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311 Cards in this Set
- Front
- Back
What is the most common type of holding device? |
3 jaw self centering chuck |
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Why is the 3 jaw celf centering chuck important |
it is the most common |
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What is the 4 jaw chuck used for? |
rectangles, but more commonly for concentrics |
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What is special about the 4 jaw chuck? |
each jaw can move independently |
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What is the chuck example in class |
concentric offset piece |
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What is the concentric offset piece an example of |
the 4 jaw independent chuck |
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What is the most harmful equipment |
4 jaw chuck with chuck key |
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why is the 4 jaw chuck dangerous |
the chuck key can fly and kill |
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what is the chuck key an example of |
a harmful tool |
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what was passed around in class as dangerous |
the chuck key |
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How does the chuck key become a problem? |
If you forget to take out the chuck key, centrifugal force drives it out and hits the bed of the laith/bends and pops out vertically upwards |
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What is another example for putting in harms way? |
Nail roofers disabling safety |
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What is the nail roofers an example of? |
disabling safety like with chuck key |
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Problems with chucks |
not easily automated |
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Describe a collet chuck |
Example is chalk holder for blackboards; push end and fingers splay out; 2 cones internal and external; one with slots |
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What is the tool used to hold chalk for blackboards |
collet chuck |
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what device has two cones |
collet chuck |
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example of collet chuck |
blackboard chalk holder |
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characteristics of collet chuck |
collet, cap and cone; slotted, flexible and springy; not a lot of motion; you will get a cap and cone and a lot of diameter collets |
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Downfall of collet chucks |
only good for holding round things |
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What is only good for holding round things? |
collet chucks |
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Revolution of squares and circles? |
describing collet chuck; used to buy square and make round; now cut circle to square |
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Positives of collet chuck |
1. better grip 2. runs concentric 3. no marring (marking/damages because of multiple little fingers) |
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What can run concentric, has good grip, and does not mar? |
collet chuck |
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Describe basics of drill chuck |
used on a drill; similar to 3 jaw chuck; example is 3 jaw chuck for drill with key; can be used on power tools/machine tools |
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What is an alternate name for the drill chuck? |
Jacob's chuck |
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What is the story for jacob's chuck? |
Vacuum in england is called hoover |
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Why is hoover important? |
comparison to jacob's chuck/drill chuck; what they call vacuum in england |
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Describe advancements of Jacob's chuck |
advancement made in keyless varieties; with own hand strength, butn colalar |
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Downfallls of jacob's chuck/drill chuck |
deliberately made to slip |
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what chuck is deliberately made to slip |
jacob's chuck/drill chuck |
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what has a terrible grip |
jacob's chuck |
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Why do chuck's slip? and which one? |
drill chuck/jacob's chuck because otherwise it would risk breaking; want chuck to keep going around; downside is they chew up drill |
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describe cutting threads |
cutting threads on laithe is not difficult; size of the hole you want is always smaller than nominal size of thread |
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describe relationship between hole size and thread size |
size of hole you want is always smaller than nominal size of thread |
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Describe basic characteristics of threaded tools |
like a bolt, but sharpened; taps come in 3's for 1 pitch and diameter |
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example of threading |
1. Plumber tap/taper taps (narrow and narrow taper) 2. 2nd tap (wide with taper) 3. Wide bottom (bottoming in US and plug tap in UK) |
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What is a plug tap |
UK name for wide bottomed 3rd tap in threading |
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What is the example of threading used? specification |
1/4" diameter with 20 threads/inch |
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Describe 3 types of threading tools |
1. plumber tap 2. 2nd tap 3. bottoming/plug tap |
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Describe threading shortcut |
some go from plumber taper tap to bottoming tap |
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example of threading tool |
tap wrench |
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describe unique tap wrench usage |
cannot just put in and turn because it will tear up threads; one forward turn then reverse 1/4 turn to break chips off |
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forward 1 turn back 1/4 |
tap wrench |
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What is the best way to use a tap wrench? |
lay on back/blow it out |
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what is tap wrench used for |
threading |
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in class example of threading |
tap wrench |
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Example of tap? |
gap toothed tap (tap with sets of teeth down side) |
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Describe gap toothed tap |
