Flexible Manufacturing Working with Machines Copyright © Texas Education Agency, All rights reserved.

Work Mounting Procedures: Lathe Material can be mounted in various ways: Three-jaw chuck Four-jaw chuck Collet chuck Turning between centers Copyright © Texas Education Agency, All rights reserved.

Chuck Copyright © Texas Education Agency, All rights reserved. A chuck is used to hold round or octagonal material in a machine.

Three-jaw Chuck Copyright © Texas Education Agency, All rights reserved. A three-jaw chuck is used to clamp material for more accuracy. The three jaws move in unison.

Four-jaw Chuck Copyright © Texas Education Agency, All rights reserved. A four-jaw chuck is used to hold square or odd- shaped material in a lathe. The four-jaw chuck is also used to turn a cam- shaped part. The four jaws move independently.

Collet Copyright © Texas Education Agency, All rights reserved. A cone-shaped sleeve used in a lathe for holding round material or milling machine to hold an end mill. Collet Taper

Collet Chuck Copyright © Texas Education Agency, All rights reserved. Collet Chuck Collet A collet chuck is round on the inside and tapered on the outside. The tapered outside tightens into the chuck causing pressure to hold the material in place.

Turning Between Centers Copyright © Texas Education Agency, All rights reserved. Faceplate with Lathe Dog

Turning Between Centers Copyright © Texas Education Agency, All rights reserved. Turning (mounting) between centers is a way to machine material between the headstock and tailstock centers. The centers are tapered to match the 60⁰ angle of the center-drilled material.

Turning Between Centers Copyright © Texas Education Agency, All rights reserved. Faceplate with Lathe Dog A lathe dog is a clamp that transfers rotation from the lathe to the material mounted between the headstock center and the tailstock center.

Turning Between Centers Copyright © Texas Education Agency, All rights reserved. Faceplate with Lathe Dog Faceplate is a flat plate with slots that screw onto the lathe headstock. This device turns the lathe dog.

Copyright © Texas Education Agency, All rights reserved. Machining a Plumb Bob

Copyright © Texas Education Agency, All rights reserved. Plumb Bob Plan

Copyright © Texas Education Agency, All rights reserved. Plumb Bob Parts Body Stem

Plumb Bob Flow Process Chart PRODUCT NAME Plumb Bob Base FLOW BEGINSFLOW ENDS DATE PREPARED BYAPPROVED BY PROCESS SYMBOLS AND # USED OPERATIONS _____ INSPECTIONS _____ TRANSPORTATIONS _____ DELAYS _____ STORAGE _____ Copyright © Texas Education Agency, All rights reserved. Task # Process Symbols Description of Task Machine RequiredTooling Required 01 cut to lengthband saw or hack saw 02 chuck in lathemetal lathe 03 face one endmetal lathe 04 center drillmetal lathechuck and center drill

Facing Base Copyright © Texas Education Agency, All rights reserved.

Plumb Bob Flow Process Chart Copyright © Texas Education Agency, All rights reserved. Task # Process Symbols Description of TaskMachine RequiredTooling Required 05 drill center of plumb bobmetal lathe#3 drill bit 06 tap hole with ¼” - 28 NF threads tap holder and ¼”-28 NF tap 07 chuck other end in lathe metal lathe 08 face second end metal lathe 09 turn taper on end metal lathe 10 sand and polish metal lathe 11 remove and store metal lathe

Turning the Taper Copyright © Texas Education Agency, All rights reserved.

