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Machine Tools Level 1 Procedure Plan [UBC]

I N T R O D U C T I O N :

Want to know how to use some of the machinery

in this shop? Well, you have come to the right

place. Welcome to Metal Machine Tools - Level 1.

This unit will introduce you to the; grinder, drill

press, horizontal and vertical band saw, and the

metal lathe.

Further, you

will be learning how to use the machine

safely and correctly, while still developing

your metal working skills. To bring all your

newly developed skills together, you will be

making a camping tool (hatchet). This camping tool will also be a test for yourself

to see what techniques or

machines require further practice.

EDCP 377 Andrew Third December 10, 2012 Aaron Glendinning


G R I N D E R S A F E T Y

Inspect the grinder prior to use to ensure there are no cracks in the abrasive disc. Check that there is nothing flammable in the area of the grinder. Check to make sure the tool rest is 1/16” - ⅛” from the stone. If there is too much room

between the stone and the rest, your work could jam causing the stone to shatter. Always stand to the side when starting the grinder. �If the stone has a flaw, it is most likely to fly

apart as it speeds up. Only grind on the face of the stone, never on the side - it could explode in your face. Work should be moved back and forth across the face of the stone to avoid creating a groove in

the center. Use moderate pressure when grinding. If you push too hard, you will stress the machine and

the stone, and generate unnecessary heat in the material you are grinding. Avoid grinding small pieces or, if necessary, hold them firmly in pliers or vice grips. Small pieces

could easily be pulled out of your grasp and cause problems. Do not grind either sheet metal or soft metals like brass or aluminum on the grinder. Sheet

metal vibrates too much and can easily get caught, and non-ferrous metals such as aluminum can quickly plug up the stones and cause them to explode.

Grinding generates a lot of heat in the metal being ground. Cool your material regularly and take care not to burn yourself when it is hot.

NO GLOVES when grinding, they can get caught in the wheel and cause injury. Full face shield, leather apron and hearing protection are required.

IF ANY PART OF THE GRINDER DOES NOT MEET SPECIFICATION, OR YOU ARE UNSURE ABOUT SOMETHING, CHECK WITH THE TEACHER FIRST!!!



G R I N D E R S A F E T Y Q U I Z

Name: _______________________________ Date: _______________________________

Class: _______________________________ Section: _______________________________

1. What is the range of distance allowed between the tool rest and the stone on a grinder?

2. What could happen if you were to grind on the side of a grinding stone?

3. Where should you stand when starting up the bench grinder?

4. Why should you avoid using excessive pressure when working on the bench grinder?

5. Why is it especially dangerous to grind small pieces on the bench grinder?

6. What kind of materials should not be worked on the bench grinder?

7. Why is there a danger of burning yourself when using the bench grinder?

8. What personal protective equipment do you need when operating a bench grinder?



G R I N D E R S A F E T Y A N S W E R S

1. What is the range of distance allowed between the tool rest and the stone on a grinder?

1/16” – 1/8”

2. What could happen if you were to grind on the side of a grinding stone?

the stone could explode

3. Where should you stand when starting up the bench grinder?

to the side

4. Why should you avoid using excessive pressure when working on the bench grinder?

the stone could explode

too much heat - half marks

5. Why is it especially dangerous to grind small pieces on the bench grinder?

Could fall in and cause problems

6. What kind of materials should not be worked on the bench grinder?

soft materials like brass and aluminum

7. Why is there a danger of burning yourself when using the bench grinder?

grinding generates heat OR friction

8. What personal protective equipment do you need when operating a bench grinder?

apron, face shield, ear protection



P R O C E D U R E : U S I N G T H E B E N C H T O P G R I N D E R

Bench grinders can be used for many tasks – sharpening tools like chisels and drill-bits, removing material much more accurately than can be achieved by (say) a hand-held angle grinder, grinding castings and sometimes on small items, cleaning-up welds.

The most difficult items to grind are those that are small and those that are thin.

Work-pieces must always be supported on the tool-rest.

If the work is supported too far from the grinding wheel, chatter will result.

o Work could be flung from hand causing injury.

Angling the work-piece too high will tend to drag the material into the gap between the wheel and the rest.

o Work can be pulled away, potentially causing a jam and damage to the grinder.