Missing teeth and rest is cut away; next position has staggered teeth; tend to use on automated machine; gives more room for chips |
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plumber's tap |
use tapered taps |
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Example of tap |
tap with teeth and put on metal |
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What to avoid? |
blind tapped holes; small diamter holes in aluminum-has affinity for PING |
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PING |
tapping aluminum |
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shearing steel? |
tapping aluminum |
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Murphy's law |
always snaps flush from surface cold welded in threaded hole |
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what is the example of tapping aluminum? |
murphy's law; always snaps flush |
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How to fix aluminum tap? |
some people tap it out; common is to drill ring of holes and pop out middle, but then has to machine larger circle |
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How else to fix aluminum tap? |
threaded inserts |
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What is flower method? |
how to fix aluminum tap |
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In class example of hole making |
twist drill |
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describe anatomy of twist drill |
1. continuous helical grooves lift chips out allowing cutting fluid in (FLUTES) 2. SHANK-thing to grip 3. NECK-transition area 4. First part of hole drilled 1st, then 2nd part is a new hole; plane drill would not have same diameter throughout; to avoid, raised area along FLUTE 5. MARGIN-all material behind is pushed back, minimizing rubbing 6. Cutting blades (LIP) 2x 7. CHISEL |
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How many types of twist drill are there |
2 types of shank with drill; straight shank can hold in a drill chuck/round and straight |
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What holds in the chuck? |
An accessory that is tapered |
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How does the chuck fit into the machine? |
tapered jacob's chuck; top is tapered too |
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Describe how the twist drill fits? |
twist drill is straight into tapered hole; certain angle of metal that jams |
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what is the name of the taper that helps twist drill fit? |
morse taper; ideal about 1.5 degrees |
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1.5 degrees |
morse taper for chuck holder |
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Example of morse taper |
piece of metal with morse taper and shank; comes out with hammer |
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how do you remove morse taper |
tap with hammer |
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Describe morse taper fittings |
mt1, mt2, and mt3; they do not vary with material; taper on outside and inside |
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Describe basic drill anatomy |
Head is caalled tang, then drift and grip |
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Describe gun creation |
want same diameter the whole way w/o curve; flute have left and right hand; cannot use twist drill for drilling barrel of gun; used to begin with hole and put metal around it MANDREL |
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uniqueness of flute |
left hand/right hand; drills not symmetrical and will wander |
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Describe gun barrel creation |
cannot use twist drill because left and right handed; iron strips and put them around and hit with hammer; all welds and pulls out mandrel; called damascus metal |
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describe damascus metal |
gun barrel creation |
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What is the result of gun barrel creation? |
damascus metal |
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Describe the typical drill set and types? |
Twist drills come with inserts; called JObbers set |
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What is the jobber's set? |
The typical twit drill set |
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What about deep small diameter? |
can have additional sets; LONG BOY DRILLS |
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Issues with long deep holes? |
tony and extremely long diameter holes do not just drill in |
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How to narrow deep holes? |
Start with jobbers, then continue with long boy to increase accuracy |
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Big diameter drills and stubby |
Fat boy drills (same length and large diameter) |
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What can fat boy drills not be used for? |
gun barrels; twist drills left and right handed; damascus-iron, steel, etc. |
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What is damascus? |
gun metal and capital of syria |
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Describe gun barrel process? |
red hot iron strips; strike with hammer to wel together; leaves decorative, pretty pattern surrounding mandrel |
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where is damascus also found? |
Decorative knife blades |
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What materials can damascus be? |
titanium, steel and irum |
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examples of damascus |
titanium and steel; 2 types of grade and carbon content; hammer until swirled together; put in acid bath to bring out nature of swrirl; heat treatment for titanium to change colors |
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What is used for straight holes? |
flutes; chips accumulate at ends and have changes to remove them |
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Difficulty with flutes |
acquiring chips |
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How to resolve flutes |
need 2 pathways for liquid to pump down and push out; PM processing for another hole; compresses powder to green state to push material through hole in center |
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Example of flute usage |
gun drill maade of tungsten carbide; 2 straight flutes; 2 holes through middle made by PM processing |
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Describe flute usage in gun barrel creation |
gun drills going to be undersized for 99% of length; also have wear pads usually made of bronze; softer material than gun barrel to avoid scoring; creates a bearing-type material |
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Describe gun drills |
