The Instrument Shop
027 Lauritsen
SHOP INSTRUCTION AND SAFETY OUTLINE

SAFETY RULES - TO BE OBSERVED AT ALL TIMES

  TWO PEOPLE MUST BE PRESENT IN SHOP AT ALL TIMES.
  EYE PROTECTION IS REQUIRED AT ALL TIMES.
  NO OPEN TOE SHOES OR SANDALS ALLOWED.
  NO LONG SLEEVES.
  LONG HAIR MUST BE TIED BACK.
  RINGS, WATCHES AND OTHER LOOSE JEWELRY SHOULD NOT BE WORN WHILE OPERATING MACHINERY.

1. INTRODUCE SHOP TO STUDENTS

A. Show them where general equipment is kept (hand tools, precision tools, taps
   and dies, with all safety rules in mind.
B. Where hardware and other materials are located.
C. Explain what type of machines there are in the shop.
D. Explain shop rules and how shop works.
E. Measuring equipment usage.

2. MACHINE SHOP EQUIPMENT USED BY STUDENTS.

A. Horizontal saw.

1) Help each student cut round pieces for use on lathe.
2) Use speed chart and change speeds for different materials.

B. Vertical saw.

1) Show how to change blades, blade guides, and how to match correct sizes.
2) Safe handling of band saw blades.
3) How to determine what blade for what job. What number of teeth (2-18), what
   width and radius of cut.
4) Show how to safely cut materials on saw.
5) Help each student cut a small piece of aluminum for
   use on drill press.
6) Use speed chart and change speeds for different materials.

C. Disc and belt sanders.

1) Show that disk sander has two directions.
2) Have students sand two sides square.
4) Use Belt Sander to remove sharp edges.

D. Drill press and tapping machine.

1) Help students lay out cross lines.
2) Center punch at intersection of cross lines.
3) Center drill and drill hole for Tap using chart.
4) Help each student Tap their piece.
5) Check hole with screw.
6) Show how counterbore’s are used for print/handout.

E. Bench Grinder.

1) Grind Tool Bit: two ends, per print or handout showing tool bit clearances necessary
   for turning operations on lathe.
2) One for general work on steel, copper, aluminum, acrylic etc.
3) One for brass.
4) Correct method of honing tool bit.

F. Lathe.

1) Show student the parts of the lathe, speeds, feeds, and the dials.
2) When to use collets - 3, 4 & 6 jaw chucks and how to change to each.
3) How to set and center the toolbit for turning.
4) Demonstrate general turning using 3 jaw chuck.
5) Drill and ream holes.
6) Use of boring bar to do odd size holes, stepped holes, tapered holes, etc.
7) Hand out prints for lathe project and have students make parts to print.
8) Show how to use a thread die. Will provide die and holder necessary to complete 
   task.

G. Mill

1) Show students the parts of the mill: speeds, feeds, the dials, and how to
   change tools.
2) How to use a vise: change angles, true vise, keys, parallel, how to use edge
   finder and indicator.
3) How to select and use an end mill (2 or 4 flute), climb or conventional cut,
   use of flycutter.
4) How to do general milling, drilling, and tapping using the vise on the mill.
5) Hand out prints for mill project and have students make parts to print.

H. All Machines.

   Advise students of other various methods of adaptive tools to use for a particular
   application, as noted on hand out.

H. Assembly operation of Project.

1) This will show how the use of tolerances and dimensions held during machining will
   apply.
2) Go through general adjustments necessary to complete assembly, including
   de-burring and other finishing methods to surface.

I. Course Completion.

   Students will receive a complete set of prints that include noted recommendations 
   and informal reminders.

   Assembled Project (Trophy)

  SHOP CLASS INSTRUCTORS:

MARK GONZALES EXT 6598   

FOR ADDITIONAL INFORMATION OR CLARIFICATION

PLEASE CONTACT:
  BOVAN BANG EXT 6641
   vanbang@caltech.edu

 

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