Section 3 Unit 4

❖ Saws
➢ Power hacksaws
■ Similar to hand hacksaw, less efficient than other machine saws since it
does not continuously cut and instead cuts like a hacksaw
➢ Band sawing machines
■ Most common type of machine saw type
■ Continuous blade cuts constantly
■ Vertical and horizontal available
■ CNC, hand powered, and hydraulic exist
■ Advantages of vertical
● Unrestricted machine geometry or angle, direction, or depth
● Can cut internal holes using a pre-drilled pilot hole and the saw
blade cut and re-welded
➢ Saw blade characteristics
■ Width
● Tip of the cutting edge to the back of the blade
■ Thickness
● Measurement of the body, Gage
■ Blade body
● The back of the blade to the bottom of the gullet
■ Tooth
● The cutting portion of the blade
■ Tooth pitch
● Distance from one tooth tip to the next tip
◆ Variable pitches exist that have variable sized tooth pitch
to relieve cutting forces
■ TPI
● Number of Teeth per inch
◆ Always keep a minimum of 3 teeth in contact with the
material that is being cut to relieve stress on the blade
■ Tooth set
● Bending of the teeth, right or left to allow clearance of kerf
■ Tooth face
● Surface of the tooth where the chip is formed
■ Tooth Back
● The angled surface of the tooth opposite the tooth face
■ Tooth Rake Angle
● Positive or straight (P or S) the angle of the tooth measured from
a line perpendicular to the back of the blade
■ Gullet
 ● The curved area between two teeth
■ Gullet Depth
● The distance from the tooth tip to the bottom of the gullet
➢ Welding
■ Blade lengths when cutting your own
● (2x center distance) + (Pi x Wheel Diameter)
■ When welding a blade, you should select the proper weld setting based
on the given dimensions of the blade
■ Clamping is important, when properly clamped you can weld
■ Lever when pulled and held it welds the blade together
■ Keep hand on the hands, then unclamp the movable jaw before removing
the weld lever to avoid breaking the weld
■ Flash needs to be ground away to be made perfectly flat
■ Then anneal the band with the annealing setting
● Tap until a pale glow then stop and let it cool
➢ Blade mounting
■ Tension new blade until the gage reads the correct pressure
■ Refer to guide in book for a visual demonstration
➢ Blade speed, consult chart on the saw for speed
■ Blade on material to be cut and the blade material
■ Set speed, indicated in fpm or surface fpm
➢ Cutoff saws, abrasive
■ Frequently called chop saws
■ Cuts hardened material using an abrasive disc
■ Generates dust, sparks, and heat
➢ Metal cutting circular saws
■ Resemble chop saws but use metallic toothed blade
■ Lower blade speed, cuts cooler and more accurately

Section 3 Unit 5
❖ Offhand Grinding Intro
➢ Grinding machines cut metal with abrasives and pressure
➢ Types include abrasive wheels, discs or belts
➢ Offhand means ground materials are held in hand
➢ Hand-eye coordination and manual dexterity are critical
❖ Pedestal and bench grinders
➢ Abrasive belt and disc machines are used for light work like deburring or surface
finishes purposes
❖ Grinding wheels
 ➢ A grinding wheel blotter shows wheel information such as abrasive type, grain
size, wheel size, and maximum wheel rpm
➢ Store with padding
❖ Grit size
➢ Lower grit numbers are coarser for faster material removal
➢ Higher grit numbers are finer and will produce smoother surfaces but remove
material more slowly
➢ Wheel type is very important, only use grinding wheel as intended
➢ Aluminum oxide is the most common type of grit
■ For general purpose and ferrous materials
➢ Silicon Carbide grits
■ More tough than aluminum oxide
➢ Diamond impregnated wheels
■ Use only for tungsten carbide cutting tools
➢ A grinding wheel may come with a reducing bushing to mount a wheel on a
slightly smaller machine arbor
❖ Pedestal grinder setup
➢ Check wheel speed rating
➢ Perform the ringing test before mounting wheel to make sure it rings when struck
with a plastic mallet
➢ Mounting: Seat wheel flanges against blotters
➢ Set tool rest to desired angle and keep within 1/16th” of the wheel
➢ Set spark breaker within 1/16th” of wheel
➢ Dress wheel before use then recheck tool rest gap
➢ Dressing the wheel uses a dresser that crushes the surface flat to make it nice
and flat

Section 3 Unit 6
❖ Introduction to drilling, threading, tapping and reaming
➢ Drills
❖ Bench working hole making operations
➢ Standard twist drill bits
■ Fractional sizes from 1/6th to ½ in 1/64th increments
■ Letter size
■ Number size or wire gage
■ Center drill and spot drill to create the starts of holes and centers for
lathes
➢ Countersink bits
 ■ Create an angled hole lead in
■ Countersink drills come in many flavors and sizes
■ Allow flat head
➢ Reamers
■ Straight and spiral flutes
■ Cut only at the tip to create very precise holes with good finishes
■ Hand reamers also exist
❖ Threading and tapping
➢ Thread
■ Spiral groove on a cylinder
■ External thread cut with cutting die
■ Internal thread cut with tap
● Tap styles include
● Hand tap
● Siral point tap
● Tap gun
● Forming tap
■ Features of a thread include
● Major diameter
● Pitch diameter
● Minor diameter
● Pitch
● Crest
● Root
● Angle
● Thread depth
■ Taps create threads in holes
➢ External thread cutting
■ Dies are used for cutting external threads
■ Split dies are the best shot at cutting good high quality threads with a die
■ Most dies are good for repairing threads but not great
■ Solid dies can’t be adjusted so all roughing and finishing is done in one
pass
■ Creating a chamfer on the end of the workpiece helps a thread cutting die
to start easily
■ Die holders are able to hold several types