Flow Process Chart PRODUCT NAME Plumb Bob Stem FLOW BEGINSFLOW ENDSDATE PREPARED BYAPPROVED BY PROCESS SYMBOLS AND # USED OPERATIONS _____ INSPECTIONS _____ TRANSPORTATIONS _____ DELAYS _____ STORAGE _____ Copyright © Texas Education Agency, All rights reserved. Task # Process Symbols Description of TaskMachine RequiredTooling Required 01 rough cut to length hack saw 02 chuck in lathe metal lathe 03 face one end metal lathe 04 center drill face metal lathe chuck and center drill 05 drill with ³∕₃₂” drill metal lathe³∕₃₂” drill bit 06 chuck other end in lathe metal lathe 07 face second end

Flow Process Chart Copyright © Texas Education Agency, All rights reserved. Task # Process Symbols Description of Task Machine Required Tooling Required 08 knurl end metal lathe knurl tool 09 tap end with ¼” -28 NF Threads metal lathe tap wrench and die 10 sand and polish metal lathe 11 remove and store metal lathe

Flow Process Chart PRODUCT NAME Plumb Bob Assembly FLOW BEGINSFLOW ENDSDATE PREPARED BYAPPROVED BY PROCESS SYMBOLS AND # USED OPERATIONS ____ INSPECTIONS _____ TRANSPORTATIONS _____ DELAYS ____ STORAGE ____ Copyright © Texas Education Agency, All rights reserved. Task # Process SymbolsDescription of TaskMachine RequiredTooling Required 01 retrieve the parts 02 insert string into stem hole 03 screw stem into base 04 inspect 05 submit for grading

Copyright © Texas Education Agency, All rights reserved. Work Mounting Procedures: The grinder is a freehand machine with a tool rest attached. Bench Grinder Hand Held Grinder Grinders

Copyright © Texas Education Agency, All rights reserved. Work Mounting Procedures: The vertical band saw is usually operated freehand. A fence or miter gauge accessory can be used. Vertical Band Saw Fence Accessory Miter Gauge Accessory Vertical Band Saws

Copyright © Texas Education Agency, All rights reserved. Work Mounting Procedures: The horizontal band saw has a vise attached to the bed. The vise holds the material. Horizontal Band saws

Copyright © Texas Education Agency, All rights reserved. Abrasive Saw An abrasive saw has a vise attached to the bed. The vise holds the material. Work Mounting Procedures:

Copyright © Texas Education Agency, All rights reserved. Work Mounting Procedures: A milling machine and a drill press mount material in the same way. Machining Vise Step Blocks Fixtures Milling Machine and Drill Press

Copyright © Texas Education Agency, All rights reserved. Machine Vise A vise secures work in a machine. This device bolts to the machine bed and usually has one fixed jaw and one movable jaw.

Copyright © Texas Education Agency, All rights reserved. Step Block Clamps Step block clamps have a series of blocks with different heights. The blocks contain a bolt and clamp to hold parts to a machine table.

Copyright © Texas Education Agency, All rights reserved. Step Block Parts Step Block Clamp T-Bolt

Copyright © Texas Education Agency, All rights reserved. Step Block with Clamp and T-Bolt

Copyright © Texas Education Agency, All rights reserved. Fixture A fixture holds an irregular part (or multiple parts) to be machined. This device improves the accuracy of work and the ability to machine various parts.

Copyright © Texas Education Agency, All rights reserved. Personal Protective Equipment Always wear your approved personal protective equipment when working in the lab.

Copyright © Texas Education Agency, All rights reserved. Machining a Tap Wrench

Exploded View of Tap Wrench Copyright © Texas Education Agency, All rights reserved.

Plan for Tap Wrench Body Copyright © Texas Education Agency, All rights reserved.

Plan for Tap Wrench Parts Copyright © Texas Education Agency, All rights reserved.

Task # Process Symbols Description of TaskMachine RequiredTooling Required 01cut to lengthhack saw 02file cut endsfile 03lay out hole location on end 04lay out hole location on face 05lay out V-groove 06lay out set screw hole Copyright © Texas Education Agency, All rights reserved. Flow Process Chart PRODUCT NAME Tap Wrench Base FLOW BEGINSFLOW ENDS DATE PREPARED BYAPPROVED BY PROCESS SYMBOLS AND # USED OPERATIONS ____ INSPECTIONS ____ TRANSPORTATIONS ____ DELAYS ____ STORAGE ____

Drilling Hole in End Copyright © Texas Education Agency, All rights reserved.

