GRT Safety Test - Hand Tools

Where are the fire extinguishers?

front door, cubicles, boneyard, Granlund’s office, machine shop entrance, paint room, bathroom, back door

Where are the exits?

front door, cubicles, side of the shop, back of the shop

Shop Safe?

Safety glasses on, hair tied back, no earbuds or headphones, no loose or dangly jewelry, shoulders, midriff, and back covered, sleeves rolled above the elbow, pants cover your knees, close toed shoes

Before Working in the Machine Shop:

Make sure you are shop safe Let mentor know you will be machining Have a GRT buddy within sight and hearing of you Turn on the vents

The Vault

Fasteners Machine replacement parts Non-metal materials

Cat Closet

Wood (Plywood, 2 by 4s, etc) Metal (Box beam, rods, sheet metal)

Yellow Cabinet

Flammable Liquids (Acetone, dykem, machining oil)

When do I use hearing protection?

Using chop saw or vertical bandsaw Cutting lots of stock on the horizontal bandsaw Cutting large sheet metal on shear Standing next to an air compressor

Cleaning:

Put away tools Put away extra stock or the scrap/recycle bin Use a vacuum to clean up area (Don’t vacuum big chips) Sweep floor

How much should you measure?

Measure Twice, Cut Once

Measuring for different materials

For sheet metal, wood, or box beam: add extra ¼ inch to measurement For rod: add extra ⅛ inch to measurement For lathe parts: add extra ⅛ inch

Marking Tools:

Sharpies, scribes, dykem

Sharpies

(mark measurement by drawing line)

Scribes

(scratch into metal to mark a line)

Dykem

(flammable liquid that can be spread on metal to stain)

Measurement Tools:

Calipers, micrometers, tape measures, combination square

Calipers

For tight tolerances, measures to nearest 0.001 or 0.0005 inch Measurements: inner diameter, outer diameter, step, depth Use procedure: wipe off jaws, zero calipers, use the wheel to change space between jaws and measure

Micrometers

For tight tolerances, measures to nearest 0.0001 to 0.001 inch Use procedure: place part between measuring faces, rotate spindle to tighten most of the way, then rotate ratchet press a few times to fully tighten, read measurement

Tape Measures

For wood, measures to nearest 1/16 to 1/8 inch Use procedure: pull out some of the measuring tape, line up the metal end and take the measurement, rewind the tape measure slowly so you don’t damage the metal tip

What Can Affect the Accuracy?

Condition of the tool Human error Temperature of the material Dirt and contamination

Use of chop saw

cut wood

Chop Saw Use procedure:

Put on hearing protection and offer to those near you Clamp down material on one side (before fully tightening, bring down blade to make sure it is lined up with the outside of your line) “Loud Noise” Open vents and make sure they are actually working With your right hand, press safety latch with thumb, use other fingers to pull main trigger, with your left hand, hold down the part where it is clamped just incase Lower saw and cut through material, then let go of trigger and wait for blade to stop

When finished with chop saw:

Close vent Remove wood pieces Don’t leave until the blade has stopped spinning Clean sawdust with wall vacuum

Drill Press Use:

drill wood, plastic, or metal

Don’t use drill press if...

you are drilling a hole more than half an inch in diameter into metal

Drill King is used for ___ holes, Drill Prince used for ___ ones

larger, smaller

Drill Press Use Procedure

Choose a drill bit by referencing the chart Put in the bit and use chuck key(on a chain connecting to machine) to tighten into the jaws, make sure bit is centered and remove chuck key after tightening If you aren’t using a vise, clamp scrap wood below your piece to protect the machine table Secure the piece you are trying to drill into with a clamp/vise, if it is a long pieces of material, make it extend to the left instead of the right Lower feed lever to line up piece (if using the Drill Prince, the laser alignment tool will help) Clamp the vice onto machine table Adjust the table height if needed with cranks at the far end of the table Turn the drill press on, change speed based on material when it is already on for the Drill King and Prince, for the Drill Princess, stop and unplug before changing speed Lower feed lever, keep at least one hand on the lever Peck at the material(drill a bit, pull up, repeat) Slowly turn the handle to lift the drill and turn off

When finished with drill press:

Put drill bit away Remove scrap pieces Use wall vacuum to clean scraps from table and floor

Arbor press use:

press things together

Arbor press use procedure:

Rotate lever counter-clockwise to lift the ram and clockwise to push down Lift lever and press down on your parts When done, move the lever so it is not hanging off the table

Rotex Punch Use:

Punch holes

Only use rotex punch on sheet metal ____ inch or less

1/16

Rotex Punch Use procedure:

Push top lever back with lots of force to change size on upper wheel Push bottom lever to rotate lower wheel to match the letter on the top wheel, make sure it clicks into place Hold material in place and use the big lever with the pool noodle to punch through Move the lever so it is over bench and clean scraps

Horizontal Bandsaw Use:

cut box beam and rod or bar stock

Horizontal Bandsaw Use procedure:

