MEM07032 - THEORY - Use workshop machines for basic operations - PRE LEARNING: Attempt review

2/4/2023, 2 : 02 p. m. MEM07032 - THEORY - Use workshop machines for basic operations - PRE LEARNING: Attempt review Página 3 de 58 https://baxter.edfibre.com/gradejet/mod/quiz/review.php ? attempt=147249&cmid=18279 In organisations where they have multiple outlets or spread across a wider geography, SOP brings consistency in their operations and clearly establishes the brand image in the consumer mind. SOP identifies the process owners who are responsible to maintain the functioning of a process. It becomes the responsibility of the process owners to continuously improve the SOP with best practices. SOP helps in auditing a process for its validity and to find out the deviation between the documented and actual performance. SOP enables the process owners and process improvement experts to quickly get an understanding of the current state of the process. SOP establishes the foundation for all process improvement efforts. While expanding the capacity of an organisation or while commissioning an additional production line, SOP comes handy to estimate the quantum of work especially the factors of production such as men, machine, material and money required. SOP demonstrates a company’s sound process orientation and their commitment towards process improvement, which is appreciated by the clients and boost your credibility, especially in a B2B environment. SOP is a tool for communicating the organisations expectation in terms of the standards of performance with reference to functions, processes and activities. When employees follow SOP, which is thoroughly evaluated for its best practices and safe operation, it tremendously increases the safety and security of not only the employees who are performing the activities, but also others in the vicinity. Organisations that establish sound SOPs for their functions and processes can have a good negotiation with the insurance companies as it mitigates the exposed risk and its degree. SOP provides a global view of processes helpful in identifying opportunities for small or large automations in processes. A good document to capture and consolidate the business rules that need to be followed while performing a transaction or operation. For public safety and national security, companies in industries such as pharma, healthcare, insurance, banking etc. are mandated by the respective national governments or regulatory bodies to establish and follow SOPs. In case of a long-repeated processes, human memory is limited and there is a possibility of missing certain activities. SOP along with a check list will be of immense help in these situations. When companies want to implement an ERP system or to move from a legacy system to a new system, SOP will help the software implementers to understand the organisations processes with greater accuracy. In the absence of SOPs, the software implementers must go through a phase of numerous meetings with the stakeholders and eventually create such documents that represent the organisational processes. 1.1 Comply with work health and safety (WHS) requirements at all times 1.1 Comply with work health and safety (WHS) requirements at all times Workplace health and safety management system Workplace health and safety management system A workplace health and safety management system are a set of policies, procedures and plans that systematically manages health and safety at work and can help to minimise the risk of injury and illness from workplace operations. A systems-based approach A systems-based approach As an employer, you can choose to establish a health and safety management system to help meet your duties and responsibilities under the Work Health and Safety Act 2011 Well-designed policies and procedures help organisations comply with work health and safety legislation and regulations. However, a workplace health and safety management system is much more than simply having safety- related forms and policies in place and documented procedures. Rather, it is about achieving the measures and contents of the safety documentation in an ongoing and managed way. A systems-based approach is far more effective in protecting people from harm and meeting safety goals than a system which relies on documentation alone. This is because a workplace health and safety management system: is evolving and continuously improving uses feedback to manage and improve safety related outcomes builds on existing health and safety processes integrates with other management systems provides for more informed decision making strengthens corporate culture and demonstrates due diligence. The Australian standard The Australian standard The Australian standard, AS/NZS ISO 45001:2018 (Occupational health and safety management systems - Requirements with guidance for use): specifies the conditions for a workplace health and safety management system gives guidance on its use. The standard aims to enable organisations to provide safe and healthy workplaces by preventing work- related injury and illness, and proactively improve its work health and safety performance. Like some other Australian standards dealing with management systems, AS/NZS ISO 45001:2018 is closely aligned with the relevant international standards, ISO 9000 series, dealing with similar issues. How to develop a health and safety system How to develop a health and safety system Every organisation will find that it has some elements of a workplace health and safety management system in place. What is less common is the linking of these elements into a coordinated overall system to improve work health and safety performance.

2/4/2023, 2 : 02 p. m. MEM07032 - THEORY - Use workshop machines for basic operations - PRE LEARNING: Attempt review Página 6 de 58 https://baxter.edfibre.com/gradejet/mod/quiz/review.php ? attempt=147249&cmid=18279 reporting any hazards or work practices you feel may be unsafe complying with any reasonable instruction, policy or procedure relating to health and safety in the workplace, such as o follow safety manuals and procedures o participate in safety training o wear personal protective equipment o exercise a level of care and responsibility in your work reinforcing and influencing safety behaviours in your workplace working with management to identify safety problems and find solutions understanding and following internal incident reporting processes acting upon health and safety matters where you have control or influence working with colleagues to promote health and safety so that it becomes a part of your daily work contributing to quality data and information which measures health and safety compliance over time – this can be used to identify trends and target preventative actions and improvements. Liabilities Liabilities If you do not follow the required procedures, you could face non-compliances under the Work Health and Safety Act 2011 (WHS Act). This may include penalties such as criminal prosecution, fines and jail sentences. Communicating and consulting effectively Communicating and consulting effectively Importance of communication and consultation Importance of communication and consultation Communication and consultation are vital to building a strong health and safety culture and minimizing injury and illness in the workplace. This process involves: talking about issues listening to and raising concerns understanding your role seeking information and sharing views discussing issues in a timely manner considering what is being said before decisions are made attending scheduled meetings. Contributing to consultation as a worker Contributing to consultation as a worker You can contribute by: speaking at team meetings talking with your work group giving feedback on policy and procedures when asked. Participation in consultation provides you with an opportunity to: think constructively about health and safety issues that affect you contribute ideas for improvement work as a team in implementing good workplace safety practices. When you should be consulted When you should be consulted The ‘person conducting business or undertaking’ (PCBU) is required to consult with you on any matters that may directly affect your health and safety. If you are a HSR or represented by an HSR, then you or your HSR, must also be included in the consultation. There are number of situations when your manager and senior leaders are required to consult with you. They include: identifying hazards and assessing risks arising from work making decisions about ways to eliminate or minimise those risks making decisions about the adequacy of facilities for the welfare of workers proposing changes that may affect the health and safety of workers making decisions about the procedures for resolving health and safety issues monitoring the health of workers or workplace conditions, information and training or consultation with workers carrying out any other activity prescribed by the WHS Regulations. When the PCBU consults with you on a health and safety issue, you need to consider the information provided and give feedback through your HSR. Barriers to effective consultation There are many barriers to how we communicate and consult with each other in the workplace. Finding the right time and delivering messages in the right way can be a challenge. Workers and HSRs should establish a relationship with their manager that encourages open and honest discussion and mutual trust. Consultation often fails due to: lack of clarity of message absence of emotional resonance in your message inaccurate targeting poor timing no genuine feedback process. Improving and promoting communication Improving and promoting communication To ensure that communication is effective in your workplace, you should use all the available and established channels to provide your ideas and concerns about health and safety. Ways to contribute to effective communication include: contribute at meetings seek information from your intranet use emails to clarify, and provide a two-way communication approach establish an open and constructive approach to talking to your colleagues and managers

2/4/2023, 2 : 02 p. m. MEM07032 - THEORY - Use workshop machines for basic operations - PRE LEARNING: Attempt review Página 9 de 58 https://baxter.edfibre.com/gradejet/mod/quiz/review.php ? attempt=147249&cmid=18279 Eye protection Eye protection Eye protection is critical to ensure that your eyes are protected from foreign bodies entering your eyes and to protect them from harmful rays. Oxy-fuel gas goggles must be worn to protect the eyes from, heat, rays and foreign objects from entering the eyes while welding. A clear face shield adds extra protection. Clear safety glasses Oxy-fuel gas cutting and welding goggles Full face shield Clear safety glasses Clear safety glasses These glasses are as a rule generally worn in the workshop to protect the eyes from foreign bodies entering them. They will also help reduce the effects of welding rays on the eyes. Shown below is a small piece of iron has lodged near the margin of the cornea, this accident was the result of not wearing proper eye protection Leather jackets and leather aprons Leather jackets and leather aprons Leather jackets and aprons provide additional protection when welding, particularly a leather jacket when welding over head Work boots Work boots In the welding and fabrication industry there is the chance that you will drop something heavy on your toes, so it is important to protect them. Your work boots should have toe protection made either of steel or a composite material to protect them. Slip on boots Lace up boots Hearing protection Hearing protection It is important that hearing protection is worn when working in the welding and fabrication industry. The noise level is generally above what is acceptable as safe for normal noise that will not affect you hearing. Shown above are the two type of hearing protection, ear plugs and muffs. Ear plugs and muffs come in a variety of shapes and sizes, choose the one that feel most comfortable for you. The major problem with hearing loss is that it slowly creeps up on you; you do not notice it until the damage has been done and you hearing has been irreversibly damaged. Ear plugs Ear muffs Others PPE at workshop Others PPE at workshop Shown below is a list of additional personal protective equipment that may be useful when performing your work tasks Safety Glasses Steel cap boots Close fitting clothing

2/4/2023, 2 : 02 p. m. MEM07032 - THEORY - Use workshop machines for basic operations - PRE LEARNING: Attempt review Página 12 de 58 https://baxter.edfibre.com/gradejet/mod/quiz/review.php ? attempt=147249&cmid=18279 Then draw the object on each of three faces as seen from that direction. Unfold the box (figure 4) and have the three views. We call this an "orthographic" or "multiview" drawing. Figure below shows the creation of an orthographic multiview drawing. Which views should one choose for a Multiview drawing? The views that reveal every detail about the object. Three views are not always necessary; we need only as many views as are required to describe the object fully. For example, some objects need only two views, while others need four. The circular object in figure below requires only two views. Dimensioning Dimensioning We have "dimensioned" the object in the isometric drawing in figure below. As a general guideline to dimensioning, try to think that would make an object and dimension it in the most useful way. Put in exactly as many dimensions as are necessary for the craftsperson to make it -no more, no less. Do not put in redundant dimensions. Not only will these clutter the drawing, but if "tolerances" or accuracy levels have been included, the redundant dimensions often lead to conflicts when the tolerance allowances can be added in different ways. Repeatedly measuring from one point to another will lead to inaccuracies. It is often better to measure from one end to various points. This gives the dimensions a reference standard. It is helpful to choose the placement of the dimension in the order in which a machinist would create the part. This convention may take some experience. Sectioning Sectioning There are many times when the interior details of an object cannot be seen from the outside. An isometric drawing that does not show all details.

2/4/2023, 2 : 02 p. m. MEM07032 - THEORY - Use workshop machines for basic operations - PRE LEARNING: Attempt review Página 15 de 58 https://baxter.edfibre.com/gradejet/mod/quiz/review.php ? attempt=147249&cmid=18279 Full and sectioned isometric views. Front view and half section. The diagonal lines on the section drawing are used to indicate the area that has been theoretically cut. These lines are called section lining or cross-hatching . The lines are thin and are usually drawn at a 45- degree angle to the major outline of the object. The spacing between lines should be uniform. A second, rarer, use of cross-hatching is to indicate the material of the object. One form of cross- hatching may be used for cast iron, another for bronze, and so forth. More usually, the type of material is indicated elsewhere on the drawing, making the use of different types of cross-hatching unnecessary. Half section without hidden lines. Usually hidden (dotted) lines are not used on the cross-section unless they are needed for dimensioning purposes. Also, some hidden lines on the non-sectioned part of the drawings are not needed (figure) since they become redundant information and may clutter the drawing. Sectioning Objects with Holes, Ribs, Etc. Sectioning Objects with Holes, Ribs, Etc. The cross-section on the right of figure is technically correct. However, the convention in a drawing is to show the view on the left as the preferred method for sectioning this type of object. Cross section. Dimensioning Dimensioning The purpose of dimensioning is to provide a clear and complete description of an object. A complete set of dimensions will permit only one interpretation needed to construct the part. Dimensioning should follow these guidelines. 1. Accuracy: correct values must be given. 2. Clearness: dimensions must be placed in appropriate positions. 3. Completeness: nothing must be left out, and nothing duplicated. 4. Readability: the appropriate line quality must be used for legibility. The Basics: Definitions and Dimensions The Basics: Definitions and Dimensions The dimension line is a thin line, broken in the middle to allow the placement of the dimension value, with arrowheads at each end (figure).

2/4/2023, 2 : 02 p. m. MEM07032 - THEORY - Use workshop machines for basic operations - PRE LEARNING: Attempt review Página 18 de 58 https://baxter.edfibre.com/gradejet/mod/quiz/review.php ? attempt=147249&cmid=18279 Question 1 Complete Marked out of 1.00 Question 2 Complete Marked out of 1.00 Produce an isometric drawing Produce an isometric drawing Produce on A3 paper using drawing equipment, apply the ordinate method of construction to produce an isometric drawing. Accuracy, line work, lettering, dimensions, and cleanliness must be shown. This is a 12 mm mild steel 250 plate. The rectangle and the square are to be spaced evenly on the drawing sheet and the circle is to be placed centrally inside the rectangle. Please upload photo (minimum-1 and maximum-3) of your work. MEM07032 Q1.pdf Review questions Write detailed responses to the following questions Write detailed responses to the following questions 1. What does WHS stand for? Work Health and Safety 2. List some of the duties of the workers in the language (minimum 8) As a worker, you have duties and responsibilities under the Work Health and Safety Act 2011 (WHS Act). Duties and responsibilities include: Taking reasonable care for your own health and safety Taking reasonable care that your actions or omissions do not harm the health and safety of others Reporting any hazards or work practices you feel may be unsafe complying with any Reinforcing and influencing safety behaviours in your workplace Working with management to identify safety problems and find solutions Understanding and following internal incident reporting processes Acting upon health and safety matters where you have control or influence 3. Under the Work Health and Safety Act 2011 (WHS Act), what is the Definition of a worker? The role of workers Definition of a worker Under the Work Health and Safety Act 2011 (WHS Act), a worker includes any person who works, in any capacity, in or as part of the business or undertaking. You are a worker under health and safety legislation if you are an: employee independent contractor or subcontractor (or their employee) employee of a labour hire company outworker, such as a home-based worker apprentice or trainee a student gaining work experience volunteer. 4. State three (3) safety precautions, relating to machine safety, which should be observed when using a lathe. Safety precautions, related to machine safety, when using a lathe are as follows: 1: Make sure all lathes and mills or machines have effective and properly functioning guards that are always in place where the machines are operating. 2: Replace lathe or mill guards immediately after any repair. 3: Before using the lathe or milling machine, do not attempt to oil, clean, adjust or repair any machine while it is running, stop the machine and lock the power switch in the off position.

