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Solutions for Fundamentals of Modern Manufacturing, 4/e (published by Wiley)  MPGroover 2010
02-07-09

22 MACHINING OPERATIONS AND MACHINE

TOOLS
Review Questions
22.1 What are the differences between rotational parts and prismatic parts in machining?
Answer. Rotational parts are cylindrical or disk-shaped and are machined on a turning machine
(e.g., a lathe); prismatic parts are block-shaped or flat and are generally produced on a milling
machine, shaper, or planer.
22.2 Distinguish between generating and forming when machining workpart geometries.
Answer. Generating refers to the creation of work geometry due to the feed trajectory of the cutting
tool; examples include straight turning, taper turning, and profile milling. Forming involves the
creation of work geometry due to the shape of the cutting tool; common examples include form
turning and drilling.
22.3 Give two examples of machining operations in which generating and forming are combined to
create workpart geometry.
Answer. The two examples given in the text are thread cutting on a lathe and slot milling.
22.4 Describe the turning process.
Answer. Turning is a machining process in which a single-point tool removes material from the
surface of a rotating cylindrical workpiece, the tool being fed in a direction parallel to the axis of
work rotation.
22.5 What is the difference between threading and tapping?
Answer. A threading operation is performed on a turning machine and produces an external thread,
while tapping is normally performed on a drilling machine and produces an internal thread.
22.6 How does a boring operation differ from a turning operation?
Answer. Boring produces an internal cylindrical shape from an existing hole, while turning
produces an external cylindrical shape.
22.7 What is meant by the designation 12 x 36 inch lathe?
Answer. A 12 x 36 lathe has a 12 inch swing (maximum work diameter that can be accommodated)
and a 36 inch distance between centers (indicating the maximum work length that can be held
between centers).
22.8 Name the various ways in which a workpart can be held in a lathe.
Answer. Methods of holding the work in a lathe include: (1) between centers, (2) chuck, (3) collet,
and (4) face plate.
22.9 What is the difference between a live center and a dead center, when these terms are used in the
context of workholding in a lathe?
Answer. A center holds the work during rotation at the tailstock end of the lathe. A live center is
mounted in bearings and rotates with the work, while a dead center does not rotate - the work
rotates about it.
22.10 How does a turret lathe differ from an engine lathe?

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Solutions for Fundamentals of Modern Manufacturing, 4/e (published by Wiley)  MPGroover 2010
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Answer. A turret lathe has a toolholding turret in place of a tailstock; the tools in the turret can be
brought to work to perform multiple cutting operations on the work without the need to change
tools as in operating a conventional engine lathe.
22.11 What is a blind hole?
Answer. A blind hole does not exit the work; by comparison, a through hole exits the opposite side
of the workpart.
22.12 What is the distinguishing feature of a radial drill press?
Answer. A radial drill has a long radial arm along which the drill head can be positioned to allow
the drilling of large work parts. The radial arm can also be swiveled about the column to drill parts
on either side of the worktable.
22.13 What is the difference between peripheral milling and face milling?
Answer. In peripheral milling, cutting is accomplished by the peripheral teeth of the milling cutter
and the tool axis is parallel to the work surface; in face milling, cutting is accomplished by the flat
face of the cutter whose axis is perpendicular to the work surface.
22.14 Describe profile milling.
Answer. Profile milling generally involves the milling of the outside periphery of a flat part.
22.15 What is pocket milling?
Answer. Pocket milling uses an end milling cutter to machine a shallow cavity (pocket) into a flat
workpart.
22.16 Describe the difference between up milling and down milling?
Answer. In up milling, the cutter speed direction is opposite the feed direction; in down milling, the
direction of cutter rotation is the same as the feed direction.
22.17 How does a universal milling machine differ from a conventional knee-and-column machine?
Answer. The universal milling machine has a worktable that can be rotated about a vertical axis to
present the part at any specified angle to the cutter spindle.
22.18 What is a machining center?
Answer. A machining center is a CNC machine tool capable of performing multiple types of
cutting operations involving rotating spindles (e.g., milling, drilling); the machine is typically
equipped with automatic tool-changing, pallet shuttles to speed workpart changing, and automatic
workpart positioning.
22.19 What is the difference between a machining center and a turning center?
Answer. A machining center is generally confined to rotating spindle operations (e.g., milling,
drilling); while a turning center performs turning type operations, generally with single-point tools.
22.20 What can a mill-turn center do that a conventional turning center cannot do?
Answer. The mill-turn center has the capacity to position a rotational workpart at a specified
angular location, permitting milling or drilling to be performed at a location on the periphery of the
part.
22.21 How do shaping and planing differ?
Answer. In shaping, the work is stationary during the cut, and the speed motion is performed by the
cutting tool; while in planing, the cutting tool is stationary, and the workpart is moved past the tool
in the speed motion.
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22.22 What is the difference between internal broaching and external broaching?
Answer. Internal broaching is accomplished on the inside surface (hole) of a workpart; while
external broaching is performed on one of the outside surfaces of the part.
22.23 Identify the three basic forms of sawing operation?
Answer. The three forms of sawing are: (1) hacksawing, (2) bandsawing, and (3) circular sawing.
22.24 (Video) For what types of parts are VTLs (vertical turret lathes) used?
Answer: VTLs are used to turn large diameter round parts that are too large to be held in a
horizontal lathe.
22.25 (Video) List the four axes for a vertical machining center (VMC) with a rotational axis on the
table.
Answer: The four axes are the three linear axes: X, Y, and Z; and the rotational axis: B.
22.26 (Video) What is the purpose of a tombstone that is used with a horizontal machining center
(HMC)?
Answer: The tombstone is a multi-sided work holding device (often rectangular) that rotates into
position for machining to occur. Parts are clamped to each of the sides of the tombstone. The
tombstone rotates the next part towards the spindle before the cycle starts.
22.27 (Video) List the three parts of a common twist drill.
Answer: The three parts of a common twist drill are the: 1) shank, 2) flutes, and 3) point.
22.28 (Video) What is a gang-drilling machine?
Answer: A gang drilling machine consist of two or more common drilling machines mounted on
a common base or table. Each machine is setup to perform a different operation on a part. The
operator can move down the line performing each operation in succession.
Multiple Choice Questions
There are 23 correct answers in the following multiple choice questions (some questions have multiple
answers that are correct). To attain a perfect score on the quiz, all correct answers must be given. Each
correct answer is worth 1 point. Each omitted answer or wrong answer reduces the score by 1 point, and
each additional answer beyond the correct number of answers reduces the score by 1 point. Percentage score
on the quiz is based on the total number of correct answers.
22.1 Which of the following are examples of generating the workpart geometry in machining, as
opposed to forming the geometry (two best answers): (a) broaching, (b) contour turning, (c) drilling,
(d) profile milling, and (e) thread cutting?
Answer. (b) and (d).
22.2 In a turning operation, the change in diameter of the workpart is equal to which one of the
following: (a) 1 x depth of cut, (b) 2 x depth of cut, (c) 1 x feed, or (d) 2 x feed?
Answer. (b).
22.3 A lathe can be used to perform which of the following machining operations (three correct
answers): (a) boring, (b) broaching, (c) drilling, (d) milling, (e) planing, and (f) turning?
Answer. (a), (c), and (f).
22.4 A facing operation is normally performed on which one of the following machine tools: (a) drill
press, (b) lathe, (c) milling machine, (d) planer, or (e) shaper?

