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1 | 1 | # Bantam Lathe |
2 | 2 |
|
3 | | -## Safety |
4 | | -### Awareness of risks |
5 | | -* Risks inherently associated with machining |
6 | | - * Direct cutting risks (including from non-spinning tools!) |
7 | | - * Hair, clothes, etc tangling in spindle/tool |
8 | | - * Crush risks from moving axes |
9 | | - * Flying chips |
10 | | - * Parts flying on workholding failure |
11 | | - * Sharp edges on stock, workpieces and chips |
12 | | - * Hot tools and workpieces after cutting |
| 3 | +<!-- There is no prescribed structure, but here is a suggestion: --> |
13 | 4 |
|
14 | | -### Use of safety measures |
15 | | -* Safety features of the machine |
16 | | - * Emergency stop button |
17 | | - * Protective cover |
18 | | -* Clothing and use of PPE |
19 | | - * Safety goggles |
20 | | - * No gloves |
21 | | - * Ear protectors for noisy jobs |
22 | | - * Aprons, boiler suits etc to protect clothing |
23 | | - * No ties / scarves / jewellery / etc |
24 | | - * Keep bed clear |
25 | | - * Keep foot on brake at all times |
| 5 | +## Safety |
26 | 6 |
|
27 | | -### Training |
| 7 | +### PPE |
| 8 | +- Safety glasses required. |
| 9 | +- Hearing protection optional. |
28 | 10 |
|
29 | | -Start with a safety briefing - go through all the points above, in front of the machine. |
| 11 | +### Risks |
30 | 12 |
|
31 | | -Main hazards/risks should also be on warning signs / posters in the tool area as a reminder. |
| 13 | +#### Entangling risks |
| 14 | +- No loose clothing. |
| 15 | +- No loose jewellery (i.e. rings, watches) or accessories (i.e. cables). |
| 16 | +- No gloves. |
| 17 | +- Long hair must be tied back. |
32 | 18 |
|
33 | | -During subsequent training, be ready to prompt if any safety measures or considerations seem to have been forgotten by the trainee. |
| 19 | +#### Stock, swarf and chip risks |
| 20 | +- Wood or flammable metals (magnesium, titanium) dust and swarf must be immediately cleaned up. |
| 21 | +- Sharp chips may fly. |
| 22 | +- Stock, workpieces, and tools may all have sharp edges. |
| 23 | +- Stock and workpiece may become very hot during cutting. |
34 | 24 |
|
35 | | -### Evaluation |
| 25 | +<!-- Usually, all of the control measures in the risk assessment should be mentioned here --> |
| 26 | +## Anatomy of the lathe |
| 27 | +- Headstock is where the part is turned from. |
| 28 | +- Bed is the portion which moves when you turn the big wheel. |
| 29 | + - Slides are mounted on the bed and controlled by little wheels. |
| 30 | +- Tailstock is the piece at the far end, used for securing work or for drilling. |
| 31 | +- Z axis is parallel to the work. |
| 32 | +- X axis is perpendicular to the work. |
| 33 | +- Autofeed knob |
| 34 | +- Fwd/reverse knob |
| 35 | +- Thread-cutting levers |
| 36 | + - TODO: Document how these actually work |
| 37 | + - TODO: Figure out how these work. |
36 | 38 |
|
37 | | -The trainee must be able to identify risks associated with the machine and the safety measures that should be used. |
| 39 | +## Startup checks |
| 40 | +### Surrounding area cleared of obstacles. |
38 | 41 |
|
39 | | -The trainee must be observed to routinely use safe working practices when working without prompting or reminding. |
| 42 | +### Other workshop users alerted to keep clear. |
40 | 43 |
|
41 | | -## Basics |
| 44 | +### Stock is secured in chuck and all jaws are tight. |
| 45 | +- The three-jaw chuck should be used for round stock. The four-jaw chuck should be used for all other shapes. |
| 46 | +- Unlike the four-jaw chuck, the jaws on the three-jaw chuck are mechanically linked. Regardless, all three sockets should be tightened. |
42 | 47 |
|
43 | | -### Parts and Axes |
44 | | - * Headstock is where the part is turned from |
45 | | - * Bed is the portion which moves when you turn the big wheel |
46 | | - * Slides are mounted on the bed and controlled by little wheels |
47 | | - * Tailstock is piece at far end, used for securing work or drilling |
48 | | - * Z axis is parallel to work |
49 | | - * X axis is perpendicular to work |
| 48 | +### The key is removed from the chuck and the chuckguard is down. |
50 | 49 |
|
51 | | -### Turning on & startup |
52 | | - * Switch on control box |
53 | | - * Ensure lathe is in gear and autofeed is disabled |
54 | | - * Manually move tool away from chuck |
55 | | - * Release emergency stop switch |
| 50 | +### The tool being used is securely attached to the toolpost. |
56 | 51 |
|
57 | | -### Training |
| 52 | +### Table and tool feeds are disengaged. |
58 | 53 |
|
59 | | -Start by demonstration. Go through the process of turning on the machine and making it ready for use, talking the trainee through each step and the reasons for it. |
| 54 | +### Machine is in correct gear. |