2/4/2023, 2 : 02 p. m. MEM07032 - THEORY - Use workshop machines for basic operations - PRE LEARNING: Attempt review Página 21 de 58 https://baxter.edfibre.com/gradejet/mod/quiz/review.php ? attempt=147249&cmid=18279 Information SECTION 2 SET UP MACHINE SECTION 2 SET UP MACHINE 2.1 2.1 Select appropriate machine and tools to meet work requirements Select appropriate machine and tools to meet work requirements Work requirements are the job qualifications and skills necessary for a certain position. Work requirements are usually written in the form of a list that contains the most important job qualifications, skills, and qualities that a candidate must possess in order to be able to perform certain job duties. The basic meaning of a job description is a list that manpower, machines and tools have which can be used by for maintaining certain tasks along with some functions and responsibilities pertaining to a certain position or machines to making the products. Why is it Important to Understand and Review Job Description? Why is it Important to Understand and Review Job Description? In a company every employee always like to know what is really expected by them working in that company from the management. Knowing a job description is a great way for the person to really understand what the management wants them to do and how they are being evaluated in the company. They also come to know how important and critical the job they are doing in the firm now is for the benefit of the company and what are the characteristics required for the employees who are new. The second step is to know what equipment and tools need to be selected for the job requirement. In most of the case the company only take the job order based on what equipment and tools they currently have. Then the only task for process worker is to select the available equipment and tools. Some of the most used criteria when choosing a machine tool include the following: production quantity, machining type, geometrical features of the machine, complexity of the workpiece, productivity etc. Mechanical Workshop: Equipment Mechanical Workshop: Equipment CNC Machining centre Manual Lathe CNC Lathe Milling machines Surface grinding Welding facilities 3D Printing and Scanning

2/4/2023, 2 : 02 p. m. MEM07032 - THEORY - Use workshop machines for basic operations - PRE LEARNING: Attempt review Página 22 de 58 https://baxter.edfibre.com/gradejet/mod/quiz/review.php ? attempt=147249&cmid=18279 Vacuum forming CNC Machining Centres CNC Machining Centres Used for the manufacture of fixtures and rigs for undergraduate and research projects these machine tools are the workhorses of the mechanical workshop. These machine tools can be programmed by the following means to machine most materials. Conversational programming – Hurco have their own conversational programming feature called WinMax which allows programming in a question and answer format using multiple choice and fill in the blank questions. Operator prompts in plain English. No codes or computer languages are used. DXF Transfer – this feature allows to quickly import the 2D data from a dxf file. This feature enables the operator to select holes and machining operations, thereby creating a conversational program at the control. CAD/CAM – the mechanical workshop uses Alphacam software for milling. Part files can be imported into our Alphacam system which enables the operator to generate tool paths for contouring, pocketing, engraving and hole-drilling complex parts. Manual lathes Manual lathes manual lathes are regularly used in the manufacture of prototype equipment used in undergraduate and research projects. CNC Lathe CNC Lathe This 5 – axis machine tool is complete with twin chucks and turrets. Each turret consists of 12 stations which can carry live tooling with speeds of between 100-4500rpm. The machine uses a Fanuc based CNC control system, OSP 7000L and programming is carried out manually at the console. Conventional milling machines Conventional milling machines conventional milling machines are regularly used where a considerable amount of user interaction with the work piece is required. They are also used where larger, more awkward work pieces need modification or re-work or where the head of the machine needs to be tilted off to one side to machine an angle.

2/4/2023, 2 : 02 p. m. MEM07032 - THEORY - Use workshop machines for basic operations - PRE LEARNING: Attempt review Página 23 de 58 https://baxter.edfibre.com/gradejet/mod/quiz/review.php ? attempt=147249&cmid=18279 Surface grinding Surface grinding Used to produce ultra-flat surfaces on metallic materials, our Jones & Shipman surface grinder can achieve surface finishes of 0.2 µ m Ra. It is used for a wide variety of engineering projects such as; The precision grinding of syringes used in electro-spraying The precision grinding of parallel surfaces in press tooling To achieve ultra- flat surfaces prior to the application of strain gauges used in undergraduate teaching laboratories Welding facilities Welding facilities The Dept. of Mechanical & Manufacturing Engineering has a dedicated welding bay where the following types of welding are carried out. MIG – Metal Inert Gas TIG – Tungsten Inert Gas Arc welding or Stick welding Gas welding 3D Printing and Scanning 3D Printing and Scanning Dimension 3D Printer and Roland 3D Laser Scanner Dimension 3D Printer and Roland 3D Laser Scanner The mechanical workshop staff have been providing a 3D prototyping service for over 15 years and have a wealth of experience in this process. Situated in the “Build Base” our Dimension 3D Printer uses the fusion deposition modelling process (FDM) to manufacture prototypes for research and undergraduate projects. We also have Roland Picza 3D Laser Scanner which is particularly suitable for the reverse engineering of components and models. Vacuum forming Vacuum forming

2/4/2023, 2 : 02 p. m. MEM07032 - THEORY - Use workshop machines for basic operations - PRE LEARNING: Attempt review Página 24 de 58 https://baxter.edfibre.com/gradejet/mod/quiz/review.php ? attempt=147249&cmid=18279 A vacuum forming machine is available for use in the mechanical workshop. 2.1 2.1 Sharpen cutting tools, as required Sharpen cutting tools, as required Cutting tools Cutting tools Cutting tools. A cutting tool is a type of cutting tool with a blade at the end of the shank. ... Reamer. A reamer is a tool to finish the hole opened by a drill according to the required accuracy. ... Drill. ... Milling tools. ... Endmill. ... Broach. ... Tap/thread cutting die Main Types of Lathe Tooling Main Types of Lathe Tooling Understanding lathe tooling, what it does and how it works is a big part of refining finishing and maximizing tool wear and tear. There are a lot of options, so it can seem confusing, but it really is not once understand the basics. There are five types of lathe tooling: External turning tools, Boring bars, Drills, Threading tools, Parting tools. First, about external turning tools. They are great at just what the name implies, cutting away the exterior of the piece. This include roughing or finishing work. Second on our list was boring bars. All these can recognize these by their circular, bar design. They come in a bunch of different sizes, with one main purpose – to make an already existing hole bigger or to refine the finish of hole. To make that initial hole, it will need a drill. If the operator is new to lathe work, it can picture this as a power tool drill, but instead of the machine spinning the cutting tool into the workpiece, it is the exact opposite. The workpiece is moving fast, and the drill is secured in a stationary position. The holes boring bars make have a rougher finish, but if to thread it later, that is perfect. Threading tools can add threads to both the interior and exterior of the workpiece. Lastly – we have parting tools. Parting tools are also very important and do much more than their name imply. These tools can part, groove, and cut off workpieces while offering a consistent, smooth finish. There are also the left hand, right hand, and neutral hand tooling. That describes how the cutting tool faces the workpiece and what direction the lathe is spinning he work piece. Normally our lathe will be spinning clockwise. It’s easy to differentiate the left handed tools from right handed tools, because if lay the tools with the insert up, left handed tools curve to the right, and right handed tools curve into the left, kind of like the finders do if making ‘c’s with them. This is also always included in the lathe tooling designation, which can find engraved into the side of the tool. Lathe cutting tools Lathe cutting tools According to the process of using the lathe cutting tools lathe cutting tools. Following are the 14 different types of lathe lathe cutting tools used in lathe: cutting tools used in lathe: 1. Turning tool. 2. Chamfering tool. 3. Thread cutting tool. 4. Internal thread cutting tool. 5. Facing tool. 6. Grooving tool. 7. Forming tool. 8. Boring tool. 9. Parting-off tool. 10. Counterboring tool 11. Undercutting tool 12. According to the method of applying feed Right-hand tool Left-hand tool

2/4/2023, 2 : 02 p. m. MEM07032 - THEORY - Use workshop machines for basic operations - PRE LEARNING: Attempt review Página 25 de 58 https://baxter.edfibre.com/gradejet/mod/quiz/review.php ? attempt=147249&cmid=18279 Round Nose 13. According to the method of using the tool Turning Tool The lathe cutting tool geometry for H.S.S. as indicated on the diagram. NOTE: Do not state the values of the angles. A Side Rake B B Side Clearance Side Clearance C C Front Clearance Front Clearance D D Top Rake Top Rake There are mainly two classes of turning tool: Rough turning tool. Finish turning tool. Rough Turning Tool The main function of a rough turning tool is to remove the maximum amount of metal in minimum time that the tool, work, and the machine will permit. The cutting angle is so ground that it can withstand maximum cutting pressure. 1.2 Finish Turning Tool 1.2 Finish Turning Tool Turning tool is used to remove the very small amount of metal. A tool angle is so ground that it can produce a very smooth and accurate surface. Chamfering Tool Chamfering Tool Straight turning tools are also used as a chamfering tool when the cutting edges are set at an angle of the chamfer. Where a large number of chamfer works are to be performed a special chamfering tool with its side cutting edge angle ground to the angle of the chamfer is used. Shoulder Turning Tool Shoulder Turning Tool

2/4/2023, 2 : 02 p. m. MEM07032 - THEORY - Use workshop machines for basic operations - PRE LEARNING: Attempt review Página 26 de 58 https://baxter.edfibre.com/gradejet/mod/quiz/review.php ? attempt=147249&cmid=18279 A square shoulder is turned by a knife-edge turning tool or facing tool. A bevelled shoulder may be turned by a straight turning tool having a side cutting edge angle and zero nose radius. A filleted shoulder is turned by a straight turning tool with a nose radius corresponding to the fillet radius of the work. Thread Cutting Tool Thread Cutting Tool External Thread Cutting Tool External Thread Cutting Tool Metric, B.S.W or American “V” thread are formed by a single point thread cutting tool. Its cutting edges sharpened to the shape and size of the thread to be cut. The shape of the tool is determined by the included angle at the nose of the tool which should correspond to the angle of the thread. It may be 60° for metric threads or 55° for B.S.W threads. The included angle at the nose of the tool which should correspond to the angle of the thread. It may be 60° for metric threads or 55° for B.S.W threads. The size or cross-section of the cutting edges of the tool depends upon the pitch of the thread. Below figure illustrates an H.S.S. thread cutting tool. So for machining different screw threads having different pitches separates tools are used to produce accurate threads. The nose of the tool is pointed, flat or rounded according to the shape of the root of the thread. A thread tool gauge is used to check the shape and size of the tool after it has been ground. Tool for cutting square threads Tool for cutting square threads The side clearance of the tool for cutting square thread is of prime importance in order to prevent the tool from interfering or rubbing against the vertical flank of the thread. As a rule, the forward side clearance angle is determined by adding 5° to the helix angle of the thread and trailing side clearance is obtained by subtracting 5° from the helix angle, if ø be the forward side clearance angle and θ be the trailing side clearance angle, then from the formula: The width of the cutting edge should be equal to half the pitch of the thread. Small clearance angle of 1° to 2° are provided at the side of the tool to prevent the surface from ribbing with the work. Internal Thread Cutting Tool Internal Thread Cutting Tool The cutting edge of the tool is exactly similar to an external thread cutting tool but the front clearance angle is sufficiently increased as in a boring tool. The tool is a forged type orbit type and held on a boring bar. The point of the tool must be set square with the work. Read also: 22 Different Types of Operations used in Lathe Machine Facing Tool Facing Tool

2/4/2023, 2 : 02 p. m. MEM07032 - THEORY - Use workshop machines for basic operations - PRE LEARNING: Attempt review Página 27 de 58 https://baxter.edfibre.com/gradejet/mod/quiz/review.php ? attempt=147249&cmid=18279 A facing tool removes metal by its side cutting edges. So no top rake in necessary in a facing tool. The figure shows H.S.S. facing tool intended for finishing operations. The tool has 2° side cutting edge angle and 34° end cutting edge angle can be accommodated in the space between the end of the work and 60° dead centre leaving a clearance of 2° on both sides. The standard shank section is 20 Χ 20, 25 Χ 25, 32 Χ 32, 40 Χ 40, and 50 Χ 55 all expressed in mm. The length of the tool is 125, 140,170, 200 and 240 mm and the nose radius varies from 0.5 to 1.6 mm. Grooving Tool Grooving Tool Grooving tool is similar to a parting-off tool illustrated in the figure. The cutting edges are made square, rounded or “V” shape according to the shape of the groove to be cut. Forming Tool Forming Tool Turning curved profiles may be affected by using 1. Ordinary lathe tools, 2. Flat forming tools, 3. Circular forming tools. An ordinary lathe turning tool may sever the purpose where a copying attachment is used to reproduce the form of a template. Flat forming tools are made of two types: 1. Simple forming tools 2. Flat dovetail forming tools. Simple forming tools Simple forming tools These tools have their cutting edges ground to the shape of the groove, undercut, or thread to be cut. Flat dovetail forming tools have a wider cutting edge corresponding to the shape desired. Dovetail end of the tool is fitted in a special tool holder. No front rake is provided but sufficient front clearance angle is given and it ranges from 10° to 15°. Regrinding is always done on the top face of the tool which does not alter the form of the tool. Circular Form Tools Circular Form Tools These tools are preferred in production work as a very long cutting surface can be used resulting in longer tool life.