Clamp stock Turn feed knob to gently lower blade and check cutting position Use stand to hold long stock Before cutting, lift blade and apply oil along cut (you can also apply it to the inside of box beam) Turn on machine Use knob to make the blade lower slowly onto the stock and wait for it to make the cut, the machine will turn itself off

When finished with Horizontal bandsaw:

Wait before removing your part or extra stock because it could still be hot Return excess stock to inventory Use vacuum to clean chips

Vertical Bandsaws Uses:

Cut aluminum sheet metal and box beam for the metal vertical bandsaw and wood for the wood vertical bandsaw

Vertical Bandsaw Use procedure:

Put on hearing protection and offer it to people nearby if you are using the metal vertical bandsaw Open the vent Adjust blade guide to be ⅛ inch above your stock by loosening the knob towards the top of the machine and moving the blade guide Oil your piece if you are using the metal vertical bandsaw Turn the machine on “Loud Noise” Guide your stock into the blade with a miter guide, sacrificial wood, or fence, if you are cutting a lot of material, have someone support the part hanging off If you are using the wood vertical bandsaw, you can use the break to slow the blade when you are finished

When Finished with vertical bandsaw:

Turn machine off Close the vent Return hearing protection and extra stock Use the wall vacuum to clean scraps from the floor and if you used the metal vertical bandsaw, a rag to clean scraps from your piece and table

Sanders Uses:

Green sander is only for wood, white sander is for metal

___ sander can be used at a time

One

Sander use procedure:

Open the vent Turn sander on Move material to sander and move back and forth to not wear out only one part of the sander, if you are using a circular sander go on the left side of the wheel If you are making a curved corner, come in from the side instead of straight on to prevent damage to the sander

When finished with sander:

Turn sander off Use scrap wood or metal (depending on what sander you were using) and go back and forth to slow the wheel until it stops Close the vent

Shear Use

Cuts Sheet material

Brake Use

bends sheet material

For the shear and brake, use flat stock only (aluminum or plastic up to ___ inch, steel up to ___ inch

1/8, 1/16

Shear use procedure:

Align material using the left-side ruler “Loud Noise” if you are cutting a large piece of metal Step on the foot pedal to cut

Brake use procedure:

Align sheet metal Lift lever to bend metal (you need to overbend by a bit) Take out your piece and secure the lever back with the rope

Deburring Use:

Removes sharp edges

Parts submitted to quality control must be ___

deburred

Tools that you can use to debur:

files, deburring tools, nylon and grinding wheels, sanders, countersink drill bit

Files:

Larger edges, outside edges Use by pushing forward over your piece

Deburring Tools:

Inside edges, holes (don’t use for outside edges) Use by rotating around the inside edge/hole

Nylon and grinding wheels:

Nylon wheel is for aluminum(on right) grinding wheel is for steel(on left) Use by turning on the switch and hold your material below the centerline of the wheel and press against the wheel while shifting left and right You can have a cup of water to cool metal if it gets hot When done, turn of the machine and use the foam pad to grip onto the axel and slow the wheel to a stop

Power drills are usually for ___, impact drivers are usually for ___.

holes, removing fasteners

For a power drill, if drilling a hole bigger than ___ inch in metal or ___ inch in wood, first drill a ___ inch pilot hole

1/4, 3/8, 1/8

Impact drivers are more powerful than ___

power drills

Power Drill and Impact Driver Use Procedure:

Get a drill or impact driver and battery and your drill bit Use a clamp or vise to secure your part Make sure that you are drilling into sacrificial wood or one of the holes in the table For a drill, put in your drill bit by loosening chuck counterclockwise and tightening clockwise (drill bit has to be less than ½ inch diameter for metal) For an impact driver lift the nozzle, place the bit inside, and let go of the nozzle More torque for drilling, less for fasteners Choose if you want to drill in or out, then press the trigger Make sure you have your other hand on the but of the drill to stabilize and keep you at the right angle

When finished with power drill or impact driver:

Remove and return bit and battery, make sure you put the battery into a charger

___ are a strong fastener and easy to take out

rivets

Use ___ rivet possible for project

shortest

Putting in rivets with rivet gun use procedure

Drill all holes the size of the rivet through one part Drill just one hole through the other part Put in a Cleco clip and drill the other holes one at a time with Cleco clips Take out one Cleco clip, size up your drill bit, and attach with a rivet To attach a rivet: put the thick part of the rivet into the hole, slide on the rivet gun, squeeze a few times until it pops Repeat this process with other rivets one at a time

To remove rivets:

drill with a bit one size bigger than the rivet until the cap comes off, use a hammer and punch to take out the part of the rivet still stuck

Hydraulic Press Use:

broaching, assembling press fits, bending thick sheet metal

For holes greater than 1/2 inch diameter on the drill press, remove the drill chuck and use a ___ drill bit

morse-taper

What is kerf?

It is the width of the cut made by the blade