Cutting Processes 140
Welcome to the Tooling University. This course is designed to be used in conjunction with the online version of this class. The online version can be found at http://www.toolingu.com.
We offer high quality web -based e -learning that focuses on today's industrial manufacturing training needs. We deliver superior training content over the Internet using text, photos,
video, audio, and illustrations. Our courses contain "roll -up -your -sleeves" content that offers real -world solutions on subjects such as Metal Cutting, Workholding, Materials, and CNC
with much more to follow. Today's businesses face the challenge of maintaining a trained workforce. Companies must locate apprenticeship programs, cover travel and lodging
expenses, and disrupt operations to cover training needs. Our web -based training offers low -cost, all -access courses and services to maximize your training initiatives.
Copyright © 2015 Tooling U, LLC. All Rights Reserved.
Class Outline
Class Outline
Objectives
Cutting Processes
Sawing
Turning and Related Operations
Threading and Grooving
Boring
Milling and Related Operations
Drilling and Related Operations
Reaming
Tapping
Broaching
Series of Operations
Summary
Lesson: 1/13
Objectives
l Describe cutting.
l Describe sawing.
l Describe turning.
l Identify operations related to turning.
l Describe threading and grooving.
l Describe boring.
l Describe milling.
l Identify different milling processes.
l Describe drilling.
l Describe reaming.
l Describe tapping.
l Describe broaching.
l Explain how cutting operations are used together.
Figure 1. Taper turning (A), contour turning
(B), and grooving (C) involve using a tool to
shape the outer diameter of the workpiece by
cutting conical, curved, or grooved parts.
Copyright © 2015 Tooling U, LLC. All Rights Reserved.
Lesson: 1/13
Objectives
l Describe cutting.
l Describe sawing.
l Describe turning.
l Identify operations related to turning.
l Describe threading and grooving.
l Describe boring.
l Describe milling.
l Identify different milling processes.
l Describe drilling.
l Describe reaming.
l Describe tapping.
l Describe broaching.
l Explain how cutting operations are used together.
Figure 1. Taper turning (A), contour turning
(B), and grooving (C) involve using a tool to
shape the outer diameter of the workpiece by
cutting conical, curved, or grooved parts.
Figure 2. Face milling (A) produces a flat
surface, while end milling produces pockets (B)
and contours (C).
Lesson: 2/13
Cutting Processes
Cutting is a traditional machining process that makes parts by creating chips. Each cutting process
involves the interaction of a single- or multi-point tool and machine tools, such as lathes, mills, or
drill presses. Cutting processes are unique steps that metal goes through to turn raw material into
finished
Different
tools,
and cutting processes enable the creation of a wide
Copyrightparts.
© 2015
Tooling U,
LLC.machines,
All Rights Reserved.
variety of metal parts, as shown in Figure 1.
Cutting processes are generally favorable when compared to other manufacturing methods such as
Lesson: 2/13
Cutting Processes
Cutting is a traditional machining process that makes parts by creating chips. Each cutting process
involves the interaction of a single- or multi-point tool and machine tools, such as lathes, mills, or
drill presses. Cutting processes are unique steps that metal goes through to turn raw material into
finished parts. Different tools, machines, and cutting processes enable the creation of a wide
variety of metal parts, as shown in Figure 1.
Cutting processes are generally favorable when compared to other manufacturing methods such as
metalworking and casting. The accuracy of cutting processes is very good. Unique part features
that are impossible to achieve with other metal processes are easily produced with cutting. Cutting
processes are ideal for almost any batch size, which makes these processes economical.
Some drawbacks of cutting processes include the production of metal waste, which in most cases is
recycled. Also, if cutting is not performed correctly, parts and tools may be damaged, resulting in
scrap. Figures 2 and 3 show by-products of machining: metal chips and bad parts.
In this class, you will learn about various metal cutting processes. You will also learn about the
accuracy of each process, as well as how various processes work together to create a part.
Figure 1. An incredible range of metal parts
are made from various machines, tools, and
cutting processes.
Figure 2. Metal chips are an intentional byproduct of cutting processes.
Figure 3. An occasional bad part is an
unintentional by -product of metal cutting
processes that should be avoided.
Copyright © 2015 Tooling U, LLC. All Rights Reserved.
