Kerry ag lathe
| A metalworking lathe, | |
| Equipment Information | |
|---|---|
| Status | Unknown |
| Manufacturer | Kerry |
| Model | 5.5" Lathe |
| Hackspace Information | |
| Induction Required | Yes |
| Induction Information | Here |
| Card RFID Enabled | No |
| Owner | Hackspace & Members |
| [More Info] | |
This page is currently under construction
The Basics
We have a 5.5" kerry AG lathe - with a 1.5hp motor.
Our lathe is suitable for turning metals and plastics. Aluminium, brass, copper, delrin/acetal and nylon shouldn't present any problems. It should be possible to machine mild steel too, though you may find some additional cooling is necessary.
Both the carriage and cross slide can be power-fed using the appropriate change gears and the feed-direction gearbox on the left-hand side.
This lathe can cut imperial and with the right change gears it can cut metric threads, we may not have a full set of metric threads
Induction
For an induction you should ask Aidan or Nav either in person, via the mailing list or on IRC.
Safety
- You must be inducted before you can use this machinery.
- Long hair MUST be tied up, long sleeves should be rolled up securely.
- Eye protection MUST be worn. Safety glasses are in the "Safety Equipment" box.
- The chuck key MUST be removed from the chuck before the lathe is turned on.
- Gloves MUST NOT be used whilst the machine is on - if you are concerned about grease and oil use barrier cream.
- The emergency stop button is located below the "Start" button.
- Ensure the work is securely fixed in the chuck.
- Keep the change-gear door shut whilst the machine is on.
- Swarf is sharp, keep an eye on it. Don't let it build up into birds-nest piles underneath the chuck.
- Use a centre drill on work before using a normal drill. The bit will wander and could break if you don't.
- Don't change the lead screw gearbox position whilst the machine is running.
- Go and check you removed the chuck key again.
Maintenance & Care
Oiling
The lathe must be oiled before each use and the headstock oil level checked. Without oil the bearings will run dry and ruin themselves and the ways will wear and become scored and inaccurate.
The oil currently used is 50 SAE yellow metal safe, the same oil used for the headstock can be used on all oiling ports.
Filling the headstock
Remove the level port on the lower left of the head stock place a rag under the port to catch any oil overflow, then fill oil into the top port until oil comes out of the lower port.
For the other lubrication Refer to the following lubrication chart. TBC
Tapers
The spindle taper will be either a 4 or 4.5 morse taper need to confirm there was a sleeve to convert to mt3 , tailstock taper is a 3 more taper and any tooling which fits into them must be free of oil, rust, dirt and grease to lock correctly and securely. Give tooling a wipe down with clean tissue/clean rag before inserting it into the taper hole to prevent damage.
Sanding & Grinding
If you are sanding on the lathe make sure that you cover the ways with cloth or paper and clean up comprehensively when you are done - including the chuck. Magnets are available to securely hold protective material down so it won't be blown into the chuck.
This is very important: the dust generated by sanding and grinding is very abrasive and will wear the ways quickly, turning the precision machinery we have at the moment into a sloppy, inaccurate pile of scrap metal.
Tools
We currently have:
- A selection of carbide tipped tools
- 2 x 13mm drill chucks and a live centre for the tailstock
- Centre drills
- Knurling tool (on loan)
- 4-Jaw Independent Chuck
- 3-Jaw Self-Centring Chuck
- 6-inch Faceplate
We'd like:
- A full set of change-gears
- A quick release tool post
Insert tools
The inserts taken by most of the lathe tools are 80 degree rhombus style - you can use CCMT 09 or CCGT 09 marked tools. Shiny silver coloured inserts are for use with aluminium, the matte gold coloured ones are for use with steel. There are some exceptions, but this is a good rule of thumb.
The inserts are held in place with a Torx screw. When swapping types be aware that you might have to re-centre the tool height using the quick change tool post screw facility.
It is still a good idea to learn how to grind a HSS tool.
Spindle speedsBig text
The Lead Screw
Power to the (tbc TPI) lead screw is controlled by a gearbox to the left hand side of the lathe. Which also control the thread cutting
- tbc: Carriage moves towards headstock, cross slide moves outwards.
- tbc Neutral. The lead screw will not turn.
- tbc: Carriage moves away from headstock, cross slide moves inwards.
When you are not using the lead screw, put it into neutral.
If you find that you can't move one of the axes of the machine check that the relevant power feed lever hasn't been engaged.
Carriage feed
Carriage motion (along the bed, left and right) is controlled by the tbc
Cross slide feed
Cross slide feed is useful on long facing cuts and, if you are brave, when parting off.
Selecting a spindle speed
The motor runs at 1420 RPM and there are dial to select the gearbox speed.
For general turning you should refer to a suitable machinist's book (or the internet) to find an appropriate spindle speed. As a general rule, the harder the material you are turning the slower the cutting speed.
All speeds below are in RPM. Source
| Direct Drive | ||
|---|---|---|
| Spindle Belt | Motor Belt | |
| A | B | |
| 1 | 380 | 975 |
| 2 | 540 | 1380 |
| 3 | 835 | 2150 |
| 4 | 2285 | 3050 |
By enabling the back gear function the speed of the spindle can be reduced (and thus the torque increased) to a speed useful for threading, turning large diameter pieces and parting off.
| Back Gear | ||
|---|---|---|
| Spindle Belt | Motor Belt | |
| A | B | |
| 1 | 55 | 145 |
| 2 | 82 | 310 |
| 3 | 125 | 415 |
| 4 | 185 | 463 |
Work-holding
There are a variety of ways to hold work to be turned in the lathe. At the Hackspace we have a 3-jaw and a 4-jaw chuck available for use.
