Machining Logs

Logs detailing machining experience

Name: John McKenna   
Job Title:  Collar Additional Evidence
Workshop Set Up

  • Health and Safety signs before entering workshop were noted.
  • Appropriate PPE – Overalls, Boots, and Safety Glasses – were worn.
  • Checked product dimensions from engineering drawing.
  • Barrier cream was applied to protect skin from infection.
  • Proceeded with safety checks (emergency stop/ safety guard) on the machine.

Technical Procedure

Power Saw and Lathe:

  • Scribe used to mark BMS at 30 mm length
  • Ø 50mm BMS material was cut to 30mm long using power saw.
  • Workpiece was tightened and centred into lathe,
  • Lathe was set at 745rpm, CS45.
  • Workpiece was faced cleaned on 1 side.
  • Edge was chamfered 1x 45º
  • Overall length was reduced by placing the opposite end of the material into the soft jaws and facing it down 25 ± 0.25mm.
  • Digital Verniers used to check length before chamfer 1x 45º applied to this side.
  • Centre drill was set up in the tail stock to mark the centre of the material.
  • Ø 26mm drill was used with lathe speed set at 230rpm to drill through the workpiece.
  • Boring bar used to take 2x 1mm cuts off inside diameter.
  • Inside diameter of 28mm checked with verniers and ensured a tight fit to shaft.
  • Chamfered both sides of inside edge, 1 x 45º.

Milling Machine:

  • Material gripped in the diving head on the milling machine
  • Machine was then calibrated using the 6mm wobbler by touching onto the material and setting x –axis to “0” and then similarly zeroing the y –axis on the DRO digital read out.
  • DRO was used to find the centre point and set 6mm slot drill at 1500rpm.
  • 3 x 1mm cuts taken off the inside bore.

Finishing

  • Set workpiece in vice and filed slot square for key piece to fit.
  • Dimensions of collar were verified using digital verniers
  • Work area was cleaned.

Tools Used

  1. Rule
  2. R.H. Carbide
  3. 20mm Boring Bar
  4. Centre Drill
  5. 26mm Drill
  6. Digital verniers
  7. 6mm Slot Drill
  8. 6mm Wobler
  9. File
  10. Power Saw

 

Materials Used

1.       BMS bright mild steel

Safety Notes

1.       Safety Footwear

2.       Safety Glasses

3.       Overalls

4.       Barrier Cream

 

 

 

 

Name: John McKenna   
Job Title: Key Additional Evidence
Workshop Set Up

  • Health and Safety signs before entering workshop were noted.
  • Appropriate PPE – Overalls, Boots, and Safety Glasses – were worn.
  • Checked product dimensions from engineering drawing.
  • Barrier cream was applied to protect skin from infection.
  • Proceeded with safety checks

 

Technical Procedure

  • Scribe was used to mark key steel at 30 mm.
  • 6mm square key steel was cut to 30mm long.
  • Workpiece was gripped in vice with soft jaws.
  • 2nd cut file was used to make one end square.
  • Smooth file was used to radius opposite end and reduce the total length down to 27mm.
  • All edges were de-burred
  • Workpiece was checked to fit into spindle and collar assembly

Tools Used

  1. 2nd Cut file
  2. Smooth File
  3. Rule
  4. Scribe
  5. Hacksaw
  6. Radius Gauge

 

Materials Used

6mm Key Steel

 

Safety Notes

1.       Safety Footwear
2.       Safety Glasses
3.       Overalls
4.       Barrier Cream

 

Name: John McKenna  
Job Title:  Steel Screw Additional Evidence
Workshop Set Up:

  • Health and Safety signs before entering workshop were noted.
  • Appropriate PPE – Overalls, Boots, and Safety Glasses – were worn.
  • Checked product dimensions from engineering drawing.
  • Barrier cream was applied to protect skin from infection.
  • Proceeded with safety checks (emergency stop/ safety guard) on the machine.

Technical Procedure
Power Saw and Lathe:

  • 16mm diameter BMS was cut on the power saw to 35mm in length
  • R.H Carbine tool was set and centred on lathe.
  • Machine set to speed 745 rpm and feed at CS4W.
  • Workpiece was placed in lathe and tightened at 25 mm from the jaw to understand where it was positioned in space.
  • Face was cleaned after power saw cut.
  • 1mm cuts were taken off the diameter until measuring 8mm.
  • Material was cut 20mm long.
  • 45° chamfering tool was set up.
  • 2 x 45° chamfers on the end of 8mm diameter.
  • 3mm U/Cut tool was set and positioned on lathe..
  • Groove of 20mm length at 1.5mm deep was formed.
  • Material was reversed in the chuck and placed cutting tool back in tool post.
  • Material was faced down until overall length was 30mm in length.

Milling Machine:

  • The material was set in milling machine and gripped at the 8mm diameter using the dividing and lock head.
  • 16mm end mill set at 800 rpm
  • Touched on to the 16mm diameter and set Z to “0” on the Digital read out,
  • Workpiece was milled flat on the y-axis.
  • Material turned 180°, process was repeated on opposite side.

Thread and Finishing:

  • Material was taken out of milling machine and de-burred using a needle file, removing any sharp edges.
  • The material set on bench vice.
  • 8mm thread cut using M8 Button Die.
  • Final checks on dimensions were made using micrometre.

Tools Used

1.       R.H Carbide
2.       Power saw
3.       45° Chamfer
4.       3mm U/ Cut
5.       16mm End Mill
6.       Digital Vernier Callipers
7.       0-75micrometre
8.       M8 Button Die

Materials Used

16mm BMS Bright Mild Steel

Safety Notes

1.       Overalls
2.       Boots
3.       Safety Glasses
4.       Barrier Cream

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