SAMPLE. MEM07005C Perform general machining. Learner guide. MEM05 Metal and Engineering Training Package. Version 1
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1 MEM05 Metal and Engineering Training Package MEM07005C Perform general machining Learner guide Version 1 Training and Education Support Industry Skills Unit Meadowbank Product code: 5449
2 Acknowledgments The TAFE NSW Training and Education Support Industry Skills Unit, Meadowbank would like to acknowledge the support and assistance of the following organisations and people in the production of this learner guide. Hare and Forbes Machinery House Fitting and Machining (Ron Culley) Electricity Commission of NSW (Lathe Manual) BHP (Machinist Manual) Blackwoods ISCAR TAFE NSW, Fitting and Machining (Theory Book 2) Writer: Andrew Gill TAFE NSW Reviewers: Mark Pollard (South Western Sydney Institute) Greg Carrol (Western Institute) Project Manager: Stephen Davies Education Programs Manager TAFE NSW Enquiries Enquiries about this and other publications can be made to: Training and Education Support Industry Skills Unit, Meadowbank Meadowbank TAFE Level 3, Building J, See Street, MEADOWBANK NSW 2114 Tel: Fax: The State of New South Wales, Department of Education and Training, TAFE NSW, Training and Education Support Industry Skills Unit, Meadowbank, Copyright of this material is reserved to TAFE NSW Training and Education Support Industry Skills Unit, Meadowbank. Reproduction or transmittal in whole or in part, other than for the purposes of private study or research, and subject to the provisions of the Copyright Act, is prohibited without the written authority of, TAFE NSW Training and Education Support Industry Skills Unit, Meadowbank ISBN Developed by Training & Education Support Industry Skills Unit, Meadowbank TAFE NSW 2011
3 Table of Contents Introduction General introduction Using this learner guide Prior knowledge and experience Unit of competency overview Assessment Topic 1: The centre lathe Introduction and safety Lathe maintenance Mounting work in the lathe Lathe chucks Mounting a chuck Holding work in a chuck Setting up in a four jaw chuck Types of cutting tools Cutting tool materials Setting up the cutting tool Feed and depth of cut Types of cutting operations Lathe centres Principles of metal cutting Cutting f uids Review questions Topic 2: The milling machine Types of milling machines Parts of the vertical mill Vertical mill controls Movements of the vertical mill Movements of the vertical mill head Developed by Training & Education Support Industry Skills Unit, Meadowbank TAFE NSW 2011
4 The bed mill Combination horizontal/vertical mill Horizontal/universal mill Milling safety Mill maintenance Types of milling cutters Cutting tools for vertical milling Selection of milling cutters Care and maintenance of milling cutters Mounting milling cutters Mounting the work piece Clamping in a vice Milling in the vice Milling operations Conventional and climb milling Speeds and feeds for milling Locating the work piece edge Review questions Topic 3: Radial arm drill Introduction Radial drilling machine types Tool holding devices Work holding Safety precautions Drilling operations Setting up in the radial drill Types of cutting tools Cutting speeds and RPM calculations Review questions Developed by Training & Education Support Industry Skills Unit, Meadowbank TAFE NSW 2011
5 Topic 4: Surface grinding Purpose Introduction Machine types Grinder classif cations Surface grinder features Operation of the surface grinder General set-up and installation Dressing and truing Operating procedure Using coolant Maintenance Safety Abrasive wheels Holding work Review questions Job 1: Introduction to the lathe Job 2: Turning to size Job 3: Turn, bore, drill and ream in the lathe Job 4: Introduction to the mill Job 5: Milling to size Job 6: Parallel strip Job 7: Toolmakers Clamp Job 8: Tee Tap Wrench Resource Evaluation Form Developed by Training & Education Support Industry Skills Unit, Meadowbank TAFE NSW 2011
6 Topic 1: The centre lathe Introduction and safety The Lathe is a machine tool in which the work can be held and rotated. A cutting tool is held and either moved along or across the work to produce cylindrical shapes (turning) or f at surfaces (facing). The speed at which the work rotates can be varied as can the speed at which the tool travels (feed). This is necessary because of the different diameters and types of materials that have to be turned. There are many and varied types of operations that can be carried out on the lathe eg, threading, boring, drilling, reaming, form turning etc. Workpiece sizes are determined by the largest diameter and length of work which can be accommodated. Lathe safety precautions Like any machine tool the lathe must be operated in a safe manner and the operator must concentrate on what is being done on the machine at all times otherwise serious injury may occur from poor operating procedures. Possible injuries include: burns, cuts, eye injury and possible entanglement. The following points should be observed to prevent possible injury. Wear suitable close f tting clothing. Wear approved eye protection. Use correct lifting methods. Keep tools or jobs from the headstock (moving parts). Use correct tools and equipment. Keep work area tidy. Keep hands away shavings. Clothing torn off the lathe operator and Do not stop the machine with wrapped around the job your hands. Always remove the chuck key from the chuck. Keep your eyes on the machine while it is operating. Switch the power off when setting the job in the lathe. Ensure all locking pins are secured when changing chucks. Beware of sharp tools in the tool post. Page 21 of 198
7 Lathe dimensions When comparing the size and working capacities of metal lathes there are several key dimensions to consider. They include: Swing over the bed Distance between centres The diameter of the largest work piece that can be rotated on the spindle without hitting the bed. The longest piece of work that can be held between centres. Swing over the carriage Diameter of spindle through hole Centre lathe components Digital readout Chuck guard Head stock Feed box Lead screw Feed screw Swarf tray The diameter of the largest work piece that can rotate over the carriage without hitting it. The diameter of the hole that passes through the spindle. Tool post Top slide Tail stock Carriage Apron Start/stop E stop Cross slide Foot brake Page 22 of 198
8 Heavily ribbed Vee bed Machine ways 1. Bed Bed J Jaw chuck Headstock Feed gear box Lead screw Feed shaft Tool post The bed is the foundation of the lathe. It is the part that aligns and supports the other parts of the lathe. Made from high quality f ne grain cast iron, it is heavily ribbed to remain distortion free. The top surface of the bed has two Vee's and two f ats, one of each for the Saddle and one of each for the Tailstock (Fig 1) and precision machined to accurately align other parts. The top surface of the bed is called "ways" or "slides". On some lathes they may be hardened to give greater wear resistance. Take care of the bed slide ways as worn or damaged ways cannot provide accurate alignment in the moving parts. Thus poor quality work will result. Cross side Compound side Saddle Froward/Reverse lever Tallstock Figure 1 Figure 2 Page 23 of 198
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