Download - 75 85p.; Part of SingleTool Skills Program, Machine ... · PDF fileProject No. Time.(hrs.) Page I. Drill Stand Job 1. Drill Stand 9 II., Parallel Clamp '13 Job 1A. Loose Jaw (inches)

DOCUMENT RESUME

2D 109 N77

AUTHOR Kagan, Alfre d; And OthersTITLE -Drill Press Operator: Instructor's Guide.INSTITUTION New York State Education Dept., Albany. Bureau of

Continuing Education Curriculum Development.; NewYork State Education Dept., Albany. Bureau ofSecondary,Curriculum Development.

PUB DATE 75NOTE . 85p.; Part of SingleTool Skills Program, Machine

Industries Occupations

CE 004 335

EDRS PPICE MIP-$0.76 HC-$4.43 PLUS POSTAGEDESCRIPTORS Adult Education; *Curriculum Guides; Machine Tool

Operators; *Machine Tools; Metal Working Occupations;Post Secondary Education; Secondary Education; ShopCurriculum; *Trade and Industrial Education

IDENTIFIERS *Drill Press Operators

ABSTRACTThe course is intended to kelp meet, in a relatively

short time, the need for trained operators in metalworking. It can beused by students with little education or experience and is suitablefar use in adult education programs and in manpower development andtraining progress. The course is designed' to be completed inapproximately 30 weeks and can be adapted for use in secondary

'schools. On successful completion of the course the student will bequalified for an entry-level job as operator in a drill press; hewill not qualify as a eachinist. The guide includes h general jobcontent outline for the teacher to use in explaining what theoperator's job includes. There are Il shop projects (comprising 19jobs) accompanied by 32 pages of drawings for the projects. Three ofthe jobs introducb students to the use of metric measurement. Foreach job there is a job sheet providing details on performanceobjectives, equipment, operations, materials, references, procedure,techniques, and time required. (Author/PR)

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,INSTRIMOR'S GUIDEFOR AN ADULT. COURSE

n.Nr)

PART OF0 SINGLE-TOOL SKILLS<-) PROGRAM SERIES

i-..k THE NT OF 14EALT14,iC`Na &WELFARE

INSTITUTE OFUC A 'NON

N 1EPRO,tCt 0.ED FROMi C. T ION OkIGINr r. iFd OR OPINIONS

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Dail Plead 0INSTRUCluR'S GUIDE

Part ofSINGLE-TOOL SKILLS PROGRAM

MACHINE INDUSTRIES OCCUPATIONSt

The University of the State of New YorkTHE STATE EDUCATION DEPARTMENT

Bureau of'Continuing Education CurriCulum DevelopmentBureau of Secondary Curriculum DeVelopment

Albany, New York 12234

1975

THE UNIVERSITY OF THE STATE OF NEW YORK

Regents of The University (with years when terms expire)

m-

1984 Joseph W. McGovern, A.B., J.D., L.H.D., LL.D., D.C.L.,Litt.D., Chancellor

1981 Theodore M. Black, A.B., Litt.D., LL.D., Pd.D.,Vice Chancellor

1978 Alexander J. Allan, Jr., LL.D., Litt.D.1987 Carl H. Pforzheimer, Jr., A.B., M.B.A., D.C.S.,

H.H.D.1975 Edward M.'M. Warburg, B.S., L.H.D.-1980-Joseph T. King, LL.B.1981 Joseph C. Indelicato, M.D.1976 Helen B. Power, A.B., Litt.D., L.H.D., LL.D.1979 Francis W. McGinley, B.S., J.D., LL.D,1986 Kenneth B. Clark,.A.B.,14.S., Ph.D., LL.D., L.H.D

D.Sc. Hastings onHudson

--1983 Harold,E. Newcomb, B.A. Owego1988 Willard A. Genrich, LL.B., L.H.D. Buffalo1982 Emlyn I. Griffith, A.B., J.D. Rome

1977 Genevieve S. Klein, B.S., M.A. Bayside1981 William Jovanovich, A.B., LL.D., itt.D., L.H.D.- - - Briarcliff

Manor

New York

Sands PointyTroy

PurchaseNew YorkShelter IslandBrooklynRochesterGlens Falls

President of The University and Commissioner of EducationEwald B.' Nyquist

Executive Deputy Commissioner of EducationGordon M. Ambach

Deputy Commissioner for Elementary, Secondary, and Continuing EducationThomas -D. Sheldon

Associate Commissioner for Instructional Services__William L. Bitner III

Assistant Commissioner for General Education and Curricular Services' Vivienne N. Anderson

Director, Division of Curriculum DevelopmentGordon E. Van Hoof t

Chief, Bureau of Continuing Education Curriculum Development_Herbert Bothamley

Assistant Commissioner for Occupational and Continuing,EducationRobert S. Seckendorf,

Director, Division of Occupational Education InstructionRobert H. Bielefeld

Chief, Buredu of Trade and Technical EducationCarl G. Benenati

4

59008

7oftewout

The Drill ?Tess Operator course contained in this book is intended tohelp fill the need for people trained to operate machine tools. The back-grounds of those who enter the course will cover a broad range of quali-fications, but it is likely that many people with little education or experi-ence will be included. Completion of this course alone, obviously willnot make anyone a full-fledged machinist. f.

This course is the fourth one to be published in a series of instructor'sguides for the Single-Tool Skills Program. (Engine Lathe Operator waspublished in 1972, Surface Grinder Operator in 1973, and Milling MachineOperator in 1974.) Although written primarily as an adult course, thesecondary level teacher can use the content of this book in ,a course he or shemight develop for the students. Drill Press Operator was produced as ajoint project of the two curriculum bureaus named on the title page.

The Single-Tool'Skills Program is one of the programs in'a broad plancovering machine industries occupations. The original plan was conceivedby Robert S. Hunter, former associate in the Bureau,of Trade and TechnicalEducation. A number of teachers were involved in the overall planning formachine industries occupations and also wrote material for the courseguides. They are Elek D. Csont, Seneca Vocational High School,- Buffalo;Jack Grossman, Alexander Hamilton High School, Brooklyn; Alfred Kagan,Sewanhaka High School, Floral Patk; Gilbert Pultz, Jefferson Vocationaland Technical Center, Watertowd; Williat G. Stewart, North Senior HighSchool, Binghamton; William F. Tiedemann, Central Technical High School,Syracuse; and Joseph Waldinsperger, College of Continuing Education,Rochester Institute of Technology, Rochester.

Other members of the State EdUcation Department took part in the overallplanning and in the further detailed planning which resulted in the pro-duction of this publication. They are E. Noah Gould, associate in theBureau of Continuing Curriculum; p. Earl Hay, supervisor in the Bureau ofSecondary Curriculum; Edward Shattuck, former associaten the Bureau ofTrade and Technical Educati 1; and Charles A. Stebbins, associate in thelast-named bureau. -

Messrs. Kagan, Stewart; and Tiedemann wrote-the DriZZ Press Operatorcourse contained in this book. Most of the drawings in this guide are takenfrom previous publications in the series. The additional drawings neededand changes in old drawings were made by Eugene F. Stalica, Jr., professorat Hudson Valley Community College, Troy. Mr. Gould, who is in generalcharge of the Single-Tool Skills series, directly supervised the writingand edited the manuscript.

GORDON E. VAN HOOFT, DirectorDivision of Curriculum Development

HERBERT BOTHAMLEY, ChiefBureau of Continuing Education

Curriculum Development

iii

Nedoar to tie Taatuares

This Drill Press Operator course is'expected to help meet the nee' for trained operators in metalworking. The course is suitable for use inthe adult education programs of school districts,and in Manpower Developmentand Training programs. It can also be adapted for use in secondary schools,

Anyone who completes this course successfully will be qualified foran entry-level job as operator of a drill press. Some students may alsocomplete other single-tool courses and qualify to operate more than one

machine tool. It is even possible that a student with outstanding ability,by completing the courses for several machine tools, could become a machinist.

The 11 projects in this course (which include 19 shop jobs) are listed

on the page after Contents. There is no requirement that any student com-

plete all projects, or even all jobs within any project. The instructormay determine which projects and jobs a given student should complete °Ad

whethet to have him use conventional or metric dimensions. The instruct*may also use other jobs not included inthis book.

The teacher fox this course would ideally be a person with not onlygood training and experience in machinist skills, but also several yearsof teaching experience. The best sources from which to draw teachers arethe faculties of schools giving machine tool courses and the ranks of

those employed as machinists and supervisors of machinists.

An administrator or instructor who has any questions or commentsabout this publication should direct them, to either the Bureau of Tradeand Technical Education or to one of tilt.: bureaus named on the title page.

CARL G. BENENATI, Chiefureau of Trade and

Technical Education

.ROBERT H. BIELEFELD, Director

Division of Occupational Education Instruction

iv

6;

.r

4.

D Page

Foreword iii

Message to the Instruqor iv

List of Shop Projects vi

List of Drawings for Shop Projects vii

INTRODUCTION 1

GENERAL JOB CONTENT

JOB SHEETS FOR SHOP PROJECTS 10

BIBLIOGRAPHY

DRAWINGS FOR SHOP PROJECTS 44

V

MACHINE INDUSTRIES OCCUPATIONSSINGLE-TOOL SKILLS PROGRAM

DRILL PRESS OPERATOR COURSE 4

LIST CF SHOP PROJECTS

ProjectNo.