2/4/2023, 2 : 02 p. m. MEM07032 - THEORY - Use workshop machines for basic operations - PRE LEARNING: Attempt review Página 28 de 58 https://baxter.edfibre.com/gradejet/mod/quiz/review.php ? attempt=147249&cmid=18279 The centre of the tool is set slightly above the centre line of the work to provide an effective front clearance angle on the tool. The tool will rub against the work if the centres are of the same height. The tool centre is usually higher than the centre line of the lathe by 1/20 to 1/10 of the tool diameter. This height is termed ‘offset’. Regrinding is done by grinding the flat only. Boring Tool Boring Tool A boring tool is similar to a left-hand external turning tool so far its cutting edge is concerned. The tool may be a bit type inserted in a boring bar or holder, or forged type having a tool shank. The figure shows an H.S.S. tool bit inserted in a boring bar. A boring bar is made of mild steel with slots or holes cut into it to accommodate the tool bit which is locked by an Allen screw. The amount of projection of the cutting edge of the tool from the centre of the bar determines the finished hole diameter of the work. The bit is generally inserted at right angles to the centre line of the bar for boring a continuous hole passing from one end to the other end. Different Design of The Boring Tool Different Design of The Boring Tool The bit is set at a single to the axis projecting beyond the end of the bar for boring a blind hole. A tool bit having two cutting edges at it two ends is used for quick machining. A wide double-bladed cutter is inserted in the boring bar to finish the boring operation. Two or more bits may be inserted in a boring bar for different diameters in one setting. Boring Bars: Boring Bars: Boring bars are held in the tailstock for boring small holes ranging from 12 to 100 mm. For boring larger hole diameters, boring bars are gripped by two clamp blocks and held in the tool post. For precision boring or boring in odd size work that is supported on cross-slide, the bar is supported on centres and is made to revolve. Clearance for Boring Tool Clearance for Boring Tool In a boring tool, the tool cutting edge most have sufficient front clearance to clear the work. To strengthen the tool point double clearance, primary and secondary, is provided. The smaller be the hole diameter the larger should be the front clearance. Larger clearance angle necessitates the reduction in rake angle in a boring tool. The nose of the tool is straight or round according to the type of finish desired. Counterboring Tool Counterboring Tool The counterboring operation can be performed by an ordinary boring tool. The tool cutting edge is so ground that it can leave a shoulder after turning. A counterbore having multiple cutting edges is commonly used.

2/4/2023, 2 : 02 p. m. MEM07032 - THEORY - Use workshop machines for basic operations - PRE LEARNING: Attempt review Página 29 de 58 https://baxter.edfibre.com/gradejet/mod/quiz/review.php ? attempt=147249&cmid=18279 Undercutting Tool Undercutting Tool Undercutting or grooving tool has a point and form of the cutting edge exactly similar to the form of the required groove. Clearance angle is given at all the sides of the tool. For the recessing groove cutting edge, the longitudinal feed is employed. The front clearance angle depends upon the bore of the work. Parting Off Tool Parting Off Tool A parting off tool is normally forged and used as bits for cemented carbide tipped tools. Parting off tool is made as narrow as possible to remove the minimum of metal. The width of the cutting-edge ranges from 3 to 12 mm only. The length of the cutting tool which inserts into the work should be slightly longer than the radius of the bar stock being machined. As the tool penetrates deep into the work, clearance is provided all around the tool cutting edge to prevent it from rubbing against the work surface. As the tool is purely ended cutting it has no side rake slight back rake is provided on the tool to promote an easy flow of the ships. According to The Method of Applying Feed According to The Method of Applying Feed Right-hand tool Left-hand tool Round Nose Right-Hand Tool Right-Hand Tool A right-hand tool is shown in the figure. Is that which is fed from lathe bed, i.e. from the tailstock to the headstock end when operations like turning, thread cutting, etc are performed. A right-hand tool is formed on its left-hand end when viewed from the top with its nose pointing away from the operator. Left-Hand Tool Left-Hand Tool The left-hand tool is shown in the figure. Is that which is fed from the Left to the right-hand end of the lathe bed, i.e. from the headstock to the tailstock end. The left-hand tool is used for left-hand thread cutting operation or turning operation which leaves a shoulder on the right-hand end of the workpiece. A left-hand tool has its cutting edge formed on its right-hand end when viewed from the top with its nose pointing away from the operator. A left-hand tool may also be used for facing operation. Round Nose Tool Round Nose Tool A round nose turning tool sown in the figure. Maybe fed from left to the right or from right to the left- hand end of the lathe bed away. For this reason, they have no back rake and side rake. In some cases, a small back rake is provided on the tool. A round nose turning tool is usually used for finish turning operation. Tool sharpening safety Tool sharpening safety When using any type of power tool in this section, the following safety equipment should be worn:

2/4/2023, 2 : 02 p. m. MEM07032 - THEORY - Use workshop machines for basic operations - PRE LEARNING: Attempt review Página 30 de 58 https://baxter.edfibre.com/gradejet/mod/quiz/review.php ? attempt=147249&cmid=18279 Eyes protection Hearing protection Coveralls, shirt/pants (cotton) Steel cap boots Hair protection Dust mask (masonry) Gloves Always disconnect the power on a portable power tool before changing or adjusting attachments such as drill bits and saw blades. Never operate a power tool with the guard removed or when it is improperly adjusted Sharpening cutting edges- lathe cutting tools Sharpening cutting edges- lathe cutting tools Cutting edges do not stay sharp forever. In fact, tools that are designed to be razor sharp - such as knives and chisels - tend to go blunt very quickly while using them, especially if cutting hard materials. Lathe Tools Lathe Tools Dressing the grinding wheel is a part of maintaining the bench grinder. Grinding wheels should be considered cutting tools and must be sharpened. A wheel dresser sharpens by “breaking off” the outer layer of abrasive grit from the wheel with star shaped rotating cutters which also must be replaced from time to time. This leaves the cutting edges of the grit sharp and clean. A sharp wheel will cut quickly with a “hissing” sound and with very little heat by comparison to a dull wheel. A dull wheel produces a “rapping” sound created by a “loaded up” area on the cutting surface. Compare what happens to grinding wheels to a piece of sandpaper that is being used to sand a painted surface; the paper loads up, stops cutting, and has to be replaced. As with any machining operation, grinding requires the utmost attention to “Eye Protection.” Be sure to use it when attempting the following instructions. Grinding lathe tools is easy, and the only reason we sell them is to help a beginner get started. Consider a carpenter who did not have the confidence to drive a nail because he was worried about missing the nail and hitting his thumb. He/she would not be in the trade very long! It should not take but a few minutes to make simple cutting tools and only a few seconds to re-sharpen them. A bench grinder does not have to be expensive to work well, but it does require good “wheels” for high- speed steels. Try to find a source for grinding wheels from an industrial supplier. Some of the wheels that come with inexpensive grinders would not sharpen a butter knife. Sixty grit is a good place to start. A wheel dresser is also a necessity. They are relatively inexpensive and are readily available from good hardware stores and on-line resources. FIGURE—A Wheel Dressing Tool and spare “star wheel” sharpening insert. For safety, a bench grinder should be mounted to something heavy enough so it will not move while being used. The tool support must be used and should be set at approximately 7°. Few people have the skill to make tools without a tool support and in essence it is wasted effort. Tool supports are usually made up of two pieces that allow an operator to set the tool rest above or below center. It really does not matter whether its above or below if the support is at 7°. FIGURE—Set tool rest at any height, but at 7° angle from centerline of wheel. The reason tool supports are designed like this is so they can be used for a variety of uses, not just tool bits. What this means is that if the tool support is above or below center it must be adjusted as the wheel diameter changes. When working around grinders it is an absolute necessity to wear EYE PROTECTION. Grinding debris is thrown out at high velocities and can damage not only eyes, but also expensive glasses. Wear safety glasses or a full-face shield. If an operator never sharpened a tool, take a close look at how ours are sharpened. Let us duplicate the right-hand tool on the opposite end of the blank. First dress the wheel by taking the dresser and setting it on the tool support square with the wheel and while applying a light pressure move the dresser back and forth with the grinder running. Unless the wheel is in bad shape, it should be ready to use in a few passes. Grinding Side 1 of the Tool Grinding Side 1 of the Tool Turn off the grinder and set the tool support for approximately 7°. If it is not good at guessing at angles use a pre-sharpened Sherline tool to set the angle. Metal cutting tools are very tolerant on angles Heel FIGURE 3—Heel of the tool. Have a cup of water handy to cool the tool with and set the blank on the tool rest and start grinding side 1.

2/4/2023, 2 : 02 p. m. MEM07032 - THEORY - Use workshop machines for basic operations - PRE LEARNING: Attempt review Página 31 de 58 https://baxter.edfibre.com/gradejet/mod/quiz/review.php ? attempt=147249&cmid=18279 Move the blank back and forth across the face of the wheel until have ground a 10° angle on approximately 3/16" (4 mm) of side 1. This is where the “positive approach” comes in. Unless pushing the tool into the wheel with enough pressure, the tool will bounce around and will never get a good flat cutting surface. It is not necessary to worry about getting the tool too hot. Modern day tool steels do not anneal, and a little discoloration does not affect the tool life in tool room use. Concentrate on holding the 10° angle while moving back and forth. We’ll give this edge a final sharpening later; it’s time for side 2. Grinding side 2 of the tool Grinding side 2 of the tool FIGURE —Grinding side 2. The reason angle B is ground less than 90° is to allow the tool to get into corners. FIGURE 7—Properly ground tool cutting into a corner Side 2 is ground the same way as side 1, moving the tool back and forth until have a point. After getting side 2 ground, cool the tool in the cup of water. The next step is to learn another aspect of tool grinding. It is important to know when have ground the surface up to the cutting edge, especially when re-sharpening lathe tools. Take the tool just ground and bring it up to the wheel at a slightly different angle than ground for this experiment. Watch the point that touches the wheel first and will notice that the sparks will bounce off the cutting edge only where the wheel has ground from top to bottom. FIGURES —Tip not yet ground flat and 8B, Tool ground flat all the way to the tip. This tells when the tool has been sharpened without taking it away to look which allows to grind flat and true surfaces. If sharpen a tool for a Sherline lathe, use a 1/4" square tool blank and keep the cutting edge up to the top of the blank; the tool will come out on center without shims. Grind until sparks just reach tip of tool FIGURE —Grinding the “Hook” into side 3. When grinding tools by hand, on average, the cutting- tip surface of the tool is going to be .005” to .0010” below the top of the tool. This will leave a .010” to .020” tit on the end of the tool when facing off the part. Use the skill have developed grinding the second side now. Set the blank on the support with the 10° (side 1) up. The tool must be brought up to the grinding wheel with a slight angle so do not grind the tip below center. With the tool setting on the rest, move the tool in and grind until seeing sparks bouncing off the cutting edge where the corner of the wheel is lined up with the back part of the 10° face. When this happens, slowly decrease the angle without pushing the tool in any more until sparks bounce all the way to the tip. Stop as soon as this happens. On most of our tool holders can adjust the tool tip height to compensate for the amount that have ground off the top of the tool (generally .005" to .010"). However, there is no adjustment on our compound slide. Therefore, on the compound slide, the cutting tip of the tool needs to be at the same height as the top of the tool blank. It must be inspected, and the surface should be entirely ground. The recommended way is to put more “hook” on the tool than previously suggested, but have found that the slight increase in performance is offset by the problems encountered re-sharpening these tools.

2/4/2023, 2 : 02 p. m. MEM07032 - THEORY - Use workshop machines for basic operations - PRE LEARNING: Attempt review Página 32 de 58 https://baxter.edfibre.com/gradejet/mod/quiz/review.php ? attempt=147249&cmid=18279 FIGURES —Normally recommended “hook” ground into tool and 10B, Simpler method suggested for Sherline tools. To put the finishing touches on the tool, it has to “kiss off” sides 1 and 2 again. Carefully line up side 1 with the wheel and bring it to the wheel in a positive manner with very little pressure; watch for the sparks on the cutting edge. What trying to accomplish is to make the tool set against the wheel on the same plane as when first ground side 1. If the tool is held too rigid, it will not align itself, too loose and it will bounce around. “Breaking” the Point Use the same method on side 2. The tool should be ready to use except for the point. It is recommend putting about a .010 (.2 mm) “break” on the point by holding the tool with the point aimed at the wheel face. Because two angles converge at the point, the angle in relation to the sides is greater. Think about it! FIGURE —Putting a .010" “Break” on the tip of the tool. Top of Tool Angles approximately equal Angles approximately equal This means that if setting the tool flat on the tool rest the tool rest angle would have to be increased to get an even flat. This would not be worth the effort, so the easy way is to free hand it. Start by touching the heel of the tool first, and then change the angle until a slight flat is put on the tip. The angle for holding it at has to be close when starting to get desired results. FIGURE 12—Hand holding the tool to “Break” the point saves resetting the angle on the tool rest. The purpose of this flat is to improve finish and tool life. That is not recommend a large radius on the tip of tools used on small machines. These machines are not rigid enough to get the desired results from this practice and cause “chatter” problems. The finished product should be a right-handed tool, have flat cutting surfaces (except for the radius caused by the wheel), have a slight flat on the tip, and a tip angle of less than 90°. Tools used on lathes such as the shearline will do all their cutting at the tip of the tool because they don’t have the horsepower for 1/4" (6 mm) cuts. That is not recommend using oil stones to improve the edges. After a few minutes use with an occasional dab of cutting oil a properly sharpened tool will hone itself in. The final sharpening to a tool should take place with the wheel cutting the cutting edge of the tool from the top of the tool to the bottom when using bench grinders. These instructions include a great deal of information about how to do what should be a simple operation, but these are very complex instructions to write because we are trying to how to control the hands, not a simple machine. Incidentally, the reason we call a tool a right-handed tool when the cutting edge is on the left is because it is designated by which way the chip leaves the cutting tool. Cutting tools such as left or right-handed tin snips are also designated in this manner because the cut-off falls to the left or right. The left-hand tools are ground the same as right, in the same order with the angles reversed. Boring Tools FIGURE 13—Typical boring tool. Boring tools are the most difficult to grind. They should always be made as rigid as possible. Tool angles around the “tip” can be the same as any cutting tool, but clearances of the tool body must be considered carefully. A tool ground with enough clearance for a finished hole may not have enough clearance to start with when the hole has a smaller diameter. If it must bore a hole in a part that has a lot of work in it, have a tool ready to use that has been checked out on a piece of scrap. Form Tools Form Tools Form tools are used to create a shape the same as the tool. To grind form tools, a pattern of the finished shape should be at hand and there should be some possibility of success with what work with. However, it cannot grind a 1/8" (3 mm) groove into the tool 1/4" (6 mm) deep with a 1/2" (12 mm) wide wheel. FIGURES 14A—A typical form tool made by a custom toolmaking shop, and 14B, a home shop method of achieving the same finished shape in two steps with a tool that can be ground on a bench grinder. This type of tool is usually made by Tool and Cutter specialists that have high shop rates using precision grinders, diamond dressers, and a large variety of wheels available to them.

