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Lesson Title: Sawing and Drilling Machine Operations
Lesson Duration: 5 hours
Industry Competencies: Participants will:
demonstrate safe operating procedures for each power saw and drill press used
research and discuss theoretical and background information about drill presses
and horizontal and vertical bandsaws
describe the relative motions of the drill press and power saw, and describe the
interactions of various subsystems, including the machine tool, machine controls,drive mechanisms, cutting tools, tool holder, work piece, and work holder.
Specific Objectives: Participants will:
identify and explain machine parts and tools for sawing operations
identify and explain machine parts and tools for drilling operations
perform sawing operations safely
perform drilling operations safely.
Assessment(s):
The following rubrics will be used in this lesson.
Competency
or Task
Highly
Competent Competent
Needs
Improvement
Measurements are
accurate using both US
and SI devices.
All measurements are
made accurately with
full understanding and
ability to use
measurement tools.
All measurements are
made with appropriate
tool and are accurate.
One or more
measurements are
incorrect and ability to
use appropriate tools is
not consistent.
Conversions within the
US system are accurate.
All conversions are
accurate with full
understanding and
appropriate units
indicated.
All conversions are
accurate with
appropriate units
indicated.
One or more of the
conversions is
inaccurate and units are
not displayed correctly.
Conversions within the
SI system are accurate.
All conversions are
accurate with full
understanding and
appropriate unitsindicated.
All conversions are
accurate with
appropriate units
indicated.
One or more of the
conversions is
inaccurate and units are
not displayed correctly.
Conversions betweenthe US and SI systems
are accurate.
All conversions areaccurate with full
understanding and
appropriate unitsindicated.
All conversions areaccurate with
appropriate units
indicated.
One or more of theconversions is
inaccurate and units are
not displayed correctly.
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Competency
or Task
Highly
Competent Competent
Needs
Improvement
Write clearly and
effectively on a specific
topic.
Topic is fully addressed
with highly effective
supporting information
with no errors ingrammar, punctuation,
or spelling.
Topic is fully addressed
with adequate
supporting information
and no errors ingrammar, punctuation,
or spelling.
Topic is not addressed or
poorly supported with
one or more errors in
grammar, spelling, andpunctuation.
Speak clearly and
present information
about a specific topic.
Topic is fully addressed
with highly effective
supporting information
with a clear voice,
excellent syntax,
excellent grammar, and
superb volume.
Topic is fully addressed
with adequate
supporting information
in a clear voice with
effective grammar and
pronunciation.
Topic is not addressed or
poorly attempted with
inadequate supporting
information, low voice,
and one or more errors
in grammar.
Production of a PartCompetency
or Task
Highly
Competent Competent
Needs
ImprovementMachine Operation
Analysis
All machine operations
were followed with high
level of quality and
superb detail.
All machine operations
were followed with high
level of quality.
One or more of the key
procedures were not
followed or poorly done.
Machine/Tool Use The actual machine and
related tool use wassuperb with no mistakes.
The actual machine and
related tool use wasdone well with required
detail.
There were one or more
instances of poor tooluse during the process.
Safety All safety rules were
followed exemplarywith assistance to
others.
All rules were followed
as directed.
One or more rules was
not followed whichestablished some risk.
Accuracy All parts were measuredand fabricated
accurately with exact
precision beyond any
tolerances.
All parts were measuredand fabricated
accurately within
acceptable tolerances.
One or more parts weremeasured wrong or
fabricated poorly outside
of required tolerances.
The following is an example of a written examination for this lesson.
1. When selecting the type of saw to use, which factors must be considered?
The factors to be considered are size of the raw material stock, properties of the
material to be sawed, accuracy, finish, and production requirements.
2. Explain the relationship between:
the size and geometry of the stock to be cut
the capacity and type of sawing machine to be used
Size and geometry of stock determine the type of machine and machine capacity
needed.
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3. What are the three factors that influence the selection of a sawing method and
machine? The factors influencing the selection are accuracy, finish, and production
requirements.
4. What variables influence the selection and performance of drills?
The variables include material used to make the drill, physical properties of thedrill, drill size, and geometry of the drill.