1. straight flutes 2. fluid passageway 3. bronze wear pads |
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General idea of flute resolution |
specialized mechanicsm to deliver fluid; usually barrel rotates; drill does not, so it does not need fluid injectors |
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describe barrel forming |
1. metal oversized 2. mandrel 3. swaging |
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Example of flute |
router drill; tunsten carbide; rough sides; designed for use on fiber glass; powder (round) |
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router drill is an example of what? |
flute |
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Example with gold bit |
flue round examplel; can never make hole correctly |
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Story of flute |
drilling under a car and end up drilling hole bigger; put through hole and push sides; titanium nitride coated |
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Example of flute |
tunsten carbide straight fluted drill; like mini gun drill; used for cutting through hard material like cast iron |
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Example of another drill |
dagger drill; flat glass fiber |
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Describe types of drills |
Router drill, dagger drill, (both GRP) straight flute drill (cast iron) |
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Describe the process of cutting holes |
straight square (no), tapered cutter (no, rounded corners), multiple cutters (yes) |
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Story about square drill |
didn't think it existed, but he donated one |
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Example of square drill |
donated one; floating chuck, ; number of blades one less than side |
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describe square drilling |
floating chuck; number of blades one less than number of sides; need a template; square hole blind in end of circular piece of metal; custom jig; surface comes with drill; tip machines out everything within square guide |
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Problem with getting a bitter drill |
make more chips |
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circular saw is called what? |
hole saw |
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What is needed with larger drill? |
cut an annular groove; useful piece of metal that will knock slug out of the middle; problem is electric bell |
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electric bell |
noise a hole saw makes |
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Describe hole saw in metal |
1. Noisy 2. Run eccentric 3. Nowhere for chips to grow; no flutes; caught in angular groove 4. Plug gets stuck inside; waste materials 5. Overheat; no access for cutting fluid |
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What is the alternative for the hole saw |
Trapanning tool |
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describe trapanning tool |
4 single point cutting tools; only cuts one diameter hole; one single point cutting tool could be put into power drill, but probably would not want to |
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Describe the extrusion on trappaning tool |
little blacdes, and Abor |
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what is an arbor? |
extrusion of metal |
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Example of trapanning tool |
single point cutting tool with arbor; can move to range of diameters by adjusting the arbor; can drill any holes with milling cutters |
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What is the conical section called? |
countersink |
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Example of countersink? |
countersinkin tool will self center |
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Describe countersink process |
With CNC there is not a worry, but if by hand, put into drill press; nice in line with vice |
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Flat bottomed larger diameter hole |
counterbore |
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tool to create counterbore |
blades on bottom and upsides |
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If you do not want a hammer, describe the process |
feature on side called set screw; hole in the end of outer and set screw on side; put pilot into that; comes with sets of pilots; shanks same size |
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what is a reamer |
bolt through the hole is you do not care; do not want brass to get caught in core manes; not just firearms; most reamers have straight blades |
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in class reamer |
no blades on end; beautifully slides inside hole; follow up tool for precision |
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steps to using a reamer |
has to be undersized; follow up gives precision; 1/32" undersized hole; reamer if correct size; cone shape |
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tools that assist in drilling a hole |
1. marking out dye; 2. scriber; 3. center pot (center punch); put over point of indentation/hammer that drives; 4. center drill stubby and does not flex much in funnel shape 5. Pilot drill (twist drill) 1/32" undersize 6. Final drill correct size |
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Story about drilling hole |
go over skyway bridge |
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Describe imagery of radial arm drill |
V8 engine block drill; low to the ground |
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name specialized drills |
multi-spindle drills, gang drilling (in a line with multiple stand drills), turret drill |
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example of turret drill usage |
product that needs large number of holes with different diameters; CNC machine could do the same, but individually |
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What are the 2 shapes in drilling/machining |
round, then the rest |
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Name key differences between shaping and planing machine |
shaping: 1. extinct 2. relatively small 3. small cuts 4. tool moves and work piece is stationary planing: 1. still used, but not extensively 2. very big 3. large cuts (why it's still used) quickly 4. Flat surfaces or grooves |
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Describe Broaches |
1. Can cut a square hole; one limitation is that you can never do blind holes 2. final to unusual shape, this is used; circle at one end, and progressively get shape |
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Example broach |
3/8" round hole w/ sharp corners |
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Describe broaches |