Use vice grips to hold small items.

o If you’re worried the work might be marked up by the pliers, consider removing material in other ways.

Ensure a container of water is nearby for cooling.

o If the work piece is too hot to hold, it is not being cooled frequently enough.



D R I L L P R E S S S A F E T Y

Tie long hair back. Remove all strings and/or jewelry that could get caught in the drill press. The material you intend to drill must be held in the drill vice or be clamped to the drill table.

o This will prevent it from spinning around and hurting you if the drill bit were to catch. Be sure to centre punch hard materials like metals before you drill them.

o The punch mark will prevent the drill bit from slipping around as you try to start the hole. Set appropriate speed for the drill.

o Too high a speed could wreck the bit. Make sure the chuck key is out of the chuck every time you go to start the drill. Make sure the bit is clear of the stock before you move it.

o If you do move the stock when the bit is still in the hole, you could break the bit. Put some scrap wood under your work, or position it in the vice so that the bit will come

through in the centre or at the side of the vice so you don’t drill in to any of the equipment!

IF ANY PART OF THE DRILL PRESS DOES NOT MEET SPECIFICATION, OR YOU ARE UNSURE ABOUT SOMETHING, CHECK WITH THE TEACHER FIRST!!!



D R I L L P R E S S S A F E T Y Q U I Z

Name: _______________________________ Date: _______________________________

Class: _______________________________ Section: _______________________________

1. Why is it important to secure the material you plan to drill on the drill press?

2. How do you prevent the bit from slipping off target and possibly breaking when drilling hard materials like metal?

3. What should you check each time you are about to start the drill press?

4. What could happen if you move the stock before the bit is completely clear of the hole?

5. How can you avoid making unwanted holes in the drill press vice?

6. Why do you need to tie long hair back and remove jewelry and/or strings when working around the drill press?



D R I L L P R E S S S A F E T Y Q U I Z A N S W E R S

1. Why is it important to secure the material you plan to drill on the drill press?

To keep the operator safe from the work piece if the drill bit gets caught in the work piece

2. How do you prevent the bit from slipping off target and possibly breaking when drilling hard materials like metal?

By using a center punch

3. What should you check each time you are about to start the drill press?

Check to make sure the chuck key is out the chuck

4. What could happen if you move the stock before the bit is completely clear of the hole?

There is a chance that the drill bit could break

5. How can you avoid making unwanted holes in the drill press vice?

By placing a piece of wood under the work piece

6. Why do you need to tie long hair back and remove jewelry and/or strings when working around the drill press?

Because there is a chance that your hair/jewelry/loose clothing could get caught in the spinning chuck and drag you in.



U S I N G T H E D R I L L P R E S S

Ensure you are following the class safety procedures before operating this machine.

1. Determine where you would like the hole on your work piece

2. Center punch the center of your hole

3. Select the diameter of your hole and select the corresponding drill bit

4. Place your work piece in a vise or clamp your work piece to the drill press table. Place a piece of wood underneath the work piece if you are drilling through.

5. Place drill bit into drill chuck, and tighten. Remove chuck key before turning on machine.

6. Select an appropriate drill speed that works with the drill bit diameter.

7. If needed apply coolant to drill bit

8. Brush swarf away with brush

9. Once hole is drilled, turn off machine. Once drill bit has stopped rotating, you can remove your work piece from the vise or table.



B A N D S A W S A F E T Y

● Set the upper guide and blade guard so they are just above the stock. This guards the blade and

helps to keep the cut straight. The upper guide should be within 1/8” of the stock.

● Use a push stick and keep your fingers at least 2 inches away from the blade at all times.

● Always feed the stock with light pressure and avoid excessive twisting of the blade.

● Too much pressure or twisting can break the blade.

● Use less pressure as you near the end of a cut - the blade will come out the last 1/16” or so.

● Plan your work so you can proceed in a sensible order. Never back out of long, curved cuts.

● Use relief cuts on sharp corners. Thinner blades can cut sharper corners without relief cuts.

● Never cut round or odd shaped pieces unless you use a jig to stabilize them. They can twist out

of your control from the force of the blade.

● If the machine has a brake, use it to stop the blade after the power has been switched off;

otherwise, stay with the machine until the blade stops moving.

