Machine Tools and Shop Work

Machine Tools and Shop Work

• Machine tools are power-driven equipment used for drilling, boring, grinding, or cutting metals.
• Machine shop work involves cold-metal work where an operator removes a portion of metal and shapes it using power driven equipment or hand tools, to a specified form of size.
• Machine shop work does not include sheet metal work and copper smithing.

Laying Out Work

• Laying out work is a shop term for scribing lines, circles, and centers on a material's surface to guide shaping a workpiece.
• Laying out work is similar to a shop drawing however lines on shop drawings are for reference only and not used for measurement or transfer

Scribers

• Scribers are layout tools to produce fine lines to use for accuracte layouts on metal.
• The point of a scriber is made of hardened steel and is kept keen by honing on an oilstone.

Dividers

• Dividers are best used when laying out circles, arcs, and radii.
• The divider legs must be the same length and kept sharp.
• Dividers can lay out and measure distances.
• To set a divider, place one point on a steel rule's inch mark and open until the other leg matches the required measurement.

Trammels

• Trammels are used for scribing circles, arcs, and radii too large for dividers.
• A trammel consists of a beam, two sliding heads with scriber points, and an adjusting screw on one of the heads.
• Trammels can scribe larger distances with extension rods.

Hermaphrodite Calipers

• Hermaphrodite calipers are used to layout lines that are parallel with workpiece edges.
• Hermaphrodite calipers also locate the center of cylindrical workplaces.

Vernier Height Gauge

• Vernier height gauges are calipers with a special foot block, and adapt for use on a surface plate
• Common English sizes include 10, 18, and 24-inch gauges.
• Metric sizes include 25 and 46-cm gauges.
• Vernier height gauges are graduated in 0.025-inch divisions with a vernier scale of 25 units to measure to thousandths of an inch.
• Always ensure the foot block's bottom is clean and free from burrs.

Jigs and Fixtures

• Jigs and fixtures align the tool and hold the workpiece during machining.
• A fixture holds the work during cutting without tool guides.
• Jigs are fixtures for locating/holding work while guiding cutting tools in operations like drilling and countersinking.

Hazards and Safety to eyes

• Hazards to eyes include metal chips, particles, and dust.
• Safety measures include wearing safety glasses, safety goggles, or a face shield.

Safety Goggles

• Safety goggles must be worn in the shop and have side guards
• Safety goggles must have a safety rating of Z87.1-1989.

Hazard to Lungs

• Grinding creates dust
• Wear a Mist and dust mask
• or wear a respirator for protection

Hazard to Hands

• Hazards to hands include sharp chips, rotating/moving parts, and cutters.
• Avoid wearing gloves except in welding.
• Keep fingers at a safe distance from moving parts and turn off machines before measuring.
• Use a brush, not hands or rags, to remove chips.

Hazards from Fire

• Keep flammable materials away from heat sources.
• Know the location of fire extinguishers.
• Keep oil rags in a safety can.
• Class A fires involve paper, plastic, cloth, and wood.
• Class B fires involve oil, solvent, and lubricant.
• Class C fires involve electrical wiring.

Carpenter Hammer

• Carpenter hammers are used to drive or pull nails.
• Carpenter hammers have either a curved or straight claw.

Machinist Hammer

• Machinist hammers are for working with metal around machinery.
• Machinist hammers are distinguished by a variable-shaped peen.
• Ball peen hammers come in different weights, such as 4, 6, 8, and 12 ounces, and 1.5 and 2 pounds.

Open End Wrench

• Open end wrenches are solid, adjustable wrenches with openings on one or both ends.
• Open end wrench handles are usually straight but may be curved.

Box Wrench

• Box wrenches are less likely to slip.
• Box wrenches most likely have 12 points
• A disadvantage of this wrench is the loss of time

Combination Wrench

• Combination wrenches have both an open end and box end.