Lesson: 3/13
Sawing
One of the first operations performed on metal is usually sawing. Manufacturers use saws to cut
unwanted portions off workpieces and to separate parts from stock. During sawing, a blade with
small teeth moves and makes contact with a stationary workpiece, as shown in Figure 1. Each tooth
creates a chip as it contacts the workpiece. Together, all the teeth eventually remove enough small
pieces of metal to cut a narrow slot through the part.
There are three types of sawing processes:
l
l
l
Band sawing (Figure 2) uses a flexible, continuous blade that constantly contacts a
workpiece.
Hacksawing uses a solid straight saw and a reciprocating motion in which only one of the
two back-and-forth strokes actually makes a cut.
Circular sawing (Figure 3) uses a flat, solid disc that also continuously contacts the
workpiece.
Figure 1. During sawing, the small teeth of the
blade make contact with a stationary
workpiece.
Sawing is the least accurate of the cutting processes. It can create a part that is accurate from
0.05 in. (1.25 mm) down to 0.01 in. (0.25 mm). After sawing, other operations may increase the
accuracy of the part. After this initial processing, the part may be headed for turning, milling, or
drilling, depending on the part's design.
Figure 2. Band sawing involves a flexible blade
that continuously contacts a workpiece.
Figure 3. Circular sawing involves a solid
cutting disc that continuously contacts a
workpiece.
Copyright © 2015 Tooling U, LLC. All Rights Reserved.
Lesson: 4/13
Lesson: 4/13
Turning and Related Operations
The basic turning operation machines the external surface of cylindrical parts. Turning uses
single-point tools to remove metal, as shown in Figure 1. A part is held at one or both ends while
it rotates. The cutting edge is forced against the surface of the workpiece, cutting metal as the tool
is guided along the surface. The point shears small pieces of metal from the part.
The basic turning operation is always performed on a lathe. The lathe is also capable of many other
operations similar to turning, which are illustrated in Figures 2 and 3:
l
l
l
l
l
l
l
Taper turning creates a conical, or tapered shape.
Profiling, also called contour turning, is used to machine any type of curved feature.
Grooving the exterior adds a narrow channel or groove into the part's surface.
Facing cuts a flat surface on the end and determines the length of the part.
Chamfering cuts an angle into the end of a part.
Cutting off, also called parting, involves separating a complete part from stock.
Knurling uses a special tool to form a rough pattern on the part, as shown in Figure 4.
Figure 1. During turning, the cutting edge is
forced against the surface of the rotating
workpiece.
Depending on the size of the part, turning accuracy varies. It is at least 10 times more accurate
than sawing. Turning can create parts within 0.005 in. (0.127 mm) down to 0.0005 in. (0.0127
mm).
Figure 2. Taper turning (A), contour turning
(B), and grooving (C) involve using a tool to
shape the outer diameter of the workpiece by
cutting conical, curved, or grooved parts.
Figure 3. Facing (A) creates a flat surface on
the end, chamfering (B) cuts an angle into the
end of a part, and cutting off (C) involves
separating a complete part from stock.
Copyright © 2015 Tooling U, LLC. All Rights Reserved.
separating a complete part from stock.
Figure 4. Knurling adds ridges to the exterior
of a cylindrical part for better handling.
Lesson: 5/13
Threading and Grooving
Threading is a special turning operation that is performed on the lathe. Threading uses a singlepoint tool, like the inserts in Figure 1, to cut spiraling ridges down the length of the workpiece, as
shown in Figure 2. Threads show up on screws, bolts, and other fasteners. Grooving creates a
rectangular valley without the spiral of a thread. The tool used in grooving is rectangular, as shown
in Figure 3. Figure 4 illustrates the creation of an internal groove.
Threading and grooving can be performed as both inner diameter (ID) and outer diameter (OD)
operations. The single-point tools used for threading generally create one side of the valley in one
pass down the length of the part. Threads are gradually finalized during subsequent passes down
the length of the part.
Threading and grooving can achieve accuracies similar to turning. These operations can create parts
within 0.005 in. (0.127 mm) or better.
Figure 1. Threading uses single -point inserts
to cut spiraling ridges down the length of a
workpiece.
Figure 2. During threading, a workpiece
rotates while a tool cuts the thread on the
outer diameter of a part.
Copyright © 2015 Tooling U, LLC. All Rights Reserved.