Time.(hrs.) Page

I. Drill StandJob 1. Drill Stand 9

II., Parallel Clamp '13Job 1A. Loose Jaw (inches) 4Job 1B. Loose Jaw (millimeters) 4Job 2, Threaded Jaw (inches) 3

III. Parallels 19Job 1A. Parallels (inches) 6Job 1B. Parillels (millimeters) 6

IV. Bench Vise 23Job 1. Screw 1-

Job 2. Fixed and Movable Jaws 32

V. Arbor Press 27Job 1. Base 3

VI. Tap Wrench ' 29Job 1. Tap Wrench Body 11

2

VII. 1-2-3 Block 30

Job 1. 1-2-3 Block (Dual Dimensioning) S

VIII. Micrometer Boring Head 32

Job 1. Dovetail Blocks 212

IX. Precision Step Loa ' 34

Job 1. Precision Step Block 212

X. Motor Plate 36

Jon 1. A, and C Holes 2

Job 2: D Holes 1-2

Job 3. E Holes 2

Job 4. F and G Holes 3

Job S. H Hole 2

XI. Close Quarters HacksawJob 1. Adjustable Blade Retainer 1

2

42

vi

0

MACHINE INDUSTRIES OCCUPATIONSSINGLE-TOOL SKILLS PROGRAMDRILL PRESS OPERATOR COURSE

LIST OF DRAWINGS FOR SHOP PROJECTS

Title of Drawing13 Close Quarters Ha ksaw: Assembly14 Close Quarters Hac saw: Details15' Bench Vise Assembly16 Bench Vise Details_17 Bench Vise: Fixed and Movable Jaws .

`21

2222.1

22.223

Tap WrenchMicrometerMicrometer-MicrometerMicrometer

Boring Head:Boring Head:Boring Head:Boring Head:

AssemblyPlateDovetail BlocksDial, Shank, and Stop Pin

a,

Drill

PressProj- Jobsect Covered Page,

XI 1 45

1 46,

'IV 1,2 A71 48

49

VI, 1 50VIII 1 51

None 52

1 53

None 54

24 Micrometer Boiing Head: Dovetail Slide'27 Arbor Press: Assembly28 Arbor Press: Gear Shaft; Rack Pad, and Rack29 Arbet Press:' Table30 Arbor Press: Sleeve, Table Pin, and Cover Plate

31 Arbor Press:32 Arbor Press:33 Arbor Press:42 ()HU. Stand44 Precision Step block

Handle and EndColumnBase

45.1 1-2-3 Block (Dual Dimensioning)50A Parallels (Inches)SOB Parallels (Millimeters)56 Parallel-Clamp: Assembly57A Parallel Clamp: Loose Jaw (Inches)

57B5 8A

58B59

60

Parallel Clamp:Parallel Clamp:Parallel Clamp:Parallel Clamp:Parallel Clamp:

61 Parallel Clamp:72 Motor Plate

V

Loose Jaw (Millimeters)Threaded Jaw (Inches)Threaded Jaw (Millimeters)Straight ClipClamping Screw

Adjusting Screw

vii

NoneV 1

None

NoneNone

NoneNone1

1

1

1B

2

None

NoneNone

SS

56

57

58

59

60

61

62

63 ,

64

65

6667

6869

70

71

72

73

74

None 75

X 1,2,3,4,5 76

err

e.. ,

9,44atifAers

4!

1

As shown\in the contents, this Drill Press Operator course consists of

\Ithis Introduct'on, General Job Content (which explains what the operator'sjob includes), ob Sheets for projects, and the drawings for the projects.The course covers the operation of the drill press only.

Objectives oi .the Cou/tde

111..

The JO for which the trainee would'be qualified upon completion of. this course is referred to in the Dict:Lonary of Occupational Titles (under

the code number 606.380) as"drill press operator; drill press operator;multiple spindlt. drill press operator, radial; gang drill press cperator.Other job titles are also used under this and oehek code numbers.

o

The general objective of the course is to train persons, in a relativelyshort time, to be placed as drill press operators. Another importantpurposeis to help those with very little background. The course is notintende4 to give a broad training in metalworking, but only.the skill tooperate one kind of metalworking machine. By keeping the objective narrow,the training time is kept to a minimum, and the trainees are made availableTor work without a long delay.

Umitcvi Measurement

Generally speaking, conventional units of measurement (inches for lineardimensions, and degrees for angles) are used in this course. Howevet, anattempt has been made to introduce the students to metric measurement byusing millimeters for dimensions in several projects, in addition to theconventional units.

The United States is the only-big country in the world which is noteither using metric measurements or in a program for changing to metrics.Legislation is now pending in Congress which is likely to start us on a10-year changeover period which would result in making metric units thepredominant means of measurement. The much greater convenience of metricunits and our increasing trade with countries on the metric system are themain forces pushing us toward metrication.

In American industry, some companies are already using metric measure-ments to a large extent in their products. Examples of such companies arethe Beloit Tool Corporation of South Beloit, Illinois, and the CaterpillarTractor Company of Peoria, Illinois. American metalworking companiesusing metric units are apparently continuing to use conventional thread

V

systems. This is because, according to some authorities, the conventional

threads have-some significant advantages over metric threads. References

listed in the bibliography contain further information on metrics.

4ettic. Units ti this Comse°

In. this course the workpieces for three shop jobs have been designed

in bah covventigDal and metric-units. Job Sheets and drawings using both *

, inches anemillimeters are included so an instructor can have a student

make thest pieces in either conventional or metric dimensions or both'.

''These jobs are:

Project JobII IA & 1B Parallel Clamp Loose Jaw

II 2A & 2B Paralier.Clamp Threaded Jaw

III IA & B Parallels

InPKojects III and III, Job Lk is in conventional units and Job 1B is

in metric units. For Ihese,,jobs,the only additional instruments suggested

arc a 15 cm, metric scale,'a 0 -25 mm. micrometer, and a metric dial

indicator.

*

btazeings.Pand Job Sheets

\The drawings in this cdu seare part of 4 serially numbered setbeginning with No. 1, which appears in the Engine Lathe Operator course.

. The numbers continue through the drawings of othericourses in the Single -

Tool Skills Series inClu4ing this one. They will be continued further in

any other courses in the *ries which might be ptiblished later. Drawings

in this course which are also in one of the other courses are reproduced

here with the same drawing numbers. Some drawings appear in this_book

which are not needed for the shop projects of this course. They are=1,

included here for the convenience of keeping. together all the drawings of an

assembly. Those in this publication run from IS through 62 of the series.

In the drawings, all ditensions are in inches unless otherwise

indicated. A number of drawings contain tables giving several different

sets of dimensions for the workpieces pictured. These tables permit the

instructor to select the set of dimensions which he finds best for each

student or for"the conditions under Which his class operates.

Lath job sheet has the words Unit'llo.' in the upper left Corner, but

no number is giVen. The instructor may wish to write a number in this

" space to fit in with his own method of organizing his classroom and shop

work.

Ass.ignment oji (otk to Students

As a shop project is assigned to a student, we recommend that the

instructor give him copies of the applicable Job Sheets and drawings. The

binding of this book permits easy removal of pages for copying. When copies

arc made the pages themselves must be kept clean and should not be used by

2

i1

AP 9

anyone working on a machine. After any eopies are made the pages shouldbe replaced in the book and the book/shouldbe kept in a.looSeleaf cover.

Each drawing has four blocks for information at the bottom and twoof them are blank. We suggest that the instructor hamthe student write

'the uumbbrs of the project and job for which he is usifit the drawing inone of these blank spaces on his own copy.

/Many of the workpieces on which drilling is to bedone in this course. are those produced in other courses in the Single-Tool Skills series.

. If a given oorkpiece is not available as the output of another course inhis shop, it.is the instructor's responsibility to obtain the workpiece.

some cases, he may need to make it himself.

AdminlAttation oi the Coume

Webelieve that enough general information about the job and morethan enough shop projects are included for he trainee to reach the general\objective of the course. All essential dril press kills are used inthe shop lobs a number of times.

The schools may use everything in the course, they may select onlysome of the material, they may make changes in it, and they may use othermaterial not contained here. They may also determine the length;of theclass periods, their frequency, and the totakamouni of time to be spentin training. For those that need a glide:\ ktypio41 adult night classruns 21 to 3 hours, either once or twice a week, f#1 30 weeks.

, . -1.1!\.

The prerequisite* for admission to an adult clUrp should be broadenough so none. wilt be barred who could be made emploAble. 'The operatingauthorities for each nrogram, school, and;schoor.diserict have the -

responsibility for determining the prerequisites for suc/61 course, andcan adapt them_ to anAlspecial local conditions.

.4 ..

. \

The minimion prerequisites wessuggest For a trainee, (and they are'not,mandatoiyJ are that he have'enough ability to understand and follow thecourse instructions (both written and oral) so he can produce the simplest'workpiece included in the course. Such a trainee will, perhaps, bemdfible toqualify only as a production machine operator, where all the machine setupsare made for him. Another trainee with more background will possiblyqualify for jobs requiring more skill, such as drill press setup man.