2/4/2023, 2 : 02 p. m. MEM07032 - THEORY - Use workshop machines for basic operations - PRE LEARNING: Attempt review Página 33 de 58 https://baxter.edfibre.com/gradejet/mod/quiz/review.php ? attempt=147249&cmid=18279 Like any skill, tool grinding is one that must develop with time. It is also the skill that allows to go one step beyond the average hacker. Sharpen Used and Dull Drill Bits (By Hand) Well before head over to the hardware store to buy a brand-new box of drill bits, try this simple technique first and save a lot of time and money! Follow these steps and it can transform the used, dull, chipped, broken, or otherwise useless drill bit, into a prime hole blasting instrument. Sharpening bits is a tricky task.—sharpening by hand on a belt sander or bench grinder. Materials: Materials: 1. A dull or chipped drill bit 2. A bench grinder or belt sander WARNING! WARNING! The hands will be very close to the sharpening device, and dangerously at risk with losing some skin. DO NOT wear gloves DO NOT wear gloves as they can get caught into the sharpening device and pull operator in. Be mindful and deliberate about where position on the sharpening device. The operator should probably wear safety glasses too. Step 1: Know the Drill Bit Step 1: Know the Drill Bit There are many features on a drill bit that can be defined. For speed sake, were only worried about 3 basic features on the bit: the lip, land, and chisel.

2/4/2023, 2 : 02 p. m. MEM07032 - THEORY - Use workshop machines for basic operations - PRE LEARNING: Attempt review Página 34 de 58 https://baxter.edfibre.com/gradejet/mod/quiz/review.php ? attempt=147249&cmid=18279 The "lip" is what does the actual cutting. The two lips on the twist drill should be symmetric if an equal cutting is to be done while drilling. If one lip is favoured while sharpening, it will become bigger than the other and most of the cutting will be performed on one side of the bit. This is bad as it makes non-straight holes. The "land" or "landing" is what follows the lip and will support the sharp edge while the bit is cutting. The landing must be angled in such a way that it leaves clearance between the part trying to drill and the lip. However, too much angle subtracts support from the lip, and will cause the bit to chip more often, especially on the corners. The "chisel" is the line which is created when the landing from both sides of the twist drill intersect. In truth, this area does no cutting motion. Don't think of it as a true chisel. In fact, while the drill is turning and being forced down into the work-piece, the chisel smears the wood or metal drilling into the lips. For this reason, it is especially important to create a very small chisel. Step 2: Understand Why Drills Chip and Dull Step 2: Understand Why Drills Chip and Dull To know how to better sharpen the bit, should know the reason for doing this. Chipped bits are caused because the landing force behind them cannot support the forces exerted by the drilling operation. So, make sure the landing has a curved shape to it. Curved shapes add support to the lip. Dull bits are caused when either the chisel is having trouble smearing the material to the lip and needs to be re-defined on the face of the bit. Or the lip is rolling over and needs to be re-sharpened so that it pushes directly into the workpiece. Step 3: Prepare the Bit Step 3: Prepare the Bit Run a file across any burrs that bay be on the shank of the drill bit. If anything were to go wrong, and the bit were to slip in the fingers, would not want these nasty burrs cutting into the skin. Step 4: Choose the Sharpening Tool Step 4: Choose the Sharpening Tool Either a bench grinder or a belt sander will work for sharpening bits. Just make sure that the guards on either one of these machines is less than 1/8" away from the belt or wheel so that the bit does not get caught between the guard! Step 5: Practice Holding the Bit Step 5: Practice Holding the Bit

2/4/2023, 2 : 02 p. m. MEM07032 - THEORY - Use workshop machines for basic operations - PRE LEARNING: Attempt review Página 35 de 58 https://baxter.edfibre.com/gradejet/mod/quiz/review.php ? attempt=147249&cmid=18279 Start in a comfortable position with the hand against the machine support and take the drill bit into both hands. Hold the bit at a 60-degree angle to the face of the belt sander. Place the end of the landing so that it is directly against the belt. Use steps 5-7 to move the bit across the belt into the finish position. Notice in these two pictures how little difference there is between the start and finish sharpening positions. Steps 5-7 are simultaneous steps to get to that finish position but notice how the only hand that moves is the left hand. The right hand stays stationary, with only the fingers guiding the drill bit. Step 6: Cut the Landing Step 6: Cut the Landing Cut the landing by raising the left hand while applying pressure to the sharpening device. Step 7: Shape the Chisel Step 7: Shape the Chisel By moving the left hand towards the right, creating the chisel angle. Practice a few times until the chisel angle is 45 degrees from the lip. Step 8: Shape the Landing Step 8: Shape the Landing By rotating or rolling the bit counter clockwise, creating a rounded landing that gives more support to the lip. Step 9: Combine Cutting, Shaping, and Rotating Step 9: Combine Cutting, Shaping, and Rotating Combine all three movements while sharpening to make the perfect cut on the drill face. Repeat this step a couple of times and rotate the drill bit 180 degrees in the hand to sharpen the other lip. WARNING: WARNING: this procedure will heat up the drill bit face. Have a cup of cool water by the belt sander or bench grinder to dip the tip of the drill bit into to cool it off. Step 10: Repetition Step 10: Repetition It may take a couple dozen times to get the two lips of the drill bit symmetric. That is normal and requires a lot of patience. But keep on trying! Often rotate which side of the bit is working on so that do not favour one side over the other. Always make deliberate cuts, do not try to "feather" a sharp tip by pressing the drill bit lightly into the sander or grinder. This almost always leads to uneven lips or will cause to roll the lip so that it no longer cuts. 2.3 2.3 Install tools according to procedures Install tools according to procedures Correct Lathe Cutter Setup Correct Lathe Cutter Setup Using a Lathe is one of the first skills learned by a beginning Machinist. There are a lot of tips and tricks that are not readily available to everybody. Here is one simple trick that is fundamental to getting a part properly turned. Setting the outside cutter to the proper height is something rather elusive to a good many aspiring lathe users. Step 1: Get the Right Tool Step 1: Get the Right Tool All the Setup steps are done with the lathe powered off. Make sure there is no chance of accidentally turning on the machine. All is needed is a simple metallic ruler, about 6 inches long. They are only a couple of dollars. They are available at any hardware store or home improvement chain in the measuring tool isle. In a pinch any metallic straight flat "Ruler-Like" object would do. Step 2: Chuck the Part Step 2: Chuck the Part Load the cylindrical part in the lathe. Here is an extra tip: as tighten the chuck rotate the part with the hand lightly, as the friction just grips the part, keep tightening with the key, until it does not move any more. This helps centering the part and gives a truer alignment along the axis of the lathe spindle. It will be less wobbly as it turns...Also it will be less waste as the truing cut taken is less. Step 3: Load Cuter Tool Step 3: Load Cuter Tool Install a regular cutting bit in the tool post. Make sure it is the tool that intend to use for the first cut. This tool height procedure needs to be repeated for every tool that will be used in outside turning. Install the tool tight in the holder and set the holder perpendicular to the part. Make sure the tool seat is clean of debris otherwise will get a false setup that is not repeatable.

2/4/2023, 2 : 02 p. m. MEM07032 - THEORY - Use workshop machines for basic operations - PRE LEARNING: Attempt review Página 36 de 58 https://baxter.edfibre.com/gradejet/mod/quiz/review.php ? attempt=147249&cmid=18279 Step 4: Set Ruler in Position Step 4: Set Ruler in Position Lock the cam on the tool post Bring the lathe Carriage close to the chuck end of lathe and using the cross-feed wheel get the tool closer to the part until can pinch the ruler against the part to be turned. Do not tighten too much as it will damage the ruler. Just tight enough so that the ruler does not fall off and stays pinched between the tool and the surface of the part. Step 5: Reading the Ruler Step 5: Reading the Ruler If the tool height is set correctly, the ruler will be vertical. Just as in the first picture. If the ruler is tilting to the right, then the cutter is sitting too low. Release tool post cam and Adjust the height wheel on the tool post to get it to the right height. See second picture If the ruler is tilted to the left toward the back of the lathe the tip of the cutter is above the centre line of the part. Release cam, and Again spin the knurled wheel to drop the tool just slightly. Adjusting might take a few tries until the ruler is apparently straight up and down (vertical) as viewed from the back of the lathe. In time the operator will develop a real knack for setting the tool straight in just one or two tries. If the ruler is vertical, set tight the locking nut sitting over the adjusting knurled wheel. The setting will be preserved Step 6: Take First Test Cut Step 6: Take First Test Cut Release cam and remove cutter. Install it again longitudinally along the lathe axis and flip it around to take a facing cut. Take a light facing cut. If the tool is not exactly on centre it will leave a little nib on the part, see photo. If the nib is left because the tool is too low or too high. Stop lathe, back off the carriage and repeated the above steps. Use small increments while adjusting the Knurled wheel on the tool holder. Step 7: Final Adjustments Step 7: Final Adjustments The setup is repeatable. Make sure all the surfaces are clean... Do this for all the tools that plan to use turning the part. It is useful to have multiple holders that once set can be just dropped in place. This procedure should be followed any time there is a tool change done. Having several holders with the tools already set at the right height will save the time. The picture above illustrates a perfectly turned part that is about to be milled.

2/4/2023, 2 : 02 p. m. MEM07032 - THEORY - Use workshop machines for basic operations - PRE LEARNING: Attempt review Página 37 de 58 https://baxter.edfibre.com/gradejet/mod/quiz/review.php ? attempt=147249&cmid=18279 How to Set up a Lathe Cutting Tool How to Set up a Lathe Cutting Tool Positioning the cutting point correctly and setting up a lathe cutting tool are critical to CNC turning process, greatly affects the removal rate, cutting efficiency and surface finish. Watch the video: Working with a Lathe Essential Machining Skills: Working with a Lathe, Part One Boring Bar secured in gang tool holding set up. Drill secured in gang tool holding set up. Threading tool secured in gang tool holding set up. Parting tool secured in turret tool holding set up. 2.3 2.3 Set guards and adjust, as required Set guards and adjust, as required

2/4/2023, 2 : 02 p. m. MEM07032 - THEORY - Use workshop machines for basic operations - PRE LEARNING: Attempt review Página 38 de 58 https://baxter.edfibre.com/gradejet/mod/quiz/review.php ? attempt=147249&cmid=18279 By using the machine in a workshop, we must understand What some good safety principles are to follow when using a lathe. What are some good safety principles to follow when using a lathe? Wear appropriate CSA-certified safety glasses. It may be necessary for others in the area to wear safety glasses too as objects will fly off the work. Make sure entanglement hazards are removed (e.g. loose clothing, jewellery, etc.). Tie back and confine long hair. Keep the floor free from obstructions, or slip hazards. Make sure the lathe has a start/stop button within easy reach of the operator. Make sure the lathe has an emergency stop button (e-stop). Follow job specifications for the speed, feed, and depth of cut for materials being turned. Make sure all work runs true and cantered. Centre-drill work deeply enough to provide support for the piece while it is turning Secure and clamp the piece being worked. Adjust tool and tool rest so that they are slightly above the centre of the work. Use a lifting device to handle heavy chucks or work. Refer to Materials Handling for additional information. Inspect chucks for wear or damage. Flying pieces can be very dangerous. Remove chuck wrench immediately after adjusting chuck. Use a barrier guard when operating the lathe in semi-automatic or automatic mode Guard all power transmission parts. Remove all tools, measuring instruments and other objects from saddle or lathe bed before starting machine. Keep all lathe cutting tools sharp. Ensure that the chip and coolant shields are in place. Shut off the power supply to the motor before mounting or removing accessories. Stop lathe before taking measurements of any kind. Use a vacuum, brush or rake to remove cuttings only after the lathe has stopped moving. Keep working surface clean of scraps, tools and materials. Keep floor around lathe clean and free of oil and grease. Less than 50 per cent of industrial machines are properly safeguarded. The unfortunate result is thousands of reported amputations, lacerations, crushing injuries, and abrasions, and hundreds of accidents that result in deaths each year. The number of moving parts and motions involved in producing components on lathes and grinders and the proximity of operators during setup and operation can create particularly precarious situations. Hazards to the operator and other employees in the machine area exist at the point of operation because of the very nature of the process; numerous rotating parts can create in-going nip points, pulling in clothing, hair, or fingers; chips and parts can fly off during production, endangering vision and creating a trip hazard around the machine; and coolant can spatter, causing slip hazards. To provide a safe work environment, a company needs to keep current on—and follow—codes regarding proper machine guarding and personal protection equipment. All employees should be aware of the safety requirements for each machine and receive frequent reminders that safety procedures are expected to be followed at all times. Shield Shop Employees Shield Shop Employees Shields secured to the lathe, probably the most common safety practice, can protect operators from several dangers, including the rotating chuck and tool, cross-slide movements, and the operation of the magnetic base. A hinged chuck can prevent items from inadvertently getting entangled with the chuck. Some chuck shields are constructed entirely of steel; some have a steel frame with a visibility window to allow viewing during operation; and others are constructed of transparent, high-impact polycarbonate, providing a full view of the operation. Chip/coolant shields can stop flying chips or parts from reaching the operator’s upper body or accumulating on the floor where they can create a slip hazard along with coolant overspray. Cross- slide travel shields travel along with the sliding carriage to provide continuous protection. Even if the operator is wearing proper personal protective equipment flying chips and coolant can create hazards, and the additional protection is recommended. Most shields can be interlocked with the machine’s electrical system to prevent operation when they are not in place. Swinging a shield from its protective position will break its electrical connection and cut the power, forcing a quick coast down. Lathe components like lead screws, cam shafts, and traverse rods that rotate slowly may appear to be harmless but they can hold a lot of torque, and their rotational energy can capture, pull-in, and crush items that get too close.

