BASIC MACHINE TRAINING GUIDETable of Contents

General Machine Shop Rules and Training Courses2Safety5Machine and Equipment Care6Precision Measurement Equipment7Milling8I.Machine Specific Setup8II.Machining Operations10III.Machining Considerations10IV.Post machining13Lathe14I.Machine Specific Setup14II.Machining Operations15III.Machining Considerations15IV.Post Machining16Saws17I.Machine Specific Setup17II.Machining Troubleshooting18Hot Shop20

General Machine Shop Rules and Training Courses

General Machine Shop RulesFollow all safety guidelines (see Safety section below)If leaving part in machine, leave name, cell number, and time of returnTime of return may not exceed 2 hours without Advanced Machinists permissionPart may be removed at Advanced Machinists discretionMust leave shop cleaner than you found itAbsolutely no chips left behind (floor or machine)Chip residue wiped off of machines with Simple GreenCoolant wiped up from floor and machine, if usedTools cleaned and put in proper placeNo machine shop tools leave machine shopIncludes drill bits, taps/dies, and measuring devicesMetal stockStore only that which is actually useful within 1 years timeLabel stock with proper gradeKeep stock organizedFixturesStore on fixtures shelf sorted by teamIf fixtures are useless or outdated, dispose Shop environmentKeyed interior doors are egress only includes visitors and toursSafety glasses must be worn by everyone if work is being performed Stay inside yellow lines without proper PPE (safety glasses must still be worn)Keep showers/eye wash stations and fire extinguishers clearKeep aisles clear must be able to egress shop easilyCategories of machinistsNewbie: Must have Advanced Machinist in machine shop at all timesBasic: Has successfully completed Newbie training must have Advanced Machinist in machine shopAdvanced: Senior machinist has highest level of authority in machine shop and must be present for any machining to take place. Will instruct on good safety practices and proper machining techniqueSetup CheckA setup check (see Safety section below) must be performed before any machine is operatedAuthorization for useNewbie: Must have Advanced Machinist check offBasic Machinist: Must have Advanced Machinist check offAdvanced Machinist: Can self-checkApproved Machinist NotebookIncludes training docs

Training CoursesBasic Machine training Attend class lectures and pass written examTeam captain nominates for continued trainingPaired with Advanced Machinist who will give machine demonstrations, general instruction, and observe student use on lathe, mill, and sawAdvanced Machinist will sign off on newbie after competency with machine and mill and lathe part checked for proper tolerancesWelding training1. Receive training from an Advanced Welder2. Must demonstrate proper welding technique by presenting 10 samples of various types of welds to Advanced Welder3. Advanced Welder signs off on newbie

Safety

I. Setup Check to be administered by Advanced MachinistA. Safety glassesB. Proper attire long pants, covered toe shoes, sleeves above elbow, no jewelry, etc.C. Hair tied back in bun if applicable, hats turned backwardsD. Work and tool mounted securelyE. Everything clear of tool through range of cutF. Improper PPE or people not training must stay behind yellow linesG. Correct speed calculated and acceptable depth of cut (see Newbie guide)H. Machining plan Describe steps on how you plan to make your partII. Potential HazardsA. Cuts1. Sharp chips2. Chips falling into shoes3. Machine or tool breakage4. Burrs on work pieceB. Projectiles1. Flying chips/misuse of air nozzle2. Flying chuck wrench keep hand on tool at all times until removed3. Tool breakage4. Poorly clamped partC. Entrainment into machine1. Improper clothinga) Long sleevesb) Glovesc) No dangly things, including jewelry2. Hair not tied back in bun - long pony tail not acceptable3. Bystanders not following proper safety precautionsD. Lack of aid1. Must have buddy in machine shop2. If no buddy, no machiningE. Poisoning1. Infected cuts from bacteria in stagnant water due to lack of Cool Mist2. Inhaling fumes from tap magicF. Fire1. Improper cutting operation which creates sparks2. Hot material placed on flammable surface (i.e. paper)3. Improper cutting of magnesiuma) Use big yellow fire extinguisher if fire eruptsG. Crushing1. Improper lifting of heavy objects get assistance from others2. Plan ahead and check foot path for obstructionsH. Falls1. Slippery floors due to coolant2. Slippery floors due to abundance of chips3. Tripping over objects plan steps in advance