| 55 | +- The speed figures are not actually correct, but they are correct relative to each other. |
| 56 | +- The gear should only ever be changed when the lathe is turned off and is stationary. |
| 57 | +- Once a gear is selected, the chuck should be manually rotated a full turn to ensure smooth movement. |
60 | 58 |
|
61 | | -Next, shut the machine down and ask them to repeat the process. They will probably need lots of prompting and help, this is fine. |
| 59 | +### The table is clear of the workpiece. |
62 | 60 |
|
63 | | -The trainee will get further practice through routine use as they go through the training process. Be ready to prompt and remind as needed. |
| 61 | +## Usage |
64 | 62 |
|
65 | | -### Evaluation |
| 63 | +### Starting the machine |
| 64 | +- Check lathe is in gear and rotate headstock. |
| 65 | +- Disengage the emergency stop. |
| 66 | +- Press the red stop button on the lathe. |
| 67 | +- Press the green start button next to the VFD and wait for the tool controller to turn on. |
| 68 | +- Tap in. |
| 69 | +- Press "Fwd." |
| 70 | +- Keep foot on or near brake at all times. |
66 | 71 |
|
67 | | -The trainee must be able to set up the machine correctly without assistance or prompting, regardless of the state they find it in. They should be able to identify the types of tool and their uses. |
| 72 | +### Loading and Unloading Tools |
| 73 | +- Lock toolholder in table |
| 74 | +- Verify height of tool |
| 75 | + - Close chuck jaws and bring cutter to near centre |
| 76 | + - Tool should be in line with centre of chuck |
68 | 77 |
|
69 | | -## Manual operation |
| 78 | +### Changing Chuck |
| 79 | +- Move each of the sockets until the mark on the socket lines up with the mark on the body. |
| 80 | +- Carefully lift chuck off |
| 81 | +- Load new chuck and carefully tighten each socket. |
70 | 82 |
|
71 | | -### Securing work |
72 | | - * Use the three-jaw chuck |
73 | | - * Secure other end of workpiece with tailstock. |
| 83 | +### Stopping the machine |
| 84 | +- Press the red stop button on the lathe. |
| 85 | +- Press the red button next to the VFD. |
| 86 | +- Log out. |
| 87 | +- Press in the e-stop. |
74 | 88 |
|
75 | | -### Tool movement |
76 | | - * Move the Z axis |
77 | | - * Move the X axis |
78 | | - * Move one axis at a time |
79 | | - * Autofeed |
| 89 | +<!-- incl estops if necessary --> |
80 | 90 |
|
81 | | -### Gearing |
82 | | - * Three big levers control spindle (and autofeed) speed |
83 | | - * Refer to chart to determine relative speeds |
84 | | - * Do not rely on numbers being accurate! |
85 | | - * Forwards/back on table feed |
86 | | - * Round black knob should be as far clockwise as possible (for autofeed left and in) or counterclockwise as possible (for right and out) |
87 | | - * Machine must be fully stationary before changing orientation of knob |
88 | | - * Fast/slow table feed |
89 | | - * Threading levers in bottom left. |
90 | 91 |
|
91 | | -### Loading and unloading tools |
92 | | - * Lock toolholder in table |
93 | | - * Verify height of tool |
94 | | - * Close chuck jaws and bring cutter to near centre |
95 | | - * Tool should be in line with centre of chuck |
96 | | - * Choosing tool type |
97 | | - * Blunt HSS is _parting_ tool for parting off |
98 | | - * Small gold diamond is _facing_ tool |
99 | | - TODO: fill in other tool types |
100 | | - * Tools can be used in unconventional ways |
101 | | - * How could the facing tool be used to decrease diameter? |
| 92 | +### Materials |
| 93 | +- Metals are fine |
| 94 | +- Wood can be turned, provided very low speeds are used and all dust and swarf is removed immediately. |
| 95 | +- Flammable metals (titanium, magnesium, et al) must be turned at very low speeds with coolant, and all dust and swarf should be removed immediately. |
102 | 96 |
|
103 | | -### Training |
| 97 | +### Cleaning up |
104 | 98 |
|
105 | | -Set up a piece of cylindrical stock in the three-jaw chuck. Secure it with the tailstock, leaving enough room on the Z axis to move the table until the tool is clear of the workpiece. Install the parting tool and have the trainee part off ~60mm of the workpiece, then back off the tailstock and remove the cut piece. |
| 99 | +## Maintenance |
106 | 100 |
|
107 | | -Have them install the facing tool and neaten the cut edge of the workpiece. Discuss feeds & speeds - faster spindle means faster movement but less clean cut. |
| 101 | +### General |
108 | 102 |
|
109 | | -Have them remove the workpiece in the chuck and replace the ~60mm piece they made. Introduce autofeed - have them align the facing tool with te rough face and use autofeed to face it. Have them flip the workpiece and face the other end. |
| 103 | +## Other |
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