Project #9 - Saw Arbor

Project finished tonight 2-25-2014

Want to know more about the different metals commonly seen today?

Click on the following names to be taken to web pages with more info:

ALUMINUM

STEEL

AISI - SAE System of Designating Carbon and Alloy Steels

AISI-SEA System of Designating Carbon and Alloy Steels

This first two digits of a steel's number designate the major alloying elements and the last two or three represent the carbon content in hundredths of a percent.

AISI-SAE Designation*	Types of Steel & Nominal Alloy Content (%)
	Carbon Steels:
10xx	Plain Carbon (Mn 1.00% max.)
11xx	Resulpharized
12xx	Resulpharized and Rephosphorized
15xx	Plain Carbon (Max. Mn range 1.00 to 1.65%)
	Manganese Steels:
13xx	Mn 1.75
	Nickel Steels:
23xx	Ni 3.50
25xx	Ni 5.00
	Nickel-Chromium Steels:
31xx	Ni 1.25; Cr 0.65 and 0.80
32xx	Ni 1.75; Cr 1.07
33xx	Ni 3.50; Cr 1.50 and 1.57
34xx	Ni 3.00; Cr 0.77
	Molybdenum Steels:
40xx	Mo 0.20 and 0.25
44xx	Mo 0.40 and 0.52
	Chromium-Molybdenum Steels:
41xx	Cr 0.50, 0.80 and 0.95; Mo 0.12, 0.25 and 0.30
	Nickel-Chromium-Molybdenum Steels:
43xx	Ni 1.82; Cr 0.50 and 0.80; Mo 0.25
43BVxx	Ni 1.82; Cr 0.50; Mo 0.12 and 0.35; V 0.03 min.
47xx	Ni 1.05; Cr. 0.45; Mo 0.20 and 0.35
81xx	Ni 0.30; Cr 0.40; Mo 0.12
86xx	Ni 0.55; Cr 0.50; Mo 0.20
87xx	Ni 0.55; Cr 0.50; Mo 0.25
88xx	Ni 0.55; Cr 0.50; Mo 0.35
93xx	Ni 3.35; Cr 1.20; Mo 0.12
94xx	Ni 0.45; Cr 0.40; Mo 0.12
97xx	Ni 0.55; Cr 0.20; Mo 0.20
98xx	Ni 1.00; Cr 0.80; Mo 0.25
	Nickel-Molybdenum Steels:
46xx	Ni 0.85 and 1.82; Mo 0.20 and 0.25
48xx	Ni 3.50; Mo 0.25
	Chromium Steels:
50xx	Cr 0.27, 0.40, 0.50 and 0.65
51xx	Cr 0.80, 0.87, 0.92, 0.95, 1.00 and 1.05
50xxx	Cr 0.50; C 1.00 min
51xxx	Cr 1.45; C 1.00 min
	Chromium – Vanadium Steels:
61xx	Cr 0.60, 0.80 and 0.95; V 0.10 and 0.15 min.
	Tungsten-Chromium Steels:
72xx	W 1.75; Cr 0.75
	Silicon-Manganese Steels:
92xx	Si 1.40 and 2.00; Ma 0.65, 0.82 and 0.85; Cr 0.00 and 0.65
	High-Strength Low-Alloy Steels:
9xx	Various SAE grades
xxBxx	B denotes boron steels
xxLxx	L denotes leaded steels

*xx in the last two digits of the carbon and low-allow designations indicates that the carbon element (in hundredths of a percent) is to be inserted.

Hazardous Material Labeling

When it comes to hazardous materials, look for the following agencies and labels:

NFPA (National Fire Protection Association)

HMIS (Hazardous Material Identification Systems)

HMIS can also be found under NFPA

Below are images of what you might see and need to know:

Some Important Links for more information on Hazardous Materials Identification:

Hazardous Materials Table

The MSDS Hyperglossary

HMIS Labeling System

Safety Tips when working around Machines

* * * * * C A U T I O N * * * * *

• Avoid any loose-fitting  clothing that can get caught in moving machinery.
• Casual shoes, open-toed shoes, sandals, high-heeled shoes and flip flops should never be worn!
• There are specific types of jewelry that should not be worn when operating machinery: Necklaces, Dangling Ear Rings, Bracelets, Watches, Rings - these items can get caught in moving parts of equipment and pull a person into a machine, causing serious injury or even death.
• Long hair should always be secured with a hat, cap or hairnet so that it does not get caught in moving machinery.
• Never wear gloves when working around running machinery or any moving parts.