always have one less blade than number of sidess; square drill only for blind hole |
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example of keyway |
collar product; has keyway; square notch that has been cutout into wall of shaft |
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Positives of keyway broach |
inexpensive |
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How does keyway broach come |
set will come with cylindrical pieces to fit inside hole; insert and broach and pulls through; usually done by hand |
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Describe milling machines |
Probably need laithe and vertical milling machine; basically a drill press on steriods; all it can do is go up, down and spin |
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What if milling machine is tilted? |
called universal vertical milling machine |
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describe universal vertical milling machine |
tilt, swing, pivot, but not rotate; spindle can rotate; can cut on side and on end of itself |
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Example of milling products |
big block with grooves and holes; 1. just after cast 2. after milling |
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example of milling cutters |
drill like look and flutes; blades with sharpened edges; blades on end, too 1. ring of blades and center is nothing 2. blades through center (more expensive) |
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Downfall of cheaper milling cutters |
cannot go straight down b/c no blades in the middle; need center cutting for that |
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Example of milling cutters |
gold titanium nitride coated; both with same diameter; came in the set; for any size they give you 2; 4 blades and 2 blades; end mill and slot drill (these are not drills by definition) |
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Describe the 2 types of milling cutters |
1. 2 blades large cuts, but pretty rough surface; roughing tool; finishing tool for smoother surface 2. Roughing tool; large amounts quickly; have to switch them out |
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Why are milling cutters declining? |
will have to switch them out |
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How do you remove a large piece of metal on flat surface? |
need to use face mill w/ inserts |
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Example of large flat surface material removal? |
chip things; typical |
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Why the inserts? |
If chipped, turn, if break, can replace them; slots in the table are called T slots |
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Describe how to drill T slots |
Multi stage operation; small dieamter end mill for vertical, then T slot cutter (horizontal) |
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Describe difference between T-slot cutter and face mill |
similar tools, but not done with same cutter; 1. enlarging (key way cutter) and 2. Key slot cutting (parallel shaft) |
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Describe difference between universal vertical milling machine and horizontal |
One is straight down, and the other is across and down with long rod of metal (arbor) with shaft stretching down |
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Example of universal milling machine |
hole through middle and key slot |
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describe trend of machines |
going away; easy to have release in CNC; in horizontal, not easily automated |
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describe horizontal machine |
held on both ends; much stiffer and can only do laithe operations |
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Machine centeres |
typically laithe and vertical milling machine; typically 5 or 6 axes; USF has 5 |
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Describe CNC Machining story |
spyro game with gears and drawing |
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describe gear cutting |
another way to use a broach; pot broach; straight cutting smaller to larger rows of teeth |
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What is a gear cutter called? |
pot broach |
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product of pot broach |
non plain cut keys in cars; gears have helical cutter keys; do not cut on CNC; need specialized machine |
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specialized machine for helical cutter keys |
Gear HOB |
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Describe file story |
not very desired; 4x4x4 cube of steel and give file to turn to sphere |
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describe basics of files |
1. have to buy handle; does not come with one; kills people |
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describe bastard file |
flat and coarse teeth; full round and 1/2 round |
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Examples of files |
bastard file, little files (needle/swiss files) |
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problem with files |
aluminum gets caught so used chalkboard chalk to fix it |
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Describe a dremmel tool, downside and fix |
flex drives for small things; tiny tool that spins fast; rotary files |
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describe a hacksaw |
blades always face forward |
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modification of hacksaw |
stainless steel rod; put on tungsten carbide hacksaw blade |
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describe bandsaws |
vertical and horizontal (stock) |
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Story of band saw |
weld came lose; sprung off |
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Machining is also known as? |
Material removal process/"subtractive manufacturing" |
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What does tool signify? |
tool is a general term, but jazz it up with modifying |
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Name 4 types of tools |
hand tool, power tool, machine tool, cutting tool |
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describe a hand tool |
no power, battery, air line, muscle power only |
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name an example of a hand tool |
hammer; hack saw |
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describe a power tool |
usually portable, add power |
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example of power tool |
drill |
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describe machine tool |
stationary tool |
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example of machine tool |