Task # Process Symbols Description of TaskMachine RequiredTooling Required 07drill hole in the enddrill press#3 drill bit 08drill hole on the sidedrill press#3 drill bit 09drill hole on the side for adjusting screw drill press ¹⁷∕₆₄ drill bit 10drill hole on the side for set screw drill press#29 drill bit 11cut V-groove3 square file 12tap end hole for handle¼ - 28 NF tap 13tap hole for adjusting screw ¼ - 28 NF tap 14tap hole for set screw8-32 NC tap 15sand and polishsand paper 16move to storage Copyright © Texas Education Agency, All rights reserved. Flow Process Chart

Filing V-Groove for Tap Wrench Copyright © Texas Education Agency, All rights reserved.

Task # Process Symbols Description of TaskMachine RequiredTooling Required 01cut to lengthhack saw 02face endsmetal lathe 03tap end¼ - 28 NF tap 04sand and polishsand paper 05move to storage Copyright © Texas Education Agency, All rights reserved. Flow Process Chart PRODUCT NAME Tap Wrench Handle FLOW BEGINSFLOW ENDS DATE PREPARED BYAPPROVED BY PROCESS SYMBOLS AND # USED OPERATIONS _____ INSPECTIONS _____ TRANSPORTATIONS _____ DELAYS _____ STORAGE _____

Drilling Screw Hole Copyright © Texas Education Agency, All rights reserved.

Task # Process Symbols Description of TaskMachine RequiredTooling Required 01 cut to lengthhack saw 02 face endsmetal lathe 03 turn screw shaft to ¼metal lathe 04 turn ¹∕₁₆ groove ¹∕₁₆ deepmetal lathecut off tool 05 tap screw shaft¼-28 NF die 06 cut adjusting screw to lengthmetal lathecut off tool Copyright © Texas Education Agency, All rights reserved. Flow Process Chart PRODUCT NAME Tap Wrench Adjusting Screw FLOW BEGINSFLOW ENDS DATE PREPARED BYAPPROVED BY PROCESS SYMBOLS AND # USED OPERATIONS _____ INSPECTIONS _____ TRANSPORTATIONS _____ DELAYS _____ STORAGE _____

Turning Screw Copyright © Texas Education Agency, All rights reserved.

Cutting a Slot With a Cut Off Tool Copyright © Texas Education Agency, All rights reserved.

Task # Process SymbolsDescription of TaskMachine RequiredTooling Required 07chuck adaptor for adjusting screw in lathe metal latheadaptor 08face adjusting screw head metal lathe 09sand and polishsand paper 10move to storage Copyright © Texas Education Agency, All rights reserved. Flow Process Chart

Tapping Handle Copyright © Texas Education Agency, All rights reserved.

Exploded View of Tap Wrench Copyright © Texas Education Agency, All rights reserved. Bases Adjusting Screw Handle Adjusting Screw

Task # Process Symbols Description of TaskMachine RequiredTooling Required 01retrieve all parts 02place adjusting screw into base with set screw hole 03screw adjusting screw into the other base that is threaded 04screw other adjusting screw into the second hole Copyright © Texas Education Agency, All rights reserved. Flow Process Chart PRODUCT NAME Tap Wrench Assemble FLOW BEGINSFLOW ENDS DATE PREPARED BYAPPROVED BY PROCESS SYMBOLS AND # USED OPERATIONS _____ INSPECTIONS _____ TRANSPORTATIONS _____ DELAYS _____ STORAGE _____

Task # Process symbols Description of TaskMachine RequiredTooling Required 05screw in set screws and fit into the groove hex wrench 06screw handles into the bases 07Inspect 08submit for grading Copyright © Texas Education Agency, All rights reserved. Flow Process Chart