FOLLOW these tips and you can cut most of your injuries and safety issues down by 80%!

Project #8 - Kurt Vise Stop

Tonight I started milling groove into middle. After thanksgiving break I will finish. Here are two photos:

Here is finished piece:

Project #7 - T nut

Tonight (11-13-2013) I finished milling the block:

Next week Monday hopefully will drill hole and add threads to finish job.

11-19-2013, finished this project:

Project #6 started 10-29-2013

Tonight I turned the blank rod down to 1 inch diameter and cut it to length of 5.650". I started on the right-most section in the image above turning it down. 

Looking for more info?

Click on one of the links below for more info:

http://www.cnccookbook.com/CCResourcesRef.htm

http://www.cnccookbook.com/CCResourcesBooks.htm

http://team358.org/files/mechanical/HowToUseALathe.pdf

http://concretelathe.wikispaces.com/file/view/How_To_Grind_Lathe_Tools.pdf

http://www.precisebits.com/?gclid=CMWF0tjzjroCFSZp7AodcRkA9A

Project #5

Project 5 blank has been turned down to 1 inch dia. Then 2 steps have been turned down on each end. Tomorrow I start threading. Will post photos tomorrow.

10-29-2013 update:

Project #5 conplete:

Project #4 complete!

Finally finished both rods and got them checked off!

Shiny!

Tonight Jeff, my other teacher, showed me a new setting and helped me to understand the numbers on the dial better. So I turned 2 new steel rods, and they started looking better. They came out smoother than previous ones. The second rod came out shinier thanks to a higher turning speed and lower cutting feed. 

Next week I finish step one on the 2nd rod and then step both rods down to req'd diameters. Then I will have 3 rods to thread and, hopefully, 3 projects checked off!

Trying to get caught up since the obe piece went wierd (see photo).

Project #4 - long rod

Well tonight I grabbed a piece of steel that was a little bigger than 1" in diameter and started working on it to create the longer rod in this project. Here is a photo of what I did tonight:

Selection of High-Speed Tool Steels

To read more about High Speed Steel (HSS) used for Tools, click on this link:

http://hudson-metals.com/pages/technical/high_speed/high-speed-tool-steels.html

Continuation of working on project #4

So tonight I worked on threading the smaller piece in Project #4. Here is the rod half threaded:

And here is a shot of the rod completed and passed by the Instructor:

Following this piece, I started to thread the longer rod. Everything went well until the machine hicupped:

So tomorrow evening I will be making this piece again from a new 5-1/4" blank!

My dad used to say this a lot to me:

(1) If at first you don't succeed, try again.

So I will try again and succeed!

Sept. 12, 2013 - Project 4

Threaded Rod & Shaft

Here is what the rods look like before threading -

Tonight (Sept. 18, 2013), I will be making 2 tools for the other parts of this process. One tool will be for cutting the separation pieces between the threaded sections and the other tool will be used for the threading process itself. Once I am done with those, I will take the rod on the right and turn the other end and get it ready for threading. I will post photos below of the new tools as well as the threading process as I get them done.

Update: Sept 25 finished turning both rod pieces shown in diagram. Worked on thread-release tool bit.

To do Sept 30: After class, finish grinding on thread release tool to get clearance for cutting.

To do Oct 1: turn thread release notches onto longer rod. Then thread both rods.

Sept. 31: turned thread releases onto one piece:

8-28-2013 Project #3

Centers

Tonight I started my third project. Here is a shot of the technical drawing:

 This one got a little more technical in that I used the cutting tool in two different positions. The object was to make two pendulums. The photo below shows both  pendulums. The one on the right is the bigger of the two and is complete. The one on the left shows half of the part milled. The part milled will become the pointed end, while the other end will become the shaft.

