Workshop

Work Folder

Version2017-03-02

Page 1

Laboratory and safety regulations of HTL Mödling

7. Safety Regulations – Accident Prevention

7.1. Directives for general student’s behaviour in workshops

7.1.0. All students working in the workshops shall be instructed by the respective teacher before starting to work.

7.1.1. Each activity in the workshop involves a high-risk of an accident. Therefore, students must follow the teacher’s instructions and undertake all safety measures.

7.1.2. Teachers must be notified about physical infirmities or diseases before starting to work.

7.1.3. Wearing rings, bracelets, necklaces, wrist watches, etc. is not allowed during the operation of machines.

7.1.4. Wearing eye protection, such as protective goggles or face shields, is obligatory for operations, which poses a hazard to the eyes.

7.1.5. Manipulations of uncoated, electrical parts or lines of devices, by students, are not allowed.

7.1.6. Lifting and transportation of heavy weights by students are only allowed upon instruction and in the presence of a teacher.

7.1.7. Behaviours like playing around, fooling, badinages, spats, etc. are not allowed as they can lead to work accidents.

7.2. Operation of machines, devices, tools and installations

7.2.1. Each operation of a machine, device, tool or installation is only allowed upon instruction and in the presence of a teacher.

7.2.2. Protective equipment and clothing must be worn and checked for proper operation before starting to work.

7.2.3. Moving parts, drives, shafts, V-belts and similar must not be touched. Cleaning and lubrication are only allowed while halting of the machines.

7.2.4. During tension, adjustment or maintenance work on a machine; all measures have to be undertaken to prevent it from accidentally restarting.

7.2.5. Persons must not be talked to during operating the machines with the potential to cause accidents.

7.3. Event of damage, injury

7.3.1. In the event of damage (fire, explosion, injury, etc.), students must follow the instructions of the teachers and school authorities.

7.3.2. In the case of injury, first aid must be administered immediately. The respective machine or device must be deactivated without delay. A first-aid kit is available in each workshop.

Page 2

7.3.3. In the case of violation of safety regulations, students will be admonished. In repeated cases of safety violations, students will be excluded from the class.

Page 3

File (page 6)

Files are multi-cutting, chip-removing tools for the removal of materials. Fillet blanks are forged from alloyed tool steel. The teeth are subsequently cut into the file sheet as a continuous line (negative cutting angle is scraped) or milled (positive cutting angle, file cuts). This distinguishes the file from the rasp, in which the teeth are individually cut in. This blank is then hardened and the fishing rod is allowed. One differentiates the tool according to the form, the blow and the application areas.

Structure of the file The file mainly consists of three different components. There is first the file-sheet, which is actually soft and elastic in the interior. Only the hewn surface is hardened. The mostly pointed end of the file is called an angel. Finally, there is still the filelet, mostly made of wood or plastic with a metal sleeve to prevent splitting of the booklet.

Page 4

Filing staplesHinge

Fileblade

File types according to the shape (page 7)

File types after the stroke The specialist also distinguishes the files after the stroke. There are five types, from 1 to 4, as well as diamond files. The individual designations are as follows:

Stroke 1 Roughing files Stroke 2 Roughing cut-to-size files Stroke 3 Cut-off files Cut-off Stroke 4 Rasping (usually used with wood or

plastic) or fine-grained diamond files (files which are galvanized instead of

the stroke)

DIN-SubdivisionThe files also differed according to DIN.

0 roughing files 1-2 roughing files 3-4 half-finishing files 4-5 finishing files 6 double-purpose files

Page 5

Flat file Half Round File Triangle Round

Selection of the vice height (page 8)

Fist under the chin, elbow must touch the upper edge of the vice!!

Care / Maintenance of the files

Clean with the filebrush made of brass.Clean with a sharp brass plate.

Page 6

Measure with the caliper (page 10)External MeasurementsFor external measurements the measuring legs should be guided as far as possible over the workpiece. The measuring legs should be used only for the measurement of narrow grooves.

Internal measurementsFor internal measurements, first the fixed measuring leg is placed in the bore and then the movable one. The measured value is displayed directly by the crossing knobs.