● If the blade breaks, turn off the machine and tell your teacher.

● Do NOT stand to the right of the vertical band saw while

someone else is using it. If the blade breaks, it might flip out in

that direction.

● Both eye and hearing protection are required when using a

bandsaw.



B A N D S A W S A F E T Y Q U I Z

Name: _______________________________ Date: _______________________________

Class: _______________________________ Section: _______________________________

1. How close to the stock should you set the upper guide?

2. What is the minimum distance you should keep your fingers from the blade?

3. If you have a number of cuts to make, what should you do before you start?

4. When are ‘relief cuts’ needed?

5. Why is it dangerous to cut round or odd shaped pieces on the band saw?

6. What should you do if the blade breaks?

7. Why should you stay away from the right hand side of the saw while it is running?

8. Identify three steps for shutting down a band saw?



B A N D S A W S A F E T Y Q U I Z A N S W E R S

1. How close to the stock should you set the upper guide?

1/8”

2. What is the minimum distance you should keep your fingers from the blade?

2 inches

3. If you have a number of cuts to make, what should you do before you start?

Plan your cut sequence

4. When are ‘relief cuts’ needed?

When cutting sharp corners

5. Why is it dangerous to cut round or odd shaped pieces on the bandsaw?

The force of the blade can twist the stock out of your hand

6. What should you do if the blade breaks?

Turn the machine off and get an instructor

7. Why should you stay away from the right hand side of the saw while it is running?

If the blade breaks it has the possibility of flipping out the right side of the machine

8. Identify three steps for shutting down a bandsaw?

a. Turn power off

b. Use foot brake to stop blade

c. Clear material from machine - blade can still cut you even though it is not turning.



C U T T I N G O N T H E H O R I Z O N T A L B A N D S A W :

Ensure you are following the class safety procedures before operating this machine

1 Determine where you would like to cut your work piece.

2 Lift upper body of band saw until it cannot go any higher. Loosen clamp, and place work piece in

clamp, but do not tighten clamp.

3 Slowly bring down band saw body and line blade up with the mark on your work piece.

4 Once you are happy with where the blade meets your mark on the work piece, tighten the

clamp.

5 Lift the upper body of the band saw just so it is above the work piece, about 1 inch is sufficient.

6 Turn on band saw.

7 Gently bring blade onto work piece and let blade slowly, but efficiently cut through work piece.

8 Once blade is completely through work piece, turn machine off.

9 Lift upper band saw body until it cannot go any higher. Loosen clamp and carefully remove

excess material. Your piece that you cut out will be in the band saw tray or on the floor. Be

careful, the work piece and excess material will be hot.



C U T T I N G O N T H E V E R T I C A L B A N D S A W :


1. Determine where you would like to cut your work piece.

2. If cutting round stock, place material against jig to prevent stock from twisting out your hand.

3. Ensure upper guide is ⅛ inch above work piece.

4. Turn machine on, and slowly, but efficiently run work piece through blade.

5. Once blade through work piece, turn machine off. Use machine brake to stop blade.

6. Once blade has stopped, remove work piece from band saw table.



L A T H E S A F E T Y

● Make sure the stock is secure and that all locks are tight before turning on the lathe. Otherwise the piece of steel might shift or fly out when it starts to spin or when you start to cut it.

● Never leave the chuck key in the chuck. It should either be in your hand, if you are using it, or on the tool rack. Leaving it in the chuck will lead to an accident!

● Material that extends more than twice its diameter out of the chuck should be supported on the tailstock end. If unsupported, the stock could flex as it spins or as you cut, causing vibration, chatter and a hazardous situation.

● Use extreme caution if your stock extends through the headstock end. Many accidents have resulted when an operator, while concentrating on the cut, failed to notice the end of the stock whip around. Others have been injured by trying to steady the protruding end (don’t do this), or by bumping into it accidentally as they pass by.

● Tuck in your shirt-tail to prevent it from getting caught in the feed and lead screws which are right by your hips.

● Wear eye protection.● Wear appropriate gloves when handling stock, but not when operating the lathe.● Ensure the stock has completely stopped rotating before attempting to handle it.