The Job Sheets show two references which are especially recommendedfor drill press work. The bibliography gives the complete citations forthese two books and also coat-gip addi-tiohal references.

-Abbreviations used ih this courip are given o the next page.

a

0

0

Abbteviationz Used ip Text and Ikawing44

ALUM. aluminum mr'w UT. height

ASSY. assembly LG. long

CHM. chamfer LGTH. length

CBORE. counterbore MATL. material

CM. centimeters) MED. medidhCRS cold rolled steel MM. millimeters

CSK. countersink PT. part

- diameter R or RAD.- radius

DP. deep REOD.. - required

DP a diametral' pitch R.H. right4hand

DR. , 'chili,.

SCR. screwDR or'DR. ROD drill rod' SOC. socket`

'. EQ. SP. equally spaced SPEC. specifi ations

FAO finish All over SPHER. spherica,,

,.,11D head: STL. steel \, HDL. handle c SQ. 4quare

HGT. height TYP. typical

HEX. hexagonal W. width

H.S....i. high-speed

;to

4

ro

i3

I Types of Machines

II. Machine Parts

fexesal fat text

Provide information on types and designs ofdrill presses, such as:

1. standard2. single-spindle sensitive3. radial

.4. gang5. multiple-spindle

Ppint_out that although treated as a category in*itself,

--numerical control drilling follows the

basic drilling-theory and techniques. Numer-ically controlled drilling differs from basicdrilling technique in that it uses a preprogrammeddata system to position and'feed the drills.

Point out and name the drill press parts: base,column, and table.

III. Machine AccessoriesA. Toolholding Establish familiarity with drill press tool-

holding devices. Someof these include: sockets,sleeves,:and drill chucks..

B. Work holding

IV. Cutting Tools

V.

Discuss work holding devices, such as: vises,and'clamps.

Describe the various types of cutting toolsused: drills, machine reamers, hand reamers,counterbores, step drills, and countersinks.

Identify the various parts of the cutting tools.Some parts of the drill are: .body, shank, neck,tang, point, and web.

Explain the procedures followed in grinding andsharpening the various cutting tools.

Measurement and In- List and explain the various types of measuringspection tools. These could inclUde: micrometer, indi-

cator, plug gages, and thread plug gages.

VI. Blueprint Reading Introduce and cover all necessary blueprintreading, such as:

S

I 4

1. theory of orthographic projection2. language of lines3. sectional views4. tolerances

VIT. Speeds and Feeds The choice of speed and feed depends on:

1. composition and hardness of work material2. cutting fluid efficiency3, type and condition of machine

4. quality of finish required

Explain how to use the formula for calculatingthe speed of a drill. For exampke:

RrM 4 x cutting speedUT of drill

Explain how to read and use tap.drill charts.

Make available charts and tables which willenable the student to select proper speeds andfeeds for hand or automatic operations.

Demonstrate how the diameter of the drill, the,material being machined, the nature of the tool-holders, and the finish required all correlate,with the proper choice of speeds and feeds.

VIII. Trade Mathematics Introduce and cover all necessary trade mathe-matics,'such as basic arithmetic, use of con-stants, and use of formulas.

IX. Coolants Develop an understanding of coolants, including:

1. water base type2. oil type3. chemically active sulphur-fatty type

4. sulphur-mineral oils

X. Care and Mainte-nance

XI. Safety

Give examples of particular drilling conditionsand the kind of coolant to use. Explain howthe proper coolant can increase tool life, givea better finish, and help maintain close holetolerance.

Provide information concerning the care andmaintenance of the various types of drill presses,

such as: wiping the spindle hole before insertinga tool and making sure the machine is properlyoiled and cleaned.

Introduce the following safe working practicesfor operating the machine:

1. Wear close fitting clothes.2. Wear safety glass.

6

S. Make sure the guards are kept in place.4. Keep hands away from moving parts.

4115. Know how to operate the controls.

Discuss particular dangers teavoid when operatingthe machine, such as:

1. Never leave the chuck key in the chuck.

2. Never hold work with your hands. Clampthe workpiece securely with standard de-vices such as: a dtill vise, straps, Cclamps, parallel clamps, and stops.

3. Always use a brush to remove chips--neveryour hands or rags.

4. Keep your head away from the turning spindleto prevent hair entwining around it.

5. Never attempt to drill brass, copper, orbronze with a drill ground for steel.Demonstrate negative rake on the drill whendrilling brass, copper,or bronze.

6. Ease up on the feed pressure as the drillbegins to break through a hole.

7. Demonstrate the proppr setup for drillingthin material including the holding device,the support, and the cutting tool.

8. Explain how the hand feed lever can injurethe operator's face if he allows it to

'rotate uncontrolled while drilling todepth or when adjusting the column.

XII. Trade Terms Explain all trade terms peculiar to the trade,such as press fit, pitch, jig, and flute.

XIII. Work ProcessesA. Drilling Mention that drilling is a very important phase

of the trade, and-that it is performed on a bide

range of equipment. For example: the sensitive

drill preSs, and thelteavy duty radial drillpress.

, Continue by explaining that drills are classifiedas: number drills, letter drills, millimeterdrills, and fractional drills.

Explain that in center drilling a combinationdrill and countersink is used to locate a holeand prevents the drill from wandering. Exhibitvarious sizes of center drills and explain howeach is selected in proportion to the size of the

drilled hole.

Discuss ways to achieve particular finishes andtolerances.

7

B. Boring

C Counterboring

D. Countersinking

E. Spot facing

F. Tapping

Explain the causes of drill failure, some ofwhich are: speed too high, feed too high,-anddrill sharpening not properly done.

Explain that boring is done to enlarge and/ortrue a hole.

Dtscuss how a counterboring tool is used toenlarge a hole to a given diameter and depth, inorder that a nut or bolthead may set flush orbelow the surface.

Point out that countersinking makes a cone-shapedenlargement on the end of a hole in order thata flathead screw seats properly to a particulardepth.

Add that spot facing is similar to counter-boring except that it is used to produce ashallow machined area on cast or forged surfaces.

Explain how tapping is done with a drill pressusing friction drive tapping heads.

Point out how the actual cutting by the tap isdone by the chamfer and the first full thread ofthe tap:

Impress upon the class the importance of rundut,,,_,--and tap alinement with the drilled hole. Ifthese factor's are not considered, then thethreaded hole may not be square or the pitchdiameter may be oversize. In extreme cases,these errors will result in broken taps.

Comment on some of the standard practices usedin tapping:

1. Never tap through a hard bushing.2. Countersink a hole before tapping.3. Use spiral point or gun taps for through

holes.

Direct attention to the importance of the tapand drill diameter and how it affects:

1. pitch diameter2. depth of thread3. amount of strain on the tap.4. quality of finish of the thread

Distribute material explaining the identificationmarking used onstaps, for example:

UNC

8

-

G. Gun Drilling Describe the gun drill and its application.Point out that it is used on a machine designedespecially for gun drilling.

Explain why the cutting fluid must be run athigh pressures for this kind of operation.

H. Sub-land and Discuss-the application of subland drills andStep Drilling.. step,drills1 _Show how the design_of_the drill

allows f4r-fhe drilling of two or more diameters,,or for the combination of a drilling operationwith counterboring, countersinking, or reaming.

I. Core Drilling Mention the core drill and why it is used toimprove the concentricity of a cast hole.

J. Reaming Demonstrate how a.reamer is used for good con-trol of both size and-finish. Explain the rela-tionship between the size of the reamer and, thepredrilled size.

K. Lapping andHoning

Mention that reaming is done to make a holeround, straight, smooth, and accurate.

Emphasize that the hole must be drilled undersizebefore reaming. For example: Drill 1/64" under-

size for holes over 3/8" in diameter.

State that reamers and drills are held in thesame way when used. Also,that reaming requires.a slower speed than.drilling.

Demonstrate that under certain conditionsabrasive cutting toors (either laps or hones)are used to size holes in hardened workpipces.

9 ,

.7

Unit No.

Project I

Job No. 1

Prawina Nos. 42_

Operator Job Title: Drill Press

Project Name: Drill Stand

Job Name: Drill Stand

Performance Objectives:Using only the equipment and materialslisted hefe, the student will be ableto perform the drilling operationsdescribed in the Procedure column belowas *shoW11 on. the drawings, in accordance

with the time and accuracy requirementsspecified. After completing this job,the student will be able to completesimilar jobs with like specifications.

Equipment:

Standard type drilling-machine

Fractional drill gageSet of fractional drillsa" I" in increments3 rn2OISelected references:McCarthy & Smith, Machine

The Use and Care of Twist

Drill chucksStraight edge6" ruleClamping boltsDrill ViseNos. 2 & 3 center

Tool Technology;

Drills

Operator

D.O.T. No. 606.380M1

TimeL

Operations:

1. Setting up.2. Clamping3. Drilling blind holes4. Center drilling

Materials:

One or more cast aluminum pcs.12" x 3" x 6" from milling andlayout operations

drills

3d edition

PROC DURF

1. Select a cast aluminum block fromstock. and remove all

2. Sit up a center drill in a quick-release drill chuck on a standarddrill press.

3. .Select drill speed and set'spindledepth stop.