Machine and Equipment Care

I. Measuring Equipment (Calipers, Dial Indicators, Micrometers, etc)A. General Care1. High precision instruments must be handled carefully2. No sudden shocks no dropping, beating, etc3. Avoid exposure to liquids (especially digital calipers), heat, dirt, etc.4. Improper use can cause them to lose their tolerances and make them uselessB. Shop usage1. Equipment designated for machine shop must not leave the room2. Always store in designated locationII. Machine Cleaning ProcedureA. Applies to all machinesB. To be performed upon completion of work1. All chips removed from machine and floor2. Chip residue wiped off of all surfaces on machine with Simple Greena) Do not use Simple Green on greased surfaces just wipe off with clean rag3. If coolant used, wiped up completely from machine and floor4. All tools cleaned and put back in designated locationIII. Milling MachinesA. Use automatic oilers to lube ways on a weekly basis Adv Machinists performB. Cup oilers will be oiled by Support EngineerC. Use chip guardsD. Do not over tighten drawbarE. Do not leave wrench on drawbar everF. Do not adjust speed unless machine is turned onG. Make sure spindle brake is not stuck in the engaged positionH. Do not allow tool to cut viseIV. LathesA. Oil Levels1. Always check sight glasses before use2. Low oil will cause damage to machine3. Fill up if low using Medium Way Oil found in prep room cabinetB. Use chip guardsC. Do not leave chuck wrench on chuck everD. Always make sure tool and holder are clear of chuck before operationE. Thoroughly clean insert holders when changing inserts1. Can cause all sorts of issues (poor surface finish, tool breakage, etc)2. Use anti-seize on threads to prevent sticking3. Do not over tighten insert screwsV. SawsA. Clear chips after every use can cause rustB. Make sure guides are adjusted properly height and blade separationC. Occasionally check rubber on large pulleys for chips to removeD. If changing gears, always do manually and make sure gear is engaged before operation

Precision Measurement Equipment

I. CalipersA. Used for general purpose measurementB. Best for quick measurement of small partsC. Measures: inside diameter, outside diameter, thickness, depthD. Can calibrate using gauge blockII. Dial IndicatorsA. Some common usages1. Dial in part on lathe2. Tram mill and vise3. Position part relative to headB. Measures: linear distanceIII. MicrometersA. Excellent for measuring diameters and large openingsB. Generally more accurate than calipersC. Some have greater range of measure than calipersD. Use gauge block to calibrateE. Measures (our set): outside diameter, thicknessIV. Gauge BlocksA. Used for measuring z-axisB. Can calibrate calipers and micrometersC. Use dab of oil on surfaces to increase precisionD. Used to get accurate distancesV. Transfer GaugesA. Used to measure places other equipment cant get toB. Does not read out a measurement, must use caliper/micrometer to obtain measurementVI. Vernier Dials on MachinesA. Lathes and mills both have dial gauges in all directionsB. Use them when other instruments arent available

MillingI. Machine Specific Setup

A. Coordinate system

B. Perfect 90 and flat surface cuts1. Head is trammed perpendicular to tablea) Thoroughly clean tables surface w/ lubricantb) Mount dial indicator on spindlec) Rotate spindle to make head perpendicular to table in X and Y directions2. Vise is trammed perpendicular to tablea) Thoroughly clean mating surfaces w/ lubricantb) Mount dial indicator on spindlec) Run indicator on back face of vise to square up to table C. Tool selection1. Ensure it is sharp by looking at the tip of each tooth2. Size tool to match cutting operation3. Determine features needed for cutD. Calculate spindle speed1. Look up cutting speed for milling in Machinerys Handbook2. RPM = 4 x cutting speed (sfm) / diameter of tool (inch)E. Speed change1. Can cause damage to machine if done when machine is off2. Perform slowly3. Ensure low/high lever is in proper position for RPM desiredF. Part clamping on table1. Use clamps to keep part from shifting2. Clean table and part well so they seat wellG. Part clamping in vise1. Must be tight to keep part from shifting2. Use parallels to make part level and adjust height3. Clean vise and part so they seat well 4. Lightly clamp part, use mallet to firmly seat, then fully tighten5. Plan ahead and do not allow the tool to cut the viseH. Locate X and Y axes1. Method 1a) Load edge finder into machine with colletb) Set speed to 1000 1400 RPMsc) Set edge finder height and slowly move X axis until finder kicks out. d) Subtract half the width of finder and zero axis.e) Repeat for Y axis2. Method 2a) Take cut with one axis (lock other axis in place)b) Measure part (do not remove part from vise)c) Subtract that figure from desired measurementd) Use DRO to obtain desired measurementI. Locate Z axis1. Using feeler gaugea) Clamp part and insert tool onto machineb) With machine off, get part close to bottom of toolc) Slide gauge between part and tool while raising part until gauge slides with minimal friction (Caution: raising too much may chip tool)d) Move part up gauge thickness2. Gauge blocka) Clamp part and insert tool onto machineb) With machine off, get part close to bottom of toolc) Move gauge block between part and tool while raising part until tool touches gauge blockd) Move part up length of gauge blockJ. Depth of Cut (radial and axial)Note: Numbers to be used as a rule of thumb1. Face milling (axial cutting)a) Steel: 0.01 (half aluminum)Width of Cut = 75% width of tool reduce DOC if moreb) Aluminum: 0.02 (2x steel)Width of Cut = 75% width of tool reduce DOC if more 2. Shoulder/contour milling (radial cutting only)a) Steel: 0.01 (half aluminum)Width of Cut = 75% width of tool reduce DOC if moreb) Aluminum: 0.02 (2x steel)Width of Cut = 75% width of tool reduce DOC if more K. Coolant1. Steel: When using HSS bits, may want to use to help with tool life2. Cutting aluminum: not needed3. Not needed with carbide indexable tools4. Not an excuse to go fasterL. Feed1. Always feed part into bit slowly to get a feel for tool2. Observe chips, if chips too hot to touch, slow feed down3. No way to accurately set feed rate, so calculation on manual mill means littleII. Machining Operations