2/4/2023, 2 : 02 p. m. MEM07032 - THEORY - Use workshop machines for basic operations - PRE LEARNING: Attempt review Página 39 de 58 https://baxter.edfibre.com/gradejet/mod/quiz/review.php ? attempt=147249&cmid=18279 Telescopic stainless-steel sleeves can cover these types of rotating components allowing them to function while providing a safety barrier between the action and employees. A small amount of carriage travel will be lost, and the sleeves will need to be cleaned and lubricated occasionally. Boost the Power of ‘Stop’ Boost the Power of ‘Stop’ Electrical updates for lathes can include the addition of emergency stop (e-stop) buttons that are main power disconnect switches to stop all machine activity. American National Standards Institute (ANSI) standards say that an e-stop is required on any machine that will tolerate a quick stop. Some lathes have a true emergency stop built into halt operation in less than a second, but most require several seconds to cease functions. An electronic motor brake can improve coast-down time, in some cases from 15 seconds to 3 seconds, which can make a significant difference in an emergency. The red, mushroom-shaped button should have a manual latch that keeps it down once it is pushed to prevent machine operation by the regular controls. Once the e-stop is engaged, the latch keeps it down until a manual quarter-turn releases the latch and allows the machine’s controls to again command the machine’s actions. Kick plates or grab-wires that go across a machine can facilitate an emergency shut- down if there is potential for an operator’s hands to be caught. E-stops need to be readily accessible. An e-stop button should be within easy reach at each location on the machine that requires operator interaction. When more than one individual is involved, each person should have his or her own e-stop. A spring-loaded button indicates that there is a magnetic motor start or anti-restart, also known as drop- out protection, to prevent a machine from unexpectedly resuming operation after shutting down because of power loss. Avoid Flying Wrench Risks Avoid Flying Wrench Risks Misuse of a standard chuck wrench is a common source of lathe accidents. When a lathe is not in use, a seemingly logical and typical but unsafe storage place for the chuck wrench is in the chuck. The danger is that an operator may turn on the lathe without checking to see where the wrench is located. It can fly out of the chuck, and across the shop, causing a serious injury to anyone in the area. Spring-loaded, self-ejecting chuck wrenches, available in several sizes, can eliminate this hazard by not allowing the wrench to remain in the chuck. They are available in several sizes. Onsite risk assessments and machine surveys can help a company get and stay up to code. Based on ANSI B11.0-2015, a risk assessment provides a hazard score with the risk level for each machine, suggestions to lower the hazard level, and detailed documentation to outline the results. A machine safeguarding assessment audits each machine for code compliance and provides customized proposals that suggest specific products and services to bring the machine into compliance. Safety principles when working with a lathe, according to the Canadian Centre for Occupational Health and safety (CCOHS), include: Wear appropriate safety glasses during operation. Remove entanglement hazards such as loose clothing and jewelry. Keep the floor should be clear of obstructions and slip hazards. Ensure the e-stop button is within easy reach of the operator. Follow job specifications for speed, feed, and depth of cut for the material being turned and take all necessary steps to ensure that work is run true and centered. Centre drill work deeply enough to provide support for the piece while it is turning. Secure and clamp the workpiece. Adjust the tool and tool rest so they are slightly above the centre of the work. Use a lifting device to handle heavy chucks or work. Inspect chucks for wear or damage to help prevent flying workpieces. Use a barrier guard when operating a lathe in a semi-automatic or automatic mode.

2/4/2023, 2 : 02 p. m. MEM07032 - THEORY - Use workshop machines for basic operations - PRE LEARNING: Attempt review Página 40 de 58 https://baxter.edfibre.com/gradejet/mod/quiz/review.php ? attempt=147249&cmid=18279 Guard all power transmission parts. Remove all tools, measuring instruments, and other objects from the saddle or lathe bed before starting the machine. Keep all cutting tools sharp. Ensure that the clip and coolant shields are in place. Shut off the power supply to the motor before mounting or removing accessories. Stop the lathe before taking measurements of any kind. Use a vacuum, brush, or rake to remove cuttings only after the lathe has stopped moving. Keep working surfaces clean of scrap, tools, and materials. Keep the floor around the lathe clean and free of oil and grease. A metal lathe is a precision turning machine that rotates a metal rod or irregular-shaped material while a tool cuts into the material at a preset position. Similar to the wood lathe, the metal lathe normally consists of a headstock and base that houses one or more spindles on which a work holding device (chuck) can drive the stock and the cutting tools can remove metal, producing mainly cylindrical and conical shapes. There are basically two main types of metal lathes: Lathes for shaft work (material supported at two or more locations) and lathes for bar (bar stock introduced through the spindle) or chucking work (individual pieces secured at the chuck). Shaft lathes include engine lathes, vertical-shaft lathes, and turning centers. Bar and chucking lathes include turret lathes (vertical and horizontal) and vertical boring mills. Hazard Severe injuries and death can occur primarily from being caught in or struck by rotating parts. An operator can be pulled into the lathe from working perilously close (e.g., polishing a slotted shaft with emery cloth) or wearing gloves, loose clothing, loose hair, jewelry, etc. Trapping spaces are also created between the cutting tool, its mounting, and the work piece or chuck. Projected parts or material such as chuck keys or unsecured work pieces can also strike nearby operators. Flying chips and coolant also present hazards to the operator. Solution Avoid wearing gloves, loose clothing, long hair, jewelry, or other dangling objects near lathe operations. Pay close attention to work pieces that have keyway slots or other surface profiles that may increase the risk of entanglement. Assess the need to manually polish (e.g., emery cloth) rotating material. If necessary, consider milling keyways or other profiles after polishing or use emery cloth with the aid of a tool or backing boards. Always use a brush or tool to remove chips. Cover work-holding devices (chucks) and tool trapping space hazards (especially in automatic or semiautomatic modes) with secured fixed or movable guards or shields. Vertical lathes and controlled turning centers are normally provided with fixed or interlocked guarding that prevents access during the automatic cycle. Make sure all work pieces and work-holding devices are secure and free from defects. Remove the chuck key from the chuck after securing the material. A good rule is to never take the hand off the chuck key until set it back onto a table. Consider using a spring-loaded wrench. Provide a chip/coolant shield unless another guard or shield already provides protection. This does not replace the need for eye and face protection, however. Note: Guards or shields used to protect lathe operators from projected parts must either be from the manufacturer or, if fabricated in-house, meet or exceed the same impact-resistance specifications as the original manufactured part. Various materials (such as polycarbonates) may possess different and less- effective impact-resistance characteristics than the original materials used by the manufacturer In one case, an operator was killed when the bell casting on a lathe came loose while the lathe was turning and was propelled through two, 1/2-inch-thick Plexiglas windows. The Plexiglas was installed as a replacement for the manufacturer’s original composite window on the machine’s door frame. The operator was fatally struck in the head and neck as he was looking through the window. The manufacturer’s original observation window was made of a 1/4-inch-thick laminated glass plate with a 1/2-inch-thick polycarbonate window, separated by an approximately 1/4-inch air space. The original window was replaced with Plexiglas material that had a lower impact resistance than the polycarbonate shield originally supplied by the machine manufacturer. Polycarbonates are a family of various polymers that includes Macrolux, Lexan, Relex, Replex, Dynaglass, Exolite, Verolite, Cyrolon, and Makrolon. These materials have different impact- resistance characteristics for different thicknesses and surface areas. It is important to note that increasing the thickness beyond a certain level does not always improve or increase the impact resistance. Some studies have shown polycarbonate degrades due to age and prolonged contact with metalworking fluids and lubricants. Milling machine A milling machine removes material from a work piece by rotating a cutting tool (cutter) and moving it into the work piece. Milling machines, either vertical or horizontal, are usually used to machine flat and irregularly shaped surfaces of metal and other tough materials, and can be used to drill, bore, and cut gears, threads, and slots. The vertical mill, or “column and knee” mill, is the most common milling machine found in machine shops today. The general construction of this mill includes the quill, which moves vertically in the head and contains the spindle and cutting tools. The knee moves up and down by sliding parallel to the column. The column holds the turret, which allows the milling head to be positioned anywhere above the table. Hand wheels move the work table to the left and right (X axis), in and out (Y axis), in addition to moving the knee, saddle, and worktable up and down (Z axis). Hazard Hazard Serious injuries and entanglement can occur if the operator contacts the rotating cutter. Metal shavings and lubricating/cooling fluids might also present a risk from the point of operation area. Material might spin and strike an operator if the material is not secured to the table. Injuries can also occur from a projected wrench if it is left in the spindle. Solution Secure the work piece, either by clamping it onto the work table or by clamping it securely in a vise that is clamped tightly to the table. Note: Computer numerical controlled (CNC) mills are rapidly replacing manually fed machines, mainly for versatility and production reasons. The increased automation does not normally require the operator to move the hand wheels (like the traditional machines), so operators must always keep their hands away from the point of operation. A guard or shield that encloses the cutter head or milling bed may be considered to protect the operator from the cutting area, flying metal shavings, and lubricating or cooling fluids. Make sure the tightening wrench is removed from the mill.

2/4/2023, 2 : 02 p. m. MEM07032 - THEORY - Use workshop machines for basic operations - PRE LEARNING: Attempt review Página 41 de 58 https://baxter.edfibre.com/gradejet/mod/quiz/review.php ? attempt=147249&cmid=18279 CNC router and cutting tables CNC router and cutting tables Computer numerical controlled (CNC) routers remove material from a work piece by rotating a cutting tool (cutter) and moving it into the work piece, but operate at higher speeds than milling machines. CNC routers are usually used to cut or shape more ornate designs into thinner and softer materials such as wood, plastic, and soft metals like aluminum. CNC cutting tables use plasma, lasers, or high-powered waterjets instead of a rotating tool, to cut and engrave metal, and other hard or soft materials. CNC routers and cutting tables, either vertical or horizontal, are commonly found in wood shops and metal fabrication shops, and vary in size to accommodate smaller work pieces, or large sheet stock. The general construction of these highly automated machines consists of a stationary table or bed featuring a turret (Z axis) with a spindle or cutting tip that moves back and forth on the rails (X axis) of a moving gantry (Y axis) above the work piece. Depending on size and application, CNC routers and cutting tables can be completely open, or partially or totally enclosed by interlocked metal enclosures equipped with thermoplastic vision panels. Operators initiate start/stop sequences from a control console that is usually a safe distance away from the point of operation. Hazard Serious lacerations, fractures, burns, and amputations can occur if an operator contacts the rotating cutting tool, or cutting tip/nozzle during operation. Fractures, lacerations, and even death can occur to the operator and others in the area from being struck by ejected material, parts, and tooling. Metal shavings and lubricating/cooling fluids might also present a risk from the point of operation area. Plasma and laser cutting produces toxic fumes and particulates, and also produces intense light and/or radiation that can cause eye damage and skin burns. Sparks and hot slag from these hot processes can ignite nearby combustibles. A potential for shock and electrocution hazards exists due to the high operating voltages of plasma and laser cutters. Dust accumulation from the laser cutting of titanium, aluminum, zinc, and their alloys can cause a thermite reaction when mixed with the dust of oxidized iron or copper and cause a combustible dust explosion. Water used in high-powered jet cutting is compressible at the pressures involved and can store energy just as compressed air does. The use of pool/ spa chemicals to control bacteria in the water tanks of waterjet cutters can cause eye injuries. Crushing injuries can occur if an operator, or any part of the body is caught between the stationary and moving parts of the machine. The operator, or others in the area, can be struck by the traveling gantry. Unexpected movement or startup caused by faults in the control system can also cause serious injury when changing tools and moving material and parts. Solution When CNC routers are not fully or partially enclosed, fixed barrier guards can protect the operator and others in the area from point of operation hazards at the cutting tool and from ejected parts. Automatic loading and unloading methods, automatic tool changing, light curtains, or pressure sensitive mats that shut off the machine can further reduce the exposure to the point of operation from unexpected movement or startup. Safe distance, barrier guards, or electronic safety devices can prevent others in the area from getting to close to the moving gantry, and other moving parts of the machine. Ensure adequate ventilation is provided to exhaust hazardous fumes and particulates. Keep dust collectors clean. Do not allow the accumulation of flammable or combustible materials and debris such as metal dust, baled paper, bulk sulfur, and oily rags. Keep a fire extinguisher readily available in the immediate area. Use proper personal protective equipment to protect operators and others from hazards caused by hot processes such as hearing protection, safety glasses and/or face shields, shock resistant gloves, and welding curtains. Establish a laser safety program and appoint a Laser Safety Officer in accordance with ANSI Z 136.1 when workers use or are exposed to Class IIIB or Class IV lasers. What are some things should avoid doing? What are some things should avoid doing? Do not wear gloves, rings, watches or loose clothing. Tie back and confine long hair. Do not lean on machine. Stand erect. Keep the face and eyes away from flying chips. Do not make adjustments while the machine is operating. Wait until the machine has come to a complete stop. Do not place hands on work turning in the lathe. Do not use calipers or gauges on a workpiece while machine is moving. Do not make heavy cuts on long slender pieces because the work could bend and fly out of the lathe. Do not leave lathe unattended while it is running. The procedure when equipment safety guard not functioning or removed The procedure when equipment safety guard not functioning or removed Mechanical equipment (plant, machinery and hand-held power tools) can cause serious injuries, including open wounds, fractures and amputations. Some injuries can result in death. Sprains and strains often result when mechanical equipment is used incorrectly. Bad working posture contributes to many such injuries. The most common mechanical equipment injuries are to hands and fingers, which may be cut, sprained, dislocated, broken, crushed, or cut off by machinery or tools. Eye injuries can be caused by heat or radiation or by objects thrown from moving mechanical parts. Key point Key point The workplace must have a maintenance program to ensure that all equipment and machines are in safe working order. Mechanical equipment injuries can cause long periods of time off work, and sometimes permanent disability. Many injuries happen in the construction, agricultural and manufacturing industries. When working with mechanical equipment, personal protective equipment may include protective gloves, arm guards, safety glasses, hard hats, and safety boots. Guards Guards Guards attached to mechanical equipment protect from the moving parts of machines. Machine guards must never be removed and if a guard is damaged or missing, the machine must not be used until it can be repaired or replaced. A missing or damaged guard must be reported at once. If guards are removed during cleaning, make sure they are replaced and checked by an authorized person before the machine is used. Never start machinery during cleaning.