Adjustable Open-End Wrench

• Adjustable open-end wrenches have an adjustable opening.
• Adjustable open-end wrenches fit various sized nuts and bolts.

Pipe Wrench

• Pipe wrenches are adjustable wrenches with curved jaws used to grip round parts.
• Pipe wrenches come in different sizes.

Socket Wrench

• Socket wrenches are cylindrical and attach to a breaker bar, ratchet, or air wrench.
• Socket wrenches offer fast and speedy operation.

Screwdrivers

• Philips screwdrivers are named after Henry F. Philips.
• Philips screwdrivers are used with Philips screws.
• Ratchet offset screwdrivers are manual screwdrivers with a ratcheting action.
• Standard screwdrivers, also known as flatheads, have a single blade.

Rules and Tapes

• Rulers and Tapes measure in inches or centimeters.
• Rulers and Tapes are for woodworking or metalworking.

Carpenter's Square

• Carpenter's squares have flat sides of the blade and the tongue are graduated in inches and fractions of an inch.
• Carpenter's squares are used for laying out and squaring up large patterns.

Try Square

• Try squares consists of two parts at right angles to each other.

Sliding T Bevel

• Sliding t bevel is adjustable with a slotted beveled blade
• Sliding t bevel is primarily for laying out angles other than right angles.

Combination Square

• Combination squares have moveable heads, including a square head, protractor head, and center head.

Cross Cut Saw

• Cross cut saws have a steel blade with a handle at one end.
• The blade is narrower at the end opposite the handle
• Tooth shape is the major difference between ripsaws and crosscut saws.

Back Saw

• Back saws are crosscut saws designed for sawing straight lines.

Key Hold Saw

• Key hold saws have a long, narrow, tapering ripsaw and are used to cut from the bored hold.

Cold Chisel

• Cold chisels are tools for chipping or cutting metal or wood.
• Cold chisels only cut metal that is softer than the material they are made of.
• Cold chisels are classified by head shape and cutting edge width.
• A matching hammer should be used with the chisel.

Wood Chisels

• Wood chisels are for woodworking tasks.

Files

• Files are graded by fineness and whether they have single or double-cut teeth.
• Files remove small amounts of metal, plastic, or wood.
• Files can be used for tooth sharpening.
• Files come in different shapes.

Pliers

• Pliers come in many styles and sizes.
• Pliers are used for cutting, holding, and gripping small articles.
• Types of pliers include slip-joint, vice grip, water pump, slide cutter, diagonal pliers, and needle-nose pliers.

Hand Drill

• Hand drills are used to drill holes into different material.
• Hand drills come in small to large sizes, use light to heavy power and have slow to fast speeds

Belt Sander

• Belt sanders are used to sand down wood and other materials for finishing.

Grinder

• Grinders are used for cutting, grinding, and polishing
• Grinders are used for removing excess material or cutting into a job.

Portable Circular Saw

• Portable circular saws can be used for crosscutting, ripping, mitering, beveling, chamfering, rabbeting, cove cuts, tapering, shaping, and molding cutting.
• Portable circular saws are used when the work cannot be moved to the shop.

Jigsaw

• Jigsaws are used for cutting arbitrary curves in wood, metal, or other materials.
• Jigsaws are used for artistic fashion.

Chopsaw

• A chopsaw is used to cut hard materials, such as metals.

Drill Press

• Drill presses are fixed drills mounted on a stand or the floor
• Drill presses used for drilling holes, sanding, honing, and polishing.

Table Saw

• Table saws are woodworking tools consisting of a circular saw blade.
• The deeper the cut needed the higher the circular saw blade protrudes above the table.

Compound Miter

• Compound miters allow the cutter head and blade to tilt sideways with a rotating vertical pivot.
• Compound miters allow the horizontal and vertical angled cuts to be angled in both planes.

Band Saw

• Band saws consists of a continuous band of metal with teeth along an edge used to cut various workpieces.
• Band saws are used for woodworking, metalworking, and cutting a variety of other materials.
• Band saws are useful for cutting irregular or curved shapes, and straight cuts.