Lesson: 5/13
Threading and Grooving
Threading is a special turning operation that is performed on the lathe. Threading uses a singlepoint tool, like the inserts in Figure 1, to cut spiraling ridges down the length of the workpiece, as
shown in Figure 2. Threads show up on screws, bolts, and other fasteners. Grooving creates a
rectangular valley without the spiral of a thread. The tool used in grooving is rectangular, as shown
in Figure 3. Figure 4 illustrates the creation of an internal groove.
Threading and grooving can be performed as both inner diameter (ID) and outer diameter (OD)
operations. The single-point tools used for threading generally create one side of the valley in one
pass down the length of the part. Threads are gradually finalized during subsequent passes down
the length of the part.
Threading and grooving can achieve accuracies similar to turning. These operations can create parts
within 0.005 in. (0.127 mm) or better.
Figure 1. Threading uses single -point inserts
to cut spiraling ridges down the length of a
workpiece.
Figure 2. During threading, a workpiece
rotates while a tool cuts the thread on the
outer diameter of a part.
Figure 3. During grooving, a rectangular tool
creates a rectangular valley without the spiral
of threads.
Copyright © 2015 Tooling U, LLC. All Rights Reserved.
Figure 4. During internal grooving, the interior
of a rotating part is cut by a grooving tool.
of threads.
Figure 4. During internal grooving, the interior
of a rotating part is cut by a grooving tool.
Lesson: 6/13
Boring
Boring generally happens to a hole drilled on the centerline of a cylindrical part. This operation
increases the accuracy and roundness of the hole. Like turning, boring uses a single-point tool, as
shown in Figure 1. This tool may perform ID operations and further cut the inside of a workpiece.
On the lathe, boring is essentially internal turning. However, boring can also be done on a mill with
a rotating tool and stationary workpiece.
During boring, a single-point tool enlarges a hole that has already been drilled. Since the hole
already exists, very little metal is removed. Chip creation is similar to that of turning. Figure 2
shows how the single-point tool is dragged across the internal surface to create metal chips.
Boring is slightly more precise than turning. Bored holes can come within several thousandths
(0.001) of an inch (0.025 mm). The increased accuracy of boring is achieved by choosing the
appropriately shaped cutting tool for the boring operation.
Figure 1. Like turning, boring uses a singlepoint tool.
Figure 2. During boring, a single-point tool is
dragged across the internal surface of a
workpiece to create metal chips.
Copyright © 2015 Tooling U, LLC. All Rights Reserved.
Lesson: 7/13
Lesson: 6/13
Boring
Boring generally happens to a hole drilled on the centerline of a cylindrical part. This operation
increases the accuracy and roundness of the hole. Like turning, boring uses a single-point tool, as
shown in Figure 1. This tool may perform ID operations and further cut the inside of a workpiece.
On the lathe, boring is essentially internal turning. However, boring can also be done on a mill with
a rotating tool and stationary workpiece.
During boring, a single-point tool enlarges a hole that has already been drilled. Since the hole
already exists, very little metal is removed. Chip creation is similar to that of turning. Figure 2
shows how the single-point tool is dragged across the internal surface to create metal chips.
Boring is slightly more precise than turning. Bored holes can come within several thousandths
(0.001) of an inch (0.025 mm). The increased accuracy of boring is achieved by choosing the
appropriately shaped cutting tool for the boring operation.
Figure 1. Like turning, boring uses a singlepoint tool.
Figure 2. During boring, a single-point tool is
dragged across the internal surface of a
workpiece to create metal chips.
Lesson: 7/13
Milling and Related Operations
Milling uses a multi-point tool to produce flat surfaces. The rotating cutter, or mill, has equally
spaced teeth on its perimeter, as shown in Figure 1. Each cutting edge of the mill creates a metal
chip by entering and exiting the workpiece. Unlike turning, milling operations involve interrupted
cutting.
Milling is incredibly versatile and includes a wide range of more specific operations, which are
illustrated in Figures 2-4:
Face milling produces a flat surface by guiding a wider mill across the workpiece.
End milling uses a narrower mill to create pockets and contours. A pocket is an internal
Copyright
© 2015
Toolinginto
U, LLC.
Rights Reserved.
recess
machined
the All
workpiece.