laithe, mill, drill press |
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describe a cutting tool |
actual piece that does work that is inside a power tool, laithe, etc. |
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examples of a cutting tool |
tool bit, drill bit, cutting insert |
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describe 2 types of cutting tools (main) |
single point and multi point |
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what does "point" mean in tools |
point=cutting edge |
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what is the rake angle |
angle of the cutting face relative to the work; these help guide chip flow |
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describe single point cutting |
often used in a laithe, from blank shapped to cutting point by cleaving; rake angle is most important angle; barges angle from point |
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what are some characteristics of rake angle |
changes based on material being cut; 15 degrees is most common angle used as compromise |
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What is the material removed during metal removal |
chip/swarf; small piece of metal removed during cutting operation |
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what is a chip/swarf? |
small piece of metal removed during cutting operation |
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how (what shape) are chips generally removed? |
helix |
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describe types of chips |
continuous chip and discontinuous chip |
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describe continuous chip |
"perfect cutting" |
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describe causes of continuous chip |
correct speed, feed, tool angles-->low friction, low wear, low energy usage, low heat |
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down sides of continuous chip |
get caught on things, clog machines, safety hazard, difficult to clean up, don't pack well, low volume |
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describe discontinous chip |
opposite of continous chip |
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describe modifications with continuous chip |
"ninja," uses a chip breaker via bending metal to snapping point |
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what is used to cut continuous chips |
chip breaker |
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describe 2 methods of chip breaking |
block and groove |
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describe chip breaking |
use a set up tool w/out chip breaker to get cutting, then swap for tool w/chip breaker |
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describe a type of chips |
serrated chips; sharp "saw blade" edge |
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Describe the chip cutting process |
high firction/heat with hardened aluminum bonds for cutting edge; built up edge (BUE) |
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describe types of cutting fluid |
water and oil |
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describe cutting fluid process |
water-it has to cool; oil-it has to lubricate; don't mix, add a surface tension |
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what happens when mixing detergent and oil |
soluble oil |
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Describe tool parameters (increasing hardness and decreasing brittleness) |
hot hardness (hardness at elevated temps), carbon steel, HSS, cobalt alloys, tungsten carbide, coated tools |
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What is HSS |
High speed steel; add vanadium, refractory metal |
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describe HSS |
add vanadium, refractory metal; inexpensive, readily available, can be easily sharpened |
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describe inserts |
harder materials are generally more expensive; if a single chip happens on tip; whole tool must be tossed even though most of it is fine |
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Example of inserts |
insert holder for single point; threaded insert |
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describe alternates to inserts |
can be plain or include chip breakers |
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describe tool inserts |
Cubic Boron Nitride (CBN), tips of insert have CBN; can still be quite expensive |
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in class example of inserts |
$150 inserts; very expensive; tungsten carbide base and 3 coats |
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Describe cutting circular shapes |
laithe operations; straight turning, taper turning, profiling, turning with external groove, facing, face grooving, forming (less often used), knurling, boring, internal grooving, drilling, threading |
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describe basic components of laithe |
1st gen engine laithe-headstock (motor inside), feed gear box, bed, spindle, chuck, compount rest, (carriage) apron, carriage, feed rod (smooth), lead screw, tail stock, quill, cross slide, tool; ways-ground track for carriage, tailsbole |
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laithe improvements |
tool holder is the chocke point; turret tool holder |
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describe type of tool holder |
turret tool holder |
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describe capstan laithe |
pirate ship story of a sailors life for me; pull of anchor chain |
|
describe 3 laithes |
tracer, CNC, and capstan |
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describe tracer laithe |
follows a pattern and traces it onto stock material example: fire arm stock |
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describe tracer laithe components |
work piece, tool, pattern, tracer |
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describe CNC laithe |
enclosed, fluid coolant, closed door guard, can be attached to tool rack, pre loads turret while in process |
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types of chucks |
3-jaw celf centering, 4 jaw and collet chuck |
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describe 3 jaw celf centering |
chuck key; holds round pieces |
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describe 4 jaw chuck |
independent; allows for eccentric axles |
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example of 4 jaw chuck |
crank shaft with eccentric center |
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describe collet cuck |
casket shaped; lots of surface area for grip; example was chalk holder; fans out; limited number of diameters per collet; very repeatedly concentric |