Depth measurementsFor depth measurements, the depth measurement is performed with the depth measuring rod

Page 7

Structure of a caliper (page 11)

Page 8

Vernier scale

Locking Screw

Movable Measuring Jaw

Lower Jaws

Depth Rodruler

Measuring Tips(Upper Jaws)

Reading a Measuring ruler (page 12)

1. Read the millimeter2. Read the tenth and hundredths of a millimeter

Page 9

Tools (page 15)

All marking tools are part of the metal technology.

They are mainly found in workshops with small series and individual production, but also in the toolmaking of large companies. In order to achieve a useful durability (metal technology: service life) and a recognizable notching effect on the workpiece, these tools are hardened or carry a tip of hard metal. Scribing tableIn order for the scribe line to be absolutely straight, helicopters are guided on a scribing plate or a scribing table made of metal or ceramic and having a high height. To facilitate the guiding of the parallel ripper, graphite is spread in flake form onto the scribing table.

ScribeTypical scribes are about 20 to 30 cm long and have a diameter of about 3 to 4 mm. Usually, they are very long sharpened on both sides, one end being angled by 90 degrees after about 3 cm. Typical models have in the middle as handle a covering of a 10 cm long,

knurled tube piece.

Page 10

Page 11

Height Gage (page 16)

Height gage or a tear-open tear is used to tear off auxiliary lines which run parallel to the base of the workpiece. Height breakers consist of a heavy foot, on which a measuring surface with a vernier is mounted vertically. At right angles to the measuring surface is a tear-off needle which can be adjusted vertically in height and horizontally to the stand by means of two screws.

Page 12

Grain (page 17)In the case of so-called precorking or indentation, the tip of the grain is driven into the workpiece by a hammer. This results in a small depression in the form of a crater, which is referred to as grain size. The grain size is usually used to give the first guide (centering) to a drill. Without this grit, the drill tends to aimlessly move upon the workpiece. That is, it does not slide over the surface, so that a dimensionally stable drilling position is not possible. In the case of purely machine drilling, for example with NC-controlled machine tools, a centering drill is used instead of a grain for this task.

Center PunchA grains is a tool for providing metal or plastic parts with a grain size. It is made of tempered tool steel, has a hardened tip and shaft. As a rule, the tip has an angle of 60°.

Page 13

Drill/ Drill bits (page 18)

A drill usually has two or more cutting edges at the tip, each cutting a chip from the material to be machined. The swarf are guided out of the resulting borehole by means of lateral grooves, which are machined in the form of a helix, counter to the feed direction. At the end of the drill there is a cylindrical shank to which it can be connected to a drilling machine via a chuck. Larger diameters (from approx. 12 mm) can also be provided with a conical mount, the so-called Morse cone.

Page 14

Cutting force

Cutting motion

Feedmotion

Feed force

Feed

Picture 2: Forces and movements during drilling

Spiral Drills (page 19)

Spiral drills have a conical cutting edge, usually a tip angle of 118° (for steel) or 135° (hard metal drill).

The two main cutting edges, parallel to the drill point, result in a cross-cutting. It is usually offset by 55 to the main cutting edges. This does not cut, contrary to the name, but has a scraping effect. The cross-cutting is transverse to the drilling or feed direction and increases the required working pressure. The feed force for the cross-cutting is 1/3 of the total feed force approximately on the drilling tool. To avoid the risk of so-called "running", i.e. To prevent the lateral positional shift during drilling, must be grained in principle before drilling.When drilling larger bores and ensuring a bore which is not visible, it is recommended to pre-drill with a center drill or a smaller drill. The diameter of this drill should be at least the size of the cross-cut.The diameter of this drill should be at least the size of the cross-cut.

Page 15

Main Cutting

Drill -face

Secondery cutting edge

Cross cutting angle

Cross cutting

Free -angle

Peak -angle

Face

Flute

Cutting edge

Side railing

Body clearance

Picture 1: Cutting part on the spiral drill

Drill materials (Page 21)Is spiral drills are made of high-speed, high-speed steel. Simple drills made of chrome vanadium steels (CV). For extreme applications in hard metals. The hardness and wear resistance of these drills can be further increased by coatings such as TiAl (titanium aluminum nitride violet color), TiCN titanium carbonitride brown-brown coloring) or TiN (titanium nitride golden color).