A contour is any curved workpiece feature.
l Slab milling uses a cylindrical milling cutter on an axis parallel to the worktable to machine a
flat surface.
l
l
Lesson: 7/13
Milling and Related Operations
Milling uses a multi-point tool to produce flat surfaces. The rotating cutter, or mill, has equally
spaced teeth on its perimeter, as shown in Figure 1. Each cutting edge of the mill creates a metal
chip by entering and exiting the workpiece. Unlike turning, milling operations involve interrupted
cutting.
Milling is incredibly versatile and includes a wide range of more specific operations, which are
illustrated in Figures 2-4:
l
l
l
l
l
Face milling produces a flat surface by guiding a wider mill across the workpiece.
End milling uses a narrower mill to create pockets and contours. A pocket is an internal
recess machined into the workpiece. A contour is any curved workpiece feature.
Slab milling uses a cylindrical milling cutter on an axis parallel to the worktable to machine a
flat surface.
Form milling uses a milling cutter with a unique shape to machine the shape into the
workpiece.
Slotting cuts a narrow ridge into the surface of a workpiece. In particular, T-slotting cuts a
T-shaped valley into the part.
Various milling operations can produce a variety of accuracies. Generally, milling is comparable to
turning. It can generate parts that come within 0.003 in. (0.076 mm) down to 0.001 in. (0.025
mm).
Figure 1. A rotating cutter, or mill, has equally
spaced teeth.
Figure 2. Face milling (A) produces a flat
surface, while end milling produces pockets (B)
and contours (C).
Figure 3. Slab milling uses a cutter on an axis
parallel to the worktable to machine a flat
surface.
Copyright © 2015 Tooling U, LLC. All Rights Reserved.
surface.
Figure 4. Slotting cuts a narrow ridge into a
workpiece.
Lesson: 8/13
Drilling and Related Operations
Drilling is another cutting process that uses multiple cutting edges. Drills are cutting tools that
have two or more cutting edges at the tip, or chisel point, as shown in Figure 1. Twisted around
the length of the drill are grooves, or flutes, which allow chips and cutting fluid to exit during
cutting. Figure 2 illustrates a typical drilling operation.
Other operations related to drilling include counterboring, countersinking, and spotdrilling.
Counterboring and countersinking cut recesses in the opening of a drilled hole to accommodate a
screw or bolt head. Spotdrilling starts a hole and improves the accuracy of subsequent drilling
operations. Figure 3 shows a profile of these drilling operations.
Figure 1. Drills are cutting tools that have two
or more cutting edges at the tip, or chisel
point.
A drilled hole is the least accurate hole. Depending on the size of the hole, it can come to within
0.008 in. (0.203 mm) up to 0.002 in. (0.051 mm). This is about as accurate as sawing. Drilled
holes are sometimes bored or reamed afterwards to improve the hole's accuracy or roundness.
Figure 2. Twisted around the length of the drill
are flutes, which allow chips and cutting fluid to
exit during cutting.
Copyright © 2015 Tooling U, LLC. All Rights Reserved.
Lesson: 8/13
Drilling and Related Operations
Drilling is another cutting process that uses multiple cutting edges. Drills are cutting tools that
have two or more cutting edges at the tip, or chisel point, as shown in Figure 1. Twisted around
the length of the drill are grooves, or flutes, which allow chips and cutting fluid to exit during
cutting. Figure 2 illustrates a typical drilling operation.
Other operations related to drilling include counterboring, countersinking, and spotdrilling.
Counterboring and countersinking cut recesses in the opening of a drilled hole to accommodate a
screw or bolt head. Spotdrilling starts a hole and improves the accuracy of subsequent drilling
operations. Figure 3 shows a profile of these drilling operations.
Figure 1. Drills are cutting tools that have two
or more cutting edges at the tip, or chisel
point.
A drilled hole is the least accurate hole. Depending on the size of the hole, it can come to within
0.008 in. (0.203 mm) up to 0.002 in. (0.051 mm). This is about as accurate as sawing. Drilled
holes are sometimes bored or reamed afterwards to improve the hole's accuracy or roundness.
Figure 2. Twisted around the length of the drill
are flutes, which allow chips and cutting fluid to
exit during cutting.
Figure 3. Various operations similar to drilling
are used to add special features to a hole.
Copyright © 2015 Tooling U, LLC. All Rights Reserved.
