1. Gang milling
1.1. Uses more than 2 cutters
1.2. Used to mill a number of diff simultaneously
2. Straddle milling
2.1. Uses 2 Side and face cuters for machining 2 parallel surafes of the work piece
2.2. Cut same depth on workpiece
2.3. Reduces machining time
3. Lathe Machine
3.1. Cutting metal
3.2. Uses cutting tool
4. Turning Operations
4.1. Boring
4.1.1. To enlarge an existing hole
4.1.2. Must be done after drilling
4.2. Turning
4.2.1. Reduce diameter of work piece
4.2.2. Parallel to the axis of rotation
4.3. Threading
4.3.1. Parallel to axis of rotation
4.3.2. Faster
4.4. Facing
4.4.1. Fed on 1 end
4.4.2. Create a flat surface
4.5. Parting/Cut-off
4.5.1. Cut of a specific length of work piece
4.5.2. From center of work piece
4.6. Grooving
4.6.1. Fed near the mid
4.6.2. To a specific depth
4.7. Reaming
4.7.1. For finishing
4.7.2. Must be done after drilling
4.8. Drilling
4.8.1. Create a hole
4.8.2. In the middle
5. Single pointed tool geometry
5.1. Positive rake angle tools
5.1.1. Higher angle = Better surface finish
5.1.2. Less cutting force and power
5.1.3. Tool becomes weaker
5.1.4. Higher tool life
5.2. Negative rake angle tools
5.2.1. Surface finish sucks
5.2.2. Thin continuous chips
5.2.3. High cutting speeds
6. Tool holding devices
6.1. Front tool post
6.1.1. Only 1 tool at a time
6.2. 4-way tool post
6.2.1. hold up to 4 diff tools
6.2.2. Can find the centre of turning tool
6.2.3. Can be rotated and clamped in any position
6.3. Quick change tool post
6.3.1. Fast in swapping out tools
6.3.2. Useful for batch prodution
6.4. Tail Stock
6.4.1. Can be mounted with a drill chuck
6.4.2. Hold drilling bits
7. Milling machine
7.1. Intro
7.1.1. Either horizontal or vertical
7.1.2. Work is fed against a revolving cutting tool
7.1.3. Material removal process
7.2. 3 types
7.2.1. Horizontal
7.2.1.1. Advantage
7.2.1.1.1. Number of surfaces can be machined in 1 go due to large cutting tool area
7.2.1.2. Disadvatage
7.2.1.2.1. Cannot drill hole
7.2.2. Vertical
7.2.2.1. Used for profiling internal and external surfaces
7.2.2.2. Drilling and boring holes
7.2.2.3. Advantages
7.2.2.3.1. Can perorm mny types of machining processes than the horizontal machine
7.2.2.3.2. Easy to mount tools
7.2.2.4. Disadvantages
7.2.2.4.1. Obstructed view of cutter and workpiece
7.2.3. Universal
8. Milling cutters
8.1. Horizontal
8.1.1. Convex cutter
8.1.2. Slab mill
8.1.3. Slide and face staggered cutter
8.1.4. Angle cuter
8.1.5. Slitting saw
8.1.6. Slotting cutter
8.2. Vertical
8.2.1. Face mill
8.2.2. End mill
8.2.3. Ball-nosed slot drill
8.2.4. T-slot cutter
8.2.5. Fly cutter
8.2.6. Dovetail cutter
9. Ductile work material, low rake angle, low cutting speed, high depth of cut, high feedrate, poor use of cutting fluid
10. Supporting for long or thin workpiece
10.1. Centres
10.1.1. Dead/plain centre
10.1.1.1. Used for heavy loading turning
10.1.1.2. Apply grease = reduce friction
10.1.2. Live/revolving centre
10.1.2.1. Reduce temp generated at the centre
10.1.2.2. Can rotate along with the workpiece
10.2. Steadies
10.2.1. Travelling
10.2.1.1. Bolted to saddle
10.2.1.2. Useful when length of workpiece is machined
10.2.1.3. Prevents the metal from bending under cuttinf pressure
10.2.2. Fixed
10.2.2.1. Bolted to bed
10.2.2.2. Used to support work or long bar a distance from the chuck
10.2.2.3. Useful for turning a part of a long slender job
10.2.2.4. For drilling, boringo reaming at end of workpiece