The spindle nose is threaded (tbc TPI, " major diameter thread) and should be cleaned every time the chuck is changed. Similarly, the female chuck thread should be cleaned before each use.
Don't assume the previous user has cleaned it well enough!
When threading the chuck onto the spindle nose do so gently but firmly - there is no need to 'snap' the chuck onto the last section of the thread. When unscrewing the chuck from the spindle do so carefully: it will come off the last thread very suddenly and you could drop it onto the ways. This has already happened a few times in this lathe's history (there are a few dents on the ways under the spindle) but it would be great if it didn't happen again!
Spin the chuck by hand before you turn the power on to check that nothing will collide at high speed and of course always, always ensure that the chuck key has been removed to prevent injury to yourself or other people and (most importantly) damage to the machine.
3-Jaw Chuck
The 3-jaw is the easiest to use, but it's also pretty inaccurate and will only get more inaccurate over time.
If you ever take the chuck apart for cleaning keep in mind that the jaws are numbered (1, 2 and 3) and they each fit into their respective slots in the body and must be inserted onto the scroll in that order. If you don't they won't meet in the centre and you'll have to start from scratch!
4-Jaw Chuck
If you are working with a part which has already been machined (or you haven't got much spare material, diameter wise) it's important to get the work running as 'true' as possible.
The 4-jaw independent chuck can, with a bit of effort, be fine tuned to hold the work very concentrically. For more information see this short (3 min) video. There are two chuck keys for the 4-jaw.
If you want to deliberately off-set the work to turn an eccentric feature this is also very easy with the four-jaw.
Faceplate
A faceplate allows you to turn oddly shaped work and to give reliable drive power to work being turned between centres using a lathe dog.
Useful References
- The Bible of Metal-Working with a Lathe
- Plain Turning on the Metal Working Lathe
- How to machine a shaft at two different diameters
- How to Shape Lathe Cutting Tools (also covers tool height adjustment)
- How to Cut a Fine Thread on a Lathe
- Tubalcain channel - The Machine Shop Tips series is really useful
- History of Atlas lathes
Tooling Wishlist
- Inserted parting/grooving tool
Risk assessment for use of Myford lathe.
Hazards.
- 1) Chips in eyes.
- 2) Hair or clothing caught in rotating parts.
- 3) Cutting tool breaking or getting ejected from holder.
- 4) Sharp objects and chips cutting fingers.
- 5) Dropping heavy parts.
- 6) Objects ejected from chuck.
Persons at risk.
- Operator.
- Persons nearby.
Initial assessment of risk.
| Hazard identified | Severity | Probability | Risk Factor |
| Chips in eyes | 3 | 2 | 6 |
| Hair or clothes caught in chuck | 2 | 2 | 4 |
| Hair or clothes caught in belt drive | 2 | 2 | 4 |
| Cutting tool breaking | 2 | 2 | 4 |
| Cuts from sharp objects | 1 | 3 | 3 |
| Injuries from dropped objects | 2 | 2 | 4 |
| Objects ejected from chuck | 1 | 3 | 3 |
Control measures.
- Users will be required to go through an induction with Nav or Aiden.
- Safety glasses will be worn at all times.
- Check everything is secure before starting the motor.
- Users will be trained to mount the cutting tools and work pieces safely.
- Guard in place over exposed drive belts
- Ensure long hair is tied back, ties not to be worn and loose clothing secured away from belts and chuck
- Always use a brush to clean away chips and swarf.
- Operators to ask for assistance when moving heavy objects.
- Operator to ensure floor of work area is clear of trip hazards.
Final assessment of risk
| Hazard identified | Severity | Probability | Risk Factor |
| Chips in eyes | 3 | 1 | 3 |
| Hair or clothes caught in chuck | 3 | 1 | 3 |
| Hair or clothes caught in belt drive | 2 | 1 | 2 |
| Cutting tool breaking | 2 | 1 | 2 |
| Cuts from sharp objects | 1 | 2 | 2 |
| Injuries from dropped objects | 2 | 1 | 2 |
| Objects ejected from chuck | 1 | 2 | 2 |
Points system
| Hazard severity | Points Rating | Definition |
| Nil | 1 | Very minor injury, bruise, graze, no risk of disease. |
| Slight | 2 | Minor injury, which would allow the individual to continue work after first aid treatment on site or at a local surgery. The duration of the stoppage or treatment is such that the normal flow of work is not seriously interrupted. |
| Moderate | 3 | Temporary disability causing injury or disease capable of keeping an individual off work for three days or more and reportable under RIDDOR |
| High | 4 | Causing death, serious injury or permanent disability to an individual. |
| Very high | 5 | Causing multiple deaths and widespread destruction eg. fire, building collapse. |
| Hazard likelihood | Points Rating | Definition |
| Remote possibility | 1 | There is really no risk present. Only under freak conditions could there be any possibility of an accident or illness. All reasonable precautions have been taken - This should be the normal state of the workplace. |
| Unlikely | 2 | This incident or illness might occur but the probability is low and the risk minimal. |
| Possible | 3 | The accident may occur if additional factors precipitate it, but it is unlikely to happen without them. |
| Highly likely | 4 | Will happen more often than not. Additional factors could precipitate an incident but it is still likely to happen without this additional factor. |
| Inevitable | 5 | If the work continues as it is, there is almost 100% certainty that an accident will happen, for example:
A broken stair or broken rung on a ladder Bare, exposed electrical conductors Unstable stacks of heavy boxes |
| Risk Rating Score | Definition | Action |
| 1 to 4 | Low | No action required |
| 5 to 9 | Moderate | Reduce risks if reasonably practicable |
| 10 to 15 | High Risk | Priority action to be undertaken |
| 16 to 25 | Unacceptable | Action must be taken IMMEDIATELY |