Lesson: 9/13
Reaming
Reaming uses a special multi-point tool to remove metal inside a hole. Unlike a drill, reaming is
designed to remove only very small amounts of material, typically no more than 0.015 in. (0.381
mm). The reamer actually looks like a drill, with straighter or perhaps completely straight flutes, as
shown in Figure 1. Reamers do not have points at the tip like a drill. The cutting points of the
reamer "peel" away metal by rotating and moving into the hole. This removes a very small spiral of
metal.
During reaming, cutting occurs along the edges of the flutes. The angled edges at the end of the
flute also serve as a cutting edge. Therefore, chips are created at the end and edge of the reamer.
The cutting action of reaming is illustrated in Figure 2.
Reaming is more accurate than drilling. The machinist reams a hole that was previously drilled to
create a good finish or achieve an accurate diameter, typically within 0.005 in. (0.127 mm) up to
0.001 in. (0.025 mm).
Figure 1. Reaming uses a multi-point tool that
is designed to remove very small amounts of
metal.
Figure 2. During reaming, cutting occurs along
the edges of the flutes.
Lesson: 10/13
Tapping
Numerous parts made in the shop rely on threads for fastening and assembly. Tapping is an
effective way to create internal threads inside a hole. A tool used to perform these operations is
called a tap and is shown in Figure 1. Like reaming, tapping generally removes a smaller amount of
metal than drilling.
Each cutting edge on the lower end of the tap removes a small layer of metal. The flutes on the tap
allow chips to be cleared from the cutting area. The increasing size of the tap gradually expands the
pathway being created. Like the reamer, chips are being created at the end and edges of the tool.
Figure 2 illustrates the tapping operation.
Tapping can achieve an accuracy between that of drilling and reaming. This places its ability around
0.005 in. (0.127 mm). Again, the actual accuracy depends somewhat on the size of the hole.
Copyright © 2015 Tooling U, LLC. All Rights Reserved.
Figure 1. A tap adds threads to the interior of
a drilled hole.
Lesson: 10/13
Tapping
Numerous parts made in the shop rely on threads for fastening and assembly. Tapping is an
effective way to create internal threads inside a hole. A tool used to perform these operations is
called a tap and is shown in Figure 1. Like reaming, tapping generally removes a smaller amount of
metal than drilling.
Each cutting edge on the lower end of the tap removes a small layer of metal. The flutes on the tap
allow chips to be cleared from the cutting area. The increasing size of the tap gradually expands the
pathway being created. Like the reamer, chips are being created at the end and edges of the tool.
Figure 2 illustrates the tapping operation.
Tapping can achieve an accuracy between that of drilling and reaming. This places its ability around
0.005 in. (0.127 mm). Again, the actual accuracy depends somewhat on the size of the hole.
Figure 1. A tap adds threads to the interior of
a drilled hole.
Figure 2. During tapping, the increasing size of
the tap gradually expands the hole and
creates threads.
Lesson: 11/13
Broaching
Broaching is a highly efficient cutting operation that can both cut and finish the surface of a
workpiece with one pass of the tool. Broaching is used to shape a part internally or externally. For
internal broaching, the broach must be able to start inside a drilled hole. Figure 1 shows a broach
used to cut a square on the inner diameter of a drilled hole. Figure 2 shows a broach used to cut
the outer surface of a metal part.
The work is held stationary as the multi-toothed broach is pulled or pushed through a drilled hole.
As the broach teeth contact the workpiece, the lead tooth takes off a small curled chip, the next
tooth takes off a smaller chip, and the next tooth an even smaller chip. This process is shown in
Figure 3.
Copyright ©is2015
Tooling
U, LLC.
All Rights
Broaching
slightly
more
accurate
than Reserved.
reaming. It is actually one of the most accurate cutting
operations. A broached part can be accurate within 0.001 in. (0.025 mm) up to 0.0005 in. (0.0127
mm). Accuracy beyond this takes you into operations such as grinding or other finishing
Lesson: 11/13
Broaching
Broaching is a highly efficient cutting operation that can both cut and finish the surface of a
workpiece with one pass of the tool. Broaching is used to shape a part internally or externally. For
internal broaching, the broach must be able to start inside a drilled hole. Figure 1 shows a broach
used to cut a square on the inner diameter of a drilled hole. Figure 2 shows a broach used to cut
the outer surface of a metal part.