5. Variations in the design and geometry of different drills can include: drill points, librelief angle, clearance angle, and flute construction.
6. Name three types of drilling machines.
Types of drilling machines include light-duty, heavy-duty, upright, radial, gang,multi-spindle, turret, deep-hole, and small-hole.
Calculate the properRPM for each of the following:
Drill Bit or Tool RPM (answers provided below)
1/2 in. counterbore RPM = 1150
11/32 in. drill RPM = 800
1/4 in. drill RPM = 1600
15/64 in. drill RPM = 1700
3/8 in. drill RPM = 1050
82 countersink RPM = 700
5/16 in. drill RPM = 1300
1/4 in. ream RPM = 300
center drill RPM = 700
in. ream RPM = 300
Resource(s):
Print Materials - Basic mathematics textbook, Basic machining textbook (to be identified)Audiovisual -
Internet sites-
Key word search -Sawing operations, sawing equipment, drilling operations, drill manufacturers,
sawing and cutting equipment, drills, saws, machine safety, material removal, drill
bits, saw blades.
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Purpose of the Lesson:
Participants will explain and demonstrate safe sawing and drilling operations for material
removal.
Required Knowledge and Skills: Participants will:
measure accurately using the US and SI systems
perform basic mathematical operations
use appropriate units within and between the US and SI measurement systems.
Tools, Materials, Equipment Needed:
1 horizontal bandsaw
1 vertical bandsaw
raw material (bar stock)
1 6" steel rule or combination square
1 vernier caliper
1 drill press
1 drill press vise
assortment of drills to show different point styles, shanks, flute styles, etc.
1 counterbore
1 countersink
assorted reamers
assorted center drills
1 center punch
raw material (same as above)
1 6" steel rule or combination square
a variety of layout tools bluing, such as Tool-Blue
1 micrometer or vernier caliper
Specific Safety Requirements:
General lab safety rules apply.
Specific safety rules for sawing and drilling operations apply.
Everyone must wear safety glasses at all times during equipment demonstrations and
operator evaluations. Observe proper safety and operating procedures at all times.
Dispose of chips and other debris as required by your facility.
Each participant must pass the Sawing and Drilling Safety Test and Operator Safety
Evaluation before being allowed to operate any saw or drill. Participants may notproceed until all safety knowledge is addressed. You must ensure that participants can
demonstrate safe and proper operating procedures before using equipment.
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Lesson Elements: (5-E model)
Engagement:
One of the most basic of all machining processes is sawing, a cutting operation in whichthe cutting tool is a blade having a series of small teeth, each of which removes a small
amount of material. Even though machining centers have become high-tech, without the
simple process of sawing, most work on a lathe, milling machine tool, or grinder wouldnot be possible. Drilling, another simple material removal process is also one of the most
efficient. Drilling has one of the highest material removal rates of all common material
removal processes.
After discussing the saw and drill press, participants are ready to observe a demonstration
of the machines capabilities. This demonstration should include a review of the parts of
the machine, proper nomenclature, and specific safety procedures.
Explain and demonstrate the following operations and concepts:
use of the power saw in your lab
recognizing a dull blade
changing saw blades
use of the drill press in your lab
use of the hand reamer in your lab
simple layout procedures (note tools used)
use of machine reaming in your lab
use of the countersink in your lab
use of the counter bore in your lab drilling and hand tapping
Discuss any observations made by participants during demonstration. Note anydifficulties you may have had during the demonstration in attaining the desired results
and discuss ways to improve those results. Participants should view the images below and
offer their explanations about sawing and drilling processes. This will help the instructor
determine prior knowledge and depth of understanding for each participant-
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Exploration:
Participants will be challenged to investigate the wide variety of horizontal and vertical
bandsaws available for unique material removal applications. This exploration should
help participants realize the common as well as unique features found from variousmachine manufacturers. This investigation must be beyond the available cutting machines
in the school manufacturing laboratory.