Page 16

Designed for soft steel, gray cast ion and stainless steel

For hard and brittle materials, eg. High strength steel

For soft and tough materials, eg. Aluminium, copper and zinc alloys

t

t

t

Coated drills are also characterized by high corrosion resistance, a long service life and significantly increased feed and cutting speeds. In addition, depending on the type and material, the coating can prevent the chips from sticking to the cutting edge and make them suitable for dry processing.

Coated Spiral Drill

HSS Drill

Page 17

Sections (Page 22)Cutting Suggestions (for Coated Spiral Drill)

Page 18

Die Bohrmaschine/Drilling Machine (23)

Page 19

Fuß, Arbeitstisch/Work Table

Höhenverstellbarer Bohrtisch/ Height adjustable rotary table

Feststellhebel für die Höhenverstellung/ Locking leaver for height adjustment

Maschinenschraubstock/Machine vice

Bohrer/Drill

Bohrfutter/Chuck

Vorschubhebel/Feed leaver

Elektromotor/electric motor

Spannvorrichtung für die Keilriemen/Jig für belt

Gehäuse für Riemenscheibe/ Housing for Pullys

Accident prevention during DRILLING

1. Ensure you have tight-fitting sleeves!2. Do not put your hair down!3. Do not wear baggy clothing!4. Do not wear jewellery!5. Do not wear gloves!6. Always wear a protective cap!7. Always use wear safety glasses!8. Use a vice, drilling fixture or stop for fixing the

drill bit!9. Never add or remove drill bits or components

while the machine is running!10. Do not remove chips by hand!11. Only use faultless clamping devices and

tensioning tools!12. Do not remove any protective equipment!13. Do not leave a wrench in the drill chuck!14. Caution, danger of slipping from drilling water

or oil!15. Always wear your safety boots during this

process

Page 20

Innengewinde/ Inner thread (28)

Gewindeschneider/Taps (29)

A common method of threading is cutting with taps and dies. Unlike drill bits, hand taps do not automatically remove the chips they create. A hand tap cannot cut its threads in a single rotation because it creates long chips which quickly jam the tap (an effect known as "crowding"[citation needed]), possibly breaking it. Therefore, in manual thread cutting, normal wrench usage is to cut the threads 1/2 to 2/3 of a turn (180 to 240 degree rotation), then reverse the tap for about 1/6 of a turn (60 degrees) until the chips are broken by the back edges of the cutters. It may be necessary to periodically remove the tap from the hole to clear the chips, especially when a blind hole is threaded.

For continuous tapping operations (i.e., power tapping) specialized spiral point or "gun" taps are used to eject the chips and prevent crowding.

Page 21

Steigung/Pitch

Nenndurchmesser/ nominal diameter

Führungsteil/ Guide part

Anschnittteil/ gate section

Anschnittwinkel/ cuting angle

Page 22

Pre-Cutter

Middle-Cutter

Finishing-Cutter

Schraubstock/ Machine vice (25)

Außengewinde/ External thread (31)

Page 23

Schneideisen/ Dies

Milling

Milling is a cutting process that uses a milling cutter to remove material from the surface of a workpiece. The milling cutter is a rotary cutting tool, often with multiple cutting points. As opposed to drilling, where the tool is advanced along its rotation axis, the cutter in milling is usually moved perpendicular to its axis so that cutting occurs on the circumference of the cutter. As the milling cutter enters the workpiece, the cutting edges (flutes or teeth) of the tool repeatedly cut into and exit from the material, shaving off chips (swarf) from the workpiece with each pass. The cutting action is shear deformation; material is pushed off the workpiece in tiny clumps that hang together to a greater or lesser extent (depending on the material) to form chips. This makes metal cutting somewhat different (in its mechanics) from slicing softer materials with a blade.

The milling process removes material by performing many separate, small cuts. This is accomplished by using a cutter with many teeth, spinning the cutter at high speed, or advancing the material through the cutter slowly; most often it is some combination of these three approaches. The speeds and feeds used are varied to suit a combination of variables. The speed at which the piece advances through the cutter is called feed rate, or just feed; it is most often measured in length of material per full revolution of the cutter.

There are two major classes of milling process:

In face milling, the cutting action occurs primarily at the end corners of the milling cutter. Face milling is used to cut flat surfaces (faces) into the workpiece, or to cut flat-bottomed cavities.

