03 lesson sawing and drilling operations 3

8/14/2019 03 Lesson Sawing and Drilling Operations 3

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Lesson Title: Sawing and Drilling Machine Operations

Lesson Duration: 5 hours

Industry Competencies: Participants will:

demonstrate safe operating procedures for each power saw and drill press used

research and discuss theoretical and background information about drill presses

and horizontal and vertical bandsaws

describe the relative motions of the drill press and power saw, and describe the

interactions of various subsystems, including the machine tool, machine controls,drive mechanisms, cutting tools, tool holder, work piece, and work holder.

Specific Objectives: Participants will:

identify and explain machine parts and tools for sawing operations

identify and explain machine parts and tools for drilling operations

perform sawing operations safely

perform drilling operations safely.

Assessment(s):

The following rubrics will be used in this lesson.

Competency

or Task

Highly

Competent Competent

Needs

Improvement

Measurements are

accurate using both US

and SI devices.

All measurements are

made accurately with

full understanding and

ability to use

measurement tools.

All measurements are

made with appropriate

tool and are accurate.

One or more

measurements are

incorrect and ability to

use appropriate tools is

not consistent.

Conversions within the

US system are accurate.

All conversions are

accurate with full

understanding and

appropriate units

indicated.

All conversions are

accurate with

appropriate units

indicated.

One or more of the

conversions is

inaccurate and units are

not displayed correctly.

Conversions within the

SI system are accurate.

All conversions are

accurate with full

understanding and

appropriate unitsindicated.

All conversions are

accurate with

appropriate units

indicated.

One or more of the

conversions is



Conversions betweenthe US and SI systems

are accurate.

All conversions areaccurate with full

understanding and

appropriate unitsindicated.

All conversions areaccurate with

appropriate units

indicated.

One or more of theconversions is




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Competency

or Task

Highly

Competent Competent

Needs

Improvement

Write clearly and

effectively on a specific

topic.

Topic is fully addressed

with highly effective

supporting information

with no errors ingrammar, punctuation,

or spelling.


with adequate


and no errors ingrammar, punctuation,

or spelling.

Topic is not addressed or

poorly supported with

one or more errors in

grammar, spelling, andpunctuation.

Speak clearly and

present information

about a specific topic.


with highly effective


with a clear voice,

excellent syntax,

excellent grammar, and

superb volume.


with adequate


in a clear voice with

effective grammar and

pronunciation.

Topic is not addressed or

poorly attempted with

inadequate supporting

information, low voice,

and one or more errors

in grammar.

Production of a PartCompetency

or Task

Highly

Competent Competent

Needs

ImprovementMachine Operation

Analysis

All machine operations

were followed with high

level of quality and

superb detail.

All machine operations

were followed with high

level of quality.

One or more of the key

procedures were not

followed or poorly done.

Machine/Tool Use The actual machine and

related tool use wassuperb with no mistakes.

The actual machine and

related tool use wasdone well with required

detail.

There were one or more

instances of poor tooluse during the process.

Safety All safety rules were

followed exemplarywith assistance to

others.

All rules were followed

as directed.

One or more rules was

not followed whichestablished some risk.

Accuracy All parts were measuredand fabricated

accurately with exact

precision beyond any

tolerances.

All parts were measuredand fabricated

accurately within

acceptable tolerances.

One or more parts weremeasured wrong or

fabricated poorly outside

of required tolerances.

The following is an example of a written examination for this lesson.

1. When selecting the type of saw to use, which factors must be considered?

The factors to be considered are size of the raw material stock, properties of the

material to be sawed, accuracy, finish, and production requirements.

2. Explain the relationship between:

the size and geometry of the stock to be cut

the capacity and type of sawing machine to be used

Size and geometry of stock determine the type of machine and machine capacity

needed.


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3. What are the three factors that influence the selection of a sawing method and

machine? The factors influencing the selection are accuracy, finish, and production

requirements.

4. What variables influence the selection and performance of drills?

The variables include material used to make the drill, physical properties of thedrill, drill size, and geometry of the drill.