4. Clamp a guide bar to the table.

S. Center drill all hole locations in theline of smallest holes.

6. Remove the guide bar-and reset toaline the middle line of holes.

7. Center drill the middle line of holes.8. Remove the guide bar and reset and

aline for the line of biggest holes.

24

11

TECHNIQUES AND-RELATED INFO.

1. Check overall dimengion§ and_layout before drilling. .

2. Demonstrate the.drill change-over procedure. Use a No. 1

center drill.3. Check the recommended drill

speed on a drill speed chart.4. The guide bar will assist in

keeping the holes in a straightline. Calculate the distancethe bar should beset from thecenterline of the drill spindle.

S. Use cutting lubricant.

6. Clean the guide bar and machinetable with a brush. Calculatethe distance the bar is to beset from the centerline of thespindle.

7. Use a No. 3 center drill.8. Use a No. 3 center drill.

PRCCEDURE.

9. Center drill the line of thebiggest holes.

10. Remove the guide bar and thecenter drill and clean the machine.

11. Set the workpiece up in a drillvise.

12.Set up a 71." drill and set thedepth stop.

13. Set the spindle r.p.m. and drillthe T17" hole to tilie depth indicated

on the drawing..14. Drill all the holes fi" through

i", using the same procedure as-above.

15. Clean all tools and the machineon completion of the job.

TECHNIQUES. AND RELATED INFO.

10. Use a brush and a wiping cloth.

11. Tap the workpiece down to seatit on the parallels, using asoft hammer.

12. Check the drillisize with adrill gage before chucking thedrill. Discuss drill nomenclature.

13. Refer to a drill chart forspindle speed.

O

c.

15. Use a wiping cloth and brush.Do not leave an excess of oilon the parallels or the drills.Return all tools to properstorage.

Unit No.

Project II

Operator's job Title: Drill Press Operator

Project Name: Parallel Clump

JOb No. IA Job Name: Loose Jaw (inches)

521._1WL. No. 3_

Performance Objectives:Using only the equipment and materialslisted here, the student will be ableto perform the drilling operationsdescribed in the Procedure column belowas shown on the drawings, in accordancewith the time and accuracy requirementsspecified. After completing this job;the student will be,able to completesimilar jobs with like specifications.

Equipment: ,

Gang drill pressi" Li

-- and No. 294) 32 Idrills

counterbore8-32 UNC tap

Tapping head8-32 Go-No-Go plug.

gageDrill jig

D.O.T. No. 606.380

Time: 4 hrs

Operations:. 1. Setting up2. Blind hole drilling3. Tapping4. Counterboring5. Through hole drilling

Materials:

2 or more loose jaws SAE 10202steel " x " x 32" from milling2

operationsCutting oil

Selected references:McCarthy & Smith, Machine Tool Technology; 3d edition

The Use and Care of Toist Dri,.Z is

PROCEDURE. Select stock from milling operationsand remove all burrs.

'2. Clamp a workpiece in the drill jig.

3. Set up the cutting toSpindle No. 1: 1"

Spindle No. 2: -IA

Spindle No. 3: N.Spindle No. 4: reSpindle No. 5: 8-32Spindle No. 6: 90°

4. Set the spindle speedspindles.

ols as follows:drill

" drill29 drillcounterboreUNC tapcountersinkfor each of the

5. Drill the 2"I 32

11", and No. 29 holes.4

6. Tap the 8-32-UNC hole.

TEauszy AND l'IWTEP INFO.1. Use a double-cut file. Check

all dimensions before starting:2. Drill jig will'have to be

constructed.3. Clamp all,tools securely. Use

drill chucks for all drills,counterbores,and countersinks.Use a tapping head for thetap.Discuss turret head drill pressas an alternate machine.

4. Look up the recommended r.p.m.for each of the operations.

5.-Set each of the :spindle depthstops. Check the depths witha depth micrometer and correctthe stops if necessary:.

6. Tapping head setup is inaccordance with type of headbeing used. Remove slip bushing

. from jig before tapping. Usecutting oil.

PROCEDURE7. Counterbore ye x deep in the

II"hole.

38. Rerove thg workpiece from the drill

jig and take off all burrs bycountersinking.

9. Inspect the workpiece for holesizes art 4pths.

10. Continue to machine remainingworkpieces.

11. On completion. of all pieces cleanthe machine and remove all iools

,

12. Submit all work for inspection andgrade.

.

14

TECHNIQUES AND RELATED INFO.'7. Review counterbore types and

sizes.

8. Use a 90° countersink.

9. Use a GO-No-Go thread pluggage.

10. Make periodic inspections ofworkpieces. -

11. Clean tools with a rag.Return tools-to'properstorage.

Unit No.

Project II

Job No. 1B

Operator's Job Title: Drill Press Operator

Project Name: Parallel Clamp

Job Name: Loose Jaw-(millimeters) D.O.T. No. 606.380

.

prcaoincc Nos._. 578, Ref. No. 3 Timel 4 hrs,=VC=

Operations::. Setting up2. Blind hole drilling3. Tapping4. Counterboring5. Through hble drilling

Performance Objectives:Using only the equipment and materialslisted here, the student will be ableto perform the drilling operationsdeseribeld in the Procedure column belowa4 shown on the drawings, in accordancewith.the time and accuracy requirementsspecified. After completing this job,the student will be able to completesimilar jobs with, like specifications.

Equipment:Gang drill press6.35 mm., 8.73 mm.,and No. 29 drills

11.11 mm. counterbore8-32 UNC tap

Selected references:McCarely & Smith, Machine Tool TechriOlogy; 3d edition

The Use and Care of Twist Drills

Tapping head

8-32 Go-No-Go pluggage

Drill jig

Materials:

2 or more.loose jaws SAE 102012.8 mm. x 13 mm. x 85.7 mm.

from milling operationsCutting oil

PROCEDURE TECHNNUESAND REIATED INFO.

1. Select stock from milling operationsand remove all burrs.

2. Clamp a workpiece in the drill jig.

3. Set up the cutting tools as follqws:Spindle No. 1: 6.35 mm. drill

Spindle No. 2: 8.73 mm. drill

Spindle No. 3: No. 29 drillSpindle No. 4: 11.11 mm. counterboreSpindle No. 5: 8-32 UNC tapSpindle No. 6: 90° countersink

4. Set the spindle speed for each of thespindles.

5. Drill the 6.35 mm., 8.73 mm., andNo. 29 holes.

6. Tap the 8-32 UNC hole.

15

24

1. Use a double-cut file. Checkall dimensions before starting..

2. Drill jig will have to beconstructed:

3. Clamp all tools securely. Usedrill chucks for all drills,counterbores, and countersinks.Use a tapping head for the tap.Discuss turret head drill pressas an alternate machine.

4. Look up the recommended r.p.m.for each of the operations.

S. Set each of the spindle depth'stops. Check the depths witha depth micrometerthe stops if necessary.

6. Tapping head set is in

accordance wit type of headbeing used. R move slip bushingfrom jig before tapping. Use

cutting oil.

PROCEDURE7. Counterbore 11.11 mm. x 2.38 mm.

deep-in the 8.73 mm. hole.8. Remove the workpiece from the drill

jig and take off all burrs bycountersinking.

9. Inspect the workpiece for holesizes and depths.

10. Continue,to machine remainingworkpieces.

11. On completion of all pieces, cleanthe machine and remove all tools.

12. Submit all work for inspection andgrade.

I

16

TESIIEZEUIISSELATEJP117. Review counteWe7it typos and

,

sizes.

8. Use a 90° countersink.

9. Use' a Go-No-Go thread plilg

gage.

10. Ma;:e periodic inspections ofworkpieces.

11, Clean tools with a rag.Return tools to properstorage.

J

.

Unit No. Operator's Job Title: Drill press Operator

Project 11 Project Name,: Parallel Clamp

Job No.- 2' Job Name: Threaded Jaw (inches) D.O.T. No. 606.380

. /

.43.3-3.33.r..3.-1 3- T. LZOWinct nop. 58A Ref. No. 3

p Performance Objectives:'iiUsing only the equipment and materials'listed here, the student will be ableto perfoiq the drilling operationsdescribed in the Procedure column belowas shown on the'drawings, in accordancewith the time and accuracy requirementsspecified. After completing this job,the student will be able to complete

-milar jobs with like specifications.

Equipment:Gang,drill press Tapping headDrill,jig 90° countersinkDrill'ehuck -Go-No-Go threadLetter t drill plug gage .5417.-18 UNC tap

Operations:1. Tapping:-

; hrs.

2. Countersinking'3. Thrdugh hole drilling

a

.

Materials:

2 or more threaded jaws SAE 1020;- -" x 1-4,

8" x 3- from milling' operations

Selected references:,MCCarthy & Smith, Machine Tool Technology; 3d editionThe Use and Care of 70ist Drills

PAOCEDUAB .___LESZEISLIV41=_FLEZe..7LDJEIX.:.:1. Select stock from milling operations

.

and remove 'all burrs.

_2. Aaace workpiece in drill jig andclamp it.

3. Set up the cutting tools as follows:Spindle No. 1: Letter F drill,Spindle No. 2: iliEN-18 UNC tap

Spindle No. 3: 90° countersink.4. Adjust the speeds and depth stops.