Examples of images from their research should be included in a small group (2)presentation. Participants should present their new knowledge about cutting machines
such as bandsaws to others in the class. The instructor should facilitate this investigation
so that all types and configurations are discussed. Examples are shown below.
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VERTICAL BANDSAWS
HORIZONTAL BANDSAWS
As part of a machine tool research project, participants should select a particular brandfor both horizontal and vertical bandsaws and obtain a comprehensive specifications
sheet that includes machine size, key features and accessories. An example of one spec
sheet is shown below.
http://www.verticut.com/baxter_saw_model_700sa.htm8/14/2019 03 Lesson Sawing and Drilling Operations 3
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24" Bandsaw
Powerful totally enclosed, fan cooled motors to keep out dust for a longer life and
maximum performance. Extra large cast iron tables for more work area in front of the blade tables tilt 45
degrees to the right and 15 degrees to the left and come standard with a T-slot
mitre gauge. Saw blade is completely guarded but easily accessible for changing.
Cast iron drive wheels are balanced and equipped with vulcanized rubber tires.
Lower wheel brush to eliminate sawdust buildup.
Convenient foot brake for rapid stops.
Solid steel and cast iron construction for additional stability and durability.
Large easy to use hand wheel for smooth adjustments.
Fully adjustable blade guard.
Comes standard with a 4" dust collection port for connection to a work shop dust
collection system.
Two speed drive pulley.
The upper wheel housing and guidepost have been designed with the rigiditynecessary for industrial use.
Extra wide flange along with a heavy-duty trunnion assembly provide extra
durability while eliminating any "flexing" of the table.
Standard Equipment
Motor 1" blade
Foot brake
Work light
Rip fence and mitre gauge
Chip blower
Optional Accessories
1/4" x .025 x 6 blade
3/8" x .025 x 4 blade
1/2" x .025 x 3 blade
3/4" x .032 x 3 blade
1" x .026 x 3 blade
1-1/4" x .035 x 1.3 blade
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SPECIFICATIONS
Stock Number(3 HP, 1 Ph, 230V): 1791259
Stock Number (5 HP, 3 Ph, 230V): 1791260
Model: 2415
Blade Speeds (SFPM): 2000 - 4000
Thickness Capacity (max/in): 14
Width Capacity (max/in): 24-1/4
Table Size (in): 24 x 28
Table Tilt: 45 degrees R, 15 degrees L
Blade Length (approx/in): 180-1/2
Blade Widths (min max/in): 1/4 - 1-1/2
Table Height at 90 (in): 35 3/8
Floor Space Required (in): 34 3/8 x 39
Motor (TEFC): 3 HP, 1 Ph, 230V, 5 HP, 3 Ph, 230V or 5 HP, 3 Ph, 460V
Shipping Weight (lbs): 1050
The wide variety and diverse nature of cutting blades for these machines should also beinvestigated by participants with discussion and demonstrations led by the instructor. Cuttingblades are critical components and vary widely in their design and application.
The same approach should be used to compare drill press machines for common and
unique machine features. Machine parts should be clearly identified and described during
participant presentations.
http://www.southern-tool.com/store/bandsaw_blade_calculator.html8/14/2019 03 Lesson Sawing and Drilling Operations 3
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DRILL PRESS
1. Motor Unit2. Top Cover
3. Cover Lock
4. Feed Handle5. Drill Chuck6. Power Switch
7. Base
8. Parallel Guide9. Column
10. Lock Screw
11. Wrench Hole12. Anchor Holes
13. Depth Gauge Knob
14. Column Adjuster Screw
Specification sheets should be obtained and compared and contrasted by participants via
their research teams.
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Powermatic PM2800 VS Drill Press
Features
Powered by a heavy duty 1HP, 1Ph, 115/230V (Prewired 115V) TEFC motor.
Lighted push button switch with safety key is located on the front of the head for ease of use.
New large table system with dual extensions for the largest woodworking table on themarket. It also features twin T-slot grooves for a miter gauge or other homemade jigs.
Newly designed table tilts 90 and has a positive stop at 0.
Head mounted dual laser guide system provides a consistent drilling cross point on work
piece.