L A T H E S A F E T Y Q U I Z

1. What two things should you secure before starting the metal lathe?

2. Why should you never leave the chuck key in the lathe chuck?

3. Any material that extends more than ______________________ its diameter out of the chuck should be supported on the tailstock end.

4. Why is stock that sticks out of the headstock end of the lathe dangerous?

5. Why is it important to remove open coats and tuck in your shirt-tails when using the lathe?

6. What personal protective equipment is required when operating a metal lathe and handling the stock?



L A T H E S A F E T Y Q U I Z A N S W E R S

1. What two things should you secure before starting the metal lathe?

a) stock is secure

b) all locks are tight

2. Why should you never leave the chuck key in the lathe chuck?

It is very dangerous and left in the chuck it becomes a flying object which will lead to an accident.

3. Any material that extends more than ____twice____ its diameter out of the chuck should be supported on the tailstock end.

4. Why is stock that sticks out of the headstock end of the lathe dangerous?

Because the operator can forget that it is spinning, and people have tried to steady the protruding end or bumped in to it when walking by.

5. Why is it important to remove open coats and tuck in your shirts when using the lathe?

To prevent your clothing from getting caught in the feed and lead screws.

6. What personal protective equipment is required when operating a metal lathe and handling the stock?

Gloves when handling stock, and eye protection when on the lathe



F A C I N G O N T H E L A T H E :


1 Ensure power is off to the lathe.2 Ensure the compound slide is set at 0 degrees.3 Mount stock in 3 jaw chuck, ensuring to rotate stock while tightening.

-Remember not to protrude stock more than twice its diameter! Closer the better!4 Tighten chuck and REMOVE chuck key from chuck.5 Ensure tool bit is centered vertically with work piece; use the metal ruler technique I showed

during the demo.6 Ensure machine on/off lever is off and also rotate the chuck by hand to ensure everything is

clear.7 Turn machine power on.8 Turn forward/reverse lever in the correct direction for cut.9 Bring the saddle towards the stock slowly so that it JUST touches the stock.10 Back the cutter out on the cross slide.11 Move the cutter in a maximum of .020” using the compound slide.12 Use the cross slide and slowly bring cutting edge of tool bit across the face of the work piece.

DO NOT GO PAST CENTER! This can damage the tool bit.13 Once you have faced the work piece, move tool away from work piece and turn machine lever

to off position.14 Clean swarf off tool bit and work piece with brush.15 Remove stock and deburr as necessary.16 If facing to length, measure stock and repeat process until final size is reached. Remember to

take off a maximum of .020 per pass.



T U R N I N G A T A P E R W I T H T H E C O M P O U N D S L I D E


1. Ensure the lathe is powered down.2. Mount stock in chuck (max 2x dia protruding!).3. Set compound to the required angle. Remember to set the angle to half the included angle.4. Ensure tool bit is vertically centered using the ruler technique. Above or below center will

generate a curved surface.5. Using the apron and cross slide handles, position the tool bit close to but not touching the edge

where you will perform the first cut.6. Rotate the chuck by hand to make sure nothing will hit.7. Turn on the lathe power.8. Engage the lathe’s forward/reverse lever in the direction of cut.9. Using the cross slide, slowly move the tool bit towards the stock just until it touches.10. Move the tool bit to the right to clear the stock.11. Using the cross slide, move the tool bit towards the stock for first cut (max .020”).12. Using the compound slide, make a pass then return the tool bit to its starting position.13. Repeat steps 10 and 11 until desired taper is achieved.14. Dress with file or emery cloth.15. Power down lathe.16. Remove stock from chuck.



L A T H E K N U R L I N G :


1 Ensure machine power is off2 Mount stock in chuck (max 2x dia protruding!) and forcefully tighten.3 Install live center in to tailstock.4 Bring live center in contact with prepared surface.5 Lock the tail stock in place firmly.6 Place knurling tool into tool bit holder. Once aligned perpendicular with stock and aligned

vertically so that the knurling head pivot is aligned with center of stock, tighten in holder.7 Select an appropriate speed for knurl (slow 70-150rpm is typical).8 Set the auto feed rate on lathe to roughly .020” per revolution.9 Align knurling tool to the right hand side of the area to be knurled.10 Get instructor to check the knurling setup.11 Apply cutting oil to the knurling tool.12 Turn machine power on.13 Turn direction lever to on the regular position.14 Engage knurling tool with stock. Once engaged do not back out!15 Leaving the knurler engaged, turn machine lever to off position and check the depth of knurl.16 If satisfied with knurl, turn machine back on and engage auto feed by pulling the lever up.17 Check the progress of the knurl by turning machine off, but do not disengage the knurler!18 Once you have knurled the desired area, disengage the knurler and turn machine lever to off

position.19 Disengage the auto feed and turn machine power off.20 Back off tail stock and remove the work from the chuck.



