Tools of the Shop

MEGR 2299

Machinery General

• Never wear long sleeves, never allow long hair to hang free.

• Always wear safety glasses.

• A cutting tool is usually an insert, drill bit, end mill, or device that contacts the work in order to remove some material in a controlled manner.

• A machine tool is a device that holds the tool.

• Always clean off your machines when done working.

• If you don’t know what speeds or feeds you need, please ask.

• Never operate a machine that uses coolant, and you notice there isn’t coolant flowing.

• If you don’t know…ask!

Vertical Band Saw

Vertical Band Saw

• Good for cutting some shape, or curved patterns.

• Good for very thin or thick sections.

• Good for hard or soft materials – band speed dependent and band material dependent. # of teeth per inch also predicates the material it can cut.

• MUST adjust speed for the material you wish to cut.

• Adjust blade guard for material size.

• Always push material through with a piece of wood.

• No coolant needed with this machine.

• Safety concern is flying chips, and fingers when pushing on stock.

• This will cut almost all materials…(except stainless)

Vertical Saw Speed Adjuster

Horizontal Band Saw

Horizontal Band Saw

• Good for cutting large and heavy sections.

• Makes a decent finish, holds a decent line.

• Speed is fixed, feed is adjustable.

• Feed is set by regulating bleed off air pressure on a cylinder. Feed faster through soft materials, and slow through hard materials.

• Thickness of blade, material of blade, and # of teeth per inch on blade will determine your ability to cut materials.

• This saw does use coolant, do not attempt to cut without coolant flowing.

• Primary safety concerns are fingers when adjusting stock in vise.

Hydraulic Shear

Hydraulic Shear

• This tool uses extreme pressure from very hard and sharp dies called blades or shears.

• The pressure is so great and so focused, the slip planes in the materials crystal structure are found and exploited, or cut.

• Limitations = steel .032” max, aluminum .065” max. Beyond these thicknesses will probably cut but wear out the ways and the edges on the dies.

• Primary safety concern is smashing of fingers. Pay particular attention to your finger placement when pressing the start button.

Manual Shear

Manual Shear

• This tool performs the same operation as the hydraulic shear, however instead of using hydraulic pressure to cut the material, it uses man-power (woman-power if applicable).

• Put material in like hydraulic shear, and with your leg, press down the yellow diamond plate bar. (Having multiple people jumping on the bar to cut material is not acceptable).

• Limitations are based on your leg power, but no more than hydraulic shear (steel .032” max, aluminum .065” max)

• Primary safety concern is smashing of fingers just like in hydraulic shear. Pay particular attention to your finger placement when pressing down on bar.

Drill Press

Drill Press

• This tool is designed to hold a drill bit, and provide a stiff platform to hold your work piece.

• It is adjustable in speed, you the operator control the feed.

• To figure the speed setting use this:

• CS X 4D

• Where:

• CS = cutting speed (found in look up chart)

• D = Diameter of drill bit

• A general principle with the drill press is the larger the drill bit, the slower the speed.

Speed and Feed Chart in the Shop

Speed and Feed Chart in the Shop cont’d

Feed Advancement ProgressionMaterial .050" Depth of Cut .250" Depth of Cut

1/8" 3/8" 1/2" 3/8" 3/4"

Plain Carbon Steels

.0005-

.001.002-.003

.003-

.004.001-.002

.002-

.004

High Carbon Steel

.0003-

.001.001-.003

.002-

.004.0003-.001

.001-

.004

Tool Steel.0005-.001

.001-

.003.002-.004

.001-

.002.003-.004

Cast Aluminum Alloy

.002 .003 .005 .003 .008

Cast Aluminum -Hard

.001 .003 .005 .003 .006

Brasses & Bronzes

.0005-

.001.003-.004

.004-

.006.002-.003

.004-

.006

Plastics *Much Variation

.002 .004 .005 .003 .008

Southbaymachine.com

Cold Saw

Cold Saw

• The cold saw is used to cut hard and thick sections of material.

• It cuts slowly and loud.

• Its called a cold saw because unlike it’s counter part –(chop box) the material is around ambient temperature after cut.

• With a sharp blade the finish is excellent, and the line through the stock is excellent.

• This tool uses coolant, never operate with out a steady flow.

• Pull steady on the handle but do not force it down.

• Low hazard for chip flying, most safety is related to the noise.

• Will cut, ferrous and non ferrous materials.

Chop Box

Chop Box

• Chop box has an abrasive cut off wheel (usually made up of aluminum-oxide) that cuts the material.

• Unlike the cold saw, the chop box rapidly heats up the cutting zone of the material and often gets it red hot. (heat treat)

• It is louder and usually faster than the cold saw but leaves a rougher cut surface.

• It does not use coolant.

• You must pull or push down on the handle to get it to cut.

• It is mainly for ferrous materials and stainless.

• Safety hazard is flying hot metal chips and noise.