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handed around |
jacobs chuck, collet chuck (chalk holder), 1, 2, 3 coat cutting bits; single point inserts |
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describe jacob's chuck |
drill chuck; relatively small; deliberately designed to be able to slip (like in a drill) |
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example of jacob's chuck on laithe |
quill on laithe tail stock |
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describe basics of thread cutting |
internal or external, internal generally tapped |
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describe internal threading |
internal thread will generally be small and prone to flex; hole drilled undersied; by hand, forward 1 turn and 1/4 back; by CNC auto feed in tap, use bottom tap only |
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complications with thread cutting |
blind holes, chips get clogged, small holes in aluminum; taps like to break; threaded inserts common |
|
set of taps for manual metal |
taper tap, tap handle wrench, second tap, bottoming/plug tap (all known as straight threads) |
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What are taper taps used for |
NPT, similar tapered thread |
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What was handed around for tap talk |
tap wrench, gap tooth taper, bottoming tap |
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order of taps |
taper tuber tap, taper 2nd tap, bottoming taper tap |
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describe the tap passed around |
gap tooth taper bottoming tap, every 2nd tooth is missing; gap tooth allows chisp to be cleared in CNC machines |
|
Describe the twist drill |
chisel point, flutes (coolant and chips), helical pattern, margin (stand off for land to prevent wear), shank, neck |
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describe tip of twist drill |
land, flutes, 2x lip (cutting edge/blade), bearing surface (margin); hole would end up tapered due to friction at entrance if no margin |
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problem if no margin |
hole would end up tap |
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What are shanks used for, and describe them |
straight: used in collet chuck or drill chuck; taper: used w/out chuck; held in with voodoo |
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What is a morse taper |
specific angle to hold in tapered shank with tang |
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Describe morse taper process |
window, spindle, drift, taper; drift used to hammer out |
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Abrasive cutting is known as? |
grinding |
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describe grinding |
machine surface finish, blade, abrasion, abrasive cutting |
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name common grit with grinding |
aluminum oxide, silicon carbide, Cubic Boron Nitride, Diamond |
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What are the positives of grinding? |
better surface finish, cut very hard surfaces; grit is very hard compared to metals, ceramic, etc. |
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What is Al2O5 |
aluminum oxide |
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What is SiC |
silicon carbide |
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What is CBN |
cubic boron nitride |
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What is grit? |
poder of various grades; bonding |
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Describe grit |
shape is randomized in grit; poor control of cutting angle; some bits cut, some bits will smooth over surface; grit brittleness is part of design |
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Where is attritious wear important |
Grit; self sharpening as brittle grit snaps, fracture |
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Where is abrasive cutting a problem |
do not use on laithe; grit will destroy ways on laithes, mills, etc. |
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Bond types |
vitrous/vitrified, resinoid, rubber |
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describe vitrous/vitrified |
glass, high temp resistant, rigid/maintain dimension; used in rigid machines; brittle |
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describe two bond types used in angle grinders |
resinoid and rubber |
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describe resinoid |
thermoset plastic; often glass fiber matte reinforcement |
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describe rubber grit |
conforms to shape |
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parameters of grit |
grit type-->grades(porosity), grit size, bond type, packing density (grit/bond) ratio |
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describe grit classification system |
code for the parameters; alternates between letters and numbers; manufacturing specific, standardized portion, and manufacturing specific |
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describe components of grinding |
grit held in matrix with material |
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Why grit? abrasive cutting |
for cutting hard materials, to get a smooth surface, precision (can get to tighter tolerances than blades; blades flex) |
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what is a common form of abrasive cutting? |
grinding wheels (grit and bonding agent) |
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describe two things about grit |
aluminum oxide/silicon carbide; will not cut particularly well/small-slow/nice finish; coarse-quick, but rough |
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fact about grit size |
bigger number, smaller grit |
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describe bond types of grit |
vitrified (glass); hot glass and pour in grit, then pour to mold (tiny bit of glass); advantages thermally stable, and rigid |
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example of bonding types (passed around) |
vitrified disc and resinoid disc (usually thin and things through center for tahbility) |
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example of bond types progression |
die casted tool and resoinoid disc |
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describe rubber grit |
flexible and accomadates (high flexibility), low temp (cannot take heat) |
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describe disc |
name what grit is made of, grit size, what is it bound together with, packing density (how many pieces of grit per unit volume of bond) |
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describe wheel classification system |