11. Components
11.1. Table
11.1.1. With a leadscrew the table can move left and right
11.2. Spindle
11.2.1. Connected to the motor
11.2.2. Drives the arbor
11.3. Base
11.3.1. Foundation of machine
11.3.2. Storage tank for coolant
11.4. Brace
11.4.1. Additional support and rigidity to a long arbor
11.5. Arbor
11.5.1. Mount cutting tools
11.5.2. Rotates the cutter about a horizontal axis
11.6. Overarm
11.6.1. Support for free end of a long arbor
11.7. Column
11.7.1. Houses the electrical circuitry, the main drive and spindle bearings
11.8. Knee
11.8.1. Acts as a support for the saddle, work table and other accessories
11.9. Saddle
11.9.1. Enables the table to move along the clomun and provides vertical motion
12. Turning feeds and speeds
13. Cutting Theory
13.1. Cutting Methods
13.1.1. Oblique
13.1.1.1. Any angle other than 90
13.1.1.2. Better at leaving a finishing than orthogonal
13.1.2. Orthogonal
13.1.2.1. Set at 90 degrees to the direction of movement
13.1.2.2. Effectiveness depends on slope
13.2. Factors affecting cutting operations
13.2.1. Work piece material
13.2.1.1. Wood, Metal, Acrylic
13.2.2. Conditions
13.2.2.1. Wet/Dry
13.2.3. Tool material
13.2.3.1. Diamond, Cast cobalt alloys, Cemented carbide
13.2.4. Machine rigidity
13.2.4.1. Machine dsign/Machine condition
13.3. Cutting conditions
13.3.1. Increase feedrate, increase depth of cut, decrease cutting speed
13.3.1.1. Quick material remover
13.3.2. Decrease feedrate, decrease depth of cut, increase cutting speed
13.3.2.1. Finishing cuts
14. Types of chips
14.1. Affected by
14.1.1. Work Material, Tool Geometry, Cutting Conditions, Presence of cutting fluids
14.2. Discontinuous chips
14.2.1. Brittle work material, small rake angle, low cutting speed, large depth of cut, large feedrate, lack of cutting fluid
14.3. Continuous chips
14.3.1. Ductile work material, large rake angle, high cutting speed, small depth of cut, low feedrate, effiicient use of cutting fluid, cutting tool with less pressure
14.4. Continuous chips with a built-up edge
15. Work holding and supporting devices
15.1. Holding workpiece
15.1.1. 3 jaws chucks
15.1.1.1. Scrolling mechanism to clamp the work piece
15.1.1.2. Advantage
15.1.1.2.1. Workpiece will be clamped in the centre of the chuck
15.1.1.2.2. Can work with workpiece with large diameter but shorter length
15.1.1.3. Disadvantage
15.1.1.3.1. Low gripping strength
15.1.1.3.2. Jaws are not interchangeable
15.1.1.3.3. Clamping restriction
15.1.2. 4 jaw chucks
15.1.2.1. All jaws are operated independently
15.1.2.2. Need 4 chuck keys to complete clmaping of workpiece
15.1.2.3. More accurate as each jaw can be adjusted individually
15.1.2.4. Advantage
15.1.2.4.1. High gripping strength
15.1.2.4.2. Clamping variability
15.1.2.4.3. Can work with workpiece with larger diameter but shorter length
15.1.2.5. Disadvantage
15.1.2.5.1. Too long to set-up
15.1.3. Mandrels
15.1.3.1. Plain solid
15.1.3.1.1. Only 1 size of bore
15.1.3.2. Expnsion
15.1.3.2.1. Suitable for slight diff in diameter
15.1.3.3. Cone
15.1.3.3.1. Suitable for workpiece with diff hole diameter
15.1.3.4. Gang
15.1.3.4.1. Suitable for many identical workpieces
16. Gears and pulleys
16.1. Gears
16.1.1. Spur gears
16.1.2. Helical spur gears
16.1.3. Bevel gears
16.1.4. Helical gears
16.1.5. Worm and worm wheel
16.1.6. Rack and pinion
16.2. Pulleys and belts
16.2.1. Round belt
16.2.2. Flat belt
16.2.3. Vee belt
16.2.4. Timing belt
16.2.5. Conveyer belt