Tube Notcher

Tube Notcher

• This machine tool is designed specifically for notching tubular material. The notches are specific to the diameter of the tool used in chuck.

• The primary purpose is notching tubes to make a chassis.

• The tool speed is adjustable, the tool is in a fixed position. The stock advances into the spinning tool. Feed rates depend on tool material, lubricant, number of teeth on the tool, tool diameter, stock size and material.

• Just like drilling, as tool diameter goes up speed goes down, and as stock harness goes up feed goes down.

• Primary safety concern is getting fingers caught between tube and cutting bit.

Tube Notcher Tools

Fine helix Course helixContinuous

helix

Bead Roll

Bead Roll

• This tool is used to make a bead in light gage sheet metal.

• Beads strengthen a open section of sheet metal.

• This machine is limited to very light gage steel, .023” thick, or up to .065” aluminum.

• The primary safety issue is related to pinching your fingers.

• The primary machine limitation is material thickness due to strength of the fixturing and power of the motor.

Electric Tube Bender

Electric Tube Bender

• This machine is used to non-mandrel bent steel tubing. It uses dies specific to the diameter you would like to bend.

• This machine is electric (208 VAC), and very powerful.

• The primary safety concerns are pinching fingers

• Machine is numerically controlled (NC) so if accidently program for a large angle bend, can have tube moving more than anticipating

Hand Roll

Hand Roll

• This tool is full manual, you need to crank the lever to make the rollers move and you also need to guide in your sheet metal.

• This machine is limited to thin materials, and slow increases of radial changes.

• The primary purposes are to curve sheet metal. (Industrial rolls come with power drives and can roll 1 inch plate…not what we have)

• The primary safety concern with a roll is pinching fingers. Since you have to crank it with one hand, its unlikely you will pinch your fingers, but people helping you hold the work material could have their fingers pinched.

Finger Brake

Finger Brake

• This machine is full manual. You place your part in the jaws and apply the clamp. Lift on the red handles and it will bend the piece of material until you stop pulling.

• You can attach a magnetic level to determine the angle you are trying to bend.

• The primary safety concern is pinching your fingers by the clamp.

Belt / Disk Sander

Belt / Disk Sander

• This machine is heavily used in the shop, and great for knocking off an edge of saw cut material.

• It has (2) powered sanding surfaces;• 1- a steel backed vertical belt.

• 2- a steel backed disk.

• The limitations depend on the grit, or roughness of the sandpaper that is on it.

• It will provide the first level of de-burring necessary, and reasonably dressed edges.

• The primary safety concerns are pieces getting hot from sanding and burning your fingers, and losing grip of your part and sanding your fingers tips off.

• Can sand anything the sandpaper is designed for.

Stone / Wire wheel

Wire wheel Stone

Falcontrading.comGrainger.com

Stone / Wire wheel

• Stone’s are vitrified and specific to ferrous metals. Never try to grind aluminum with one of these stones. The aluminum gets imbedded into the stone, heats up, expands, then can explode the stone.

• Stones come in different grits. This will drastically change the finish after grinding. The stone should be between 1/16th and 1/8th away from the rest. Larger gaps can cause your part and fingers to get sucked in.

• The wire wheel is good for lightly cleaning threads, removing rust, and some coatings.

• Both the stone and the wire wheel are very dangerous, they each can quickly remove skin, and the stone throws sparks and material into the air, usually at your eye balls.

Buffer Wheel

Grainger.com

Buffer Wheel

• Buffer wheels are specifically designed to lightly de-burr edges without leaving directional grooves and leaving a highly polished finish.

• They can lightly de-burr anything hard, metallics and some non-metallics. Wheels come in different grits, and different densities.

• They are meant to be a last step in the de-burring process.

• Must wear safety glasses, and high quality dust mask. The particulate from the wheel is very bad for your lungs.

• Make sure the material your buffing isn’t sensitive to other materials. For example buffing on aluminum when the previous person was buffing on carbon steel. The steel was embedded into the wheel, now is embedded into your aluminum.

Levels of De-Burring

• In industry a rough saw cut, laser cut, water jet cut, plasma cut, or flame cut will earn you a bad reputation. Never deliver someone a as cut piece unless the prints instruct you to do so.

• De-burring edges can be done with several tools, a simple file can go a long way. The most important thing is the finished edge is consistent with the remainder of the part. For example a fully machined piston would not receive a belt sanded edge as finish prep, but a chassis would.

• Here we expect you to ask, and consider the tools available to you.

• Proper finishing technique is important to the operation of some parts and a good indicator of your thoroughness and attention to detail. If your going to be a designer, you can specify how you want your edges dressed, there are many options.

De-burring cont.

• After saw cutting you can de-burr in many ways, here are a few options.

• Saw cut, die grinder with 80 grit disk, die grinder with 120 grit disk, rough buffer wheel, soft buffer wheel. –(all depending on what your starting with)

• Saw cut, belt sander, buffer wheel

• Plasma Cutter, stone pedestal grinder (if ferrous), belt sander, buffer wheel

• If you start with a flame or plasma cut, you may have to stone the edge first, then move through the steps above. Heat cutting leaves a hardened edge.