on label description, series of numbers and letters 1. number, purely used by manufacturer as their own catalog (always numbers) 2. letter: what grit is made of A: aluminum oxide S: silicon carbide 3. alternates; another number; grain/grit size; number of digits do not matter 4. porosity (amount of sponginess)/aluminum oxide has one hardness and can vary by adding air 5. structure relates to packing density |
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Difference between file and grinding wheel |
file will be loading and grdinging loaded with particles; don't put chalk on grinding wheel; not going to get resistance; avoid grinding aluminum |
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describe packing density |
normally name and number; left is material you can grind with that |
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example of grinding |
grinding aluminum with dremmel; mounted almost completely slimed with aluminum; aluminum fairly ductile |
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describe stresses of grinding |
residual tensile surface failure |
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describe grinding process (basics) |
never done in isolation, must deal with it like illness; preventative or cure |
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how can I prevent? |
gentle grinding; fine cuts and doing it slowly; residual amount of tensile stresses |
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how to cure? |
cannot peen form; heat treatment; get rid if you get them; low temp and lengthy |
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describe a bench grinder |
light and guard with table; never put grinding wheel on laithe or milling machine because attricious wear would knock powder and greate |
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example (passed around) of grinding machine |
small bench grinder; general purpose sharpening, siren song, awkward bolt, attritious wear causes wheel to get smaller; grows to big gap; take piece and shoves it down |
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describe surface grinder |
work piece will keep moving under the wheel; tend to have magnetic table; series of horshoe magnets; no overall magnetic field; USF moved from manual to electromagnets |
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sory of surface grinder |
turned right handle too far; table up fast and hit; wheel gone; only give away is high pitch; vitrified so it shatters |
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describe circular grinding/round |
cylindrical grinding: complex motion of rotating and translating/holding chuck; if eccentric, whole thing is off 2. centerless grinding: no chuck, wedged between wheels; regulating wheel; work piece between the 2 |
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describe truing |
when grinding, center wears down faster than edge; tool has diamond tip; tool is called dressing tool |
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how is wear fixed on a grinding wheel? |
dressing tool with diamond tip |
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describe secondary processes |
machining, grinding, finishing, honing, polishing, buffing |
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describe honing |
after finishing; inside of holes; look at diagram; complex motion, rotates and vertically translates |
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describe lapping |
after finishing |
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done on a flas surface |
describe superfinishing |
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finishing outside of circular shaft |
stone pushed against side |
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describe polishing |
aftern finishing; cotton polishing discs with very fine grit; tends to stretch/push surface |
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example in class of polishing |
cotton polishing discs with very fine grit |
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describe buffing |
what makes it shiny is buffing compound; wax and grit; used by a lot of jeweler's; while spinning, put wax |
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example in class of buffing |
cotton disc with fluffed up edges |
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what is buffing compuound |
wax and grit; known as jeweler's rouge (french word for red) used by a lot of jewelers |
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Describe tumble grinder |
barrel finishing with tumblind stones; triangular and cone shapes, but not for too long |
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what is sandpaper? |
emory cloth; water and oil resistant adhesive; can rip across, but strong the other way |
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describe tool parameters (cobalt alloys) |
can be sharpened carefully; light supaw temperaing color |
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Describe tool parameters (tungsten carbide) |
last of materials to be used in solid piece; not sharpenable w/out special tools; slate grey color |
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describe tool parameters (coated tools) |
HSS has coated cutting edge for ductility; single coating, gold color TiN; next coat with red-bronze color, TiN+something; last coat is slate grey TiN+something+something |
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describe tool parameters (cubic boron nitride) |
CBN; inserts 2nd hardest known material |
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describe tool parameters (diamond) |
powdered industrial grade deposited on tool |
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Describe drilling order |
center drill, pilot drill, final drill, reamer |
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what does a pilot do |
pilot helps center the counter bore; multiple pilots available |
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what is reaming? |
hole clean up; drill hole slightly undersize prior to reaming; drill 7/16" for 1/2" hole; adjustable reamer |
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Describe drills |
markout: blue dye/purple dye (scriber for layout); center pot w/center punch either hammer or onto punch-->CNC: center drill: shorter to prevent walking around; pilot drill: twist drill 1/32" undersized; finish drill: find size optioinal: ream hole use 1/16 instead; use 1/32 undersize |
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what is an arbor |
long tool holder |
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Name all the things talked about |
tool types, machining, chips, tool parameters, inserts, laithes, chucks, thread cutting, taps, drills, broaching, milling, files, band saw, hacksaw, grinding, bond types, finishing, polishing, buffing, barrel finishing |