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Solutions for Fundamentals of Modern Manufacturing, 4/e (published by Wiley)  MPGroover 2010
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Answer. (b).
22.5 Knurling is performed on a lathe, but it is not a metal cutting operation: (a) true or (b) false?
Answer. (a). It is a metal forming operation.
22.6 Which one of the following cutting tools cannot be used on a turret lathe: (a) broach, (b) cutoff tool,
(c) drill bit, (d) single-point turning tool, or (e) threading tool?
Answer. (a).
22.7 Which one of the following turning machines permits very long bar stock to be used: (a) chucking
machine, (b) engine lathe, (c) screw machine, (d) speed lathe, or (e) turret lathe?
Answer. (c).
22.8 The twist drill is the most common type of drill bit: (a) true or (b) false?
Answer. (a).
22.9 A tap is a cutting tool used to create which one of the following geometries: (a) external threads, (b)
flat planar surfaces, (c) holes used in beer kegs, (d) internal threads, or (e) square holes?
Answer. (d).
22.10 Reaming is used for which of the following functions (three correct answers): (a) accurately locate a
hole position, (b) enlarge a drilled hole, (c) improve surface finish on a hole, (d) improve tolerance
on hole diameter, and (e) provide an internal thread?
Answer. (b), (c), and (d).
22.11 End milling is most similar to which one of the following: (a) face milling, (b) peripheral milling,
(c) plain milling, or (d) slab milling?
Answer. (a).
22.12 The basic milling machine is which one of the following: (a) bed type, (b) knee-and-column, (c)
profiling mill, (d) ram mill, or (e) universal milling machine?
Answer. (b).
22.13 A planing operation is best described by which one of the following: (a) a single-point tool moves
linearly past a stationary workpart, (b) a tool with multiple teeth moves linearly past a stationary
workpart, (c) a workpart is fed linearly past a rotating cutting tool, or (d) a workpart moves linearly
past a single-point tool?
Answer. (d).
22.14 A broaching operation is best described by which one of the following: (a) a rotating tool moves
past a stationary workpart, (b) a tool with multiple teeth moves linearly past a stationary workpart,
(c) a workpart is fed past a rotating cutting tool, or (d) a workpart moves linearly past a stationary
single-point tool?
Answer. (b).
22.15 The three basic types of sawing, according to type of blade motion involved, are (a) abrasive cutoff,
(b) bandsawing, (c) circular sawing, (d) contouring, (e) friction sawing, (f) hacksawing, and (g)
slotting?
Answer. (b), (c), and (f).
22.16 Gear hobbing is a special form of which one of the following machining operations: (a) grinding,
(b) milling, (c) planing, (d) shaping, or (e) turning?

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Solutions for Fundamentals of Modern Manufacturing, 4/e (published by Wiley)  MPGroover 2010
02-07-09
Answer. (b).