Tumbler (Deburring cont’d)

Tumbler (Deburring cont’d)

• The tumbler uses metal or ceramic pellets that contact your work piece and deburr, radius, burnish and clean your small work piece.

• Ferrous parts use the metal pellets and non-ferrous usually use the ceramic pellets.

• This machine needs to run for an extend period of time and main safety hazard is the loud noise it produces.

Surface Grinder

Surface Grinder

• The surface grinder produces a smooth finish on flat surfaces, and can grind very hard materials

• Not for student use. If you have a project where you think this machine would be of use, see Luke.

• It is an abrasive process (kind of like grinding wheel) that uses coolant

• Safety hazards are getting fingers between grinding wheel and work piece, table moving could hit something or someone.

Iron Worker

Iron Worker

• The iron worker can punch holes, bend, and shear ferrous and non-ferrous materials.

• Machine uses hydraulic power, and can cut ¼” thick steel plate.

• To use this, you must be checked out on this machine by a shop manager or shop TA.

• Safety hazards are cut off/smashed fingers and flying debris from punch.

Hydraulic Press

Hydraulic Press

• The press uses hydraulic pressure to usually press things apart or together

• A lot of consideration must be taken into account when fixturing your work piece to ensure it only sees force in the vertical direction.

• Safety hazard is smashing fingers and improper fixturing and having your work piece shoot out at you.

Manual Vertical Mill

Manual Vertical Mill

• There are 2 manual vertical mills in the Kulwicki shop

• Only those who have taken Sophomore Design and passed the machine shop Green Badge test and motorsports Pink Badge test can use them.

• Main safety hazard is flying chips and getting fingers caught between end mill and work piece.

Manual Lathe

Manual Lathe

• There are 2 manual lathes in the Kulwicki shop

• Like for the mills, only those who have taken Sophomore Design and passed the machine shop Green Badge test and motorsports Pink Badge test can use them.

• Main safety hazard is flying chips and getting fingers caught between cutting tool and work piece.

Haas CNC Mill

Haas CNC Mill

• The Haas is a computer numerically controlled (CNC) milling machine that can mill out 3D parts.

• It can mill almost any material, given the right end mills and programming.

• The Haas CNC mill is not for student use. Luke runs the machine and makes parts for the student design SAE teams and different research projects.

• We will discuss preparing a solid model for CNC machine later in the class.

• Main safety concern is noise. It cuts in a closed cabinet and prevents chips from flying out.

Torchmate – CNC Plasma Cutter

Torchmate – CNC Plasma Cutter• The Torchmate is a computer numerically controlled (CNC)

plasma cutter table that can cut out 2D parts, using plasma.

• It can cut ferrous and non-ferrous materials, just has to be conductive.

• Minimum thickness to produce good results is 1/16”, and can cut up to 1/2” thick steel plate. ¼” thick aluminum plate is the maximum thickness to produce good finish on part.

• The Torchmate is not for student use. Luke runs the machine and makes parts for the student teams and research projects.

• We will discuss preparing a solid model for the Torchmatelater in the class.

• Main safety concern is UV light it emits. You must wear a welding hood if you are around this machine while in use. It also throws sparks out and can be noisy.

Safety Kleen Red Tank (Part Cleaning)

Safety Kleen Red Tank (Part Cleaning)

• Used in cleaning of parts for engines, cars, projects ect.

• After getting excess dirt, oil or debris off with towel, this is first the first step in solvent cleaning parts. (not an oil dump, leaves residue)

• “ON” button on left side

• Solvent is a chemical and can give you small chemical burn so wear gloves (wash off after use)

• Solvent will stain clothes (don’t wear good clothes)

• Solvent is flammable (don’t grind or weld near)

• Solvent is poisonous (don’t drink it)

Safety Kleen Ultrasonic Tank(Part Cleaning cont’d)

Safety Kleen Ultrasonic Tank(Part Cleaning cont’d)• Used in cleaning of parts that have build up of hard carbon,

oxide coatings, or other hard contaminants/coatings

• Will not remove grease or dirt (used Red tank)

• Used once part is clean of all other contaminates (Red Tank then Black tank first)

• Use once tank is up to temp (170°F, burn hazard)

• Tank contains very small amount of soap and a lot of water.

• Still wear proper PPE

• Tank makes loud noise when on (hearing protection)

Sand Blaster (Part Cleaning cont’d)

Sand Blaster (Part Cleaning cont’d)• Sand blasting uses compressed air to shoot media at your

work piece to remove rust, paint and surface contaminates

• (part must be clean of oil, grease, solvents, water and be completely dry)

• Won’t take off heavy rust or paint

• The sand blast media is enclosed in cabinet so minimal inhalation hazard

• It can be loud so hearing hazard

• If concentrate blast media at gloves for prolonged period it can cause holes in gloves…so don’t fall asleep