Feed handles can be mounted on either side of the drill press for convenient handle
positioning.
Extension wing provides additional support for longer work pieces.
Variable speed system adjusts quickly and easily in one full range.
Built-in dual LED work light.
5/8" keyless chuck.
Quick setting depth stop.
Adjustable split fence with dust collection port.
Front mounted switch control, laser guide and LED work light.
Front mounted digital LED display shows spindle speed.
SPECIFICATIONS
Model No. PM2800
Stock No. 1792800
Swing (in) 18Chuck Size (in) 5/8, Keyless
Spindle Travel (in) 4-3/8
Chuck Distance to Table (in) 30
Chuck Distance to Base (in) 46
Table Size (L x W/in) 16 x 14
Table Size Fully Extended (L x W/in) 16 x 26
Spindle Taper MT2 x JT33
Column Diameter (in) 3-1/8
Spindle Speed Range (RPM) 400-3000
Base Size (in) 11-7/8 x 19-5/8
Motor (TEFC) 1HP, 1Ph, 115/230V, prewired 115V
Overall Dimensions ( H x W x D/in) 68 x 23-1/2 x 31-1/2
Ship Weight (lbs) 302
Again, critical cutters for each machine, including the drill press should be furtherinvestigated so participants are very familiar with the diverse design features and unique
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applications for drill bits, reamers, fluting tools, etc. Basic drill cutter or bit information
should be provided or obtained through participant investigation directed by the
instructor. Examples are shown below-
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Drilling on a lathe is another technique often ensuring extreme accuracy for challenging
material removal in unique parts. The image above can be used to help participantsdiscuss the process and the resulting benefits.
The same approach for sawing operations with bandsaws, horizontal bandsaws, jigsaw,
scroll saws and more can be presented, demonstrated and discussed to ensure participantunderstanding of how material is removed, cutters used, geometry of cutting, and related
speeds and feeds for diverse materials. Examples for cutting are shown below-
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JET Drill Bit Sets
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5-PIECE TIN COATED BRAD POINT DRILL BIT
SET
If you want the best in wood boring bits, look no
further. Our 25-piece set contains the most commonly
used sizes, with the added benefit of a TIN coating for
longer life and durability.
TIN coated
Angle-ground spurs and center point
Spiral fluted for fast chip removal
25-piece set includes:
Bits from 1/8" to 1/2" in increments of 1/64"
Indexed steel case
SPECIFICATIONS
Stock No
228241
228239228240
Description
25-pc Set
7-pc Set
25-pc Set
Coating
TIN Coated
Black Oxide
Black Oxide
Sizes (in)
1/8 to 1/2 in increments of 1/64
1/8 to 1/2 in increments of 1/64
1/8 to 1/2 in increments of 1/64
7- PIECE CARBIDE-
TIPPED BRAD
POINT DRILL BIT
For the ultimate in drilling for tough and exotic
woods, our carbide-tipped brad-point bit sets are
the ones to use.
Specially ground "ears" virtually eliminate tear
out, ensuring a clean, smooth hole.
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Participants should be exposed to a wide variety of cutters and various manufacturers to
compare common and unique features as well as prices to fully realize the scope ofcutters available for drilling operations.
Explanation: Identify the three primary types of saws currently used in industry.
Discuss the different purposes for which each type of saw might be used.
Identify the types of blades used on bandsaws and the purpose of each blade
Discuss the advantages and/or disadvantages that sawing might have over other
material removal processes.
Answer the following questions concerning cutting teeth:
When cutting a piece of 3" bar stock, what effect would you expect from
increasing the number of teeth per inch?
How does the number of teeth per inch affect surface finish?
