Difference between revisions of "Kerry ag lathe"

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This page is currently under construction  
 
This page is currently under construction  
  
== The Basics ==
+
==The Basics==
  
 
We have a 5.5" kerry AG lathe -  with a 1.5hp motor.
 
We have a 5.5" kerry AG lathe -  with a 1.5hp motor.
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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  
 
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 ==
+
==Induction==
  
 
For an induction you should ask [[User:Ad|Aidan]] or [[User:Nav|Nav]] either in person, via the mailing list or on IRC.
 
For an induction you should ask [[User:Ad|Aidan]] or [[User:Nav|Nav]] either in person, via the mailing list or on IRC.
  
== Safety ==
+
==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.
+
*You must be inducted before you can use this machinery.
* Ensure the work is securely fixed in the chuck.
+
*Long hair '''MUST''' be tied up, long sleeves should be rolled up securely.
* Keep the change-gear door shut whilst the machine is on.  
+
*Eye protection '''MUST''' be worn. Safety glasses are in the "Safety Equipment" box.
* Swarf is sharp, keep an eye on it. Don't let it build up into birds-nest piles underneath the chuck.
+
*The chuck key '''MUST''' be removed from the chuck before the lathe is turned on.
* Use a centre drill on work before using a normal drill. The bit will wander and could break if you don't.
+
*Gloves '''MUST NOT''' be used whilst the machine is on - if you are concerned about grease and oil use barrier cream.
* Don't change the lead screw gearbox position whilst the machine is running.
 
* Go and check you removed the chuck key again.
 
  
== Maintenance & Care ==
+
*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.
  
=== Oiling ===
+
==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 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.  
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TBC
 
TBC
  
=== Tapers ===
+
===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.
 
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 ===
+
===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.  
 
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.  
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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.
 
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 ==
+
==Tools==
  
 
We currently have:
 
We currently have:
* A selection of carbide tipped tools
+
 
* 2 x 13mm drill chucks and a live centre for the tailstock
+
*A selection of carbide tipped tools
* Centre drills
+
*2 x 13mm drill chucks and a live centre for the tailstock
* Knurling tool (on loan)
+
*Centre drills
* 4-Jaw Independent Chuck
+
*Knurling tool (on loan)
* 3-Jaw Self-Centring Chuck
+
*4-Jaw Independent Chuck
* 6-inch Faceplate
+
*3-Jaw Self-Centring Chuck
 +
*6-inch Faceplate
  
 
We'd like:
 
We'd like:
* A full set of change-gears
 
* A quick release tool post
 
  
=== Insert tools ===
+
*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 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.
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It is still a good idea to learn how to grind a HSS tool.
 
It is still a good idea to learn how to grind a HSS tool.
  
=== <big>Spindle speeds</big><big><big>Big text</big></big> ===
+
==The lead screw and Power Feed==
 +
This lathe has a lead screw for thread cutting and the powerfeed, the direction of both is controlled by a lever on the left hand side of the head stock is has three positions forward, neutral and reverse, when not in use it should be left in the neutral position.
  
== 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
+
==The Lead Screw for thread cutting==
  
* '''tbc:''' Carriage moves ''towards'' headstock, cross slide moves outwards.
+
When not in use the right hand tumbler should be placed in the neutral position to reduce wear on the lead screw.
* '''tbc''' Neutral. The lead screw will not turn.
+
The lead screw drives the screw cutting mechanism only there is separate drive shaft for the power feed, there is a level on the gears to the right that control the direction of the leadscrew and powerfeed.  
* '''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.
+
Power to the (tbc TPI) lead screw is controlled by a gearbox to the left hand side of the lathe.
  
=== Carriage feed ===
+
By following the the chart on the front of the gearbox, there are 60 standard english threads and by changing gears on the side of the machine metric threads can be cut.
  
 +
When you are not using the lead screw, put it into neutral.
  
Carriage motion (along the bed, left and right) is controlled by the tbc
+
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.
  
=== Cross slide feed ===
 
  
Cross slide feed is useful on long facing cuts and, if you are brave, when parting off.
 
  
*
+
==Power Feed==
 +
When using the power feed the right hand tumbler should be placed into its neutral in order to reduce wear on the lead screw.
  
== Selecting a spindle speed ==
+
When using the lathe in 1500 rpm speeds on the left hand tumbler only power feeds E, F and G only should be used in order to protect the gearbox. With the left hand tumbler in positions A or B  the spindle RPm must not exceed 36rpm.
  
