, and the machines used.

Chapter 4: Determining Tolerances and Finishes

Topics: Linear dimensions; Tolerances; Limits; Tolerance stackup; Rough cuts; Allowances for finishing; Finish cuts; Surface texture and finish

Learning Objectives:

• Define dimensional factors, including linear and angular dimensions.
• Compute tolerances and tolerance stackup.
• Describe allowance for finishing, including procedures for finish cuts.
• Compute surface texture in terms of an average used for final machining.
• Analyze surface finish requirements as specified for the job.

Chapter 5: Variables Affecting Job Efficiency

Topics: Machinability; Chip formation; Selection and application of cutting fluids; Solid lubricants; Machining efficiency; Selecting tooling/fixtures

Learning Objectives:

• Define machinability of workpiece stock, including machining variables, and workpiece variables.
• Explain machinability ratings.
• Select cutting fluids, cutting lubricants, and solid lubricants.
• Describe machining efficiency, including minimal workpiece setups and standard versus special tooling and fixtures.
• Identify the correct machine and cutting tool for a given job.

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