L E S S O N P L A N 1

Teacher’s Name: ____________________________________________________Subject: __Metal 11__

Lesson Topic: Cutting on Band Saw and Facing on Lathe

Rationale

Why these students? Because they do not yet know the processes for creating their next project, the survival tool.

Why at this time? Students are in the finishing stages of their previous project, and early finishers are ready to move on.

What background knowledge do these students need to know up to this point? Bandsaw and Lathe safety.

Prescribed Learning

Outcomes

Metal 11- identify, organize, and execute processes required to accomplish a task Metal 11 - consistently use safe work practices Metal 11 - demonstrate a knowledge of safety features and practices associated with

metal-related tools and equipment Metal 11 - estimate the solutions to calculations involving whole numbers, decimals,

and fractionsStudent Learning

Objectives SWBAT: safely perform the tasks required to make the handle for their survival tool.

Required Vocabulary

and/or Language Strategies

Sch (schedule), tube, pipe, cutting speed, surface feet per minute, lathe, chuck, carriage, RPM, knurl, face, toolbit, ways, cross feed, compound feed, tail stock, live center

Timeline Teacher Activity Student Activity Time

Teacher will call students to the demo and distribute the handout.

Teacher will show students a completed project and emphasize the importance of the mil-scale and the fit and finish.

Teacher will explain difference between pipe and tubing.

Students will write their names on the handout.

Students will view the project be quizzed on why they think the mil scale is important.

Students will be asked if they know the difference and guess to get them

1 Min

2 Min.

4 Min



Teacher will explain what schedule is and explain the importance of proper use of terminology in a shop.

Teacher will demonstrate safe use of band saw in cutting the pipe to length. While the band saw is cutting, teacher will re-enforce safety considerations for the band saw.

After having a student read out the next step, will move group to lathe. Teacher will explain safety considerations, explain basic nomenclature for lathes, and face off and face to length the piece of pipe.

Students will be dismissed to continue work on their own projects.

thinking about possible answers.

Students will be reading the points of the handout and encouraged to use proper terminology.

Students will witness the safe use of the band saw.

Students will be asked regularly if they know what various parts of the lathe are called. Also will be asked what safety considerations they should take while working on the lathe.

Students will continue work on projects until clean-up is called.

3 Min

5 Min

10 Min

~ Min

Extensions/

Modifications/ &

Early Finishers

Since this lesson is introducing a new project, all students should have work to do. Students that are ahead will also be encouraged to help students that are struggling.

Assessment Standard employability assessment and safety assessment.

Materials 10+” length of Sch/40 pipe, tape measure, marker, handout



L E S S O N P L A N 2

Teacher’s Name: ____________________________________________________Subject: __Metal 11__

Lesson Topic: Turning a taper using the compound slide and knurling

Rationale

Why these students? Because they do not yet know the processes for creating their next project, the survival tool.

Why at this time? Students are in the finishing stages of their previous project, and early finishers are ready to move on.

What background knowledge do these students need to know up to this point? Bandsaw and Lathe safety.

Prescribed Learning

Outcomes

Metal 11- identify, organize, and execute processes required to accomplish a task Metal 11 - consistently use safe work practices Metal 11 - demonstrate a knowledge of safety features and practices associated with

metal-related tools and equipment Metal 11 - estimate the solutions to calculations involving whole numbers, decimals,

and fractionsStudent Learning

Objectives SWBAT: safely perform the tasks required to make the handle for their survival tool.

Required Vocabulary

and/or Language Strategies

Sch (schedule), tube, pipe, cutting speed, surface feet per minute, lathe, chuck, carriage, RPM, knurl, face, toolbit, ways, cross feed, compound feed, tail stock, live center

Timeline Teacher Activity Student Activity Time

Teacher will call students to the demo and distribute the handout.