In peripheral milling, the cutting action occurs primarily along the circumference of the cutter, so that the cross section of the milled surface ends up receiving the shape of the cutter. In this case the blades of the cutter can be seen as scooping out material from the work piece. Peripheral milling is well suited to the cutting of deep slots, threads, and gear teeth.

Page 24

Working rules for end millig

1. The milling-axis should be within the components width.2. The shell end mill´s diameter should be 7/5ths of the components width.3. An approximate compensation of the cutting forces is achieved by the milling

cutter sticking out on the counter rotation side.4. Milling cutter diameter as small as possible, milling arbor diameter as big as

possible.5. Small circular pitch with tough materials and when smoothing.6. Big circular pitch with soft materials and when scrubbing.7. “Stirnen” instead of “Walzen”.8. Direction of rotation and cutting have to match.9. Milling cutter should be clamped close to the machine.10.Clean milling arbor and milling cutter, to guarantee flawless rotation.11.Cool to effectively remove the chips.12.When shutting down, first turn off the feed, then the spindle.13.Fix components well. (danger of accident)14.Correctly adjust cutting depth.

Gegenlauffräsen/ Counter Milling (35)

Innengewinde/ Internal thread (30)

Die Werkzeugfräsmaschine/ The Milling Machine (39)

Page 25

Fertiges Gewinde/ Finished thread

Bedienpult/ Control panel (39)

Page 26

Vertikal Fräskopf/ Vertical Milling head

Aufspanntisch/ Clumping table

Maschinenständer/ machine stand

Maschinenuntersatz/ machine subassembly

Kühlmitteltank/ coolant tank

Bedienpult/ control panel

Digitalanzeige/ digital display

Getriebekasten und Horizontalfrässpindel/ gear box and horizontal milling spindle

Page 27

Hauptschalter/ Main switch

Not AUS/ emergency stop switch

Fräser EIN/AUS / cutter on/off

Kühlmittel/ coulant pump

Eilgang X-Y Achse/ rapid traverse y-axis

Vorschub EIN X-Y Achse/ feed on x-axis

Vorschub AUS/ feed off

Vorschub mm/min /feed mm/min

Fräswerkzeuge/ Milling tools (37)b

1.

Shank cutter (90° corner cutter)2. Slot mill (accurate slot mill)3. Long hole milling4. End mill5. Radius milling cutter6. Die sinking cutter (copying cutter or ball mill cutter)7. Roll end mill8. Side milling cutter9. Metal cutting saw10. Form cutter (halfround, prism, angle)11. Plan milling cutter12. Corner milling cutter13. Copy milling cutter14. Roll end cutter15. Chamfer end mill16. Copy milling cutter17. Disc milling cutter18. Cutting bur

Page 28

End millworking tools made of

high speed steel, solid carbit or cermet

Arbor mountingworking tools made of high

speed steel

Milling cutter tools with indexable inserts

made of hard metal,ceramic or diamond

Turning s. 43

Turning is a cutting process for metals and plastics. Turned manually on a lathe or automated on a lathe. Contrary to milling, the workpiece rotates the main cutting motion with its rotation. The tool, which is firmly clamped, moves on the rotating workpiece with the help of the tool carriage collect the metal chips. In classic turning, mainly around parts are machined, But it differs from the turning over the non-guidance of the one lathing machine and only guides of a rotatory type for the rotary movement of the liner work piece, but also linear guides to the (usually two axis) infeed of the tool: the longitudinal support and generally 90 degrees transversely there to Assembled plan support.

Axis when turning s. 44The reference axis during rotation is the axis of rotation of the main spindle around which the workpiece rotates. This is usually referred to as the Z axis and points from the chuck towards the tailstock. The X axis is perpendicular to this. With pure rotation, there is no y-axis, the height of the tool above the XZ plane is fixed during set-up, and usually the cutting edge is exactly in the XZ plane. The scale division and possible measuring systems on the X axis double the actual movement. A movement of the tool by one millimetre is indicated with two millimetres, since the movement affects the workpiece radius and thus the workpiece diameter is changed by two millimetres. Electrical current. AC current designates electrical current. Which changes its direction (polarity) in a regular repetition and in which positive and negative instantaneous values complement each other in such a way that the current is in time. Discharges is the alternating current from the dc current, which is (apart from or temporally not, and from as a superposition of both.) Alternating current is often referred to in English with alternating current or with the abbreviation AC But the electrical current is also referred to as a direct current when the fluctuations of the current are insignificant for the intended effect, or if the fluctuations are caused by n, then the direct current is the arithmetic mean value of the current. The English