5. Variations in the design and geometry of different drills can include: drill points, librelief angle, clearance angle, and flute construction.

6. Name three types of drilling machines.

Types of drilling machines include light-duty, heavy-duty, upright, radial, gang,multi-spindle, turret, deep-hole, and small-hole.

Calculate the properRPM for each of the following:

Drill Bit or Tool RPM (answers provided below)

1/2 in. counterbore RPM = 1150

11/32 in. drill RPM = 800


15/64 in. drill RPM = 1700


82 countersink RPM = 700


1/4 in. ream RPM = 300

center drill RPM = 700

in. ream RPM = 300

Resource(s):

Print Materials - Basic mathematics textbook, Basic machining textbook (to be identified)Audiovisual -

Internet sites-

Key word search -Sawing operations, sawing equipment, drilling operations, drill manufacturers,

sawing and cutting equipment, drills, saws, machine safety, material removal, drill

bits, saw blades.


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Purpose of the Lesson:

Participants will explain and demonstrate safe sawing and drilling operations for material

removal.

Required Knowledge and Skills: Participants will:

measure accurately using the US and SI systems

perform basic mathematical operations

use appropriate units within and between the US and SI measurement systems.

Tools, Materials, Equipment Needed:

1 horizontal bandsaw

1 vertical bandsaw

raw material (bar stock)

1 6" steel rule or combination square

1 vernier caliper

1 drill press

1 drill press vise

assortment of drills to show different point styles, shanks, flute styles, etc.

1 counterbore

1 countersink

assorted reamers

assorted center drills

1 center punch

raw material (same as above)

1 6" steel rule or combination square

a variety of layout tools bluing, such as Tool-Blue

1 micrometer or vernier caliper

Specific Safety Requirements:

General lab safety rules apply.

Specific safety rules for sawing and drilling operations apply.

Everyone must wear safety glasses at all times during equipment demonstrations and

operator evaluations. Observe proper safety and operating procedures at all times.

Dispose of chips and other debris as required by your facility.

Each participant must pass the Sawing and Drilling Safety Test and Operator Safety

Evaluation before being allowed to operate any saw or drill. Participants may notproceed until all safety knowledge is addressed. You must ensure that participants can

demonstrate safe and proper operating procedures before using equipment.


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Lesson Elements: (5-E model)

Engagement:

One of the most basic of all machining processes is sawing, a cutting operation in whichthe cutting tool is a blade having a series of small teeth, each of which removes a small

amount of material. Even though machining centers have become high-tech, without the

simple process of sawing, most work on a lathe, milling machine tool, or grinder wouldnot be possible. Drilling, another simple material removal process is also one of the most

efficient. Drilling has one of the highest material removal rates of all common material

removal processes.

After discussing the saw and drill press, participants are ready to observe a demonstration

of the machines capabilities. This demonstration should include a review of the parts of

the machine, proper nomenclature, and specific safety procedures.

Explain and demonstrate the following operations and concepts:

use of the power saw in your lab

recognizing a dull blade

changing saw blades

use of the drill press in your lab

use of the hand reamer in your lab

simple layout procedures (note tools used)

use of machine reaming in your lab

use of the countersink in your lab

use of the counter bore in your lab drilling and hand tapping

Discuss any observations made by participants during demonstration. Note anydifficulties you may have had during the demonstration in attaining the desired results

and discuss ways to improve those results. Participants should view the images below and

offer their explanations about sawing and drilling processes. This will help the instructor

determine prior knowledge and depth of understanding for each participant-


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Exploration:

Participants will be challenged to investigate the wide variety of horizontal and vertical

bandsaws available for unique material removal applications. This exploration should

help participants realize the common as well as unique features found from variousmachine manufacturers. This investigation must be beyond the available cutting machines

in the school manufacturing laboratory.

Examples of images from their research should be included in a small group (2)presentation. Participants should present their new knowledge about cutting machines

such as bandsaws to others in the class. The instructor should facilitate this investigation

so that all types and configurations are discussed. Examples are shown below.