0

4

S. Drill the 2 holes (letter F.drill)for the 4"-18 UNC tap.

6. Tap the holes.

7. Remove the work from the drill jigand take off all burrs.

17

447 rs

1. Use a double -cut file. 'Check

all sizes before proceeding.2. Drill jig will have to be

constructed.3. Use a 2-fluted gun tap.

4. Calculate the r.p.m. in each

case using the formula4xCS

'RPM =

or use a, drill speed chart.

Set depth stop so the drilldoes not penetrate the machine.table.

5. Use cutting oil.

6. Use cutting oil.7. Use a 90° ,countersink.

PROCEDURES TECHNIQUES AND RELATED INFO.8. Inspect workpiece.

9. Remove all tools. C

machine and tools.

10: Submit all work forand grade.

I4

lean the,

inspection

18

8. Remove all burrs' and checkthe work with a A"- 18 UNCGo-No-Go thread plug gage.

9. Use a wiping cloth. Returnall tools to their properlocations.

-Unit No.

Project III

Job No. lA

Nos. 50A

Operator's Job Title: Drill Press_Operator

Project Name: Parallels

Job Name: Parallels (inches)

Performance Objectives:Using only the equipment and materialslisted here, the student will be ableto perform the drilling operationsdescribed in the Procedure column belowas shown on the drawings, in. accordancewith the time and accuracy requirementsspecified. .After completing this job,the student will be able to completesimilar jobs with like specifications.

'Equipment:10-spindle drilling machineSuitable drilling fixture10 suitable 11" drills

D.O.T. No. 606.380 .

Time: 6 hrs. =

Operations:1. Setting up fixture2. Setting up spindle3. Through hole drilling4. Multiple spindle drilling

Materials:2 or more parallels from milling

operations

Selected references:Mc arely & Smith, Machine Tool Technology; 3d edition

PROCEDURF

1. Select workpieces from millingoperations and remove all burrs.

2. Set up the drilling fixture.

'3. Set up the 10 tapered-shankdrills of A" dia.

4. Clamp the work in the drill fixture.

5. \line the 10 drills to the drillbushings and clamp the spindlesin place, If space is restricted,

do 5 holes at a time in twosettings.

6. Set the spindle speed, depth stops,and all other necessary contxols.

7. Set all coolant nozzles.

l)

_TECLISISLIEZ AND !?ELATED INFO.

1. Inspect workpieces for sizesbefore proceeding..

2. Discuss the design and purposesof work holding fixtures.

3. Explain the Morse tapered systemas applied to machine tools anddrill diameters. Be sure allmating surfaces are clean andfree of nicks and dirt.

5. Fixtures are usually providedwith hardened guide bushings.Discuss the use of laps to fithardened bushings.

6. Be sure all drills are of thesame approximate length.Demonstrate the freehand methodof sharpening a twist drill.Use a drill point gage.

7. Coolant flow should be directedon the drill bushings.

te

PROCEDURE TECHNIQUES AND RELATED _INFO. -----

08. Drill the holes. 8. Observe the drill enteringthe drill bushings fot drilldeflection.

9. Remove and inspect the workpiece.10. If 'first piece is correct, continue

to drill the assigned number ofpieces. If not,, make necessaryadjustments.

11. Remove all tools. Clean the tools'and machine on completion of thework.

12. Submit All workpieces for inspectionand grade.

20

/

10.Clean the fixture of chipsbefore inserting each newpiece.

11. U.se a shop cloth. Returnall tools to their properstorage places.

Unit No. Operator's Job Title: Drill Press Operator

Project III Project Name: Parallels

Job No. 1B Job Name: Paraliels (millimeters) D.O.T. No. 606.380

PelegaA22450B

Performance Cbjeipes:Using only the equipMeht and materialslisted here, the student will be ableto perform,the drilling operationsdescribed in the Procedure column belowas shown on the drawings, in accordancewith the time and accuracy requirementsspecified. After completing this job,the student will be able to completesimilar jobs with like specifications.

Equipment:

10-spindle drilling machineSuitable drilling fixture

10 suitable 8 mm.N.drills

Time: f)

Operations:1. Setting up fixture2. Setting up spindle3. Through hole drilling4. Multiple spindle drilling

Materials:2 or more parallels from milling

operations SAE 102013 mm. x 19 mm. x 150 mm.

Selected, references:McCarthyAt Smith, Machine Too'l Technology; 3d editionThe Use and Care of Twist Drills

PROCEDURE

I. Select workpieces frClim milling

operations and remov all burrs.2. Set up the drilling ixture.

3. Set up the 10 tapered-shankdrills of 8 mm: dia.

4. Clamp the work in the drill fixture.5. Aline the 10 drills t the drill

bushings and clamp th spindles-

in place. If space iS restricted,do 5 holes at a time i;11 two

settings.

6. Set the spindle speed,, depth stops,and all other necessa4 controls.

7. Set all coolant nozzles.

21

TECHNIQUES AND REZATED ==1. Inspect workpieces for sizes

before proceeding.2. Discuss the design and purposes

of work holding fixtures.3. Explain the Morse tapered system

as applied to machine tools anddrill diameters. Be sure all- -

.mating surfaces are clean and

free of nicks and dirt., 5. Fixtures are usually provided

with hardened guide bushings.Discuss the use of laps to fithardened bushings.

6. Be sure all drills are of the,:.-.1me approximate length.

uemonstrate the freehand methodof sharpening a twist drill.Use a drill point gage.

7. Coolant flow should be directedon the drill bushings.

PROCEDURE TECHNIQUES AND RELATED INFO.8. Drill the holes.

9. ReMove and inspect the workpiece.10. If first piece is correct, continue

to drill the assigned number ofpieces. If not, make necessaryadjustments.

11. Remove all tools. Clean the toolsand machine on completion of thework.

,12. Submit all workpieces for inspectionand grade.

22

8. Observe the drill enteringthe drill bushings for drilldeflection.

10. Clean the fixture of chipsbefore inserting each newpiece.

Use, a shop cloth. Returnall tools to their properstorage places.

Unit No.

Project IV

Job No.

Operator's Job Titlr: Drill Press Operator

Project Name: Bench Vise

Job Name: Screw

Drawing Nos. 16

Performance Objectives:Using only the equipment and materialslisted here, the student will be ableto perform the drilling operationsdescribed in the Procedure column belowas shown on the drawings, in accordancewith the time and accuracy rgluirementsspecified.' After completing /this job,the student will be able po,ccipplete

similar jobs with like specffications.

Equipment:

Standard drill pressV-blockSpeed chuck900 countersinkN" drill

Selected references:McCarely & Smith, Machine Tool Technology; 3d editionThe Use and Care of Twist Drills

D.O.T. No. 606.380

Time: 17hrs.

Operations:

1. Through hole drilling2. Center drilling

Materials:Bench vise screw from latheoperations

PROCEDURE'

1. Select workpiece from lathe andlayout operations.

2. Clamp workpiece in a suitableV-block.

3. Clamp a center drill in the speedchuck.

4. Set the spindle speed and centerdrill.

S. Remove the center drill and inserta L2" dia. drill.64

6. Drill the -1-2" hole through the64

piece.

23

TECHN7QyS AND RELATED INFO.

1. Check all dimensions beforeproceeding.

-2. Review uses and purposes ofXi-blocks as well as the

various types. Do not clampon the thread.

3. Point out that center drillscome in various designs andsizes. Also, that there are

charts recommending the sizesto be used. Illustrate thevarious kinds of drill chucksavailable and their purposes.

4. Use a moderate feed pressure.

S. Point out that the spindle doesnot have to be stopped to changethe cutting tools.

6. Use cutting oil., Be careful that

the V-block does not tilt whichcould result in a slanted hole.Use a jack if necessary.

'

C

,PROCERNZ:7. Remove the 6T' drill and insert

a 60° 'countersink.

8. Break all sharp edges around the

9. Clean all tools and machine.

10. Submit for inspection and grade.

24

TEGANISLIES A NE RELATED INFO._

8. Point out that countersinkscome in various angles anddiameters.

9. Return all tools to properlocations.


Project IV Project Name: Bench Vise

Job No. 2 Job Name: Fixed and Movable Jaws D.O.T. No. 606.380

Drawing Nos. 17

Performance Objectives:Using only, the equipment and materialslisted here, the student will be ableto perform the drilling operationsdescribed,in the Procedure column belowa shown on the drawings, in accordance,with the time and accuracy requirementsspecified.. After completing this_job,,

___Ahe_student will be ableto complete,similar jobs with like specifications.

Time:. 3

Operations:

1. Center drilling2. Drilling3. Deep hole drilling4. Setting up5. Hand tapping

Equipment: Materials:

Standard drill press Tap wrench Fixed and movable jaws from lathe

14-6.643" 3.2"

9and 24" drills Drill chuck center and layout operations

rose reamer Drill viseDrill chuck 90° countersink ,

1"-13 UNC tap

Selected references:McCarthy & Smith, Machine Tool Technology; 3d editionThe Use and Care of Twist Drills

PROCEDURE

1. Select stock from lathe and layoutoperations.

2. Clamp the work to the machine tablein the step jaws cf a drill vise.

3. Mount a center drill in the drillchuck and center drill all holelocations.

'4. Remove the center drill and replaceit with a A" drill. Drill all holelocations (5 hole),

5. Remove the Ti" drill.6. Mount a N" "rill in the machine

spindle.