2/4/2023, 2 : 02 p. m. MEM07032 - THEORY - Use workshop machines for basic operations - PRE LEARNING: Attempt review Página 42 de 58 https://baxter.edfibre.com/gradejet/mod/quiz/review.php ? attempt=147249&cmid=18279 Question 4 Complete Marked out of 1.00 'Locking out' equipment 'Locking out' equipment Locking out is one way of stopping electrically powered machinery from starting during maintenance. A lock is attached to the machine switch so it cannot be turned on. The person working with the machine should hold the only key to the lock. A lock must only be removed by the person who attached it to the equipment or machinery. Procedures must be put in place for the removal of the lock should that person not be available (for example, if there has been a change of shift workers, or if the person authorized to remove the lock has been called away). 'Danger' and 'Out of Service' tags 'Danger' and 'Out of Service' tags Red and black 'DANGER' tags are designed for the protection of individual people. The only person permitted to remove a personal 'DANGER' tag is the person whose name is on the tag. Yellow and black 'OUT OF SERVICE' tags are used to prevent accidents or damage to machinery that is out of service for repairs. All faulty equipment should be tagged so that it cannot be used until it is replaced or repaired. The safe work procedures for removal of 'DANGER' and 'OUT OF SERVICE' tags at all workplace must be followed. Review questions Write detailed responses to the following questions Write detailed responses to the following questions 1. State three (3) safety precautions, relating to machine safety machine safety, which should be observed when using a lathe. NOTE: NOTE: Do not state any safety precautions relating to personal safety equipment. E.g. safety glasses, etc. 1. Make sure the lathe has an emergency stop button (e-stop). 2. Centre-drill work deeply enough to provide support for the piece while it is turning 3. Secure and clamp the piece being worked. 2. Name three measuring tools that you would use when machining? The measurement tools that we are going to use in machining are numerous, although depending on the work that we are doing, we will use more than others, for example squares, templates and gauges, goniometer, dial indicator, feeler gauge, alexometer, vernier. calibrate. , micrometer, gauge or height gauge, pattern blocks among others. 3 tools and how to use them are described below. 1) A micrometer is a tool that measures the size of an object by enclosing it. Some models can even perform measurements in units of 1 μ m. Unlike manual calipers, micrometers adhere to the Abbe principle, allowing them to make more precise measurements. In general, the term "micrometer" refers to outside micrometers. 2) Vernier caliper, an instrument for making very precise linear measurements introduced in 1631 by Pierre Vernier of France. It uses two graduated scales: a ruler-like main scale and a specially graduated auxiliary scale, the vernier, which slides parallel to the main scale and allows readings of a division fraction on the main scale. Vernier calipers are widely used in scientific laboratories and manufacturing for quality control measurements. 3) A goniometer is a device in the form of a semicircle or circle graduated at 180º or 360º, used to measure or construct angles. This instrument allows you to measure angles between two objects, such as two points on a coast, or a star, usually the Sun, and the horizon. With this instrument, if the observer knows the elevation of the Sun and the time of day, he can determine his latitude quite precisely by means of simple mathematical calculations. 3. State three reasons for using coolant when using workshop machines? Coolants are an instrumental part of machining, including grinding, milling, and turning. They help extend tool life and provide an improved surface finish of the parts being machined. Understanding the role and types of coolant help you select a coolant that is the right fit for your machine and operation. By properly maintaining the concentration levels of your coolant, you extend not only the life of the coolant but also your tools and machine. The critical functions of coolant in the machining process include: 1. Reducing and removing the heat build-up in the cutting zone and workpiece 2. Provides lubrication to reduce friction between the tool and removal of the chips 3. Flushes away chips and small abrasive particles from the work area and protects against corrosion. 4. Why is it necessary to thin the web of a drill after the drill has been shortened by repeated sharpening? The rake angle of the cutting edge of a drill reduces toward the centre, and it changes into a negative angle at the chisel edge. During drilling, the centre of a drill crushes the work, generating 50–70% of the cutting resistance. Web thinning is very effective for reduction in the cutting resistance of a drill, early removal of cut chips at the chisel edge, and better biting.

2/4/2023, 2 : 02 p. m. MEM07032 - THEORY - Use workshop machines for basic operations - PRE LEARNING: Attempt review Página 43 de 58 https://baxter.edfibre.com/gradejet/mod/quiz/review.php ? attempt=147249&cmid=18279 Question 5 Correct Mark 1.00 out of 1.00 Question 6 Complete Marked out of 1.00 Information Clearly label the following features of the twist drill shown below. Flute La Your answer is correct. Review questions Write detailed responses to the following questions Write detailed responses to the following questions 6. Why when a lathe is not in use, does a seemingly logical and typical but unsafe storage place for the chuck wrench is in the chuck? Misuse of a standard chuck wrench is a common source of lathe accidents.When a lathe is not in use, a seemingly logical and typical but unsafe storage place for the chuck wrench is in the chuck. The danger is that an operator may turn on the lathe without checking to see where the wrench is located. It can fly out of the chuck, and across the shop, causing a serious injury to anyone in the area. Spring-loaded, self-ejecting chuck wrenches, available in several sizes, can eliminate this hazard by not allowing the wrench to remain in the chuck. They are available in several sizes. 7. Fill in the missing words: When machine guards removed and if a guard is damaged or missing, the machine must not be used until it can be repaired or replaced . 8. What are the correct Lathe cutter setup 7 steps? Step 1: Get the Right Too: All the Setup steps are done with the lathe powered off. Make sure there is no chance of accidentally turning on the machine. Step 2: Chuck the Part: Load the cylindrical part in the lathe. Step 3: Load Cuter Tool: Install a regular cutting bit in the tool post. Make sure it is the tool that intend to use for the first cut. Step 4: Set Ruler in Position: Lock the cam on the tool post. Step 5: Reading the Ruler: If the tool height is set correctly, the ruler will be vertical. Step 6: Take First Test Cut: Release cam and remove cutter. Install it again longitudinally along the lathe axis, and flip it around to take a facing cut. Step 7: Final Adjustments: If you wanted to take a facing cut only, then you are done, if not and you need to turn a part along its axis, you need to take the tool out and set it up again perpendicular to the part. 9. What are some good safety principles to follow when using a lathe? - Do not wear gloves, rings, watches or loose clothing. Tie back and confine long hair. - Do not lean on machine. Stand erect. Keep the face and eyes away from flying chips. - Do not make adjustments while the machine is operating. Wait until the machine has come to a complete stop. - Do not place hands on work turning in the lathe. - Do not use calipers or gauges on a workpiece while machine is moving. - Do not make heavy cuts on long slender pieces because the work could bend and fly out of the lathe. - Do not leave lathe unattended while it is running. SECTION 3 OPERATE MACHINE SECTION 3 OPERATE MACHINE 3.1 Mount material to be machined and secure using clamping device/ 3.1 Mount material to be machined and secure using clamping device/

2/4/2023, 2 : 02 p. m. MEM07032 - THEORY - Use workshop machines for basic operations - PRE LEARNING: Attempt review Página 44 de 58 https://baxter.edfibre.com/gradejet/mod/quiz/review.php ? attempt=147249&cmid=18279 appropriate to the material and work requirements appropriate to the material and work requirements Lathe Accessories Lathe Accessories a. Chucks. (1) General. Workpieces are held to the headstock spindle of the lathe with chucks, faceplates, or lathe centers. A lathe chuck is a device that exerts pressure on the workpiece to hold it secure to the headstock spindle or tailstock spindle. Commonly used with the lathe are the independent chuck, the universal scroll chuck, the combination chuck, the hollow headstock spindle chuck, the lathe tailstock chuck, the collet chuck, and the step chuck. (2) Independent Chuck. (a) The independent chuck (figure 14) generally has four jaws which are adjusted individually on the chuck face by means of adjusting screws. The chuck face is scribed with concentric circles which are used for rough alignment of the jaws when chucking round workpieces. The final adjustment is made by turning the workpiece slowly and using gages to determine its concentricity. The jaws are then readjusted as necessary to align the workpiece to desired tolerances. (b) The jaws of the independent chuck may be used as in figure 14, or may be reversed so that the steps face in the opposite direction; thus, workpieces can be gripped either externally or internally. The independent chuck can he used to hold square, round, octagonal, or irregular shaped workpieces in either a concentric or eccentric position due to the independent operation of each jaw. (c) Because of its versatility and capacity for fine adjustment, the independent chuck is commonly used for mounting workpieces that require extreme accuracy. (3) Universal Scroll Chuck. (a) The universal scroll chuck (figure 14 on the previous page) usually has three jaws which move in unison as an adjusting pinion is rotated. The advantage of the universal scroll chuck is its ease of operation in centering the work for concentric turning. This chuck is not as accurate as the independent chuck but, when in good condition, it will center the work automatically within 0.003 of an inches of complete accuracy. (b) The jaws are moved simultaneously within the chuck by means of a scroll or spiral threaded plate. The jaws are threaded to the plate and move an equal distance inward or outward as the scroll is rotated by means of the adjusting pinion. Since the jaws are individually aligned on the scroll, the jaws cannot be reversed. However, the chuck is usually supplied with two sets of jaws which can be interchanged. (c) The universal scroll chuck can be used to hold and automatically center round or hexagonal workpieces. Having only three jaws, the chuck cannot be used effectively to hold square, octagonal, or irregular shapes. (4) Combination Chuck. A combination chuck combines the features of the independent chuck and the universal scroll chuck and can have either three or four jaws. The jaws can be moved in unison on a scroll for automatic centering or can be moved individually if desired by separate adjusting screws. (5) Drill Chuck. The drill chuck is a small universal-type chuck which can be used in either the headstock spindle or in the tailstock for holding straight-shank drills, reamers, taps, or small- diameter workpieces. The drill chuck has three or four hardened steel jaws which are moved together or apart by adjusting a tapered sleeve within which they are contained. The drill chuck is capable of centering tools and small-diameter workpieces to within 0.002 or 0.003 of an inch when firmly tightened. (6) Hollow Headstock Spindle Chuck. The hollow headstock spindle chuck is similar to a drill chuck but is hollow. It is provided with threads to screw it onto the headstock spindle nose. This chuck can be used to hold rods, tubes, or bars which are passed through the headstock spindle. It is generally capable of centering workpieces to an accuracy of 0.002 of an inch. (7) Collet Chuck. (a) The collet chuck is the most accurate means of holding small workpieces in the lathe. The collet chuck consists of a spring machine collet and a collet attachment which secures and regulates the collet on the headstock spindle of the lathe. (b) The spring machine collet (figure 15 on the following page) is a thin metal bushing with an accurately machined bore and a tapered exterior. The collet has three lengthwise slots to permit its sides to be sprung slightly inward to grip the workpiece. To grip the workpiece accurately, the collet must be no more than 0.001 inch larger or smaller than the diameter of the piece to be chucked. For this reason, spring machine collets are generally supplied in sets with various capabilities in 1/16, 1/32, or 1/64 inch increments. For general purposes, the spring machine collets are limited in capacity to 1 inch in diameter. (c) The collet attachment which, with the spring machine collet, forms the collet chuck and consists of a collet sleeve, a draw bar, and a handwheel or hand lever to move the draw bar. The collet is fitted to the right end of the headstock spindle. The draw bar passes through the headstock spindle and is threaded to the spring machine collet. When the draw bar is rotated by means of the handwheel, the collet is pulled inward and the collet walls are cammed together by contact with the collet sleeve, (d) Collet chucks are usually standard equipment on toolroom-type engine lathes and on horizontal turret lathes. Spring machine collets are available in different shapes in order to chuck square and hexagonal workpieces of small dimensions as well as round workpieces. (8) Jacobs Rubber-Flex Collets. The rubber flex collet (figure 16 on the following page) is comprised of hardened alloy steel jaws bonded together with oil-resistant Hycar synthetic rubber. The collets have a range of 1/8 inch per collet and the gripping power and accuracy remain constant throughout the entire collet capacity. These collets are designed for heavy- duty turning and possess 2 to 4 times the grip of conventional split steel type collets sleeve, tightening the chuck to the workpiece.

2/4/2023, 2 : 02 p. m. MEM07032 - THEORY - Use workshop machines for basic operations - PRE LEARNING: Attempt review Página 45 de 58 https://baxter.edfibre.com/gradejet/mod/quiz/review.php ? attempt=147249&cmid=18279 (9) Step Chuck. The step chuck is a variation of the collet chuck, but is intended for accurate holding of workpieces larger than 1 inch in diameter. The step chuck consists of the handwheel or hand lever collet attachment and a step chuck machine collet in place of the regular spring machine collet. The step chuck machine collet, which is split into three sections like the spring machine collet, is threaded to the draw bar of the collet attachment. As the step chuck machine collet is drawn into the collet sleeve, the three sections of the collet are cammed against the workpiece by an inside taper in the collet sleeve. The step chuck is supplied in 2, 3, 4, and 5-inch sizes, the size indicating the maximum diameter of the workpieces that can be supported. The step chuck machine collets are furnished blank and machined on the lathe to the desired step diameter. (10) Lathe Tailstock Chuck. The lathe tailstock chuck is a device designed to support the ends of the workpieces in the tailstock when a lathe center cannot be conveniently used. The chuck has a taper arbor that fits the lathe tailstock spindle. The three bronze self-centering jaws of the chuck will accurately close upon the workpieces that are between 1/4 and 1 inch in diameter. The bronze jaws provide a good bearing surface for the workpiece. The jaws are adjusted to the diameter of the workpiece and then locked in place. b. Lathe Faceplates. (1) A lathe faceplate (figure 17 on the following page) is a flat, round plate that threads to the headstock spindle of the lathe. The faceplate is used for clamping and machining irregularly shaped workpieces that cannot be successfully held by chucks or mounted between centers. The workpiece is either attached to the faceplate using angle plates or brackets or is bolted directly to the plate. Radial T- slots in the faceplate surface facilitate mounting workpieces. The faceplate is valuable for mounting workpieces in which an eccentric hole or projection is to be machined. The number of applications of the faceplate depends upon the ingenuity of the machinist. (2) A small faceplate, known as a driving faceplate, is used to drive the lathe dog for workpieces mounted between centers. The driving faceplate usually has fewer T-slots than the larger faceplates. When the workpiece is supported between centers, a lathe dog is fastened to the workpiece and engaged in a slot of the driving faceplate. c. Lathe Centers. (1) General. Lathe centers (figure 18 on page 39) are the most common devices for supporting workpieces in a lathe. Most lathe centers have a tapered point with a 600 included angle to fit the workpiece holes with the same angle. The workpiece is supported between two centers, one in the headstock spindle and one in the tailstock spindle. Centers for lathe work have standard tapered shanks that fit into the tailstock directly and into the headstock spindle, using a center sleeve to convert the larger bore of the spindle to the smaller taper size of the lathe center. The centers are referred to as live centers or dead centers, depending upon whether they move with the workpiece or remain stationary. The most common types of centers are described below. (2) Male Center. The male center or plain center is the type used in pairs for most general lathe turning operations. The point is ground to a 60° cone angle. When used in the headstock spindle, where it revolves with the workpiece, it is commonly called a live center. When used in the tailstock spindle, where it remains stationary when the workpiece is turning, it is called a dead center. Dead centers are always hard and must be lubricated very often to prevent overheating. (3) Pipe Center. The pipe center is very similar to the male center, but its cone is ground to a greater angle and is larger in size. It is used for holding pipe and tubing in the lathe while they are being machined. (4) Female Center. The female center is conically bored at the tip and is used to support workpieces that are pointed at the end. (5) Half-Male Center. The half-male center is a male center that has a portion of the 60° cone cut away. The half-male center is used as a dead center in the tailstock where complete facing is to be performed. The cutaway portion of the center faces the cutting tool and provides the necessary clearance for the tool when facing the surface immediately around the drilled center in the workpiece. (6) V-Center. The V-center is used to support round workpieces at right angles to the lathe axis for special operations such as drilling or reaming. d. Lathe Dogs. (1) Lathe dogs (figure 19 on page 39) are cast metal devices used in conjunction with a driving plate or a faceplate to provide a firm connection between the headstock spindle and the workpiece that is mounted between centers. This firm connection permits the workpiece to be driven at the same speed as the spindle under the strain of cutting. Frictional contact alone, between the live center and the workpiece, is not sufficient to drive the workpiece. Three common types of lathe dogs are illustrated in figure 19. Lathe dogs may have bent tails or straight tails. When the bent tail dogs are used, the tail fits into a slot of the driving face plate. When straight tail dogs are used, the tail bears against a stud projecting from the faceplate. (2) The bent tail lathe dog with a headless setscrew is considered safer than the dog with the square head screw because the headless setscrew reduces the danger of the dog catching in the operator's clothing and causing an accident.