A. Face milling1. Taking large portions of metal off top of part to get to certain depth2. Fastest way is to use the Bearclaw indexable cuttera) Speed: 900 RPM, material: aluminum only, DOC: 0.04 max3. Never engage ~50% of tool due to improper insert loading. 70% ideal, 25% okB. Slot milling1. Uses 100% width of tool2. Reduce depth of cut by 50%3. Is the hardest operation a tool will experienceC. Shoulder/contour milling1. Cutting on outsides of part which engages less of tool2. Can take larger depth of cut but width of cut is shallowD. Pocket milling1. Cutting the inside of the parta) Not typically a manual milling operation2. First pass is similar to slot milling3. If extra passes are required, depth of cut may be slightly increaseda) Take it slow in corners since it will engage more of the toolE. Drilling1. Use drill press or drill chuck with integrated taper for mill2. Find sharp bit3. Determine hole size and find 2-3 bits to step up to that size(if over ) larger drill bits dont cut in the center well4. For deep holes, peck drill pick up quill to clear chips every or so5. If gets hot, find sharper drill or use some coolantNote: Drilling does not provide very accurate or round holes see reamingF. Reaming1. Follow procedure for drilling2. Reduce final size of hole by ~1/32 for small holes (less than )3. Install reamer into proper collet4. Reduce spindle speed by at least half

III. Machining Considerations

A. Surface finish1. Use sharp tool2. Take smaller depth of cut (ie, finishing cut)3. Take larger depth of cut too small and cutter radius may be too large to cut4. Increase or decrease speed and feed 10% to see if finish improves5. Use climb milling

B. Tool life1. Use proper speeds and feeds2. Possible use of coolant3. Proper depth of cut and width of cutC. Accuracy1. Do not get in a hurry, take your time2. Measure twice (with precision tools), cut onceD. Noise reduction1. Check speed adjust 150 RPMs2. Increase feed rate tool is possibly rubbing3. Use sharp bitE. Part getting too hot 1. Identified by a) physically feeling chips catch some chips in hand with cautionb) chip discoloration only observable with steel chips turn bluec) continuous smoke2. Adjust speed3. Use slower feed rate4. Take less depth of cut5. Use sharper toolNote: Excessive heat reduces strength of tool and damages itF. Square stock1. Clamp round rod in with part in vise2. Keep rotating part till each surface is machined

G. Small diameter hole (less than )1. Use DRO and center drill to locate hole2. Use 2-3 drill bits to increase size to desired diameterFor highest accuracy, undersize hole 1/32 and use reamer for the final cutH. Large diameter hole (greater than )1. Follow above procedure and continue increasing drill bit sizes2. When size exceed drill bit available, use boring headNote: Dont be afraid to ask for help to set up properlyI. Cut part to specified height1. Measure height of part and locate end of tool to top of part2. Calculate depth of cut 3. Use vernier scale on Z axis to raise table incrementally to desired heightJ. Cut part to specified length or width1. Clamp part such that cut can be performed (ie, hang off end of vise)2. Use edge finder and DRO to locate both ends (be sure to account for tool diameter if it applies)3. Make incremental cuts to desired length or widthK. Ridges in surface of part1. Head not trammed2. Tool has teeth missingL. Insert installation - Bearclaw1. Find correct tool to undo screws do not strip!2. Remove old insert and install new one3. Put anti-seize on threads of screws and do not over tighten

