Lesson Notes By Weeks and Term v4 - SHS 2
ENGINEERING MATERIALS, TOOLS, AND MACHINES
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ENGINEERING MATERIALS, TOOLS, AND MACHINES
Download the Lessonotes Mobile Ghana app for faster lesson access on Android and iPhone.
Subject: Applied Technology
Class: SHS 2
Term: 1st Term
Week: 12
Grade code: 2.2.1.LI.4
Strand code: 2
Sub-strand code: 1
Content standard code: 2.2.1.CS.1
Indicator code: 2.2.1.LI.4
Theme: METAL TECHNOLOGY
Subtheme: ENGINEERING MATERIALS, TOOLS, AND MACHINES
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Welcome, future engineers and technicians! Today, we are exploring one of the most versatile and powerful machines in any modern workshop: the milling machine. Think of it as the master sculptor of the metal world. While a lathe rotates the workpiece, the milling machine rotates the cutter to precisely shape metal blocks into useful components. From making spare parts for a car engine in Suame Magazine, Kumasi, to creating components for a corn mill in a rural community, the milling machine is essential. We will also learn about cutting fluids, the special liquids that help the machine work efficiently and safely, just like oil helps a car engine run smoothly.
A. The Milling Machine A milling machine is a machine tool that removes metal by rotating a multi-toothed cutting tool (called a milling cutter). The workpiece is fed into the rotating cutter, allowing for the creation of flat surfaces, slots, gears, and other complex shapes. The two most common types are Vertical and Horizontal milling machines, named according to the orientation of their main spindle. We will focus on the Vertical Milling Machine, which is common in school workshops.
Major Parts of a Vertical Milling Machine
| Part | Description & Function | | :--- | :--- | | Base | The heavy foundation of the machine. It provides stability and support for all other parts. Often contains the coolant reservoir. | | Column | The main vertical structure that rises from the base. It houses the motor and gear mechanisms and provides guideways for the knee. | | Knee | A casting that slides up and down the column on guideways. It supports the saddle and the table. It is used to adjust the height of the workpiece. | | Saddle | Sits on top of the knee and can be moved towards or away from the column (in-and-out motion). It supports the worktable. | | Table | Mounted on top of the saddle, it moves left and right. The workpiece is clamped onto the table using T-slots. The combination of knee, saddle, and table movements allows the workpiece to be positioned precisely in three axes (X, Y, Z). | | Spindle | The rotating part of the machine that holds and drives the cutting tool. On a vertical machine, the spindle is oriented vertically. | | Head (or Ram) | Contains the spindle, motor, and the mechanism for changing speeds. It is mounted on top of the column and can often be swivelled to perform angled cuts. | | Quill | A sleeve around the spindle inside the head that can be moved up and down to perform operations like drilling and boring. |
B. Cutting Fluids Cutting fluids (also known as coolants or lubricants) are liquids or gases applied to the cutting zone during a machining operation. Their role is absolutely critical for quality work and safety.