2/4/2023, 2 : 02 p. m. MEM07032 - THEORY - Use workshop machines for basic operations - PRE LEARNING: Attempt review Página 46 de 58 https://baxter.edfibre.com/gradejet/mod/quiz/review.php ? attempt=147249&cmid=18279 Between Centres Between Centres Advantages Advantages Work may be removed and replaced accurately in position without any additional resetting. Can be easily transferred to milling machine or cylindrical grinder. Work can be turned at each end and the diameters will be concentric 3.2 Operate machine to suit work and material requirements 3.2 Operate machine to suit work and material requirements Functions of the Centre Lathe Functions of the Centre Lathe The purpose of the Centre Lathe is to produce: Cylindrical shapes (turning), form flat surfaces (facing). Angles/bevels To cut threads Lathes vary considerably in size. The size of the lathe is determined by the swing (largest diameter of work) and the distance between centers (longest work that can be held) Common engineering materials Common engineering materials Introduction: Introduction: This unit refers to selecting the correct materials for the application in which the engineered part is being used. This selection process includes choosing the material, paying attention to its specific type or grade based on the required properties. Engineers will select a grade of material based on its properties such as malleability or tensile strength. Composites comprise two materials, such as a metallic mesh and a resin, the combination of which also depends on the properties required. Materials from which the item is to be manufactured are noted on the engineering drawing using standard material and grade codes. It is important that manufacturers do not interchange materials because the switch may make the products susceptible to failures. Classification of materials: Classification of materials: Metals and non-metals Ferrous and non-ferrous metals Polymers (thermoplastics, thermosetting and elastomers) Ceramics and glasses Composite materials Properties of materials: Properties of materials: Ferrous materials Ferrous materials Contain iron in their internal structure, i.e. tool steel, cast iron, carbon and alloy steels, coated steel, etc. Contain small amounts of other metals or elements to give them the required properties, Are magnetic and give little resistant to corrosion. ·Stainless steel, magnetic state is called ferritic stainless steel. Non-ferrous materials Non-ferrous materials Aluminum: lightweight, low strength, easily shaped, Cooper: Highly malleable, with high electrical conductivity, Lead: heavy, soft, malleable metal, low melting point, low strength, Tin: Soft, malleable, low tensile strength, used to coat steel to prevent corrosion, Refractory metals, Silver, platinum and gold Nickel: is a metal magnetic at or near room temperature, high electrical and thermal conductivity. Bulk nickel is non-magnetic. Polymer materials: Polymer materials: Polyethylene (low density), polyethylene (high density), polyvinyl chloride, polytetrafluoroethylene, polypropylene, polystyrene, polymethyl methacrylate, phenol formaldehyde, nylon (6,6), polyester (PET), polycarbonate.

2/4/2023, 2 : 02 p. m. MEM07032 - THEORY - Use workshop machines for basic operations - PRE LEARNING: Attempt review Página 47 de 58 https://baxter.edfibre.com/gradejet/mod/quiz/review.php ? attempt=147249&cmid=18279 Composite materials: Composite materials: Reinforced concrete (concrete alone will not compress or shatter, will not survive tensile loading it will quickly break, steel bars added to became reinforced concrete) and masonry, Cob or mud bricks using clay and straw, Composite wood such plywood, Reinforced plastics, such as fibre-reinforced polymer i.e. fiberglass (strong and stiff but also brittle, flexible and ductile); Ceramic matrix composites (composite ceramic and metal matrices) Metal matrix composites, Advanced composite materials like carbon fibers and silicon carbide, Fiber reinforced used in swimming pools are non-corrosive. Thermosetting materials: Thermosetting materials: RIM thermosetting: (pDCPD) (polydicyclopentadiene), polyurethanes, polyureas, structural foams, RTM Thermosetting (Fiberglass reinforced): polyester, vinyl Ester, polyimides, Other types of thermosets and thermoset resins: Epoxy (e.g. carbon fiber epoxy resin), phenolics, bismaleimide (BMI), fluoropolymers, polytetrafluoroethylene (PTFE), polyvinylidene fluoride (PVDF), melamine silicone, formaldehyde, polyester and urea formaldehyde are: Available moulded-in tolerances, Choice of color and surface finishes, High strength-to-weight ratio and performance, Outstanding dielectric strength, Low thermal conductivity and microwave transparency, Resistance to corrosion effects and water, Low tooling/set-up costs Reduced production costs over fabrication using metals. Good electrical insulator, hard, brittle unless reinforced, resists chemicals well, Used for casting and encapsulation, adhesives, bonding of other materials, Thermoplastic: Thermoplastic: PVC or CPVC, polypropylene, PDVF, ABS, nylon and polyethylene, polyamide, Polyethylene gas thanks used to transport natural gas. High pressure polyethylene to encapsulate rigid objects like electrical equipment, low pressure polyethylene is very elastic ideal for insulating electrical cables. Polyamide is associated with the production of ropes and belts. Thermoplastics can withstand corrosive materials and corrosive environments, Being able to carry materials of extreme temperatures (hot or cold), Their capacity to handle virtually any type of fluid transport application. Ceramics: Ceramics: High melting points (they are heat resistant) Great hardness and strength, Considerable durability (they are long-lasting and hard-wearing) Low electrical and thermal conductivity (good insulators), Chemical inertness (they are unreactive with other chemicals), Ferrites (iron-based ceramics) happen to make great magnets (because of their iron content), but most ceramics are nonmagnetic materials, They are fragile and brittle like glass and porcelain. Composite materials: Composite materials: Not isotropic (independent of direction of applied force) in nature, but they are anisotropic (different depending on the direction of the applied force or load). The stiffness of a composite panel will often depend upon of the applied forces and/or moments. Three Three different types of cutting tool materials used for cutting material in a workshop machine different types of cutting tool materials used for cutting material in a workshop machine High Speed Steel (HSS) Tungsten Carbide Sintered Inserts Ceramics Basic Operations of a Lathe Basic Operations of a Lathe Facing Facing Parallel Turning Parallel Turning Taper Turning Taper Turning Form Turning Form Turning Boring Boring Thread Turning Thread Turning Knurling Knurling Drilling Drilling Facing Facing in machining can be used in two different areas: facing on a milling machine and facing on a lathe. Facing on the milling machine involves various milling operations, but primarily face milling . On the lathe, facing is commonly used in turning and boring operations. Other operations remove material in ways similar to facing, for example, planning, shaping , and grinding , but these processes are not labeled by the term "facing." Facing on the lathe uses a facing tool to cut a flat surface perpendicular to the work piece's rotational axis. A facing tool is mounted into a tool holder that rests on the carriage of the lathe . The tool will then feed perpendicularly across the part's rotational axis as it spins in the jaws of the chuck. A user will have the option to hand feed the machine while facing or use the power feed option. For a smoother surface, using the power feed option is optimal due to a constant feed rate . Facing will take the work piece down to its finished length very accurately. Depending on how much material needs to be taken off, a machinist can choose to take roughing or finishing cuts. [1] Factors that affect the quality and effectiveness of facing operations on the lathe are speeds and feeds , material hardness , cutter size, and how the part is being clamped down.

2/4/2023, 2 : 02 p. m. MEM07032 - THEORY - Use workshop machines for basic operations - PRE LEARNING: Attempt review Página 48 de 58 https://baxter.edfibre.com/gradejet/mod/quiz/review.php ? attempt=147249&cmid=18279 Parallel machining (or turning) Parallel machining (or turning) on a lathe refers to a cut taken on a workpiece along its outside or inside diameter on the longitudinal axis, which is parallel to the bed of the lathe. This really could apply to Metal or Wood lathes, but it is the sense of achieving a purely PARALLEL object, that is the basic premise of a Horizontal Lathe. Which is the most common version and perception of the machines. VERTICAL LATHES also exist in great numbers. Parallel turning on them is Vertical. We Parallel Turn the giant objects of our time, as VERTICAL is not really an option when things are 25 to 100+ feet long. Things like Gun Barrels and Propeller shafts for Battleships and most all other Naval vessels and commercial ships. The most common companion operation, turning in the PERPENDICULAR sense, is generally referred to as “Facing”. Often the same general tooling, but the “Cross Slide” moves 90 degrees from the parallel. This process can be at other angles, but this is most common. This allows Cylinders, Tubes, Discs, and most other variations to be a practical process. Taper turning Taper turning as a machining operation is the gradual reduction in diameter from one part of a cylindrical workpiece to another part. Tapers Tapers can be either external or internal. A Drift A Drift is used to remove a Morse taper drill from the spindle of a drilling machine Form Turning Form Turning Turning Turning is a form form of machining, a material removal process, which is used to create rotational parts by cutting away unwanted material. The turning turning process requires a turning turning machine or lathe lathe, workpiece, fixture, and cutting tool. Lathe boring Lathe boring Lathe boring Lathe boring is a cutting operation that uses a single point cutting tool or a boring boring head to produce conical or cylindrical surfaces by enlarging an existing opening in a workpiece. For nontape red holes, the cutting tool moves parallel to the axis of rotation. Thread turning Thread turning Both inch and metric screw threads threads can be cut using the lathe lathe. A thread thread is a uniform helical groove cut inside of a cylindrical workpiece, or on the outside of a tube or shaft ........ Hand coordination, lathe lathe mechanisms, and cutting tool angles are all interrelated during the thread thread cutting process.

2/4/2023, 2 : 02 p. m. MEM07032 - THEORY - Use workshop machines for basic operations - PRE LEARNING: Attempt review Página 49 de 58 https://baxter.edfibre.com/gradejet/mod/quiz/review.php ? attempt=147249&cmid=18279 Knurling Knurling is a manufacturing process and technique of creating concave and bumps on the surface of workpiece, presented as the pattern of straight, angled or crossed lines is rolled into the material, the knurling knurling operation is usually performed on the lathe lathe machine, including CNC turning lathes lathes. Drilling Drilling The tailstock of a lathe lathe can be used for drilling drilling, with the aid of a drill drill chuck attachment. The drill drill chuck has a morse taper shaft which can be push into the shaft of the tailstock, locking it in position. The usual starting point for drilling drilling with a centre lathe lathe is to use a countersink bit. The two most common shanks found on twist drills The two most common shanks found on twist drills 1. 1. Taper Taper 2. 2. Straight Straight Types of drills shown below. Types of drills shown below.

2/4/2023, 2 : 02 p. m. MEM07032 - THEORY - Use workshop machines for basic operations - PRE LEARNING: Attempt review Página 50 de 58 https://baxter.edfibre.com/gradejet/mod/quiz/review.php ? attempt=147249&cmid=18279 Cutting Speed Cutting Speed This is the rate, expressed in metres per minute(m/min), at which a point on the circumference of the rotating work passes the tool bit. If it were possible to measure the length of the chip removed in one minute, this length in metres would be the cutting speed. Feed Feed Feed is the distance that the tool advances along the work during each revolution. It is usually expressed in millimetres per revolution (mm/rev). Finishing feed rate 0.05 mm/rev (0.002”/rev) Roughing feed rate 0.25 mm/rev (0.010”/rev) Factors Affecting Cutting Speed Factors Affecting Cutting Speed Type of material being cut Cutting speed is determined by type of material being cut (from chart) Cutting tool material HSS (high speed steel) Tungsten carbide inserts Ceramics Depth of cut Finishing cuts, the speed may be increased to improve the finish Rate of feed Roughing cut, where course feeds are used, the speed should be reduced. Rigidity of the work Short work held in four jaw chuck maybe turned faster than long work supported by steadies. Power, strength, and condition of the lathe larger more powerful lathes can handle higher cutting speeds. Coolant or lubricant used. Cutting speeds for most materials can be increased by using the correct lubricant. Shape of tool In general, the cutting speed should vary inversely with the width of the cutting edge in contact with the work. RPM FORMULA RPM FORMULA REVS PER MINUTE = E.G E.G Calculate the RPM for a diameter 80 job if the cutting speed is 30 m/min? RPM = 3.1 Check machined component against work requirements and 3.1 Check machined component against work requirements and predetermined finish predetermined finish Parts of a Lathe Parts of a Lathe

2/4/2023, 2 : 02 p. m. MEM07032 - THEORY - Use workshop machines for basic operations - PRE LEARNING: Attempt review Página 51 de 58 https://baxter.edfibre.com/gradejet/mod/quiz/review.php ? attempt=147249&cmid=18279 The Carriage The Carriage The Carriage and Saddle provide the mechanisms and tool holding to allow the Lathe to machine accurately. Most centre lathes have some form of power feed mechanism to provide automatic movement to the cutting tool. Power feed can be applied to both the saddle and cross slide. Feed and Lead Screw Feed and Lead Screw When the feed lever is engaged power is connected from the feed shaft to the saddle and cross slide. This provides automatic feeding for facing and turning. Centre lathes equipped with power feed also have provision for screw-cutting. When the Leadscrew lever is engaged threads can be cut. The Tailstock The Tailstock The tailstock is used mainly to support the right-hand end of the work. It may be moved and clamped in position along the bed. Lathe Size Lathe Size r - Radius of work (Centre height of lathe) d -Diameter of work (Swing of lathe) Lc - Length between centres

2/4/2023, 2 : 02 p. m. MEM07032 - THEORY - Use workshop machines for basic operations - PRE LEARNING: Attempt review Página 52 de 58 https://baxter.edfibre.com/gradejet/mod/quiz/review.php ? attempt=147249&cmid=18279 Lb - Length of the bed Centre Lathe work holding Centre Lathe work holding Reference Fitting & Machining (Culley) pp247 – 261 (TJ1185 .f3 2003) Types of spindles Types of spindles Jaws are adjusted one at a time to hold regular and irregular work Much greater gripping force Jaws can be reversed for holding larger work Disadvantages Disadvantages Longer to setup Three Jaw Self-cantering Chuck Three Jaw Self-cantering Chuck Advantages Advantages Less time to setup Disadvantages Disadvantages Work must be accurately Machined round or hexagonal in section Less gripping force than four jaw Jaws cannot be reversed, there is a second set of reversed jaws

2/4/2023, 2 : 02 p. m. MEM07032 - THEORY - Use workshop machines for basic operations - PRE LEARNING: Attempt review Página 53 de 58 https://baxter.edfibre.com/gradejet/mod/quiz/review.php ? attempt=147249&cmid=18279 Between Centres Between Centres Advantages Advantages Work may be removed and replaced accurately in position without any additional resetting Can be easily transferred to milling machine or cylindrical grinder. Work can be turned at each end and the diameters will be concentric. Face Plate Face Plate Faceplates are used for holding work that cannot be conveniently held in a chuck. Types of Centres Types of Centres Plain centres Plain centres Used in the tail stock and head stock. Must be lubricated if used in tail stock. There are two types Hard centres which have an inserted tip and are held in tail stock. Soft centres which are held in head stock and rotate with workpiece. Live centres use taper roller and ball bearings. This allows them to run at higher speeds.