Teacher will have students move to 2nd lathe and start demo by showing the cut on the compound slide. Emphasis will be on the cutting direction.

Students will write their names on the handout.

After reading the step, students will observe a cut on the compound slide. One student will perform a few cuts to show how easy it is.

1 Min

10 Min.



Teacher will have students move to 3rd lathe and continue demo by showing them how to knurl. Emphasis will be on the tail stock and auto feed.

Students will be dismissed to continue work on their own projects.

After reading the step, students will observe knurling in conjunction with the auto feed. One student will knurl a section of pipe.

Students will continue work on projects until clean-up is called.

10 Min

~ Min

Extensions/

Modifications/ &

Early Finishers

Since this lesson is still introducing a new project, all students should have work to do. Students that are ahead will also be encouraged to help students that are struggling.

Assessment Standard employability assessment and safety assessment.

Materials 10+” length of Sch/40 pipe, tape measure, marker, handout



U N I T P L A N

Name + Grade of Course:

Metal Technology 10.

Rationale:

To introduce students to machinery in the metal shop.

Goals:

To have students use the metal shop equipment safely, and comfortably.

Title of Unit:

Machine Tools Level 1

Curriculum Organizers: (IRPs)`

Technology Education 8-10

Accommodations:

2 students with IEPs - discuss strategy with SEA.

LESSON TOPIC

SPECIFIC LESSON OBJECTIVES (SWBAT)

(PLOs)

TEACHING METHODS + ACTIVITIES

(include Closing Activities)