Oxy-Acetylene

• Oxy-Acetylene is used for welding and cutting metal.
• Oxy-Acetylene has two cylinders: oxygen and acetylene.

MIG Welder

• In MIG welding, the wire acts as an electrode and the source of the filler metal.
• MIG welding shields with an inert gas shield and continuously feeds a consumable wire electrode.
• MIG welding is fast, portable, and can be done in a vertical process.

Arc Welder

• Arc welders join metal pieces.
• Arc welders form an arc using a stick or wire electrode between the work and the electrode and can be guided along the joint manually or mechanically.

Plasma Cutter

• Plasma cutters cut steel and other metals of different thicknesses.
• Plasma cutters use a plasma torch.
• Inert gas is blown at high speed out of a nozzle and once an electrical arc is formed some of the gas turns to plasma cutting the surface.

Drilling

• The purpose of Drilling is to creates round holes

Floor Drill Press

• A floor drill press is a drill press which sits on the floor.
• Floor drill presses are used for drilling small to medium sized holes and other light drilling operations

Twist Drill

• The most common tool used in a drill press to cut a hole is the twist drill
• Twist drills are rotary cutting tool which is made of round steel stock
• Twist drills have cutting edges near the point that cut away materials as the drill is brought into contact with the work piece.

Types of Twist Drills

• Twist drills are classified according to their shank shape into
• straight (parallel) shank drill and Morse taper shank drill.

Straight (Parallel) Shank Drill

• Most small drills up to 13 mm in diameter have straight shanks.

Morse Taper Shank Drill

• Tapered drills are supplied in diameters ranging from 3 mm to 100mm diameter.
• Most drills that are larger than 13 mm are tapered.

Determining Drill Size

• Most drills have a diameter size stamped on the shank
• Micrometers and drill gauges are used to determine and check the drill diameters.

Drill-Holding Devices

• The holding device is used to hold the drill during the drilling operation.
• Two main methods to hold the drill which are chucks and tapered spindles

Chuck

• The chuck is an adjustable moving jaw mechanism mainly used for drills with straight shanks.

Tapered Spindles

• Tapered spindles use a tapered opening for drills with taper shanks.
• The drill is locked in the spindle with friction is removed using a drift

Work-Holding Devices

• Work-holding devices are used to hold the work piece during the drilling operation
• The work holding devices are vises and T-bolts and clamps

Vises

• Vises are widely used to hold the work piece during drilling
• The vise must be bolted to the drill ensure safe operation

T-Blots and Clamps

• T-bolts and clamps are used to hold a round work piece onto the drill press table.

Cutting Speed and Material

• Cutting speed is how fast the outside edge of the tool is cutting.
• Cutting speeds varying according to the material being cut and the type of cutting tool being used.
• The harder the work material, the slower the cutting speed. The softer the work material, the faster the cutting speed.

Drilling Procedures

• Always wear safety gear
• First use measuring and layout tools locate the center of the hole to make an indentation using a center punch to mark the center of the hole.
• Before placing the drill into the chuck, determine drill size to be used
• Tighten the chuck with a chuck key, or turn the shank until the tang fits in the slot and, remove the chuck key
• Adjust the table to the desired height using the table handle. and turn the feed handle to lower the drill
• Secure the material to be drilled and set the the drilling machine speed
• Turn feed handle to align first marks

During Drilling

• Turn the feed handle and apply light pressure to lower the drill at the surface
• Too much pressure can potentially break the drill bit
• If the drill bit is binded, withdraw the drill and turn the drilling machine off, remove the the work piece from the work table and remove the drill
• Place the drill in its proper storage location
• Clean the machine table using a brush

Drilling Safely

• First locate the position of the emergency stop
• Wear the required safety gear
• Make sure the chuck key is removed and tighten the clamps and vise
• Tighten the table lock, do not wear loose clothing and do not hold the work use a clamp.