7. Drill the two cuter holes.8. Replace the 264" drill with the

271164 tap drill.

9. Drill the 27 ,re hole.10. Remove the N" drill and replace

with a 1" rose reamer.

25

TECHNIQUES AND RELATED INIT.

1. Remove all burrs and checkthe sizes and layout beforeproceeding.

4. Review the reasons for theuse of pilot holes. Usecutting oil. Do not allowchips to clog the drill flutes.

10. Check the condition of thereamer before using. Checkthe -reamer dia. with a wicre-meter.

PROCEDURE11. Ream the two Outer holes.12. Replace the reamer with a drill

chuck and a 90° countersink.13. Break all sharp edges on both ends

of all holes:14. Insert a drill chuck center in

the drill chuck and aline itwith the14" hole.

15. Tap the hole.

16. Send the work to the band

beeutintofhTTiZTOjaws and thento milling for finishing.

17. On return from milling,ream theremaining middle. 22:" hole in the

movable jaw.

18. Clean all tools and the machine.

19. Submit for inspection and grade.

26

TECHNIQUES AND RELATED INFO.11. Use cutting oil.

14. Center will be used tokeep tap square with hole.

15: Use a flat tap wrench todrive the tap by hand.(Demonstrate the procedure.)

18. Return all tools to theproper'places.

4

a


Project V PPoject Name: Arbor Press,

Job No. 1 Job Name: 4se

Prawina Ndse 33

Performance Objectives:Using only the equipment and materialslisted here, the student will be ableto perform the drilling operationsdescribed in the Procedure column belowas shown on the drawings, in accordancewith the time and. accuracy requirements

specified. After completing this job,the student will be able to completesimilar jobs with like specifications.

D.O.T. No. 606.380

Equipment:Standard drill press1

and

1511rg an(' t7 drills

n rose reamer

Letter F drillg" - 16 UNC tap

T-bolts and nutsGooseneck clampsParallelsAngie plateViseTapping head

Operations: 111

1. Small hole drilling2. Clamping3. Reaming .

4. Blind hole drillingS. Tapping .

Materials:Arbor press base 1" x 3" x 34"

from milling and layout operations

SeZected references:McCarthy & Smith. Machine Tool Technology; 3d editionThe Use and Care of Twist Drills

1. Select stock from Milling andlayout operations before the slotsare milled.

2. Clamp the workpiece in a drill visewith step jaws.

3. Insert a .g" drill in the drillchuck.

4. Drill the two g" holes.

. Remove the g" drill and replace itwith a 4" drill.

6. Drill the two ]g" holes.

7. Remove the A" drill, insert a--" drill, and drill the hole for64 ,

the h-" reamer.

TECHNIOSAND RELATED INFO.

1. Inspect workpiece for correctnessof sizes,beforo proceccling withthe drilling.

2. Tap the work down with a softhammer to seat it.

3. Use a quick release chuck. Check

the drill for runout.`4. Do not allow the chips to become

clogged'in the flutes of the

drill. Raise spindle frequently.Use cutting oil.

S. Do not allow the chips to becomeclogged-in the flutes of thedrill.' Raise spindle frequently.Use cutting oil.

6. Clear the chips from the hole

frequently.7. Drill to v depth and check hole

for oversize condition with thereamer before drilling through.

PROCEDURE

8. Remove the fr5." drill, replace'it

with a rose reamer, and ream thehole.

9. Remove theworkpiece from the viseand clamp it to an angle plate.

,10. Locate the point for drilling thetapped hole and clamp the angleplate to the machine table.

11. Set the depth stop to 4" and drillthe i" drill hole for the 1" - 16'UNC tapped hole..

12. Open the j4" hole to 1" dia. to adepth of

13. Tap the 1" thread.

,14..Clean machine and all tools'

TECHNIQUES AND RELATED INFO.

'8. Check the reamer to see thatit is in good condition.before using it. Use cuttingoil.

'9. Check the angle plate for'squareness. Use parallelclamps.

10. Use T-bolts,..straps, clamps,and step blocks:

.11. Use cutting oil. Hole depthis at full dia.

12. This will provide relief forthe tap.,

13. Use an extension tap. /Followlocal shop setup procedure.

14_ Use a brush and a shop cloth.15. Return all tools to their proper Kt;

'storage places,,. , .

..,\:-

16. Submit work for inspectionand grade, . .

28p".

*Nil(

UnitNoi

Prod VI PPoject Name: Tap Wrench

Job No. 1 Job Name: Tap Wrench Body

21,

Operator's Job Title: Drill Press

Performance Objectives:U.Sing only the equipme and materialslisted here, the student will be ableto perform the drilling operationsdescribed in the Procedure column belowas shown on the drawings, in accordancewith the time and accuracy requiremehtsspecified. After completing this job,the student will be able to completesimilar jobs with like specifications.

Equipment:Standard drill pressCenter drillDrill chuck111q , drill

90° countersinkRapid index head311 colletClamps

D.O.T. No. 606.380

hrs.

Operations:1. Setting up2. Drilling3. Alining spindle with hole layout

Materials:

Wrench body from lathe and layoutoperations

Selected references:McCarthy & Smith, Machine Tool Technology; 3d editionThe Use and Care of Twist Drills

PROCEDURE

1. Select material from lathe operationsand layout. Remove all burrs.

2. Clamp work in a rapid index head with,,3a g collet.

3. Insert a drill chuck in the spindle.

4. Clamp a center drill in the dri?lchuck and center drill for the e

' hole.5,. Drill the 'h" hole through the !" dia.

6. Remove the 1" drill and replace itwith a 90° countersink.

7. Couhtersink both ends of the e hole.8. Remove all-tools. Clean the tools

and the machine.

9. Submit job for inspection and grade.10. Send to lathe for drilling and tapping

of the 10-32 UNC-2A hole.

sec

29

TECHNIQUES AND RFLA,.TED INFO.

1. Check all sizes before proceedingwith drilling operations.

! 2. Aline spindle with hole clayoutand index head with tab10. Usea surface gage and suitable clamp.

3. Clean the tapered shank and thespindle hole with a shop cloth.

4. Check drill for runout. Use

cutting oil.

5. Ease the feed pressure when thedrill breaks through the work.

8. Return all tools to proper storage.Use a rag to remove all chips andoil.

Unit No.

Project VII

Job No. 1


Project Name: 1-2-3 'Block

Joi Name: 1-2-3 Block

akdla-So,=.14a---

Performance Objectives:.Using only the eqUipment and materialslisted here, the student will be ableto perform the (!rilling.operationsdescribed in the Procedjv column belowas shown on the drawings, in accordancewith the time and accuracy requiremeAtsspecified. After completing this job,the student will be able to complete'similar jobs with like specifications.

D.O.T. No. 606.380

Time: 5 hrs.z-zs.

Operations:1. Setting up2. CountersinkingZ.Reaming4. Drilling

Equipme t:- Materials:

Standar drill press 1" reamer 2 or more pcs. SAE 1020Box drill jig Fractional drill gage. 1.020" x 2.020" x 3.020"r431" drill - Countersink front milling operations

Select.d references:Made loy & Smith, Machine Tool Technology; 3d edition km.

The U e and Care of Twist Drills, .

1. Se

at

2. Ch

ect material from milling oper-ons. 'Remove all burrs.ck a 2-." drill.

64

3. Clamp theyorkpiece in a drill jig.

4. Select and set spindle speed and depthstop.

5. Drill the 13 holes. Drill first holeto i" depth and check hole for oversizecondition before drillingthrough.

6. Replace the drill with a 1" rosereamer.

7. Change the spindle speed and thedepth stop.

8. Ream all 13 holes.

30

TfarEQUTAVafflEUR-JLEZ-,1. Check sizes before proceeding

with drilling operations.2. Check the drill size with a

drill gage.

3. For hole location, use a platetemplate or a box drill jig..

4. Look up speed ona chart.

S. Use cutting oil and power feed.6. If a box jig is used, change

the slip bushings to accommodatethe 1" reamer, otherwise followlocal shop practice. Anothermethod that could be used is tolayout the holes and drill themwhile holding the work in a drill4vise.

8. Use cutting oil and hand feed.

PROCEDURE

9. Replace the reamer with a 1" 90°countersink and change the spindlespeed.

10. Remove the wt,...k from the box drill

jig. Clean the work and the machinetable.

11. Remolle all burrs.

12. Set the work up in,a drill vise.13. Set the depth stop to countersink

to -- depth.,32

14. Countersink all 13 holes, both ends.15. Clean the machine and all tools.

16. Submit all work for inspectionand trade.

(g'

TENYI04L4114.-alaTD INFO-9. Use a slow speed to avoid

chatter.