Section 4 Unit 1
❖ Introduction to the drill press
➢ Drills drill
➢ Reamers have square head for hand reaming, and chuck head reamers for use
in a chuck
❖ Upright drill press
➢ Upright
➢ Traditional
➢ Will find it in most shops
➢ Older will have geared heads, speed is selection has fewr options
➢ Drill press size is determined by the largest diameter of workpiece that can be
drilled on center
➢ Parts include
■ Speed selector
■ Switches
■ Column
■ Worktable
■ Cranks
■ Quill
■ Spindle
■ Base
■ Table clamp
■ Quill feed hands
■ Head
■ Depth stop
➢ Gang drill presses are multiple drill heads on one table
❖ Radial arm drill press
➢ Drill press can be moved along arm
➢ Parts include
■ Column
■ Drill head
■ Radial arm
■ Positioning lever
■ Feed handle
■ Spindle
■ Feed clutch
■ Base
■ Handwheel
■ Feed controls
■ Speed selection controls
❖ Micro drill press
➢ Referred to as a precision drill, can be used to drill holes with a 2 thou diameter
and speeds up to 20k rpm
 Section 4 Unit 2
❖ Introduction to work holding and cutting tools
❖ Types of cutting tools
➢ High speed steel
■ Standard
■ Cheap but not super hard
➢ Tungsten carbide
■ Harder but more brittle
➢ Titanium nitride coatings
■ Offers specific benefits usually including chips not sticking
❖ Drill types
➢ Twist drill bits
■ Parts include
● Drill point
◆ Has various angles
◆ Where the actual cutting happens
◆ Can be reground
◆ Angles should be checked when confirming drill angles or
regrinding the tips
● Drill body
● Shank
■ Sharpening at the proper angle is very important
➢ Starter drills
■ Drills designed to start a drilling operation
❖ Reamers
➢ Designed to dimension holes, not drill them
➢ Types
■ Chucking
■ Expansion
● Adjustable sizes
■ Shell
● Rests on an arbor
● Allows many sleeves of different sizes
■ Spiral flute
■ Straight flute
■ Taper reamers
● Used for reaming tapers
❖ Countersinks and counter bores
➢ Countersinks chamfer hole openings
■ Come in single and multi flute options
 ➢ Counterbores add smooth pockets so holes for fasteners to seat flush
■ Have pilots to guide the counterbores
● Either have integral or interchangeable pilots
❖ Toolholding
➢ Morse taper shank holding
■ Adapters, sleeves and extension sockets
➢ Straight shank tool holding
➢ Tapered sleeves are available to adapt spindle tapers to those on drills, reamers
and chucks
➢ Jacobs type chucks require a key
➢ Keyless chucks don't need keys
➢ Pin vise chucks can be keyed or keyless but hold incredibly small stuff
➢ Spring loaded micro drilling adapter are used for sensitive drilling in larger drilling
machines
❖ Workholding
➢ Vices
■ Drill press, mill, and various other types exist
➢ V-blocks help hold round stock, or square stock at 45%
➢ Angle plates
■ Hold workpieces at certain angles
■ Also used to hold exotic shaped parts
➢ Hold down clamps
■ Clamp workpieces to the tool table
■ Comes in many shapes and sizes
■ Uses T nuts for holding the clamps in pace
➢ When drilling on a drill press the piece always needs to be raised

Section 4 Unit 3
❖ Cutting speeds
➢ Surface feet per minute
➢ Rpm = 3.82 * cutting speed/diameter
➢ Speed and feed calculators provided by tool suppliers, whitney tool website is a
good option
❖ Calculating feed rates
➢ Feedrate defines chip thickness in feet per tooth
➢ Chart provides guidelines for appropriate twist drilling feed rates
❖ Calculating hole depth
➢ 90* included angle tip 0.5 * drill dia = tip length
➢ 118* included angle tip 0.3 * drill dia = tip length
➢ 135* included angle tip 0.207 * drill dia = tip length
 ➢ Blind holes are dimensioned to the full hole depth not the tip depth
❖ Reamers
➢ Will slightly enlarge a hole to more accurate size and finish than produced by
drilling
➢ Droll 10 thou under size for a hole up to ¼ inch
➢ Drill 15 thou for a whole between ¼ and ½ inch
➢ Drill 25 thou for a whole between ½ and 1 ½ inch
➢ When possible, ream the hole without moving the workpiece after drilling
➢ Half speed of regular drill
❖ Counterboring and spot facing
➢ When possible, perform tasks without moving workpiece after drill hole
➢ If workpiece has been moved, pilot can be used for alignment
■ Pilot 3-5 thou smaller than hole
➢ Speeds are about 50-50% of those used for drilling
➢ Use depth stop to get the specified depth
❖ Chamfering and countersinking
➢ Performed on existing holes
➢ Clamping vise to table not necessary, countersink/chamfer aligns itself to the
hole
❖ Tapping
➢ Spring loaded tap centers maintain alignment and applies pressure downard for
starting a tap