2/4/2023, 2 : 02 p. m. MEM07032 - THEORY - Use workshop machines for basic operations - PRE LEARNING: Attempt review Página 54 de 58 https://baxter.edfibre.com/gradejet/mod/quiz/review.php ? attempt=147249&cmid=18279 Pipe centre has various cone centres to suit diameters of pipe. Driving centres are used to turn along the entire length of job without stopping. This eliminates the need for a lathe carrier. 3.4 Make adjustments, as required 3.4 Make adjustments, as required 7 major Problems with Lathe 7 major Problems with Lathe Lathe machine is the most common and oldest equipment to be used in industries to cut, groove, drill, and do other machine-related operations. As it is a machine, from time to time, there can be problems. Metal lathe chattering Weird vibration on a wood lathe Carriage problem Threads cutting issues Improper metal cuts Tailstock slipping Lathe machine fails Some solutions and adjustment as below: Some solutions and adjustment as below: 1. Metal lathe chattering 1. Metal lathe chattering Chattering is the enemy of every machinist that will face it sooner or later unless a CNC machinist and familiar with the HAAS Automation’s SSV technique. However, for the regular machinists who are using general lathes like a small-sized lathe, it can get tricky. Therefor will create a rough-cut surface and leave the chatter mark in the metal piece. It is like a car tire leaving its mark on the dessert. And the sound it makes is the chattering noise. The golden rule to stop chattering is to “reduce the speed and increase the feed.” Chatter frequently originates if going too high in speed or not hitting it strong enough. Though some operations are destined to chatter, there are few things can always do to win over. Step 1: Make sure the rigidity is higher Chatter occurs when the cutting pressure is too high than the rigidity of the setup. Rigidly is critical in overcoming chatter. Always make the setup as ridge as possible. Check all the slides are tight enough, nothing is loose. Remove compound if it is not using it. Make sure everything is locked firmly before starting Using tailstock every time possible is a good practice. Just keep everything close and tight is the key to maintain rigidity. Step 2: Decrease Tool Pressure Check out the tool bit how it is shaped, how the operator wants the finishes. If for deeper cuts, using a rounded nose tool for a more delicate finish, the tool pressure will be higher. But we want to lower the pressure. Step 3: Some other tricks that work Flip the tool upside down and machine on the other side of the hole. It will make the springy tool post/top slide/carriage act in a completely different way and might be the one trick to get away from chatter. Sharpen the tool bit and then try to do a pass that is deeper than the chatter area. ·Wrapping elastic bands or sticking plasticine around the work can be a good trick. The Harding demo where they turn a 1 ″ bar down to 0.5mm in one hit with a knife tool. Check if the tool is well above the centreline when boring. Make sure the top slide is locked in place if having a tool post on the top slide. Put a bolt & nut under the tool against the carriage top and tighten it to provide more support for the tool. Using chatter grease or spray does help. 2. Vibration Problem in Lathe: 2. Vibration Problem in Lathe: The vibrating issues occur in a lathe for numerous reasons. It could be a balancing problem. Maybe the turning object is not cantered well, or the machine itself could have mechanical issues, and so on. It is coming from an imbalance situation of the lathe attached to the ground. The problem is between the workpiece and the cutting tool. Priority 1 Priority 1 Run the lathe without attaching anything. Then it indeed is a mechanical problem. The more solid and robust the attachment of the chunk is with the faceplate, the more it will reduce the vibration. Irregular large bowl blanks produce the vibration often. Run the lathe and increase the speed gradually in this case. See at what point the chunk is turning smoothly. Checking leg extension if it is settled with the floor in a proper flat situation is critical. If any imbalanced surface contact, either move the whole lathe to a new place or just use a flat rubber piece or a chunk of paper folded. Put it right beneath the leg where the surface is not contacting smoothly. Put some extra weight on lathe if it is possible to ground it more firmly. It will absorb the movement more to the ground. It is not recommended but still effective. Priority 2 Priority 2 If working with small object and experiencing vibrations, this is where steady rests are a must-try option, no matter if turning spindle or bowl. There are steady rests specially designed for bowl turners now. Check if motor, drive belt, or headstock bearings are making any noises. May need to change them if possible or at least repair it.

2/4/2023, 2 : 02 p. m. MEM07032 - THEORY - Use workshop machines for basic operations - PRE LEARNING: Attempt review Página 55 de 58 https://baxter.edfibre.com/gradejet/mod/quiz/review.php ? attempt=147249&cmid=18279 Try to use the tailstock almost every time. Tailstock is all about the support. The workpiece to be mounted firmly between the centres. It is evident that it dramatically reduces the vibration. If the motor does not have the vibration, then trying to mount the motor rigidly will not help that much. Check out the leg again and try to isolate the motor entirely from the stand. 3. Carriage Problem 3. Carriage Problem Getting a ‘stuck carriage’ in lathe machine. Not only the carriage but also the handles need to be working perfectly for the machine to move and run efficiently. Carriage helps the cutting tools to move in between headstock and tailstock. At the top of the carriage, it is the Tool post that holds the cutting tools. Compound rest holds the tool post and has a handle to rotate it to any angle for making different cutting angles with the tools. Cross slide holds the tool rest, and the compound rest together. Has a handle that helps to perform the up-side movements of the tool post and compound rest together. Then comes the saddle that holds all the components mentioned above. It moves right to the left also by a handle. 4. Threads Cutting Problem: 2 Steps 4. Threads Cutting Problem: 2 Steps Step 1: setting up the lathe for threading Step 1: setting up the lathe for threading The compound and toolpost must be clean and steady. Check that first before running the project. It should be fine if that is a new lathe. Always use the manual from the manufacturer of the machine to select the right gear need to cut the thread. Look for the gear table in the book. Then set the threading tool to the diameter of the part to be threaded. It will be the starting depth. The scale should be set to zero both for the cross slide and the compound. Step 2: Start cutting the thread Step 2: Start cutting the thread Start with aluminium instead if it is the first project. It will make life a bit easier. Run the lathe at a slower speed and start cutting a scratch pass. Stop the machine whenever running the tool at the end of the cut. Do the cut one at a time to avoid any damage. Use a thread gauge to double-check the pitch after one scratch pass. Back the carriage away to clear the tool. Run the lathe again, but in reverse, to track the tool back to the start point. The tool will not touch the material while backing off the carriage. Then go for the next pass. Turn the carriage to scale zero again. The compound and the cross slide. 5. Improper Metal Cuts 5. Improper Metal Cuts If the lathe cutting tool has not been installed properly or ignoring the proper tool height settings, then likely to have improper metal cuts. It will ruin the projects and will never be satisfied. The trick for perfect installation is to remember to get an accurate and immaculate cut. Before start working, do not forget to centre the lathe tool correctly. Getting the right cutting tools for the lathe is a fundamental thing to start cutting. Select the cutting tools that can sharpen easily. Take HSS tools for example. They are easy to repair and sharpen if gets worn. Do not forget to set the “tool height” correctly. Because if the centre rotation of the chuck is interrupted. The piece will loosen up very easily during operation. Pause the machine frequently. Let it cool down and then start again. 6. Tailstock Is Slipping from The Centres 6. Tailstock Is Slipping from The Centres It is common in turning lathe. The tailstock is slipping while trying to tighten the work-piece between the centers. This can happen even with the new lathe when the tailstock is not fixed properly before working. Lock it down firmly before start cutting or turning. 7. Fails 7. Fails Lathe machines can lead to accidents as well. Safety is a crucial key while working with any machine. Nothing can be better than using safety goggles to protect the operator’s eyes from the dust. The clothes can get caught within the machine; the proper workshop clothes must be worn. The best way is clean the carriage on a regular basis to avoid metal dust on it. Use a brush to take off metal particles but be in the distance as much possible. This distance can help to avoid the direct contact of metal particles with the operator’s skin. These particles may cause scrapes and bruises.

2/4/2023, 2 : 02 p. m. MEM07032 - THEORY - Use workshop machines for basic operations - PRE LEARNING: Attempt review Página 56 de 58 https://baxter.edfibre.com/gradejet/mod/quiz/review.php ? attempt=147249&cmid=18279 Question 7 Correct Mark 1.00 out of 1.00 Question 8 Complete Marked out of 1.00 Question 9 Correct Mark 1.00 out of 1.00 REVIEW QUESTIONS REVIEW QUESTIONS Drag and drop the names from below and put them on the diagram in the best place to Drag and drop the names from below and put them on the diagram in the best place to describe each part of the lathe. describe each part of the lathe. Headstock Feedshaft Feed mechanism Tailstock Lead Screw Compound slide Your answer is correct. - Review questions Write detailed responses to the following questions Write detailed responses to the following questions 2. What is the purpose of the slideways? The slides and slideways of a machined tool locate and guide members which move relative to each other, usually changing the position of the tool relative to the workpiece. the movement generally takes the form of translation in a straight line, but is sometimes angular rotation, e.g. tilting the wheelhead of a universal thread grinding machine to an angle corresponding with the helix angle of the workpiece thread. 3. If a live centre was to be used while turning on a lathe, where would the live centre be located? Live centres use taper roller and ball bearings. This allows them to run at higher speeds. Pipe centre has various cone centres to suit diameters of pipe. Driving centres are used to turn along the entire length of job without stopping. This eliminates the need for a lathe carrier. This firm connection permits the workpiece to be driven at the same speed as the spindle under the strain of cutting. Frictional contact alone, between the live center and the workpiece, is not sufficient to drive the workpiece. If a machine is fitted with a safety guard or shield can you remove these If a machine is fitted with a safety guard or shield can you remove these guards once you become familiar with that machine? guards once you become familiar with that machine? Select one: True False !

2/4/2023, 2 : 02 p. m. MEM07032 - THEORY - Use workshop machines for basic operations - PRE LEARNING: Attempt review Página 57 de 58 https://baxter.edfibre.com/gradejet/mod/quiz/review.php ? attempt=147249&cmid=18279 Question 10 10 Complete Marked out of 1.00 Question 11 11 Complete Marked out of 1.00 Learning Activity 3 Write detailed responses to the following questions Write detailed responses to the following questions 5. Name three different types of cutting tool materials used for cutting material in a workshop machine. Here are many types of cutting process done in different conditions. In such conditions along with the general requirements of the cutting tool, they need some unique properties. To achieve this properties the cutting tools are made up of different material. The material chosen for a particular application depends on the material to be machined, type of machining, quantity and quality of production. According to the material used the tools are classified into: Carbon tool steel High speed steel tool (HSS) Cemented carbide Ceramics tool Cubic boron nitride Tool (CBN) Diamond tool 6. Give an advantage of using correctly sharpened cutting tools? Smooth Cut Sharpening saves you both time and money. With regular precision sharpening, you’ll have clean and smooth-edged tools, clear of chips and burrs. Sharpening will also prolong the life of your blades. 7. What is the name of the chuck shown? Four Jaw independent chuck 8. Name the two (2) most common shanks found on twist drills. The two most common shanks found on twist drills 1. Taper 2. Straight - Review questions Write detailed responses to the following questions Write detailed responses to the following questions 9. Name the two (2) types of drills shown below. 1. Counterbore. 2. Countersink 10. Calculate the RPM for a diameter 40 brass job, with a cutting speed of 60 m/min? (320* cutting speed)/ diameter of work piece (320*60)/40 =RPM 480 11. Calculate the RPM for a diameter 10 cast iron job, with a cutting speed of 18m/min? (320* cutting speed)/ diameter of work piece (320*18)/10 =RPM 576 12. Calculate the RPM for a diameter 25 mild steel job, with a cutting speed of 30m/min? (320* cutting speed)/ diameter of work piece (320*30)/25 =RPM 384 13. What is the name of the tool that is used to remove a Morse taper drill from the spindle of a drilling machine? A Drift is used to remove a Morse taper drill from the spindle of a drilling machine.

2/4/2023, 2 : 02 p. m. MEM07032 - THEORY - Use workshop machines for basic operations - PRE LEARNING: Attempt review Página 58 de 58 https://baxter.edfibre.com/gradejet/mod/quiz/review.php ? attempt=147249&cmid=18279 Stay in touch Baxter Institute RTO No: 7030 CRICOS Provider No. 02233M ! http://www.baxter.vic.edu.au " 03 9650 0367 # mail@baxter.vic.edu.au $ % & ' Data retention summ ( Get the mobile ap