 +
===Carriage feed===
  
The motor runs at 1420 RPM and there are dial to select the gearbox speed.
+
Carriage motion (along the bed, left and right) is controlled by the tbc
  
For general turning you should refer to a suitable machinist's book (or [http://its.fvtc.edu/machshop2/speeds/rpmcalc.htm the internet]) to find an appropriate spindle speed. As a general rule, the harder the material you are turning the slower the cutting speed.
+
===Cross slide feed===
  
All speeds below are in RPM. [http://scottandersonpipes.com/atlas_press/tb_6lube.htm Source]
+
Cross slide feed is useful on long facing cuts and, if you are brave, when parting off.
  
{| class="wikitable"
+
*
! colspan="3" style="text-align: center; font-weight: bold;" | Direct Drive
 
|-
 
! rowspan="2" style="text-align: center; font-weight: bold;" | Spindle Belt
 
! colspan="2" style="text-align: center; font-weight: bold;" | Motor Belt
 
|-
 
! style="text-align: center; font-weight: bold;" | A
 
! style="text-align: center; font-weight: bold;" | B
 
|-
 
! style="text-align: center; font-weight: bold;" | 1
 
| style="text-align: center;" | 380
 
| style="text-align: center;" | 975
 
|-
 
! style="text-align: center; font-weight: bold;" | 2
 
| style="text-align: center;" | 540
 
| style="text-align: center;" | 1380
 
|-
 
! style="text-align: center; font-weight: bold;" | 3
 
| style="text-align: center;" | 835
 
| style="text-align: center;" | 2150
 
|-
 
! style="text-align: center; font-weight: bold;" | 4
 
| style="text-align: center;" | 2285
 
| style="text-align: center;" | 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.
 
  
{| class="wikitable"
+
==Work-holding==
! colspan="3" style="text-align: center; font-weight: bold;" | Back Gear
 
|-
 
! rowspan="2" style="font-weight: bold;" | Spindle Belt
 
! colspan="2" style="text-align: center; font-weight: bold;" | Motor Belt
 
|-
 
! style="text-align: center; font-weight: bold;" | A
 
! style="text-align: center; font-weight: bold;" | B
 
|-
 
! style="text-align: center; font-weight: bold;" | 1
 
| style="text-align: center;" | 55
 
| style="text-align: center;" | 145
 
|-
 
! style="text-align: center; font-weight: bold;" | 2
 
| style="text-align: center;" | 82
 
| style="text-align: center;" | 310
 
|-
 
! style="text-align: center; font-weight: bold;" | 3
 
| style="text-align: center;" | 125
 
| style="text-align: center;" | 415
 
|-
 
! style="text-align: center; font-weight: bold;" | 4
 
| style="text-align: center;" | 185
 
| style="text-align: center;" | 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.  
 
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.  
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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.
 
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 ===
+
===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.  
 
The 3-jaw is the easiest to use, but it's also pretty inaccurate and will only get more inaccurate over time.  
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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!
 
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 ===
+
===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.  
 
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.  
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If you want to deliberately off-set the work to turn an eccentric feature this is also very easy with the four-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 ===
+
===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.
 
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 ==
+
==Useful References==
* [http://www.youtube.com/watch?v=B5pjWkJ9ewU The Bible of Metal-Working with a Lathe]
+
 
* [http://www.youtube.com/watch?v=sQRfBHUqQs4 Plain Turning on the Metal Working Lathe]
+
*[http://www.youtube.com/watch?v=B5pjWkJ9ewU The Bible of Metal-Working with a Lathe]
* [http://www.youtube.com/watch?v=oLT2GEzOWO0 How to machine a shaft at two different diameters]
+
*[http://www.youtube.com/watch?v=sQRfBHUqQs4 Plain Turning on the Metal Working Lathe]
* [http://www.youtube.com/watch?v=a3YpkCYKY00 How to Shape Lathe Cutting Tools (also covers tool height adjustment)]
+
*[http://www.youtube.com/watch?v=oLT2GEzOWO0 How to machine a shaft at two different diameters]
* [http://www.youtube.com/watch?v=90EuSPWkLrY How to Cut a Fine Thread on a Lathe]
+
*[http://www.youtube.com/watch?v=a3YpkCYKY00 How to Shape Lathe Cutting Tools (also covers tool height adjustment)]
* [http://www.youtube.com/channel/UCKLIIdKEpjAnn8E76KP7sQg Tubalcain channel - The Machine Shop Tips series is really useful]
+
*[http://www.youtube.com/watch?v=90EuSPWkLrY How to Cut a Fine Thread on a Lathe]
* [http://lathes.co.uk/atlas/ History of Atlas lathes]
+
*[http://www.youtube.com/channel/UCKLIIdKEpjAnn8E76KP7sQg Tubalcain channel - The Machine Shop Tips series is really useful]
 +
*[http://lathes.co.uk/atlas/ History of Atlas lathes]
 +
 
 +
==Tooling Wishlist==
  
== Tooling Wishlist ==
+
*Inserted parting/grooving tool
* Inserted parting/grooving tool
 
  
  
 +
==Risk assessment for use of Myford lathe.==
  
== Risk assessment for use of Myford lathe. ==
 
  
 +
===Hazards.===
  
=== 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.
  