10. Use a brush.

11. Use a double-cut file.

13. CAUTION: Each dimensionwill require a change in thedepth stop.

15. Return all tools to theproper locations.

ti

2

4

11

p


Project VIII Project Name: Micrometer Boring Head

Job No. 1

Prawing Nos. 22.2

Job Name: Dovetail Blocks

Performance Objectives:Using only the equipmen-t; and' materials

risted here, the student will be 'ableto perform the drilling operationsdescribed in,the ProCedure column belowas shown on the draWiligs, in accordanceKith.the time and accuracy requirementsspecified. After completing this job,the student will be-able to completesimilar jobs with like specifications:

0,

Equipment:Standard drill pressNo. 2 center drill

ft,drill,, 4

x. .437" subland

drill

Selected references:McCarthy & Smith, Machine Tool

The Use and Care of Twist

D.,O.T. No. 606.380. -

2Time: 2? hrs.

Operations:

1. Center drilling2. Through hole drilling3 Countersinking4. Subland drilling

Materials:

Drill' vise and special 2 dovetail blocks from millingclamping jaw operations

Flush gage90° countersinkDrill gage

Technology; 3d edition

PROCEDURE

1. Select stock from milling operationsand remove all burrs.

2. Clamp the laid-out dovetail block in

a drill vise using a special 8° soft,parallel clamping block,

3. Clamp a-center drill in a drillchuck and center drill all 6 holes.

4. Set up a Tr. drill and 'drill 4 holes.

S. Remove the R" drill and replace it

with a :E.11;" x .437" subland drill.6. Set the .p.m. and the depth stop.7. Drill and counterbore the x .437"

holes to .343" depth.

8. Remove the workpiece from the vise andturn it and the 8° clamping block over.

TECHNIQUE;_ AND RELATED INFO.,

1. Check all sizesjcfore proceeding.

2. Either an 8° clamping blockshould be constructed or an .

alternate machinin method. Thealternate method ould be to cutthe block in two/and clamp thepieces in a vise/.

3. Set the spindlejdepth stop toobtain a 4" dila. countersink.Use cutting of /l.

4. Check the drill size using afractional #ill gage. Do notallow drill ,to become cloggedwith chips.'

S. Describe the advantages and theuses of subland and step drills.

7. Use cutting oil. Check thecounterbdre depth using a flushgage.

8. Clean and remove burrs from work-piece, dlamping block, and vise.

PROCEDURE

9. Remove the-subland drill and replaceit with a 900 countersink.

10. Adjust the r.p.m. of the machineskndle.

11. Countersink the four 11" holes to- 64

" dia.12. countersink the two U" holes to

break the sharp edges.13. Clean all tools and the machine.

14. Submit workpiece for inspection andgrade.

4

TECHNIQULS 1IND RELATED INFO

10. Calculate the r.p.m. usingthe formula

R.P.M. =

or a chart.11. Set the spindle depth stop.

12.llu dia. should be suitable.32

13. Return all tools to properstorage places.

14. Send to Power Saws and MillingMachine for completion ofoperations.

4 x CS

Unit No. Operator's Job Title: Drill,Press,Operator

Project IX Project Name: Precision Step Block

Job No. 1 Job Name: Precision Step Block

rawin Nos. 44

2

D.O.T. No. 606.380

Time: 22 hrs.

Performance Objectives:Using only the equipment and materialslisted here, the student will be ableto perform the drilling operationsdescribed in the Procedure column belowas shown on the drawings, in accordancewith the time and accuracy requirements

/ specified. After completing this job,the student will be able to completesimilar jobs with like specifications.

Equipment:Standard drill press rt5" drillDrill vise 7

rr" counterboreT-bolts and nuts =" x 90° countersink4Dial indicatorWiggler

Center drillSelected references:McCarthy & Smith, Machine Tool Technology; 3d edition.The Use and Care of Twist Drills

Operations:1. Clamping2. Center drilling3. Drilling4. CounterboringS. Countersinking6. Spindle alinement7. Deep hole drilling

Materials:

Tool steel step block from millingand,layout operations

PROCEDURE

1. Check the machine table for squarenessto the drill press spindle.

2. Select stock from milling and layoutoperations and check dimensions.

3. Clamp the work in a vise With stepjaws.

4. Set up a centerfinder and locate

the centerlines for the hole.5. Clamp the vise securely when location

is found.

6. Centerdrill for the A" hole.7. Remove the center drill and drill the

-" hole through the work.16

8. Remove the 14" drill and replace itwith a

176 " counterbore.

34

TEgIATEE6 AND RELATED INFO.

1. Use a dial indicator mounted ina drill chuck on a bent bar, andsweep the table by revolving the.spindle. Indicator should read \the same at four points opposite '\to each other. Adjust table ifnecessary.

2. Do not proceed if dimensions arenot correct.

3. Use a soft hammer to seat thework.

4. Demonstrate the use of the center-finder.

S. Check with centerfinder again,

after clamping the vise, to be surethe latter did not shift.

7. Use cutting oil and raise thespindle frequently to clear outthe chips.

8. Review types and sizes ofcounterbores.

PROCEDURE TECHNIQUES AND RELATED INFO.

9. Set the r.p.m. and counterbore toA" depth.

10. Remove the counterbore and set up a90° countersink.

11. Countersink to A" depth.

12. Remove the burrs and turn theworkpiece over in the vise.

13. Loosen the vise and chuck a jg"counterbore.

14. Counterbore the k hole to a depthof

156".

1S. Remove the counterbore and chucka 90° countersink.

16. Countersink to r" depth.17. Remove burrs.

18. Submit work for inspection and grade.

3S

2.14

9. Use cutting oil. Set thedepth stop. Use a moderatehand feed rate.

11. Use a slow spindle speed toavoid chatter. Use cutting

oil.

12. Clean.the.vise,and put sideD down on the-parallels.

13. Aline the pilot of thecounterbore lin the A" holeand carefully clamp the

vise.14. Use cutting oil and a

moderate feed pressure.

17. Clean all tools and machine.Return all tools to theirproper locations.

4

Unit No

Project

Job No. 1

prawina Nos. 71


Project Name: Motor Plate

Job Name: A, B, and C Holes D.O.T. No. 606.380

Performango--06,jectives:

Usin my the equipment and materials

-------------1----"

fisted here, the student will be able

to perform the drilling operationsdescribed in the Procedure column belowas shown on the drawings, in accordancewith the time and accuracy requirementsspecified. After completing this job,the student will be able to completesimilar jobs with like specifications.

Equipment:Single-spindle upright-driDrill press vise with step-13-3" and -" counterboresDepth gage

13;" facer with

7-2." pilot

Mill file,

11"19

.17 back facer with n pi

Center drill19" drill32

Time: 2 hrs.

Operations:

1. Locating spindle in relation tolayout

2. Center drilling3. Drilling

'4. Counterboring5. Facing6. Back .facing

11,or small radial drilljaws

Material.:14" X 4 41 X 64"cast iron platefrom milling andlayout operations

Selected references:

lot McCarthy & Smith. Machine Tool Technology;3d edition

The Use and Care of Twist DriZZs


1. Select stock and deburr. 1. Check overall dimensions andlayout before starting.

2. Insert part, clamp,and seat instep jaws.

3. Mount center drill in chuck, andmove vise on table until centerpunch mark is directly belowthe drill for one of the "A"holes.

4. Clamp vise to table.

5. Hand feed center drill to full60° depth.

6. Drill the }.?" hole through.

7. Cbunterbore .594"x.531"deen.

8. Loosen vise and repeat aboveprocedure for the other 3 "A" holes.

9. Move to the "B" hole and drill 11"through.

36

3. Discuss alternate methods. Forexample: using wiggler orspotting with small diameterdrill.

4. If radial drill is being used,move head over punch mark.

6..Use power feed .005"-.007" andproper r.p.m.

7. Use hand feed and proper r.p.m.Demonstrate use of depth gage.

9. Use power feed .005"-.007"and proper r.p.m.

tri

-


10. Face to depth with ;" facer. 10. Use hand feed.11. Move too- location of "C" hole.

12. Drill N" hole through. 12. Use power feed .005"-.007"

13. Insert back facer with 4" shankin chuck and drop through hole.Attach facer tool on shank andraise spindle up to face undersideof part.

yr

and proper r.p.m.13. Hand feed upward to clean up

surface. 'Discuss theimportance of proper toolassembly so that theopposing cutting force doesnot pull out the back facer.

Unit No.

Project X

Job No. 2

72



Job Name: D Holes D.O.T. No. 606.380

Time: 11 hrs.

Performance Objectives:Using only the equipment and materialslisted here, the student will be ableto perform the drilling operationsdesdribed in the Procedure column belowas shown on the drawings, in accordancewith the time and accuracy requirementsspecified. After completing this job,.the student will be able to completesimilar jobs with like specifications.

Equipment:Single-spindle uprightdrill or small radialdrill

Drill press vise withstep jaws 7

Center drill

Selected references:McCarthy & Smith, MachineThe Use and Care of Twist

Operations:1., Locating spindle in relation to

layout2. Center drilling3. Drilling

with 4. Machine reaming5. Hand reaming

Materials:1" drillzi x 4I;" x q" cast iron pi

late" drill

" Go-No-Go plug 1" machine reamer (undersize)gage. Flat tap wrenchspiral fluteexpansion hand reamer

Tool Technology; 3d editionDrills

PROCEDURE

1. Locate spindle on layout for one"D" hole and center drill it.

2. Drill through with N" drill(2 "D" holes) .

3. Ream I"- 010 hole. Check with a2micrometer. Locate the chamfer of thereamer in the drilled holes. Repeatfor other "D" hole.