IV. Post machining

A. Deburring1. Improves accuracy if performing more machining operations2. Prevents cuts on hands3. Removes crack inception sites4. Makes part look finishedB. Tapping1. Determining hole sizea) Locate tap chart and find thread desiredb) Select drill size according to chartc) Note percent of thread changes depending on drill size2. Keep part in machine and accurately locate holes do NOT turn on machine!3. Loosely put tap in chuck and start by hand a few threads to line up tap4. Ensures tap is perpendicular to part5. Use cutting fluid liberallyC. Clean up1. Leave machine and shop cleaner than you found it2. Put all tools back in their proper place3. Properly label extra stock and put in designated place on shelf4. Remove all chips with brush use air nozzle only for hard to reach places5. Prevents lost tools and promotes safe working environment6. Clean precise tools make clean precise parts

LatheI. Machine Specific Setup

A. Coordinate system

B. Tool selection1. Determine type of cut (facing, inner/outer diameter, cut off, etc)2. Select proper tool for cuta) Boring use boring toolb) Facing, turning WNMG/CNMG insert toolC. Set tool height1. Face part and reduce size of nub to nothing - tool is set2. Put center in tailstock and set tool height3. Use height adjustment tool (soon to be built)D. Speed selection1. Look up cutting speed for turning in Machinerys Handbook2. RPM = 4 x cutting speed (sfm) / diameter of tool (inch)3. Set levers to closest calculated numberE. Clamp part1. 3 Jawa) Use chuck tool to clamp down part dont get super tightb) Remove chuck tool before starting machine tool never leaves handc) Part will be between 0- ~0.005 from centerd) If part not perfectly centered, on first pass of tool, working area of part will be perfectly centered2. 4 Jawa) Line up part using dial indicator w/ magnetic baseb) Rotate chuck and use chuck tool to clamp down partc) Remove chuck tool before starting machine tool never leaves handF. Depth of CutNote: Numbers to be used as a rule of thumb1. Steel: 0.015 (half aluminum)2. Aluminum: 0.03 (2x steel)G. Maintenance issues1. Be sure to check oil level before use2. Fill up if low using Medium Way Oil found in prep room cabinetH. Measuring1. DRO defaults to measure on the diameter (can be set to read on the radius)2. Vernier dials read on the diameterI. Coolant1. Not advised to use coolant with carbide inserts creates micro cracks in insert2. Definitely used on drilling and HSS toolsJ. Changing inserts1. Find correct tool to undo screws do not strip!2. Use air to blow out any chips in socket3. Remove old insert and install new one4. Put anti-seize on threads of screws and do not over tighten II. Machining Operations

A. Facing1. Machine end of part2. Must use some form of right hand tool cutter3. Set depth and use X axis feed to face offB. Turning - Outer diameter1. Machine outside surface of part2. Can use any form of tool holderC. Drilling1. Puts holes through part2. Install drill chuck in tailstock use coolant3. Peck drill (move drill bit in and out of hole every ~ to clear chips)4. Gradually increase size of drill bit (if over ) until desired size is reached5. Use boring tool if hole needs to be bigger than available drill bit sizeD. Boring - Inner diameter 1. Makes part that requires an inner diameter2. Use boring tool that corresponds to the size hole in the part3. Only stick bar out as far as absolutely necessary more overhang = less rigid4. Max overhang HSS: 4x diameter of bar, Carbide: 6x diameter of barE. Parting - Cut off1. Cut off part from stock clamped in chuck2. Must reduce speed by 50%3. May need to take a multiple cuts as tool has tendency to wander4. Adjust so insert overhang is minimizedIII. Machining Considerations

A. Surface finish1. Adjust speed 150 RPMs2. Adjust tool to centerline of part3. Make sure tool is sharp4. Use proper tool for the job (see Tool selection above)5. Take larger depth of cut too small and insert radius may be too large to cut6. Leave a few thousandths and sand part down for best finishB. Accuracy1. Use DRO with caution. Always stop and measure often2. Leave plenty of time to stop and measureC. Noise reduction1. Check speed adjust 150 RPMs2. Increase feed rate tool is possibly rubbing3. Use sharp bitD. Part getting too hot1. Use slower feed rate2. Tool is dull3. Too large a depth of cutNote: Excessive heat reduces strength of tool and damages itE. Chip clearing1. Do NOT remove chips while machine is turning. Stop machine first then remove2. Do NOT use gloves to clear chips while machine is running. This is worse than above. Gloves ok after machine is stoppedIV. Post Machining