The work is held stationary as the multi-toothed broach is pulled or pushed through a drilled hole.
As the broach teeth contact the workpiece, the lead tooth takes off a small curled chip, the next
tooth takes off a smaller chip, and the next tooth an even smaller chip. This process is shown in
Figure 3.
Broaching is slightly more accurate than reaming. It is actually one of the most accurate cutting
operations. A broached part can be accurate within 0.001 in. (0.025 mm) up to 0.0005 in. (0.0127
mm). Accuracy beyond this takes you into operations such as grinding or other finishing
operations.
Figure 1. This broach creates a square shape
from a drilled hole.
Figure 2. A broach can cut and finish the
exterior of a metal part in one pass.
Figure 3. As the broach teeth contact the
workpiece, the lead tooth takes off a small
curled chip, the next tooth takes off a smaller
chip, and the next tooth an even smaller chip.
Copyright © 2015 Tooling U, LLC. All Rights Reserved.
Lesson: 12/13
Series of Operations
Very few cutting operations are ever used on their own. Instead, most parts are manufactured by
going through a series of operations, one after another. The series of operations is determined by
the desired finish and accuracy specified in the part drawing.
Imagine that you wanted to make a threaded hole in a workpiece. First, you would drill the hole.
After drilling, you might bore the hole to improve accuracy, and then ream the hole to improve
finish. Finally, you would tap the hole to create the threads. Figure 1 shows these possible
operations together.
There is no "magic" combination of cutting operations; one operation is not always better than
another. Instead, designers and machinists select the series of operations that is the most
productive and creates parts of the best quality at the lowest cost.
After the cutting operations described, your part may be sent to other machining operations that
can increase the accuracy of its dimensions. These finishing operations, which are not traditional
cutting processes, include grinding, honing, and even lapping.
Figure 1. A part specifying a threaded hole
may require drilling (1), boring (2), reaming (3),
and tapping (4).
Lesson: 13/13
Summary
Cutting processes are the unique steps carried out by machines and cutting tools to make a
specific part. Different tools, machines, and cutting processes enable the creation of a wide variety
of metal parts.
Turning, boring, threading, and similar operations use single-point tools to remove metal. Turning
operations rotate a cylindrical workpiece and then move the cutting tool along the outside surface.
Threading creates a spiral on the outside of a cylindrical part. Boring operations insert a single point tool into a hole to make internal cuts.
Milling, drilling, reaming, tapping, and broaching operations use multi-point tools. Milling removes
metal from a flat surface of a workpiece. Drilling uses a long tool with cutting tips and twisted flutes
to create holes. Reaming uses a drill-like tool to finish the surface of a hole that has already been
drilled. Tapping uses a threaded tool to cut internal threads in a hole. Broaching uses a saw-like
tool to cut and finish either an edge or a hole with one pass of the tool.
Figure 1. Taper turning (A), contour turning
(B), and grooving (C) involve using a tool to
shape the outer diameter of the workpiece by
cutting conical, curved, or grooved parts.
Copyright © 2015 Tooling U, LLC. All Rights Reserved.
Lesson: 13/13
Summary
Cutting processes are the unique steps carried out by machines and cutting tools to make a
specific part. Different tools, machines, and cutting processes enable the creation of a wide variety
of metal parts.
Turning, boring, threading, and similar operations use single-point tools to remove metal. Turning
operations rotate a cylindrical workpiece and then move the cutting tool along the outside surface.
Threading creates a spiral on the outside of a cylindrical part. Boring operations insert a single point tool into a hole to make internal cuts.
Milling, drilling, reaming, tapping, and broaching operations use multi-point tools. Milling removes
metal from a flat surface of a workpiece. Drilling uses a long tool with cutting tips and twisted flutes
to create holes. Reaming uses a drill-like tool to finish the surface of a hole that has already been
drilled. Tapping uses a threaded tool to cut internal threads in a hole. Broaching uses a saw-like
tool to cut and finish either an edge or a hole with one pass of the tool.
Figure 1. Taper turning (A), contour turning
(B), and grooving (C) involve using a tool to
shape the outer diameter of the workpiece by
cutting conical, curved, or grooved parts.