4. Check the holes with a .500" Go-No-Gogage.

5. Use expansion hand reamer until theGo-Gage enters and the No-Go does not.

38 -

TECHNIQUES AND REL7UD2L'0.

. Use same proceduretas for holesA, B, and C in Job 1.

2. Use .007" feed and proper r.p.m.

3. Discuss the.differences betweenrose and chucking reamers. Engagefeed lever :then engage r.p.m.lever. Feed .015". The r.p.m. forreaming is one-half of that fordrilling.

4. At this stage neither end shouldenter.

5. Demonstrate how to back the reameroff so it just passed throughthe hole; then expand it k turnfor each pass.

41.7

Unit No.

Project X

Job No. 3

Drawing Nos. 72



Job Name: E Holes

Performance Objectives:'Using only the equipment and materialslisted here, the student will be ableto perform the drilling operationsdescribed in the Procedure column below-as shown on the drawings, in accordancewith the time and accuracy requirementsspecified. After completing this job,the student will, be able to completesimilar jobs with like specifications.

Equipment:

Single-spindle upright drillor small radial drill ;"-16 plug tap

Drill Press vise ;"-16 plug threadCenter drill gage (Go-No-Go)1." drill16 90° countersink

Selected references:McCarthy & Smith, Machine Tool Technology; 3d editionThe .Use and Care of Twist Drills

D.O.T. NO. 606.380

Time: 2 hrs.

Operations:1. Locating spindle in relation

to layout2. Center drilling3. Drilling4. Countersinking5: Power tapping

Materials:

14',

x 44" x 64" cast iron plate

PROCEDURE

1. Locate the spindle on the layoutfor one of the "E" holes and centerdrill it.

2. Drill through with drill. Repeatfor the other 3 "E" holes.

3. Countersink 90° to width at at top

of hole.4. Tap through a "716. Use soluble oil.

S. Check threads with ;"-16 thread pluggage. The "Go" end should enterfreely, the "No-Go" end only 1 to11 threads deep.

39

TECHNIQUES AND RELATED INFO._

I. Usp same procedure as for holesA,B,C,,Jand D.

2. Use 407" feed. Figure r.p.m.

3. Discuss purpose of countersinking.

4. Use proper r.p.m. Put spindlein forward,and allow tap to pullitself in and through the hole.Before tap reaches end of threads,reverse it and apply light liftingpressure.


Project X Project Name: Motor Plate

Job No. 4 Job Name: F and G Holes D.O.T. No. 606.380

Time: 3 hrs.

Performance Objectives: Operations:

Using only the equipment and materials 1. Locate spindle in relation to

listed here, the student will be able layout

to perform the drilling operations 2. Center drilling

described in the Pr6cedure column below 3. Drilling

as shown on the drawings, in accordance 4. Powertapping

with the time and accuracy requirementsspecified. After completing this job,the student will be able to completesimilar jobs with like specifications.

EquipMent:Single-spindle upright 1"-27 pipe tapdrill or small radial i7T" counterbore

drill.

- -27 NP thread plug gage--"

gdrill

e 337.64

i

-18 hole gageLett,r. iR drill "-27 hole gage

3L18 National pipe tap ;"-18 NP thread plug gageelected references:McCarthy & Smith, Machine Tool Technology; 3d editionThe Use and Care of T0ist Drills

Mfterials:1-4 " x 4k" x 6k" cast iron plate

PROCEDURE

1. Locate spindle in relation to layoutfor "F" holes and center drill.

2. Drill through with N" drill (2 holes).

3. Tap with ;"-18 pipe tap (2 holes).

4. Clean out thread and check withthread gage. Repeat until desireddepth is obtained.

5. Recheck with hole gage.

6. Turn part on end, locate the spindleon the layout for hole "G", and centerdrill.

7. Drill through with R drill.

8. Tap with 1"-27 pipe tap.

9. Counterbore 16" x .0625.

TECHNIQUES AND RELPED INFO.=

1. Use same procedure as forholes A, B, and C.

2.. Demonstrate that hole gageshould not enter hole.

3. Discuss importance of threaddepth. Tap should not enterover half the threads.

4. Gage should not go beyondground flat on gage.

5. After tapping to proper depth,the hole gage should not enterhole more than 1 to 11 threadsdeep.

6. Use same procedure as for holesA, B, and C.

7. Demonstrate that the hole gageshould not enter the hole.

8. Use same procedure as for holeF,' steps 3 and 5.

9. Use depth gage.

Unit No. Operator'S Job Title: Drill Press Operator

Project X Project Name: Motor Plate

Job No. S Job Name: n Hole

Performance Objectives:Using only the equipment and materialslisted here, the student will be ableto perform the drilling operationsdescribed in the Procedure column belowas shown on the drawings, in accordancewith the time and accuracy requirementsspecified. After completing this job,the student will be able to completesimilar jobs with like specifications.

Equipment:Center drill No. 4 taper pin2-" drill3 2 Drill press viseNo. 4 straight or spiral-'flute taper-pin reamer

Tap wrenchHailither

Selected references:McCarthy & Smith, Machine Tool Technology; 3d editionThe Use and Care of Drills

D.O.T. No. 606.380

Time: 2 hrs,

Operations:

1. Locating spindle in relationto layout

2. Drilling3. Machine reaming4. Hand reamingS. Countersinking

Mates ials:

11" x 41" x 61" cast iron plate4 4 4

====c1. PROCEDURE

1. Turn the ?art back to its originalposition the vise and positionthe spindle on the layout for holeH. Center drill for the hole.

2. Drill through with ii" drill.3. Machine ream part way. Use hand

feed.

4. Clean out hole, try pin, ream untilpin extends out top of hole about 1".

S. Hand ream until pin extends outabout V.

6. Countersink both sides of all holesto break edges 512".

7. After completion of piece, clean themachine.

8. Submit all work for inspection and grade.

41 4

ATECH_ RELATED INFO

1. Use the same procedure as forholes A,B, and C.

3. Use r.p.m. of half the drillspeed.

S. Clean hole and pin. Oil pin toprevent pickup. Tap pin intoposition with hammer. 'Rounded

portion of large dia.-of pinshould be flush or barely abovesurface.

7. Clean tools with a rag. Returntools to proper storage places.

Unit No.

Project XI

Job No. 1

N . 14


Project Name: Close Quarters Hacksaw

Job NaMe: Adjustable blade retainer D.O.T. No. 606.380

1 hr.

\ Performance Objectives:\Using only the equipment and materials

isted here, the student will be ableto perform the drilling operations

des ibed in the Procedure column below .

as s wn on the drawings, in accordancewith e time and accuracy requirements.specifi d. After completing this job,the Itild nt will be able to complete

similar with like specifications.

Equipment:'Sensitive single-spindle drill pressDrill jigNo. 31 drill \

Operations:

1. Setting up2. Drilling3. Drill jig clamping

Materials:OneOne or more retainers from latheand layout operations CRS 1020,2." long16

Selected references:\McCarthy & Smith, Machine Tool Technology; 3d editionThe Use and Care of Taist Drills

PROCEDURE TECHNI UES AND RELATED INFO.

1. Select workpiece fromlayout 'operations and

burrs,2. Set up a No. 31 drill

chuck.

lathe andremove all

in the drill

3. Clamp the work in a drill jig.

4. Drill the No. 31 hole in the 1"

diameter.S. Drill the No. 31 hole in the ,1-."

diameter.6. Remove the workpiece from the drill

jig and inspect it.7. Remove all tools.

1. Inspect workpieces for size beforeproceeding.

2. Discuss the reasons for using highr.p.m. when drilling smalldiameter holes.

3. Drill jig will have to be constructed.Explain other alternatives suchas "V"-blocks, superspacers, anduniversal shaft jigs.

4. Use oil, Aline drill in bushing.

6. Remove all burrs.

7. Clean the machine and tools.Return tool to proper locations.

8. Submit work for inspection and grade.

42

6

reasredit4

Anderson,-James & Tatro, Earl E. Shop theory; 6th ed. New York, N.Y.McGraw-Hill. 1974.

Beloit Tool Corp. U.S.A. goes metric; t. ed. Swani Publishing Co.,Box 248, Roscoe, Ill. 61080. Undated.

Colvin, Fred H. New American machinist's handbook. New York, N.Y.McGraw-Hill. 19S.

\

Feirer, John L. Machine tool metalworking: principles and practices;2d ed. New York,' N.Y. McGraw-Bill. 1973.

McCarthy, Willard J..&.Smith, Robert E. Machine tool technology; 3d ed.Bloomington, Ill. McKnight & WcKnight. 1968. (Order frOm TaplingerPublishing Co., 200 Park Ave., S., New York, N.Y. 10003.)

Obeigi Erik & Jones, Franklin D. Machinery's handbook; 19th ed. New York,N.Y. Industrial Press. 1971.

Use and care of twist drills. Cleveland Twist Drill Co., 1242 E. 49th St.,Cleveland, 0. Undated. (Freelh limited quantities.)

Walker, John R. Machining fundamentals. South Holland, Ill. Goodheart-Wilcox Co. 1973.

43

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