Here is another shot of the completed pendulum standing up on end:

Tuesday, Sept 3, I will finish the 2nd pendulum and show you what it looks like in comparison to the first one.

August 28, I finished the other pendulum:

Educational Info on Metals and Alloys

Click on this link to learn more about various metals and alloys used in Machining:

Metals and Alloys

How to use a Lathe

This is the machine I have been using since the first day in the Machine Tools Technology Program.

Click on this link to see how a Lathe is used:

How to Use a Lathe

Click on this link for an enlarged Diagram of a Lathe:

Enlarged View of a Lathe

8-27-2013 Project #2

Step Shaft

Tonight I started my 2nd project and got 3/4th finished in 3 hrs time. Getting better.

This project is called a Step Shaft

Here is a detail showing what it will look like when done:

And here is a photo of what it looks like after tonight's work:

Tomorrow evening I will finish the 2nd side (bottom end in photo). I have a 0.40" piece to mill and then I have to deburr the edges at the end.

8-26-2013 Project 1 Completed

Tonight after spending about an hour in the classroom going into book material, we went out into the shop to continue work on our Project. Here are photos of my alignment rod that I finished:

(Top View of Alignment Rod Completed)

(End Views of Completed Alignment Rod)

8-20-2013 Class MTT-101

Project #1:

Tonight I created my first cutting tool bit and then learned how to use a lathe and started on my first project. 

Here is a photo of my first cutting tool I created:

Once this was done, I moved on to my first project. The first project is an Alignment Rod:

Here is the result from the first night of cutting done after I made the cutting tool:

(Top view of entire of piece)

(End view showing first section milled)

Tonight (8-21-2013) I finished one half of the rod:

Here is a close-up shot of the end:

Not bad for a guy who has spent the past 23 yrs designing architectural plans on a computer. Next week I get to do the other side of the rod.

Welcome!

The process known as Machining:

"In the process known as machining, a machinist is a person who uses various types of machine tools to make or somehow modify parts, generally metal parts. This is done by using machine tools to cut away materials and produce work. Machinists produce work that conforms to a specific set of instructions such as engineering drawings, pr blueprints. Within the title of machinist, there are specific skills that are need for job positions such as die maker, tool maker, pattern maker and mold maker."

"Machinists use metalworking equipment, such as lathes, shapers, grinders and saws, to form either unique and carefully shaped individual pieces, or multiple pieces of specifically tailored metal. Machinists work for large concerns that use metal in their final products, such as heating-vent manufacturers or automobile factories, or they work for specialty shops that take specific orders for needed parts and equipment. Machinists must be able to read blueprints and be familiar with laser and optical measuring devices that can test the degree of precision of their work. Some specifications call for shaping a piece of metal to within one-one-thousandth-of-an-inch accuracy. Machine shops usually employ between four and fifteen machinists, so those who work in this part of the industry should be comfortable working in close quarters. Machinists often know more about the metals they work with than do the clients who order pieces made from these metals. The machinist can and does act as an advisor, if the client makes false or misleading assumptions about the materials being used or the finished product. Quality machinists have good vision, endurance, an eye for detail, excellent hand-eye coordination, a love for quality and precision, and respect for the tools of their trade. Working with metals can be dangerous for someone who is careless or easily distracted. Indeed, the biggest concern with being a machinist is the daily threat of serious injury. Few professions place employees in such regular contact with high-powered and potentially destructive tools. Surprisingly, however, the average injury rate in this profession is only slightly above the national average. Machinists must wear protective safety goggles and earplugs, and they must carefully decontaminate themselves after working with high-viscosity lubricants, as many of these lubricants are quite toxic. These worries, however, only slightly diminish the satisfaction machinists derive from shaping something out of nothing in an expert and craftsman-like way every day." (www.princetonereview.com)

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I started attending Wallace State Community College this past Monday, August 19, 2013 in the field of:
Machine Tool Technology

On this blog I will be sharing with you photos of my projects and metal creations I make during my Course of Study.

Enjoy! Updated weekly. Comments welcome!