* 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.===
  
=== Persons at risk. ===
+
*Operator.
* Operator.
+
*Persons nearby.
* Persons nearby.  
 
  
  
=== Initial assessment of risk. ===
+
===Initial assessment of risk.===
 
{| class="wikitable"
 
{| class="wikitable"
| Hazard identified || Severity     || Probability ||   Risk Factor
+
|Hazard identified||Severity||Probability||Risk Factor
 
|-
 
|-
| Chips in eyes || style="text-align:right;" | 3 || style="text-align:right;" | 2 || style="text-align:right;" | 6
+
|Chips in eyes|| style="text-align:right;" |3|| style="text-align:right;" |2|| style="text-align:right;" |6
 
|-
 
|-
| Hair or clothes caught in chuck   || style="text-align:right;" | 2 || style="text-align:right;" | 2 || style="text-align:right;" | 4
+
|Hair or clothes caught in chuck|| style="text-align:right;" |2|| style="text-align:right;" |2|| style="text-align:right;" |4
 
|-
 
|-
| Hair or clothes caught in belt drive   || style="text-align:right;" | 2 || style="text-align:right;" | 2 || style="text-align:right;" | 4
+
|Hair or clothes caught in belt drive|| style="text-align:right;" |2|| style="text-align:right;" |2|| style="text-align:right;" |4
 
|-
 
|-
| Cutting tool breaking   || style="text-align:right;" | 2 || style="text-align:right;" | 2 || style="text-align:right;" | 4
+
|Cutting tool breaking|| style="text-align:right;" |2|| style="text-align:right;" |2|| style="text-align:right;" |4
 
|-
 
|-
| Cuts from sharp objects || style="text-align:right;" | 1 || style="text-align:right;" | 3 || style="text-align:right;" | 3
+
|Cuts from sharp objects|| style="text-align:right;" |1|| style="text-align:right;" |3|| style="text-align:right;" |3
 
|-
 
|-
| Injuries from dropped objects || style="text-align:right;" | 2 || style="text-align:right;" | 2 || style="text-align:right;" | 4
+
|Injuries from dropped objects|| style="text-align:right;" |2|| style="text-align:right;" |2|| style="text-align:right;" |4
  
 
|-
 
|-
| Objects ejected from chuck || style="text-align:right;" | 1 || style="text-align:right;" | 3 || style="text-align:right;" | 3
+
|Objects ejected from chuck|| style="text-align:right;" |1|| style="text-align:right;" |3|| style="text-align:right;" |3
  
 
|}
 
|}
 
   
 
   
  
=== Control measures. ===
+
===Control measures.===
  
* Users will be required to go through an induction with Nav or Aiden.
+
*Users will be required to go through an induction with Nav or Aiden.
* Safety glasses will be worn at all times.
+
*Safety glasses will be worn at all times.
* Check everything is secure before starting the motor.
+
*Check everything is secure before starting the motor.
* Users will be trained to mount the cutting tools and work pieces safely.
+
*Users will be trained to mount the cutting tools and work pieces safely.
* Guard in place over exposed drive belts
+
*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
+
*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.
+
*Always use a brush to clean away chips and swarf.
* Operators to ask for assistance when moving heavy objects.
+
*Operators to ask for assistance when moving heavy objects.
* Operator to ensure floor of work area is clear of trip hazards.  
+
*Operator to ensure floor of work area is clear of trip hazards.
  
  
=== Final assessment of risk ===
+
===Final assessment of risk===
  
 
{| class="wikitable"
 