STUDENT ACTIVITIES

MATERIALS/ RESOURCES

ASSESSMENT STRATEGIES +

CRITERIA

1 Grinder ● Identify safety concerns

● Proper use of grinder● Be aware of material

you are grinding

● Explain safety concerns with grinder

● Demo proper use of grinder

●

● Listen/understand to safety concerns

● Be able to properly/safely use grinder

● Grinder● Tool to

sharpen or stock to grind

● Grinder handout

● Able to use equipment safely and correctly

● Passed safety test

2 Drill press ● Identify safety ● Explain safety ● Listen/understand ● Drill press ● Able to use



concerns● Proper use of drill

press● Be aware of material

orientation

concerns with drill press

● Demo proper use of drill press

● Introduce types of drill bits

to safety concerns● Be able to

properly/safely use drill press

● Drill bit● Stock to demo

on● Drill press

handout

equipment safely and correctly


3 Project ● Ability to use equipment correctly and safely

● Ability to follow plans/work independently

● Introduce “Camping Tool” project

● Go over project plans and criteria

● Understand what is required for project

● Ask any questions or concerns

● Stock● Tool bits● All shop

equipment in working order

● Able to use all equipment safely and correctly

● Shows signs of skill development

4 Horizontal band Saw

● identify safety concerns

● proper use of horizontal bandsaw

● Allow blade to naturally cut material - dont force

● Explain safety concerns with with horizontal band saw

● Demo proper use of horizontal band saw


● Be able to properly/safely use horizontal band saw

● Horizontal band saw

● Stock to demo on

● Horizontal band saw handout



5 Vertical band saw

● identify safety concerns

● proper use of vertical bandsaw

● Be aware of hand

● Explain safety concerns with vertical band saw

● Demo proper use vertical band saw


● Be able to properly/safely use vertical band

● Vertical band saw

● Stock to demo on

● Vertical band


● Passes safety



placements saw saw handout test

6 Lathe ● identify safety concerns

● proper use of lathe● Be aware of chuck

key

● Explain safety concerns with metal lathe

● Demo measuring, facing, and facing to length


● Be able to properly/safely use metal lathe

● Metal lathe● Tool bits● Stock to

machine



7 lathe ● identify safety concerns

● proper use of lathe● Be aware of chuck

key

● Explain safety concerns with metal lathe

● Demo knurling and angled cuts


● Be able to properly/safely use metal lathe

● Metal lathe● Tool bits● Stock to

machine


● Passes safety test



C A M P I N G T O O L P R O C E D U R E

Handle

1. Cut a piece of 1/2” Sch 40 pipe 1-1/8” long.2. Mount in 3-jaw chuck and face the first end square.3. Turn the handle, remount and face to length.4. Chamfer the inside of the second end at 30deg for ½ the wall thickness.5. Mound the handle in the chuck with 8” protruding, supported by a live center in the tailstock.6. Lightly knurl 5” nearest the tailstock.7. Machine ½ the head of a 7/16” x 3/4” bolt to fit snugly into the plain end of the handle.8. Press the bolt into the handle, have it checked and then weld it in place.9. Thread the knurled end of the handle with a 3/8 NPT tap.10. Press a 5/8” nut ont a 3/8” pipe plug and weld it solid.

Attachment

1. Select a suitable piece of 1/8” HRMS, layout the attachment and have it checked.2. Shear, saw, grind and file the blank to dimension to fit the insert.3. Use OFW to weld the Hardox insert to the attachment.4. Grind all edges smooth.5. Align with the center of the hammer block and weld in place with 6011 and 7018.6. Harden and temper insert.

Hammer Block

1. Cut 1-9/16” x 1-1/2” HRMS square stock and machine to length.2. Layout the two holes as per the diagram and have them checked.3. Drill and counter bore the holes as per the diagram.4. Thread the holes as per the diagram.

Tab

1. Cut a piece of 1/8” HRMS – 3/4” x 1-1/2” and deburr all edges with a file.2. Drill to match the holes in a hammer block. Drill or file the large hole oversize if necessary.

Assembly

1. Place the tab over the holes in the hammer block and secure with the 1/4-20 bolt.2. Screw the handle firmly into place and tack it to the tab.3. Remove the handle/tab assembly and weld all around with GMAW.4. Reassemble the unit and give it a final cleaning and inspection before handling it.



C A M P I N G T O O L L A Y O U T



M A R K I N G R U B R I C – C A M P I N G T O O L

Handle /34o 10” long (-1 / .050) - /10o Knurl

5” long (-1 / .100) - /5 Consistent knurl - /4 Depth of knurl - /4

o Bolt Straight - /2 GMAW Weld - /6

o Tapping quality - /3 Hammer block /26

o 1-1/2” tall (-1 / .020) - /10o Large hole location - /3o Large hole correct size - /3o Large hole tap quality - /2o Small hole location - /3o Small hole correct size - /3o Small hole tap quality - /2

Attachment /14o Layout accuracy - /10o Correct thickness - /4

Tab /22o 1-1/2” long (-1/ .020) - /10o Large hole location - /3o Large hole correct size - /3o Small hole location - /3o Small hole correct size - /3

Assembly /34o Mil scale intact - /4o GMAW Welding - /10o OFW Welding - /10o SMAW Welding - /10

Total /130



R E F L E C T I O N

Coming together as partners we decided that we would like to focus on a metal program designed for

beginner students. We wanted to introduce students to a variety of entry level procedures spanning the

integral machinery in the metal shop. The reasoning behind choosing machine tools level one was

because it’s a unit that we can and will be applying to our classes during our extended practicum. We

took this assignment very seriously because we plan to use this content in our teaching next semester,

so we have a vested interest in the content.

When we first started this booklet, we were having troubles coming up with what to call the unit. Other

subjects have very defined units, such as the renaissance and the industrial revolution in social studies.

But in metal fabrication and machining, there is more of a flow between sections of learning. There are

no defined sections, just a gradual progression of knowledge and experience. So defining a unit proved

to be a problem in this environment. Thankfully we already had in mind the "flow" of what we wanted.

So it was just a matter of assigning a name to a section of that flow.

The result of our efforts was "machine tools level 1", the second unit in a metal 11 class. Here we focus

on entry level machine tools and their safety; starting with the bench top grinder, the drill press, the

band saw, and finally an introduction to the lathe. The lessons will include many components like a

lecture with handout, teacher demo, student demo, and safety quizzes.

Because this was designed for entry level students, it focuses on a single project. Once students develop

a base of knowledge to work from, the projects would start becoming more and more open ended and

design based. After all it has been proven that the first level of motivation in technology education is

autonomy.


machine tools level 1 procedure plan - dlc-ubc.ca web viewmachine tools level 1 procedure plan [ubc]...

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