Figure 2. Face milling (A) produces a flat
surface, while end milling produces pockets (B)
and contours (C).
Copyright © 2015 Tooling U, LLC. All Rights Reserved.
Figure 3. Various operations similar to drilling
are used to add special features to a hole.
Figure 3. Various operations similar to drilling
are used to add special features to a hole.
Class Vocabulary
Term
Definition
Accuracy
Band Sawing
The exactness of a measurement produced compared to the desired result.
The use of a flexible saw blade constructed from a continuous loop or band of metal.
Boring
The process of using a single-point tool to enlarge a preexisting hole. Boring is commonly performed on a lathe but
is also possible on a mill.
Broach
A multi-point cutting tool with a series of progressively changing teeth that can both remove metal and finish the
surface of a workpiece in one pass.
Broaching
Casting
Chamfering
Circular Sawing
Contour
The use of a multi-point cutting tool to shape and finish either the interior of a hole or the surface of a workpiece.
A manufacturing process that pours a liquid material into a hollow mold until the material cools into a solidified
shape.
Machining an angled edge around the end of a cylindrical workpiece.
The use of a round saw blade with teeth around its perimeter.
A curved surface or part feature that is cut into a workpiece.
Counterboring
An operation that enlarges the end of a predrilled hole to allow room for a head of a screw or nut.
Countersinking
The cutting of a beveled edge at the end of a hole so that the head of a screw can rest flush with the workpiece
surface.
Cutting
Cutting Off
Drilling
End Milling
Face Milling
Facing
Fastener
Flute
Form Milling
Grinding
Grooving
Hacksawing
Honing
A machining process that uses a tool to create chips and remove metal from a workpiece.
A cutting process, also known as parting, that cuts a finished part from bar stock.
The process of using a multi-point tool to penetrate the surface of a workpiece and make a round hole.
A milling process that uses the sides and end of an end mill to cut a variety of shapes.
A cutting process that uses a mill to cut a flat surface by positioning the tool at a right angle to the workpiece.
An operation performed on a lathe that feeds a cutting tool across the end of a cylindrical workpiece to shorten its
length.
Devices that are used to join and assemble parts together.
The passageways that twist up the length of the drill and allow for the exit of chips and cutting fluids.
A milling process that uses a mill with a unique shape that is imparted to a workpiece.
The use of an abrasive wheel to wear away at the surface of a workpiece.
The process of cutting a narrow channel or passageway into the outside diameter of a cylindrical workpiece.
The use of a long blade mounted in a bow-shaped frame. Cutting takes place using a reciprocating, or back-andforth, motion.
A process that uses abrasive stones to reshape dimensions from a previous operation. Honing can also be used to
achieve a certain surface finish.
Inner
Diameter
surface
of a hole in a workpiece.
Copyright
© 2015
Tooling U, The
LLC.interior
All Rights
Reserved.
Interrupted Cutting
Any machining operation involving a cutting edge that enters and exits a workpiece. Milling operations involve
Class Vocabulary
Term
Definition
Accuracy
Band Sawing
The exactness of a measurement produced compared to the desired result.
The use of a flexible saw blade constructed from a continuous loop or band of metal.
Boring
The process of using a single-point tool to enlarge a preexisting hole. Boring is commonly performed on a lathe but
is also possible on a mill.
Broach
A multi-point cutting tool with a series of progressively changing teeth that can both remove metal and finish the
surface of a workpiece in one pass.
Broaching
Casting
Chamfering
Circular Sawing
Contour
The use of a multi-point cutting tool to shape and finish either the interior of a hole or the surface of a workpiece.
A manufacturing process that pours a liquid material into a hollow mold until the material cools into a solidified
shape.
Machining an angled edge around the end of a cylindrical workpiece.
The use of a round saw blade with teeth around its perimeter.
A curved surface or part feature that is cut into a workpiece.
Counterboring
An operation that enlarges the end of a predrilled hole to allow room for a head of a screw or nut.
Countersinking
The cutting of a beveled edge at the end of a hole so that the head of a screw can rest flush with the workpiece
surface.
Cutting
Cutting Off
Drilling
End Milling
Face Milling
Facing
Fastener
Flute
Form Milling
Grinding
Grooving
Hacksawing
Honing
Inner Diameter
Interrupted Cutting
A machining process that uses a tool to create chips and remove metal from a workpiece.
