III.

TEST REVIEW EXERCISES

Instructions: Copy and answer on your long bond paper. Submit an image to your instructor as
your output.
1. Draw, label and explain each of the part of a shaper machine.
 2. Differentiate a milling machine to a shaper machine.
Primarily, milling machine and shaper machine both functions as machine tools that remove
metal to a workpiece. However, some differences can be distinguished between the two
machines. Firstly, milling machine removes metal as the work is fed against a rotating multi-
point cutter (rotary motion being the main motion). The milling cutter rotates at high speed and it
removes metal at a very fast rate with the help of multiple cutting edges. On the other hand,
shaping machine utilizes a reciprocating motion of the ram by the mechanism housed within the
column or the machine (linear motion being the main motion). Metal is removed through the
forward stroke of the aforementioned motion while the returning stroke goes idle and no metal is
removed during this period. Second, in milling, the Cutting done by multi-point cutting tool or
milling cutter while on a standard shaping machine, a single point cutting tool; is used. Lastly,
since multiple cutters can be mounted simultaneously on the arbor of milling machine and also
due to its rotary motion, milling machines can also process more complex profiles with higher
efficiency than shapers. While, in shaping machine, the productivity is lower (except for long and
narrow planes), so it is mainly used in single-piece, small-volume production, and machine
repair workshops.

3. After watching the video from this link

https://www.youtube.com/watch?v=JVX70JRihhY
Explain how a shaper machine works.

A shaping machine is a type of machine tool that uses linear relative motion
(reciprocating motion) between the workpiece and a single-point cutting tool to machine a linear
toolpath. So, this machine is used for certain operations such as, machining horizontal, vertical,
and angular surfaces, slot cutting, key ways cutting, machining irregular surface and machining
splines and cutting gears. This type of machine works by having a single point cutting tool
attached to the ram which reciprocates over the workpiece and the metal is cut from the
workpiece which is carefully bolted down over a table. The reciprocating motion by the ram is
due to the rotary motion of the drive within the column or the machine. When the ram
reciprocates, the cutting tool held in tool holder moves forward and backward over the work
piece. Here forward stroke performs the shaping action on the work piece by cutting the extra
material and backward stroke or return stroke does not perform cutting action, it is kind of
restoring stroke for the next actionable forward stroke. The feed is given to the work piece and
depth of cut is adjusted by moving the tool downward towards the workpiece. The time taken
during the idle stroke is less as compared to forward cutting stroke and this is obtained by quick
return mechanism. The reciprocating movement of the ram and the quick return mechanism of
the machine are generally obtained by any of the following methods: crank and slotted link
mechanism, Whitworth quick return mechanism and hydraulic shaper mechanism.
III. TEST REVIEW EXERCISES
Instructions: Encircle the Correct Answer.
1. B
2. B
3. D
4. C
5. D
6. C
7. B
8. A
Instructions: Write your answer on the space provided.
1. Differentiate Grit and Structure.
Both the grit and structure are related to grains, however, there is a distinguishable
difference between then two. Grit or Grit Size is a term used to refer to the size of individual
abrasive grains in the wheel. It corresponds to the number of openings per linear inch in the
final screen size used to size the grain. While on the other hand, Structure or Grain Spacing
is the relative spacing of grains in a wheel. In technical words, it is the number of cutting
edges per unit area of wheel face as well as to the number and size of void spaces between
grains. So simply, the difference between the two is that grit refers to the size of individual
grains while structure refers to the distance or spacing between several abrasive grains.
2. Differentiate Bond and Grade.
The main difference between a bond and grade is that bond is the post or the emulsifying
agent that holds the abrasive grains of cutting edges together. This bond withstands a
grinding force and rotary stress and simultaneously need characters to generate the
abrasive grains adequately in accordance with the increase of grinding force by abrasive
grain wear. On the contrary, grade is the bonding strength between these abrasive grains.
This means that it is the measurement of the tenacity with which the bond holds the
abrasive grains together within a wheel. In simpler terms, bond is the posts which holds the
abrasive grains together and the grade is the measurement of how strong these bonds are.
III. TEST REVIEW EXERCISES………………
Instructions: Write your Answer on a long size Bond Paper and send it to your Instructor.
1. Please list five Safety Precautions.
• Always wear safety glasses as this machine may send shavings in all directions.
• Always wait for the wheel to reach maximum speed before using it, as there may be
• Always make sure the magnetic table is clean before placing material on it, as shavings
may
scratch your material or even cause the material to slide wheel you are using the
grinder.
• Ensure that the grinder has a start/stop button within easy reach of the operator.
• Check the grinding wheel before mounting it. Make sure it is properly maintained and in
good
working order.
2. Please list five main parts of the surface grinders.
 Table
 Base
 Three types of traversing wheel (Crossfeed handwheel, longitudinal handwheel,
downfeed handwheel)
 Grinding Wheel
 Coolant tank/ grinding coolant