Page 29

name is direct current with the abbreviation DC. The Circuit Diagram Circuit Diagrams a circuit diagram (also circuit diagram) is in electrical engineering and representation of a circuit. They components, does not take into account the real shape and arrangement of the is but an abstracted representation of the electrical functions and the current flows. A circuit diagram is understood as a document which is addressed to the customer, to a builder or to the maintenance technician. Wiring diagrams are particularly common in some typical types. This is a simplified representation (often single-pole) of the essential parts of a circuit. The actual circuit diagram is the exact representation of a circuit with all and lines. The parts of each device are drawn together in a cohesive manner, the spatial position is not taken into account. The circuit diagram is the circuit diagram of a circuit with all the details and lines. The spatial position and the mechanical relationship are not taken into account. The installation plan is the line layout, which is stored in a building in a building, with the help of circuit symbols. The wiring diagram shows the arrangement of the terminals and the numbering on devices and terminal blocks as well as the lines to be connected. Wiring diagrams and circuit diagrams are standardized representations of electrical devices, which show details necessary for a better understanding of the function, a circuit diagram The depiction of components in a single unit Bending of eyelets. Eyelets are used for single-wire cables, which must be fastened with screws or nuts (eg: sockets, motors). Eyelets are bent with a round nose plier. Otherwise it is not necessary to raise or lower the eyelet as there is a risk of fracture. The inner diameter of the eyelet is equal to the clamping screw diameter plus 0.5 mm. The clamping screw must be easily inserted into the eyelet. The position of the eye when clamping is to prevent opening. The gap of the eyelet is equal to the wire diameter d plus 0.1

Page 30

Connecting protective contact plugs s. 66

http://slideplayer.org/slide/913542/

The external conductor, the neutral conductor and the protective conductor are plugged into the power supply connections.

german version:

Page 31

Clamping screw for protective conductor

Holding clamp

Three-core cable cable

protective contact

Clamping screw for power supply

That means:

The strands are not tightened; they have small loops. The protective conductor is longer than the other ones. The stands are bolted in with the right screws. The result is

a conducting connection and the conductor itself can´t be seen anymore.

The wire has to be clamped into the strain relief so that 1mm of the wire protrudes.

The cables are placed in the bottom part of the plug; the top part can be easily mounted and the isolation of the conductor can´t be damaged.

Soldering s. 67

Soldering is a thermic method of positive substance jointing of materials. A liquid phase will be developed by a melting solder or by diffusion at the boundary layers. A melted filler material, which has a liquidus temperature coats the surface of the Page 32

component. When the material solidifies a positive substance connection is produced.As a connecting material, easy melting metal alloys are often used. That helps to get a metallic connection between the materials. Apart from soldering there are other connection methods, such as sticking, bonding or riveting.Soldering is one of the most important electric connection methods.

http://www.sciencebuddies.org/science-fair-projects/project_ideas/Elec_primer-solder.shtml

German version:

Page 33

Classification of the soldering process by energy carrier s. 68

Until 450°C soft-solderingAbove 450°C hard-solderingAbove 900°C high temperature-soldering (in vacuum or inert gas)

The stability of hard-soldering components is often not as good as the stability of bonding-connections but it´s still higher than the stability of soft-soldering work pieces.

Solder

The material you need to get a soldering connection is called solder. Metal-solders are often alloys as a wire or as a soldering paste. They often include fluxes. Page 34

Fluxes

In order for the above-described diffusion process to take place, all metal surfaces must be bright and free of oxides and soiling. Almost without exception, air is used for heating the solder joint, which is an oxidation of the surfaces, which compromises a reliable and thus successful soldering. Therefore, in such cases, a flux is applied before the brazing operation. The flux reduces (deoxidizes) the surface during soldering and is intended to prevent the reoxidation before and during the soldering process, which otherwise would greatly reduce the flow and wetting properties and also to reduce inclusions of foreign substances. Another effect is the reduction of the surface tension of the liquid solder. The type of flux is dependent on the application area. Many fluxes have to be removed after soldering, since they would otherwise be corrosive.