A cutting process, also known as parting, that cuts a finished part from bar stock.
The process of using a multi-point tool to penetrate the surface of a workpiece and make a round hole.
A milling process that uses the sides and end of an end mill to cut a variety of shapes.
A cutting process that uses a mill to cut a flat surface by positioning the tool at a right angle to the workpiece.
An operation performed on a lathe that feeds a cutting tool across the end of a cylindrical workpiece to shorten its
length.
Devices that are used to join and assemble parts together.
The passageways that twist up the length of the drill and allow for the exit of chips and cutting fluids.
A milling process that uses a mill with a unique shape that is imparted to a workpiece.
The use of an abrasive wheel to wear away at the surface of a workpiece.
The process of cutting a narrow channel or passageway into the outside diameter of a cylindrical workpiece.
The use of a long blade mounted in a bow-shaped frame. Cutting takes place using a reciprocating, or back-andforth, motion.
A process that uses abrasive stones to reshape dimensions from a previous operation. Honing can also be used to
achieve a certain surface finish.
The interior surface of a hole in a workpiece.
Any machining operation involving a cutting edge that enters and exits a workpiece. Milling operations involve
interrupted cutting.
Copyright © 2015 Tooling U, LLC. All Rights Reserved.
Knurling A forming process that adds a pattern on the exterior of a workpiece, either for cosmetic reasons or better handling.
Lapping
An abrasive process that removes the last bit of unwanted material. A lapping process sometimes uses an abrasive
Interrupted Cutting
Any machining operation involving a cutting edge that enters and exits a workpiece. Milling operations involve
interrupted cutting.
Knurling
A forming process that adds a pattern on the exterior of a workpiece, either for cosmetic reasons or better handling.
Lapping
An abrasive process that removes the last bit of unwanted material. A lapping process sometimes uses an abrasive
paste that is rubbed across the part to gradually smooth it.
Machine Tool
A power-driven machine that uses a cutting tool to create chips and remove metal from a workpiece.
Metalworking
A material manufacturing process that produces parts by mechanically deforming metal into parts. Stamping and
forging are two major types of metalworking processes.
Mill
Milling
A multi-point tool that is used to remove metal from the surface of a workpiece.
The use of a rotating multi-point cutting tool to machine flat surfaces, slots, or internal recesses into a workpiece.
Milling includes a wide range of versatile metal cutting operations.
Multi-Point Tool
A machining tool that has two or more cutting edges.
Outer Diameter
The outer surface of a cylindrical workpiece or feature.
Pocket
An interior recess that is cut into the surface of a workpiece.
Profiling
An operation performed on a lathe that feeds a cutting tool along a non-linear path to create conical or curved
features in a cylindrical workpiece.
Reaming
The use of a cutting tool with straight cutting edges to enlarge or smooth holes that have been previously drilled.
Reciprocating
Saw
Sawing
Single-Point Tool
Slab Milling
Slotting
Spotdrilling
Tap
Taper Turning
Tapping
Having a repeated back-and-forth movement.
A multi-point cutting tool that is used to rough cut a part to a certain length.
The use of a multi-point blade to cut through metal and separate it into pieces.
A machining tool that has a single cutting edge.
A milling process that uses the slab mill that rotates on an axis parallel to the workpiece. Slab milling produces flat
surfaces.
A milling process that uses a mill to cut a narrow ridge into the surface of a workpiece.
The use of a shorter, sturdier drill to locate a hole for drilling. Spot drilling often uses a drill size slightly larger than
the hole diameter to leave a chamfer after the hole is drilled.
A multi-point tool that is used to cut internal threads into a hole.
An operation performed on a lathe that feeds a tool at an angle to the length of the workpiece in order to create a
conical shape.
The process of cutting internal threads in a round hole with a multi-point tool.
Threading
The process of cutting a long, spiraling groove into a workpiece with a single-point tool. Threading processes are
essential for the creation of fasteners.
T-Slotting
A milling process that uses a t-shaped milling cutter to machine a ridge or slot the shape of an inverted T into the
surface of a workpiece.
Turning
A machining operation that rotates a cylindrical workpiece while a single-point tool is guided along the length of the
part. Turning is performed on a lathe.
Copyright © 2015 Tooling U, LLC. All Rights Reserved.