3. What is a diamond wheel dresser?

 A diamond dresser has single or multiple diamonds mounted on a tip or shank by
a sintering process. Diamond dressers are widely used for truing and dressing of
abrasive grinding wheels.
 A diamond dresser is a tool which has one or more diamond(s) mounted on a
shank by sintering and is used to true and dress grinding wheels by its sharp
cutting edge in order to maintain their performance high for effective and high
precision grinding work.

4. 4. When Dressing the Wheel how far Diamond dresser should be located to the left of
the center of the wheel?
 Keep the diamond dresser ¼ of an inch to the left of the center of the wheel.
5. What is a Ring Test?
 Grinding wheels must be inspected and “ring-tested” before they are mounted to
ensure that they are free from cracks or other defects. Wheels should be tapped
gently with a light, nonmetallic instrument. A stable and undamaged wheel will
give a clear metallic tone or “ring.”
 Cracks in abrasive wheels are often impossible to see. Two effective methods to
detect cracks are the ring test and the vibration test. Always test your wheel
immediately before mounting it. Make sure that the wheel is clean and dry before
you begin the test.
 The ring test assesses the sound coming from a grinding wheel when it is lightly
tapped. An undamaged wheel sends out a clear ringing tone. Use this test on
vitrified bonded wheels.
6. How do you Performing the ring test?
Make sure the wheel is dry and free of sawdust or other material that could deaden the
sound of the ring.

You will need a hard plastic or hard wood object, such as the handle of a screwdriver or
other tool, to conduct the test. Use a wood mallet for heavier tools. Do not use metal
objects.

1. Suspend the wheel on a pin or a shaft that fits through the hole so that it will be easy
to turn, but do not mouth the wheel on the grinder. If the wheel is too large to suspend,
stand it on a clean, hard surface.

2. Imagine a vertical plumb line up the center of the wheel.

3. Tap the wheel about 45 degrees on each side of the vertical line, about one or two
inches
from the wheel’s edge. (Large wheels may tapped on the edge rather than the side of
the wheel.)
4. Turn the wheel 180 degrees so that the bottom of the wheel is now on top.
5. Tap the wheel about 45 degrees on each side of the vertical line again.
6. The wheel passes the test if it gives a clear metallic tone when tapped at all four
points.
If the wheel sounds dead at any of the four points, it is cracked. Do not use it.

Heres’s how the ring test works:

1. Suspend the wheel from the hole on a small pin or finger. If the wheel is too heavy,
rest it on its outer edge on a clean, hard floor.
2. Tap the wheel gently with a non-metallic tool. For light wheels, use the wooden handle
of a screwdriver. For heavy wheels, use a wood mallet. The best spot to tap a wheel is
about 45 degrees from either side of the vertical centerline, about 2.5 to 5 centimeters (1
to 2 inches) from the outside edge. (See Figure 2 on the next page). Note: If you tap
directly on the centreline, even an undamaged wheel may give off a muffled sound.
3. Listen for the sound that comes from the wheel when it is tapped. Turn the wheel 45
degrees to the right or left, and repeat the test.
4. Compare the sounds from the wheel being tested with those from other wheels of the
same lot and type.
5. Set aside any wheel that has a suspiciously different ring for further testing. If you
need help, call the manufacturer.
7. When select the grinding wheel, there are eight factors which affect the choice of the
grinding wheel specifications. Please list five out of eight factors.
  Grinding wheel manufactures instruction.
 Material to be ground and its hardness.
 Amount of stock to be removed and finish required.
 Are of grinding contact.
 Severity of the grinding operation.
8. Aluminum oxide grinding wheel are best for what?

 Aluminum oxide for steels and steel alloys.

9. A standard wheel marking system is used for the identifying factors in grinding wheel
selection. Please all five major factors?

 Type of abrasive
 Grit size
 Grade or hardness
 Structure
 Bond

10. A w heel marked WA 80-L9B, Please indicate the following.

First Symbol: Type of Abrasive
White Aluminum oxide
Second Symbol: Grit Size
8 0 Medium Fine Grain?
Third Symbol: Grade of Hardness
H to P are more medium grades.
Fourth Symbol: Structure
8 is a more medium structure.
Fifth Symbol: Bond
B – Resinoid