Differences

This shows you the differences between two versions of the page.

--- metal_shop [2025/03/18 10:55] – chris_santacroce
+++ metal_shop [2025/10/24 18:55] (current) – [Machine Tools] samantha_sullivan
@@ Line 1: / Line 1: @@
 ====== Metal Shop ======
-===== Equipment =====
-__Machine Tools__
+The Metal Shop is captained by Chris Santacroce
-  * Bridgeport Series 1 (round ram, M-head)
+====== Equipment ======
-  * Delta 28-560
-  * Mini Lathe (7x16)
-  * Green Instruments Pantograph engraver
-__Metrology__
+====Machine Tools====
+  * [[bridgeport_series_1|Milling Machine: Bridgeport Series 1 (round ram, M-head)]]
+    * [[mill_tooling|Mill Tooling]]
+  * [[horizontal_bandsaw|4x6 Horizontal Bandsaw]]
+  * [[mini_lathe|Mini Lathe (7x16)]]
+    * [[lathe_tooling|Lathe Tooling]]
+    * [[lathe_dro|Digital Read Out (Touch DRO)]]
+  * [[pantograph_engraver|Pantograph Engraver]]
+  * Coming soon
+    * Delta Rockwell 20" Drill press
+    * Delta Vertical Bandsaw
+    * Boyar-Schultz 612 Surface Grinder
-  * Granite surface plate (36"x36")
+====Metrology====
-  * Height gauge
+  * [[metrology_equipment|General Metrology Practices]]
+  * [[calipers|Calipers]]
+  * [[micrometers|Micrometers]]
+  * [[indicators|Indicators]]
+  * [[surface_plate|Standridge Granite Surface Plate]]
+  * [[etalon_height_gauge|Etalon Dual Beam Dial Height gauge]]
+  * [[surface_gauge|Brown & Sharpe No.621 Surface Gauge]]
+  * [[cylinder_square|Cylinder Square]]
+  * [[gauge_blocks_pins|Gauge Blocks/Gauge Pins]]
-__Other Tools__
+====Welding====
+  *
-  * Bench grinder
+====Other Tools====
-  * Drill bit sharpener
+  * [[bench_grinder|Bench Grinder]]
+  * [[drill_bit_sharpener|Drill Bit Sharpener]]
-===== General Guidelines =====
-==== Lathe ====
-__General__
+======Shop Policy======
-  - Check chuck key removal before starting
+====General Safety====
-  - Secure workpiece properly
+  - Members must have completed MAKE Roanoke’s new member orientation before using the Metal Shop.
-  - Remove chips with brush or vacuum only
+  - Digital calipers, scales, files, and other simple hand tools are considered Green tools. Use of these tools requires completion of general space orientation.
-  - Never leave chuck key in chuck
+  - Micrometers, indicators, and other precision metrology equipment are considered Yellow tools, due to the delicate nature of said equipment, and knowledge requirements for use.
+  - All machines in the Metal Shop are considered Red tools. Tool-specific competency & safety training must be completed prior to use.
-__Before Use:__
+  - Food or drinks are strictly prohibited in the shop.
-  - Oil all ways and sliding surfaces
+  - Do not leave chuck keys in the chucks.
-  - Verify smooth carriage movement
+  - All files must have handles.
-  - Ensure chuck key is not in chuck
+  - Do not take measurements with the machine running.
-__After Use:__
+  - Do not walk away from a running machine.
-  - Wipe down all surfaces
+  - Make sure the machine is stopped before changing speeds/gears/etc..
-  - Remove all chips
+  - Machines must be allowed to spin down on their own. DO NOT slow/stop a spindle with your hand.
-  - Clean and store any tools used
+  - Do not clear chips with your hands. Use a brush, tweezers, pliers, or another suitable tool.
-    * Especially the chuck key.
+  - Do not use compressed air to clear chips from machines, yourself, or others.
+  - No mist coolant allowed.
-__Lathe Maintenance__
+  - Do not attempt to use dull or damaged cutting tools. Place all unusable cutters and inserts in the appropriate container.
+  - Long hair must be tied back in such a manner, as to keep it behind your shoulders.
-  * Weekly:
+  - Necklaces, hood strings, and the like must be tucked into your shirt, or removed.
-  - Clean and inspect chuck jaws
+  - The following clothing/items are not allowed under any circumstances:
-  - Check belt condition
+    - Long sleeves
-  - Clean and oil change gears
+    - Rings
-  * Monthly:
+    - Watches
-  - Inspect electrical cables
+    - Gloves of any kind, including latex/nitrile gloves.
-  - Clean and adjust gibs if needed
+  - Unless performing an operation that requires hearing protection, you must have at least one ear open. Having earbuds in both ears is prohibited.
-  - Check tailstock alignment
+  - Materials placed in the scrap bin must be deburred.
-  - Level machine
+  - The bench grinder is for ferrous materials only (steel, iron). Grinding soft materials such as aluminum, brass, or plastic can clog the wheel, resulting in a potentially dangerous condition.