A. Deburring1. Improves accuracy if performing more machining operations2. Prevents cuts on hands3. Removes crack inception sites4. Makes part look finishedB. Tapping1. Keep part in machine and accurately locate holes do NOT turn on machine!2. Put chuck in tailstock3. Loosely put tap in chuck and rotate head by hand a few threads to line up tap4. Ensures tap is perpendicular to part5. Use cutting fluid liberallyC. Clean up1. Leave machine and shop cleaner than you found it2. Put all tools back in their proper place3. Properly label extra stock and put in designated place on shelf4. Remove all chips with brush use air nozzle only for hard to reach places5. Prevents lost tools and promotes safe working environment6. Clean precise tools make clean precise partsV.

SawsI. Machine Specific Setup

A. Blade1. Three teeth contact part at all times more the bettera) Aluminum uses larger pitch to aid in chip clearingb) Steel uses smaller pitch to engage more teeth in the cut2. Valleys in blade remove chips3. Adjust blade guide height to fit material thickness4. Blade typesa) Carbon steel Good for soft metals, cheaperb) Bimetal HSS cutting teeth bonded to carbon steel backing. Good for harder steels and improves blade lifec) Carbide blade Ideal for hardened steel, expensive5. Variable pitch blade reduces vibration and increases blade life and finisha) Horizontal saw: 5-8 TPI (teeth per inch) good for or larger materialb) Vertical saw: 10-14 TPI good for and belowB. Speed1. Vertical Sawa) See chart on side of machineb) Determine type of material used and thicknessc) Adjust dial to proper speed indicated2. Horizontal Sawa) Speed adjusted by belts. Typically good for general purpose.

C. Part holding Vertical saw1. Do not use hands with small parts2. Use V-type part holder should be located close to saw3. Use wood to push through4. Use small vise to hold round material do NOT allow round stock to rotate, it will destroy bladeD. Feed1. Vertical Sawa) See chart on machine and use specified feedb) Feeds listed in rabbit, donkey, and elephant. For rabbit, do NOT push hardc) Use part holder to prevent injury2. Horizontal Sawa) Feed automaticb) For thin wall tubing slow feed manually or dont usec) Can adjust weight to apply more force on cutII. Machining Troubleshooting

A. Hot material1. Feeding too fast2. Dull blade3. Improper speedB. Poor surface finish1. Feeding too fast2. Dull blade3. Improper speed4. Blade guides adjusted improperlyC. Poor blade cutting1. Dull blade2. Speed too high3. Blade guides adjusted improperly4. Teeth pointed wrong direction/blade installed backwardsD. Saw not cutting in straight line1. Blade guide height too high2. Blade guides not set properly reduce separation3. Too high feed rate4. Not holding part rigid enoughE. High force required to cut see Poor blade cuttingF. Loud noises1. Feeding too fast2. Dull blade3. Improper speedG. Teeth stripping1. Feed pressure too high2. Tooth stuck in cut3. Part spinning4. Speed too lowH. Chip test see following chart

Hot Shop

I. SafetyA. Follow machine shop safety rulesB. Everyone must have safety glasses if work is occurringC. No flammable material allowed in areaD. Before any hot operation (sparks, etc) check for accidental placement of flammable material near areaE. Be extra cautious of sharp objects (burs on metal, sharp edges, etc). Always place materials in place someone cannot accidentally walk past and cut themselvesF. Make sure all gas bottles are securedII. Grinders A. Bench grinders1. Ensure guards are properly adjusted2. Steady part when grinding if it slips, can cut skin3. Use pliers/vise grips to hold partB. Side grinder/dremel/air grinder1. Determine path of sparks before starting and make sure area is clear2. Ensure part is clamped securelyIII. Chop sawA. Use ear protection in addition to eye protectionB. Announce to shop beginning of operation so everyone is prepared for the loud soundC. Do not put excessive pressure on handle when cutting can prematurely wear bladeIV. WelderA. Do not touch must take and pass welding training classB. Do not look at pretty blue light when someone is welding or if you are forced to hold something in place

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