machining on the lathe

Make sure to bring safety glasses and wear your closed toe shoes for today's class. You will also want to print out the following handouts. I would like for you to read through these. Some of the information will seem foreign to you, but reading through this will help make the demo's easier to digest. In addition to the handouts, please print out the diagram from above (this will serve as a good example of what profiles the different shaped lathe tool bits can cut).

1. Lathe Safety

2. Lathe

3. Getting Started

4. Facing Operations

5. Drilling Operations

6. Turning Operations

7. Parting Operations

8. Threading


There are some great videos on MIT's website that discusses shop safety and techniques. I have listed the links below along with their contents. You will be most interested in the lathe videos for our current use, but the other videos are very informative.


Machine Shop 1 – Machining Skills for Prototype Development (Length: 40:32)

• Basic tour of the machine shop
• Layout techniques (including transferring hole locations)
• Basic tools: drill press, band saw, belt sander and grinder
• Locating and drilling holes (includes using a center finder and deburring)
• Tapping holes (including using a tap guide)

Machine Shop 2 – Machining Skills for Prototype Development (57:33)

• Drilling holes
• Special drills for plastics and hard or abrasive materials
• Drill press limitations
• Bandsaw
• Suitable speeds, feeds and materials
• Bandsaw setup
• Using the drill press vise

Machine Shop 3 – Machining Skills for Prototype Development (30:02)

• Good practice – clean up
• Small belt sander configurations
• Grinder operations and materials
• Deburring and buffing
• Finishing techniques

Machine Shop 4 – Milling Machine 1 (50:33)

• Parts and controls of a Bridgeport Mill
• Quill feed
• Axis handfeeds (11:20) backlash explanation (12:15)
• Gib locks (14:40)
• Power feed (18:33)
• Digital readouts (21:07)
• Milling machine set-up – squaring/tramming  the head square (22:37)
• Squaring the vise – adjusting the vise so the stationary jaw is parallel to the bed (32:33)
• Milling machine accessories and workholding techniques  (41:15)

Machine Shop 5 – Milling Machine 2 (1:03:33)

• Square and hex collet blocks – used to hold/clamp parts to machine features on 4 and 6 sides of a part respectively (1:02)
• V-blocks  (2:10)
• Hold-down clamps – used to hold large or irregularly shaped parts (3:40)
• Using angle blocks – used to hold materials to machine features not perpendicular on a part (6:15)
• Drill press vise – using a vise within a vise (8:29)
• Lathe chuck with vise  – can be used to hold parts in the milling machine (11:11)
• Double sided tape – can be used to securely hold a part without distortion (12:00)
• Squaring high aspect ratio parts  (16:02)
• Right angle attachment (23:04)
• Slitting saws – used to cut slots/slits/features in a part (33:21)
• Rotary table – used to machine circular parts, grooves, circles, and segments (41:16).  A dial indicator (43:20) or Coaxial indicator (47:25) can be used to square/center the table to the X & Y axes
• 5C collet indexer – used to hold collets and to position parts in up to 24 positions  (52:42)

Machine Shop 6 – Milling Machine 3 (42:36)

• Squaring a part  – machining a piece of metal so all of the surfaces are flat, perpendicular and milled to the nominal size(1:00). Also covers using a fly-cutter (4:50) and deburring (8:40)
• Squaring a plate (17:52)
• Using the edgefinder (32:00)
• Drilling holes with a mill (35:32)

Machine Shop 7 – Milling Machine 4 (23:07)

• Reaming holes  (1:00)
• Boring holes with a boring Head (3:04) - also covers using Plug Gages to measure hole sizes (8:54)
  
• Milling a slot (10:45)
• Milling a shoulder, conventional and climb milling (17:11)
• Cleaning the machine (21:05)

Machine Shop 8 – Lathe 1 (42:37)

• The Lathe components
• Turning tools  (6:40)
• Turning and facing (11:04)
• Cutting off a part (22:45)
• Drilling (32:20)

Machine Shop 9 – Lathe 2 (46:15)

• Tapping
• Boring (7:31)
• Knurling with a bump knurler (15:30)
• Cutting tapers with the compound (22:21)
• Turning shafts – using a live center (26:18)
• Single point thread turning (31:03)

Machine Shop 10 – Lathe 3 (29:00)

• Lathe chuck
• Lathe arbors (6:42)
• Turning between centers (15:40)
• Face plate irregular shapes (19:00)
• Face plate thin materials (21:13)

metals sources

Here are some of the links that I mentioned in the first week of class:
http://www.lindsaybks.com/
Source for various old out of print metal working books. Home of the Dave Gingery books I mentioned in class. Various topics of books include metalworking, automobiles, living off of the grid, casting, etc. make sure to order a free catalog while you're there.


http://www.onlinemetals.com/
This site is good for ordering small amounts of metals. They have starter packs that have various sizes/gauge of metal that seem reasonably priced. I have not compared prices with other sources, but the convenience of ordering is maybe worth any price difference.

http://www.speedymetals.com/
Metals source in New Berlin.

Additional information that might be of use:
is a link to Small Parts http://www.smallparts.com/
catalog request: http://www.smallparts.com/Forms/Catalog%20Request%20form.htm
They are a supplier of precision tools, metals, and parts. They have specialty metals, bearing, micro bolts, and tools suited for the metalsmith, jeweler, or small scale engineer. I order most of my micro bolts from here. They are one of the few suppliers of stainless micro bolts.