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VERTICAL BANDSAWS

HORIZONTAL BANDSAWS

As part of a machine tool research project, participants should select a particular brandfor both horizontal and vertical bandsaws and obtain a comprehensive specifications

sheet that includes machine size, key features and accessories. An example of one spec

sheet is shown below.
http://www.verticut.com/baxter_saw_model_700sa.htm


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24" Bandsaw

Powerful totally enclosed, fan cooled motors to keep out dust for a longer life and

maximum performance. Extra large cast iron tables for more work area in front of the blade tables tilt 45

degrees to the right and 15 degrees to the left and come standard with a T-slot

mitre gauge. Saw blade is completely guarded but easily accessible for changing.

Cast iron drive wheels are balanced and equipped with vulcanized rubber tires.

Lower wheel brush to eliminate sawdust buildup.

Convenient foot brake for rapid stops.

Solid steel and cast iron construction for additional stability and durability.

Large easy to use hand wheel for smooth adjustments.

Fully adjustable blade guard.

Comes standard with a 4" dust collection port for connection to a work shop dust

collection system.

Two speed drive pulley.

The upper wheel housing and guidepost have been designed with the rigiditynecessary for industrial use.

Extra wide flange along with a heavy-duty trunnion assembly provide extra

durability while eliminating any "flexing" of the table.

Standard Equipment

Motor 1" blade

Foot brake

Work light

Rip fence and mitre gauge

Chip blower

Optional Accessories

1/4" x .025 x 6 blade

3/8" x .025 x 4 blade

1/2" x .025 x 3 blade

3/4" x .032 x 3 blade

1" x .026 x 3 blade

1-1/4" x .035 x 1.3 blade


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SPECIFICATIONS

Stock Number(3 HP, 1 Ph, 230V): 1791259

Stock Number (5 HP, 3 Ph, 230V): 1791260

Model: 2415

Blade Speeds (SFPM): 2000 - 4000

Thickness Capacity (max/in): 14

Width Capacity (max/in): 24-1/4

Table Size (in): 24 x 28

Table Tilt: 45 degrees R, 15 degrees L

Blade Length (approx/in): 180-1/2

Blade Widths (min max/in): 1/4 - 1-1/2

Table Height at 90 (in): 35 3/8

Floor Space Required (in): 34 3/8 x 39

Motor (TEFC): 3 HP, 1 Ph, 230V, 5 HP, 3 Ph, 230V or 5 HP, 3 Ph, 460V

Shipping Weight (lbs): 1050

The wide variety and diverse nature of cutting blades for these machines should also beinvestigated by participants with discussion and demonstrations led by the instructor. Cuttingblades are critical components and vary widely in their design and application.

The same approach should be used to compare drill press machines for common and

unique machine features. Machine parts should be clearly identified and described during

participant presentations.
http://www.southern-tool.com/store/bandsaw_blade_calculator.html


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DRILL PRESS

1. Motor Unit2. Top Cover

3. Cover Lock

4. Feed Handle5. Drill Chuck6. Power Switch

7. Base

8. Parallel Guide9. Column

10. Lock Screw

11. Wrench Hole12. Anchor Holes

13. Depth Gauge Knob

14. Column Adjuster Screw

Specification sheets should be obtained and compared and contrasted by participants via

their research teams.


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Powermatic PM2800 VS Drill Press

Features

Powered by a heavy duty 1HP, 1Ph, 115/230V (Prewired 115V) TEFC motor.

Lighted push button switch with safety key is located on the front of the head for ease of use.

New large table system with dual extensions for the largest woodworking table on themarket. It also features twin T-slot grooves for a miter gauge or other homemade jigs.

Newly designed table tilts 90 and has a positive stop at 0.

Head mounted dual laser guide system provides a consistent drilling cross point on work

piece.

Feed handles can be mounted on either side of the drill press for convenient handle

positioning.

Extension wing provides additional support for longer work pieces.