-==== Milling Machine ====
-__General__
-**IMPORTANT: Fill spindle oil cup before each use - machine must not be run without proper lubrication**
-  - Always use proper workholding (vise, clamps, or fixtures)
-  - Check that workpiece and vise are securely mounted
-  - Remove chuck key before starting machine
-  - Use appropriate speeds and feeds for material
-  - Never adjust workpiece while machine is running
-  - Keep hands away from rotating cutters
-  - Use climb milling only when appropriate
-  - Check cutter rotation direction before starting cut
-  - Clean table surface and ways after use
-  - Never leave tools on machine table
-  - Use brush or vacuum to remove chips, never compressed air
-  - Keep area around machine clear of obstacles
-  - Monitor for excess vibration or unusual sounds
-__Before Use:__
-**CRITICAL: Fill spindle oil cup - machine must not be run without proper lubrication**
-  - Oil all ways and leadscrews
-  - Check drawbar tightness
-  - Verify smooth table movement in all axes
-__After Use:__
-  - Wipe down all surfaces
-  - Clean table and T-slots
-  - Remove all chips
-  - Clean and store any tools used
-__Mill Maintenance__
-  * __Weekly:__
-  - Check belt condition
-  - Clean and oil leadscrews
-  * __Monthly:__
-  - Inspect electrical cables
-  - Check gibs and adjust if needed
-  - Verify head tram
-  - Level Machine
-==== Bandsaw ====
-__General__
-  - Ensure the work area is clean and free of debris
-  - Select the appropriate blade for your material (tooth pitch, blade material)
-  - Adjust the blade speed to match the material (lower speeds for harder materials)
-  - Secure the material firmly in the vise, ensuring it's perpendicular to the blade
-  - Position the blade guide as close to the workpiece as possible
-  - Use push sticks or handling tools when working with small pieces
-  - Support long pieces with roller stands or other appropriate supports
-  - Start the machine and allow it to reach full speed before beginning the cut
-  - Allow the machine to complete the cut without forcing or rushing
-  - In case of binding or jamming, stop the machine immediately
-  - Replace blades when dull or damaged
-  - Store blades properly when not in use
-__Before use__
-  - Check the blade for cracks, missing teeth, or damage
-  - Ensure blade tension is proper according to manufacturer specifications
-  - Verify all guards are in place and functioning
-  - Check that the blade guides and support bearings are properly adjusted
-__After Use__
-  - Clean the machine after each use
-  - Remove chips and debris from the blade and work area
-__Maintenance__
-  * __Weekly__
-  - Lubricate moving parts according to manufacturer recommendations
-  - Verify blade tension
-  * __Monthly__
-  - Check and adjust blade tracking
-  - Inspect and replace worn blade guides
-  - Check drive belt for condition
-==== Pantograph Engraver ====
-__General__
-Verify the pantograph ratio settings match your project requirements
-Secure the master template firmly to the template table
-Mark reference points on blanks for alignment
-Select appropriate holding fixtures for your workpiece
-Secure the workpiece firmly to prevent movement during engraving
-Ensure the workpiece surface is perpendicular to the cutting tool
-Adjust depth settings in small increments
-Test depth settings on similar material before final engraving
-Consider multiple passes for deeper engravings
-__Before Use__
-  - Choose the appropriate cutter type based on material:
-    * Carbide for metals and hard plastics
-    * High-speed steel for softer materials
-    * Diamond-tipped for glass or stone
-  - Select the proper cutting angle for your material
-  - Verify cutter sharpness before starting
-  - Set the correct depth of cut for your application
-__After Use__
-   - Clean machine after each use
-   - Remove all chips and debris
-   - Wipe down surfaces
-__Maintenance__
-  * __Daily__
-  - Check for loose components
-  - Check belt for condition and tension
-  * __Monthly__
-   - Lubricate moving parts according to manufacturer specifications
-   - Check and tighten all fasteners
-   - Inspect stylus and cutters for wear
-==== Metrology Equipment ====
-__Handling and Storage__
-  - Handle all measuring instruments with care to prevent damage
-  - Store instruments in protective cases when not in use
-  - Maintain a clean environment for storage
-  - Keep instruments away from moisture, dust, and extreme temperatures
-__Usage__
-  - Select the appropriate instrument for the measurement task
-  - Clean measuring surfaces before and after use
-  - Follow manufacturer's operating instructions
-  - Apply consistent measuring force when using contact instruments
-  - Allow temperature stabilization between instrument and part
-  - Take multiple measurements for verification
-  - Report inaccurate or out-of-calibration equipment to Shop Captain.
-__Maintenance__
-  - Perform regular visual inspections for damage or wear
-  - Clean instruments according to manufacturer recommendations
-  - Lubricate moving parts as specified
-  - Check batteries and power supplies regularly
-  - Verify zero settings before measurements
-  - Perform periodic performance checks between calibrations
+====Shop Policy & Courtesy====
+  - Clean up after yourself.
+  - Mark raw materials whenever possible:
+    - Type of material
+    - Alloy
+    - Heat Treat, if applicable
+  - If a piece of material is marked, cut your stock off the end opposite the mark.
+  - Do not machine wood or fiberglass.
+  - Do not use grinding equipment of any kind on workpieces in machines.
+  - Cover or otherwise protect machine ways/slides when cutting hard materials (i.e., hardened steel).
+  - Avoid the use of excessively smoky cutting fluids. Use correct PPE as appropriate.
+  - Return machines to their default state when you’re finished. Some examples:
+    - If you removed the vise from the mill, put it back and tram it in.
+    - If you set-over the tailstock on the lathe, re-center it.
+    - If you tilted/nodded the mill head, tram it back in.
+  - Keep measuring equipment clean, and put away when not in use.
+  - Keep the surface plate covered when not in use.
+  - Be mindful of others. Do not monopolize machines, and do not touch other’s projects.
+  - Do not leave projects on machines when you’re done for the day. The use of fixture plates, sub-vises, and other methods of quickly restoring a setup, is encouraged.
+  - Storage of in-progress projects subject to space restrictions and Parking Permit rules, unless otherwise approved by the Shop Captain.
+  - If you suspect a measuring instrument is inaccurate or requires calibration, label the instrument as suspect, and inform the Shop Captain.