Another interesting supplier is Reactive Metals http://www.reactivemetals.com/
They sell niobium, titanium, and pnp products. They also sell micro bolts as well but they are brass bolts that are sold raw or coated.

interesting forms

These are some images I took at a Architecture exhibit last year that used ordinary materials and digital fabrication to make some unique forms. Cool stuff.

anodizing aluminum

Today we will begin anodizing and dying aluminum and then hopefully get to an introduction of using a manual lathe. I have included handouts on both topics in the content section of D2L for you to download and print out for the demonstrations. Remember I have additional info on anodizing in the content section on resists, etc for anodizing. There may be some addition information that you find interesting. It would be beneficial to add this information to your notebook. I have included information on the anodic coating of different alloys, details on the alloys themselves and the handout on anodizing and dying that I will go over in class. 
Additional references for your interest are as follows: (LaPlantz book is number 4 and it's a great book)


References:

1. Aluminum (Volume 3): Fabrication and Finishing Kent Van Horn, Editor American Society for Metals, 1967 Library of Congress #66-16222 813 pages

2. Electroplating for the Amateur, by L. Warburton. Model & Allied Publications. Available via Argus.

3. The Surface Treatment and Finishing of Aluminum and its Alloys, Edited by S. Wernick, R. Pinner, and P.G. Sheasby. Published 1987 by ASM International, Metals Park, Ohio. 2 volumes.

4. ARTISTS ANODIZING ALUMINUM- the sulphuric acid process, by David LaPlantz. ISBN: 0-942002-03-2, apparently published by Press de LaPlantz Inc. Box 220 Bayside, CA USA 95524; It's about $20 US. There is also a book and tape for about $45. Both should be available from Rio Grande Supply. The book is extremely thorough and contains several methods of anodizing with lots of pictures and references. It is intended for small individual pieces, at home or in the studio.

5. Metal Finishing - Guidebook and Directory. Metals and Plastics Publications, Inc. One University Plaza, Hackensack, NJ 07601

6. Anodizing Aluminum, by Harold Hoffman. Available from H & H Publishing, 7174 Hoffman Road, San Angelo, Texas, USA 76905, or Centaur Forge. This book seems fairly complete, with supplier sources.

7. Anodizing Aluminum in the Amateur Workshop, Ham Radio Magazine, January 1979, pages 62-69, by David W. Hembling. Sadly, this magazine is out of business, but should be in larger libraries, or available via inter-library loan. This article lists several other references, including addresses for dye makers.

8. Passivating Aluminum Alloys, in 73 Magazine, September 1965, pages 74-80, by Robert A. Kidder.

9. Reynolds Aluminum, years ago, published "Finishes For Aluminum", now available as a reprint from Lindsay publications, P.O. Box 12 Bradley, IL 60915-0012 (Don't call, write). It covers many different finishes including anodizing.

10. Some jewelry-making suppliers deal with anodizing.

11. The magazines StrStrictlytly IC and Model Engineer allegedly have discussed this, but I don't have exact references.

12. Argus Workshop Practice Series, number 11, by J Poyner.

13. Sandoz Chemicals Corp (now apparently Clarion Corp) supplies dyes for aluminum anodizing. Their phone number is (704) 331-7000.

14. Kepro in Fenton, MO sells black aluminum anodizing dye for their aluminum anodized nameplate kit. They sell it in small quantities. The phone number is (800) 325-3878 or (314) 343-1630.

15. How to Anodize Aluminum, Popular Science February 1963, pages 144-146.

student blogs

courtesy of Sarah's blog and artist Elizabeth Brim

Hello All,

I have compiled a list of blogs from everyone in the course. Please make sure to visit and sign up to "follow" each others blogs. I will keep tabs on your progress and try to post interesting activity on this main course blog from time to time. Please use these blogs as a way to document what you are doing in the studio as well as complete the mandatory weekly postings. Remember, we take what we do as metalsmiths for granted. Use this opportunity to share what you do with the rest of the world. No matter how small and insignificant your efforts may seem, each step contributes to the process of making; document this. Anything from sketches, to models, to samples, to major pieces in progress, to finished documented work is fair game. Contrary to what you may think, there is no need to feel like only finished work is worthy of posting......EVERYTHING is fair game as long as it relates to this course and making.

I look forward to reading about your progress.

F
Sarah
Lucy
Christof
Karvari
Kendra
Jesse
Kristin
Kelly
Hannah
Catie
Caitlin
Rachel
Steve
Patrick
Madeline
Sam
Melanie
Nina

first week

Thank you for your attention during our first class on Wednesday night. I'm really looking forward to this semester and looking forward to seeing what you choose to make. Please spend some time thinking about your Bespoke Object as we will be discussing your research and drawings soon. I have already heard from some of you about your plans and I'm excited to hear and see more on this.

Please make sure to set up your Blog before next class. I will be around early before class in case anyone needs help. We can go in the office or the 3rd floor computer lab to review how to set things up if need be. Once you have your blog setup, please email the web address to me and I will compose a master sheet so we can all become "followers" of each other.

Also, here is the link to my UWM Metals site that I have linked from my website:

I have created a drop box if you would like to place images in it for consideration for the website. The instructions are located in the Dropbox on D2L.

Please do not hesitate to ask if you have any questions about anything pertaining to the course.

I will be covering Anodizing Aluminum and dying along with introducing the large manual lathe next. I look forward to seeing you all.

Best,

Frankie

welcome

Welcome to Industrial Processes. I'm looking forward to a productive and fun semester and I'm anxious to be able to work with each of you. Many of you are advanced Metals students who know your way around the studio and are quite comfortable with each other. Please use this semester as a chance to welcome the other "new" students to UWM Metals and make them feel welcome.