Define the following sawing terms:
kerf
tooth face
tooth back
tooth back clearance angle
gullet depth
width
tooth spacing
contour cutting
ripping
internal cut
angular cuts
stack cutting
shaping
straight set
raker set
wave set
Define the following drilling terms:
shank
boring
tang
reamer
morse taper
countersink
counter bore
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spot face
pilot
center drill
chisel edge (point)
cutting edge
flute
margin
point angle
helix angle
lip clearance
Discuss the advantages and disadvantages of these drilling machines used in industry:
drill press
radial drill
gang drill
other special types of drills
Discuss the following drill press sizing and feature options:
largest diameter work piece that can be drilled in its center (work envelope)
horsepower
chuck size or taper size
vertical clearance between spindle and lowest table position
power feeds
variable speeds
gang drill
other special types of drills
Discuss and show examples of the following drill press tolerances and surface finishes:
all features, including those done on the drill press, should be designated with
size, location, and surface finishes on part prints
various methods for accurately and quickly locating holes, given various
tolerances
problems that can occur with the shape, size, and surface finish of holes
methods to correct or avoid common shape, size, and surface finish problems
Discuss the following types of drills and types of points (all available in left-hand orright-hand; mostly right-hand):
twist drill
parabolic flute
long/deep hole
carbide tip
high helix
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center drill
short or stub or spot
Discuss these types of shanks: straight
straight with tang
hex
morse taper
taper with tang
Discuss the various drill size series available:
fractional
letter
number/wire gage metric
Discuss various types of reamers:
hand reamers
machine reamers
expandable reamers
shell reamers
taper reamers
Discuss reaming operations: slower speed
turn clockwise only (in most cases)
faster feed
coolant or lubricant
leave the correct amount of materials in the drilling operation
chamfer on work piece impedes proper cutting
Discuss various ways to hold work on a drill press:
vise
bolt to table rotary table
clamps
jigs and fixtures
Discuss the following parameters on which RPM depends: (RPM = (cutting speed x 4) diameter of drill) and each of the following.
work material
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cutter material and diameter
coolants
depth of cut
feed rate
Extension:
Participants will be divided into smaller teams (2-3) and be challenged to participate in
two major performance activities that will help them make choices between cutting and
drilling operations using appropriate cutters and related tooling safely. The instructor willguide this experience and ensure all operations are conducted properly and safely.
A detailed drawing should be provided that offers specific size and shape guidelines for
an object made from a variety of common manufacturing materials (wood, plastic, or softmetals). The following drawing is provided as an example for such a project. Of course,
the instructor may choose to present an alternative project design. Participants willprovide a detailed production plan which shows the intended operation for each part withthe corresponding machine and cutter or attachment. In addition, specific notes should be
added on this chart to ensure all details are explained for review by the instructor in the
fabrication of the final product.
Participant or Production Team Name _________________________________________
Part Operation Machine/ToolCutter or
Attachment
Special Notes for
Fabrication
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Participants should complete a chart similar to the one below to identify key informationas part of effective planning to produce the needed part. This approach continues
developing participant knowledge and skill with respect to safe, accurate and appropriate
sawing and drilling operations.
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If a more basic project would be needed or preferred by the instructor, the following
example could be used to guide a basic sawing and drilling series of operations:
Evaluation:
Participant performance assessment should include the following:
Explain and demonstrate the following operations and concepts:
use of the power saw in your shop
recognizing a dull blade
changing saw blades
use of the drill press in your shop
use of the hand reamer in your shop
simple layout procedures (note tools used)
use of machine reaming in your shop
use of the countersink in your shop
use of the counter bore in your shop
drilling and hand tapping
Describe and demonstrate each of the following operations and examples of cutters used:
drill
countersink
bore
pilot drill
tap
counter bore
spot face
reamer
The instructor can present this drawing with US or SI measurements or both or require
participants to convert from one to the other which can help participants refine theirmeasurement and conversion skills.
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gun drill
center drill
Perform the following:
Calculate the feed rate using the RPM calculated above.
Locate the appropriate feed rate in Machinerys Handbook, based on drill type,
material used, and size. After recommended speeds exceed drill press capacity, use the highest RPM
possible and adjust feed rates accordingly.
Note - Feeds can range from .001-.002 per revolution for drills with diameters of1/8" and smaller to around .015 per revolution for drills with diameters of 1"
and larger.
Enrichment:
Participants can be challenged to take on more sophisticated part machining to refinesawing and drilling operations through part drawings provided by the instructor. An
example is presented below.
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