Variable speed system adjusts quickly and easily in one full range.

Built-in dual LED work light.

5/8" keyless chuck.

Quick setting depth stop.

Adjustable split fence with dust collection port.

Front mounted switch control, laser guide and LED work light.

Front mounted digital LED display shows spindle speed.

SPECIFICATIONS

Model No. PM2800

Stock No. 1792800

Swing (in) 18Chuck Size (in) 5/8, Keyless

Spindle Travel (in) 4-3/8

Chuck Distance to Table (in) 30

Chuck Distance to Base (in) 46

Table Size (L x W/in) 16 x 14

Table Size Fully Extended (L x W/in) 16 x 26

Spindle Taper MT2 x JT33

Column Diameter (in) 3-1/8

Spindle Speed Range (RPM) 400-3000

Base Size (in) 11-7/8 x 19-5/8

Motor (TEFC) 1HP, 1Ph, 115/230V, prewired 115V

Overall Dimensions ( H x W x D/in) 68 x 23-1/2 x 31-1/2

Ship Weight (lbs) 302

Again, critical cutters for each machine, including the drill press should be furtherinvestigated so participants are very familiar with the diverse design features and unique


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applications for drill bits, reamers, fluting tools, etc. Basic drill cutter or bit information

should be provided or obtained through participant investigation directed by the

instructor. Examples are shown below-


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Drilling on a lathe is another technique often ensuring extreme accuracy for challenging

material removal in unique parts. The image above can be used to help participantsdiscuss the process and the resulting benefits.

The same approach for sawing operations with bandsaws, horizontal bandsaws, jigsaw,

scroll saws and more can be presented, demonstrated and discussed to ensure participantunderstanding of how material is removed, cutters used, geometry of cutting, and related

speeds and feeds for diverse materials. Examples for cutting are shown below-


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JET Drill Bit Sets


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5-PIECE TIN COATED BRAD POINT DRILL BIT

SET

If you want the best in wood boring bits, look no

further. Our 25-piece set contains the most commonly

used sizes, with the added benefit of a TIN coating for

longer life and durability.

TIN coated

Angle-ground spurs and center point

Spiral fluted for fast chip removal

25-piece set includes:

Bits from 1/8" to 1/2" in increments of 1/64"

Indexed steel case

SPECIFICATIONS

Stock No

228241

228239228240

Description

25-pc Set

7-pc Set

25-pc Set

Coating

TIN Coated

Black Oxide

Black Oxide

Sizes (in)

1/8 to 1/2 in increments of 1/64



7- PIECE CARBIDE-

TIPPED BRAD

POINT DRILL BIT

For the ultimate in drilling for tough and exotic

woods, our carbide-tipped brad-point bit sets are

the ones to use.

Specially ground "ears" virtually eliminate tear

out, ensuring a clean, smooth hole.


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Participants should be exposed to a wide variety of cutters and various manufacturers to

compare common and unique features as well as prices to fully realize the scope ofcutters available for drilling operations.

Explanation: Identify the three primary types of saws currently used in industry.

Discuss the different purposes for which each type of saw might be used.

Identify the types of blades used on bandsaws and the purpose of each blade

Discuss the advantages and/or disadvantages that sawing might have over other

material removal processes.

Answer the following questions concerning cutting teeth:

When cutting a piece of 3" bar stock, what effect would you expect from

increasing the number of teeth per inch?

How does the number of teeth per inch affect surface finish?