Heat Input s. 69

Heat is introduced by means of a soldering iron, a (gas) flame, hot air, hot steam, heat radiation, laser or induction, in some cases also by ultrasound, electron beam or an arc (arc brazing). The most common is soldering in electrical engineering and electronics. The soldering is performed there almost exclusively with soft solder. Normally only fluxes which are so-called acid-free fluxes, for example rosin, are used in the electronics.

Page 35

https://www.hometheater.co.il/vp2309594.html

German version:

The soldering iron s. 70

The soldering iron should provide heat for soldering. One can get between gas soldering irons and electric soldering irons Electric soldering irons have penetrated soft solder. The advantage of electrically operated is due to the low current is cheap compared to gas cartridges and can be used almost everywhere Special electric soldering irons can be set to a temperature that is then automatically maintained.

Page 36

https://thaiphd.wordpress.com/2015/11/27/diy-soldering-station-part1/

German version:

Cold solder joint

A particularly feared phenomenon in the field of electronic soldering is the so-called cold solder joints. In the case of a cold solder joint there is no material connection between the solder and the joining partner. Contrast Cold solder joints are often difficult to detect. In the correct solder joints, they may look dull (lead-containing solders solidify high-gloss, lead-free solders are generally dull) or have a slightly lumpy surface.

Pictures Page 44

Page 37

https://www.slideshare.net/palanivendhan/metal-cutting-38254541

German version:Vf Vorschubgeschwindigkeit, Vc Schnittgeschwindigkeit

Pictures page 45

Page 38

https://www.uspto.gov/web/patents/classification/cpc/html/defB23B.html

German version:Drehverfahren

Picture page 45

Page 39

http://inchbyinch.de/pictorial/turning-tools/

German version Drehwerkzeuge

Picture page 46

Page 40

https://mechanical-engg.com/gallery/image/577-lathe/German version:

Accident prevention during MILLING Page 41

1. Always wear work cap and safety glasses!2. Always ensure you are wearing close-fitting

work clothing!3. NEVER switch on a machine if its operation has

not been explained to you, and ask if you are uncertain!

4. A machine which has been switched on may NEVER be left unattended!

5. NEVER measure while a machine is running!6. Do not add or remove components while a

machine is running!7. Switch off milling machine fully before setting

up or cleaning!8. Milling tools are sharp; remember this when

mounting!9. NEVER place fingers near the razor-sharp

cutting area!10.Use the available safety device against flying

hot chippings!11.Do not remove chippings by hand; instead use

the designated tools (hand brush, paintbrush)!12.Keeping the workstation in order is essential!13.Wear your safety boots14.Make sure to turn the machine off when you are

finished with it15.Make sure that the area around the milling

machine is clean otherwise swarf can cause the machine to clog up and therefore malfunction.

Page 42

Picture page 47

http://www.iloencyclopaedia.org/part-xiii-12343/metal-processing-and-metal-working-industry/metal-processing-and-metal-working/136-metal-processing-and-metal-working/lathes

German version:

Page 43

Picture page 47

http://www.lathes.co.uk/latheparts/

German version:

Page 44

Accident prevention during TURNING

1. Never switch on a machine which has not been explained to you!

2. Use safety glasses, protective visor, work clothing and safety shoes!

3. When working at the lathe, wrist watches, rings and necklaces must be removed!

4. Before switching on, the following should be checked:a. Has the correct speed been set?b. Ensure that the chuck and the slide are not abutting

anywhere.c. Check that the jaw chuck and the turning chisel have

been tightly clamped!d. Is the advanced feed switched off?e. Is the chisel as short as possible and set centrally?

5. Never leave the chuck key in!6. Never leave a switched on machine unattended!7. Before cleaning a machine, switch off at the main switch!8. Only remove chippings using a chip hook!9. Switch the machine off before measuring a workpiece!10. Never touch rotating workpieces or machine parts!11. When deburring and filing workpieces, never reach

across the chuck!12. Avoid contact of cooling lubricants with skin!13. The bed should be covered against filings and emery

splinters!14. Do not store tools in the headstock!15. Make sure that the area is clean before you start using

the machine otherwise this can cause problems as I have mentioned before

Page 45

Picture page 54

http://www.clipartkid.com/electrical-warning-sign-cliparts/

Elektrische Gefahr

Page 46