{| class="wikitable"
| Hazard identified || Severity     || Probability ||   Risk Factor
+
|Hazard identified||Severity||Probability||Risk Factor
 
|-
 
|-
| Chips in eyes || style="text-align:right;" | 3 || style="text-align:right;" | 1 || style="text-align:right;" | 3
+
|Chips in eyes|| style="text-align:right;" |3|| style="text-align:right;" |1|| style="text-align:right;" |3
 
|-
 
|-
| Hair or clothes caught in chuck   || style="text-align:right;" | 3 || style="text-align:right;" | 1 || style="text-align:right;" | 3
+
|Hair or clothes caught in chuck|| style="text-align:right;" |3|| style="text-align:right;" |1|| style="text-align:right;" |3
 
|-
 
|-
| Hair or clothes caught in belt drive   || style="text-align:right;" | 2 || style="text-align:right;" | 1 || style="text-align:right;" | 2
+
|Hair or clothes caught in belt drive|| style="text-align:right;" |2|| style="text-align:right;" |1|| style="text-align:right;" |2
 
|-
 
|-
| Cutting tool breaking   || style="text-align:right;" | 2 || style="text-align:right;" | 1 || style="text-align:right;" | 2
+
|Cutting tool breaking|| style="text-align:right;" |2|| style="text-align:right;" |1|| style="text-align:right;" |2
 
|-
 
|-
| Cuts from sharp objects   || style="text-align:right;" | 1 || style="text-align:right;" | 2 || style="text-align:right;" | 2
+
|Cuts from sharp objects|| style="text-align:right;" |1|| style="text-align:right;" |2|| style="text-align:right;" |2
 
|-
 
|-
| Injuries from dropped objects || style="text-align:right;" | 2 || style="text-align:right;" | 1 || style="text-align:right;" | 2
+
|Injuries from dropped objects|| style="text-align:right;" |2|| style="text-align:right;" |1|| style="text-align:right;" |2
 
|-
 
|-
| Objects ejected from chuck || style="text-align:right;" | 1 || style="text-align:right;" | 2 || style="text-align:right;" | 2
+
|Objects ejected from chuck|| style="text-align:right;" |1|| style="text-align:right;" |2|| style="text-align:right;" |2
  
 
|}
 
|}
 
   
 
   
  
=== Points system ===
+
===Points system===
  
 
{| class="wikitable"
 
{| class="wikitable"
| Hazard severity || Points Rating     || Definition
+
|Hazard severity||Points Rating||Definition
 
|-
 
|-
| Nil || 1     || Very minor injury, bruise, graze, no risk of disease.  
+
|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.  
+
|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
+
|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.  
+
|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.  
+
|Very high||5||Causing multiple deaths and widespread destruction eg. fire, building collapse.
 
|}
 
|}
 
  
  
 
{| class="wikitable"
 
{| class="wikitable"
| Hazard likelihood   || Points Rating     || Definition  
+
|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.
+
|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.  
+
|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.  
+
|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.  
+
|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:  
+
|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  
 
A broken stair or broken rung on a ladder  
 
Bare, exposed electrical conductors  
 
Bare, exposed electrical conductors  
Line 336: Line 288:
  
 
{| class="wikitable"
 
{| class="wikitable"
| Risk Rating Score   || Definition     || Action
+
|Risk Rating Score||Definition||Action
 
|-  
 
|-  
| 1 to 4   || Low     || No action required  
+
|1 to 4||Low||No action required
 
|-  
 
|-  
| 5 to 9 || Moderate     || Reduce risks if reasonably practicable  
+
|5 to 9||Moderate||Reduce risks if reasonably practicable
 
|-  
 
|-  
| 10 to 15   || High Risk     || Priority action to be undertaken  
+
|10 to 15||High Risk||Priority action to be undertaken
 
|-  
 
|-  
| 16 to 25   || Unacceptable     || Action must be taken IMMEDIATELY
+
|16 to 25||Unacceptable||Action must be taken IMMEDIATELY
 
|}
 
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[[Category:Tools_and_Equipment]]
 
[[Category:Tools_and_Equipment]]

Revision as of 00:32, 10 January 2020

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.

The lead screw and Power Feed

This lathe has a lead screw for thread cutting and the powerfeed, the direction of both is controlled by a lever on the left hand side of the head stock is has three positions forward, neutral and reverse, when not in use it should be left in the neutral position.


The Lead Screw for thread cutting

When not in use the right hand tumbler should be placed in the neutral position to reduce wear on the lead screw. The lead screw drives the screw cutting mechanism only there is separate drive shaft for the power feed, there is a level on the gears to the right that control the direction of the leadscrew and powerfeed.


Power to the (tbc TPI) lead screw is controlled by a gearbox to the left hand side of the lathe.

By following the the chart on the front of the gearbox, there are 60 standard english threads and by changing gears on the side of the machine metric threads can be cut.

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.


Power Feed

When using the power feed the right hand tumbler should be placed into its neutral in order to reduce wear on the lead screw.

When using the lathe in 1500 rpm speeds on the left hand tumbler only power feeds E, F and G only should be used in order to protect the gearbox. With the left hand tumbler in positions A or B the spindle RPm must not exceed 36rpm.

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.


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

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