Define the following sawing terms:

kerf

tooth face

tooth back

tooth back clearance angle

gullet depth

width

tooth spacing

contour cutting

ripping

internal cut

angular cuts

stack cutting

shaping

straight set

raker set

wave set

Define the following drilling terms:

shank

boring

tang

reamer

morse taper

countersink

counter bore


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spot face

pilot

center drill

chisel edge (point)

cutting edge

flute

margin

point angle

helix angle

lip clearance

Discuss the advantages and disadvantages of these drilling machines used in industry:

drill press

radial drill

gang drill

other special types of drills

Discuss the following drill press sizing and feature options:

largest diameter work piece that can be drilled in its center (work envelope)

horsepower

chuck size or taper size

vertical clearance between spindle and lowest table position

power feeds

variable speeds

gang drill

other special types of drills

Discuss and show examples of the following drill press tolerances and surface finishes:

all features, including those done on the drill press, should be designated with

size, location, and surface finishes on part prints

various methods for accurately and quickly locating holes, given various

tolerances

problems that can occur with the shape, size, and surface finish of holes

methods to correct or avoid common shape, size, and surface finish problems

Discuss the following types of drills and types of points (all available in left-hand orright-hand; mostly right-hand):

twist drill

parabolic flute

long/deep hole

carbide tip

high helix


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center drill

short or stub or spot

Discuss these types of shanks: straight

straight with tang

hex

morse taper

taper with tang

Discuss the various drill size series available:

fractional

letter

number/wire gage metric

Discuss various types of reamers:

hand reamers

machine reamers

expandable reamers

shell reamers

taper reamers

Discuss reaming operations: slower speed

turn clockwise only (in most cases)

faster feed

coolant or lubricant

leave the correct amount of materials in the drilling operation

chamfer on work piece impedes proper cutting

Discuss various ways to hold work on a drill press:

vise

bolt to table rotary table

clamps

jigs and fixtures

Discuss the following parameters on which RPM depends: (RPM = (cutting speed x 4) diameter of drill) and each of the following.

work material


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cutter material and diameter

coolants

depth of cut

feed rate

Extension:

Participants will be divided into smaller teams (2-3) and be challenged to participate in

two major performance activities that will help them make choices between cutting and

drilling operations using appropriate cutters and related tooling safely. The instructor willguide this experience and ensure all operations are conducted properly and safely.

A detailed drawing should be provided that offers specific size and shape guidelines for

an object made from a variety of common manufacturing materials (wood, plastic, or softmetals). The following drawing is provided as an example for such a project. Of course,

the instructor may choose to present an alternative project design. Participants willprovide a detailed production plan which shows the intended operation for each part withthe corresponding machine and cutter or attachment. In addition, specific notes should be

added on this chart to ensure all details are explained for review by the instructor in the

fabrication of the final product.

Participant or Production Team Name _________________________________________

Part Operation Machine/ToolCutter or

Attachment

Special Notes for

Fabrication


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Participants should complete a chart similar to the one below to identify key informationas part of effective planning to produce the needed part. This approach continues

developing participant knowledge and skill with respect to safe, accurate and appropriate

sawing and drilling operations.


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If a more basic project would be needed or preferred by the instructor, the following

example could be used to guide a basic sawing and drilling series of operations:

Evaluation:

Participant performance assessment should include the following:

Explain and demonstrate the following operations and concepts:

use of the power saw in your shop

recognizing a dull blade

changing saw blades

use of the drill press in your shop

use of the hand reamer in your shop

simple layout procedures (note tools used)

use of machine reaming in your shop

use of the countersink in your shop

use of the counter bore in your shop

drilling and hand tapping

Describe and demonstrate each of the following operations and examples of cutters used:

drill

countersink

bore

pilot drill

tap

counter bore

spot face

reamer

The instructor can present this drawing with US or SI measurements or both or require

participants to convert from one to the other which can help participants refine theirmeasurement and conversion skills.


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gun drill

center drill

Perform the following:

Calculate the feed rate using the RPM calculated above.

Locate the appropriate feed rate in Machinerys Handbook, based on drill type,

material used, and size. After recommended speeds exceed drill press capacity, use the highest RPM

possible and adjust feed rates accordingly.

Note - Feeds can range from .001-.002 per revolution for drills with diameters of1/8" and smaller to around .015 per revolution for drills with diameters of 1"

and larger.

Enrichment:

Participants can be challenged to take on more sophisticated part machining to refinesawing and drilling operations through part drawings provided by the instructor. An

example is presented below.


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03 lesson sawing and drilling operations 3

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