Metal Machining Course

Lesson 1 • Cutting Temperatures and Their Effects

Quantifies temperature distribution at tool-chip interface and its effect on tool wear and workpiece integrity. Introduces thermal management as a design variable.

Lesson 2 • Workpiece Material Properties

Analyses hardness, ductility, thermal conductivity, and machinability ratings of common metals. Connects material properties to appropriate cutting strategies.

Lesson 3 • Physics of Metal Cutting

Covers force vectors, shear plane theory, and energy distribution during cutting. Provides the mechanical basis for all subsequent tool and parameter decisions.

Lesson 1 • Tool Wear Mechanisms and Criteria

Identifies flank wear, crater wear, notch wear, and chipping as distinct failure modes with different causes. Establishes wear criteria for tool change decisions.

Lesson 2 • Tool Geometry and Angles

Defines rake, clearance, wedge, and cutting-edge angles and their effect on cutting forces and finish. Builds ability to read and specify tool geometry from standards.

Lesson 3 • Tool Coatings and Surface Treatments

Explains TiN, TiAlN, DLC, and multilayer coating technologies and their wear-resistance mechanisms. Guides coating selection for specific material-speed combinations.

Lesson 4 • Cutting Tool Material Grades

Surveys high-speed steel, cemented carbide, ceramics, CBN, and PCD grades with their property profiles. Enables material selection based on hardness, toughness, and thermal resistance.

Lesson 1 • Feed Rate and Chip Load

Defines feed per tooth, feed per revolution, and table feed rate and their effect on chip thickness. Connects feed selection to surface roughness and tool load.

Lesson 2 • Process Planning Documentation

Structures operation sequences, setup sheets, and parameter tables for a complete machining plan. Ensures traceability and repeatability across production runs.

Lesson 3 • Cutting Speed and Spindle Speed

Derives the relationship between surface cutting speed and spindle RPM for various diameters. Applies formulas to set correct spindle speeds on machine controls.

Lesson 4 • Material Removal Rate Optimization

Calculates MRR and balances it against tool life using Taylor's tool life equation. Produces parameter sets that maximise productivity within tool life constraints.

Lesson 1 • Boring and Internal Operations

Performs internal boring, drilling, and reaming on the lathe to achieve precise bore diameter and finish. Addresses boring bar deflection and chatter control.

Lesson 2 • Turning and Facing Operations

Executes OD turning, facing, shoulder turning, and taper turning with correct tool paths and parameters. Achieves dimensional tolerances and surface finish targets.

Lesson 3 • Lathe Machine Components and Controls

Identifies headstock, tailstock, carriage, cross-slide, and compound rest and their functions. Provides the operational vocabulary needed for safe and accurate lathe use.

Lesson 4 • Workholding for Turning

Covers three-jaw, four-jaw, collet, and between-centres setups with runout measurement and correction. Ensures workpiece rigidity and concentricity for accurate turning.

Lesson 1 • Indexing and Rotary Table Operations

Uses direct, simple, and differential indexing to machine equally spaced features. Extends milling capability to angular and circular patterns.

Lesson 2 • Face Milling and Peripheral Milling

Executes face milling for flat surfaces and peripheral milling for profiles with correct cutter engagement. Achieves flatness, parallelism, and surface finish requirements.

Lesson 3 • Milling Machine Types and Axes

Distinguishes vertical, horizontal, and universal milling machines and their axis configurations. Establishes machine selection criteria for different feature types.

Lesson 4 • Slot Milling and Pocket Milling

Performs full-slot, partial-slot, and pocket milling with appropriate entry strategies and tool paths. Controls width and depth tolerances in enclosed features.

Lesson 1 • Reaming for Precision Bores

Applies hand and machine reaming to achieve H7/H6 tolerance bores with fine surface finish. Specifies pre-ream allowance and reamer selection by material.

Lesson 2 • Tapping and Thread Milling

Performs rigid tapping and thread milling for internal threads with correct tap drill sizing. Compares tapping and thread milling for blind-hole and hard-material applications.

Lesson 3 • Drill Geometry and Selection

Analyses point angle, helix angle, web thickness, and flute design for various drill types. Matches drill geometry to workpiece material and hole requirement.

Lesson 4 • Drilling Parameters and Peck Cycles

Sets speed, feed, and peck depth for through-holes and blind holes in different materials. Prevents chip packing and drill breakage in deep-hole drilling.

Lesson 1 • Tool Path Verification and Simulation

Uses machine control graphics and CAM simulation to verify tool paths before cutting. Identifies gouges, collisions, and parameter errors without scrapping material.

Lesson 2 • CNC Setup and First-Article Inspection

Executes tool loading, offset entry, programme transfer, and first-article measurement on a CNC machine. Closes the loop between programmed and actual dimensions.

Lesson 3 • CNC Machine Architecture and Controls

Describes CNC axes, servo drives, encoders, and control panel layout for turning and machining centres. Establishes safe machine operation and homing procedures.

Lesson 4 • G-Code and M-Code Programming

Writes linear, circular, and canned-cycle G-code blocks with correct modal and non-modal syntax. Integrates M-codes for spindle, coolant, and tool change control.

Lesson 1 • Dimensional Measurement Instruments

Operates micrometers, vernier calipers, bore gauges, and height gauges with correct technique and calibration. Achieves measurement uncertainty appropriate for tolerance class.

Lesson 2 • Surface Roughness Measurement

Measures Ra, Rz, and Rmax using contact profilometers and interprets results against drawing callouts. Links surface roughness to cutting parameters and tool condition.

Lesson 3 • Statistical Process Control in Machining

Applies control charts and process capability indices to monitor and control machining dimensions. Identifies special-cause variation and triggers corrective action.

Lesson 4 • Geometric Dimensioning and Tolerancing

Interprets GD&T symbols for flatness, roundness, cylindricity, position, and runout on engineering drawings. Selects inspection methods matched to each geometric control.