Machine Shop Committee

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Committees are voluntary groups, formed by members in order to achieve certain goals.
To join this committee, contact the committee chairperson. See Rules and Policies#Committees for more information.

About

The Machine Shop Committee covers the machine shop equipment, such as:


Governance: The committee is a benevolent dictatorship with teams and Special Interest Groups built around the equipment.

Purpose

  1. Maintain and provide tooling for the Machine Shop equipment
  2. Train people on the safe operation of this equipment
  3. Oversee the usage of all Machine Shop assets

Committee Meeting Minutes

Machine Shop Committee meeting minutes are primarily maintained on the Committee drive in this location: \machineshop\Meeting Minutes\

Members

  • Chair: Nick Silva
  • Procurement Officers:
    • Nick Silva (does not have a CC)
    • David Kessinger

Machine Teams

  • Team Leader Clausing Colchester Lathe: Bob Karnaugh
    • Instructors:
      • Bob Karnaugh
      • David Kessinger
    • Mentors:
      • Jay Phelps (helped with rebuild)
  • Team Leader Bridgeport: David Kessinger
    • Instructors:
      • David Kessinger
      • Tanner Fontenot
    • Mentors: David Kessinger
  • Team Leader Sherline Lathes: Nick Silva
    • Mentors:
      • Nick Silva
      • Chris Marlow
      • Richard Meyer (cnc ready lathe)
  • Team Leader Sherline Mill: David Kessinger
    • Instructors: David Kessinger
    • Mentors:
      • David Kessinger
  • Team Leader HAAS Vertical Mill: Nick Silva
    • Instructors: Nick Silva
    • Mentors:
      • Walter Anderson - created the Fusion 360 Domino class.

General Members

  • Aaron Leiter
  • Adam Oas
  • Alyssa Pipe
  • Andrew Falgout
  • Andrew Spencer
  • Art Givens
  • Benjamin Groves
  • Carey Ritchey
  • Charles Wahlert
  • Chris Marlow
  • Christopher Wischkowsky
  • Dave Fenyes
  • David Kessinger
  • David Ratcliff
  • David Steele
  • Doug Williams
  • Dylan Halsey
  • Ed Koffeman
  • F Bones Alia
  • Frank Lima
  • Frank Scranton
  • James McQuirter
  • Jason Daniels
  • Jason Henrikson
  • Jay Phelps
  • Jeff Ray
  • Jerrel Kenemore
  • Joel Braby
  • John Horne
  • Jonathan Brandenburg
  • Jose Quinones
  • Josepf Setne
  • Joseph Helmstetter
  • Josh Bond
  • Joshua Masseo
  • Justin Carroll
  • Justin Hrbacek
  • Ken Purcell
  • Lance Preston
  • Levi Corcoran
  • Lisa Selk
  • Mathew Busby
  • Michael Ivison
  • Mike Glass
  • Mitch McDaniel
  • Nolan Wright
  • Raymond Jett
  • Reece Maganzine
  • Rich Thompson
  • Richard Bauman
  • Rick Lowe
  • Romeo Espana
  • Ryan Caldwell
  • Tim Bene
  • Trae Greenlee
  • Travis Zinger
  • Walter Anderson
  • William Redmond
  • Zach Metzinger
  • Don Satterfield

Role of the Chair

This has been added here to give any new or incoming Chair a starting point for the things that being the Chair of the Committee will face.

Duties of the Chairman

-Head Janitor: Someone once told me that Chairman in another langague means Janitor. He was right - you always seem to be cleaning up after others.

-Keep the conversation going: Constantly looking for content to post that generates interest or fosters conversation. The internet is your best friend.

-Purchasing: The chairman is constantly keeping track of what is needed and ordering replacement stock/parts/consumables.

-Head Cheerleader: there are people that go the extra mile like cleaning up when they see the need, contribute time and supplies, and unselfishly help others. It is the chairman's job to take notice and publicy thank and praise those individuals.

-Keeping everyone informed: TALK is the main method we use and I post as much as is necessary to get feedback on current issues.

-Keeping everyone safe (despite themselves): we have several UNWAIVERING rules which include the use of safety glasses and proper clothing among other rules. If someone is in violation of that, it is important to remind them and to be hard and ask them to leave if the do not want to comply.

-Keeping the motors running: things break. it is a fact of use. that doesn't mean you have to be the main mechanic for fixing things. But it is the chairs job to find someone to do the fix, and to schedule the work and arrange for the parts to be present and for payment when necesary.

-Making the hard decisions: There is the old addage that 90% of the work is done by 10% of the people. It is simply unreasonable to have to call a meeting of the committee for every decision. except in the case where large amounts of money are at stake, the chair makes on the spot decisions with the understanding they may catch heck for the decision from the small percentage of people who would have been against it no matter what.

-Leadership: Keep members involved, interested and have them be an integral part of the decision making process for what we want Machine Shop to be in terms of: equipment maintenance, purchases, teaching, and rules of Machine Shop.

-I spy with my little eye: The chair generally gains access to the cameras. In cases of damage, theft or malfeasance the chair generally is the one that will search thru the video looking for necessary evidence to specify or recommend a penalty.

Training

Minimum Age To Use Tools: You MUST be a minimum of age of 18 to use any powered tools unsupervised in the Machine Shop.

If between age of 16 and 18 years old and a member (add-on) that has been trained on that machine, they may use it under the close, immediate, and active supervision of the Parent or Guardian that has also received training and qualified to use that machine. "Close, immediate, and active supervision" means the parent/guardian is physically standing next to the minor, observing and supervising so as to be capable of taking immediate action in the event of injury or machine malfunction. Texting, talking on a phone or use of another electronic device while the machine is operating constitutes failure to actively supervise. If you need to use the device, stop the machine and resume when you can resume full attention.

Exception: 16 and 17 year old add-on members. You may take the Bench Top Sherline Mill and Lathe classes concurrently with a parent or guardian or if the parent or guardian has completed the class. This is an exception to the Machine Shop Rule that powered machines may only be used by members 18 or older. 16 or 17 year old that completes these requirements may use the machine unattended by a parent or guardian.

The HAAS VF-2 requires training, as does the Bridgeport mill, the Colchester lathe, the Sherline bench top tools and the Kalamazoo cold cut saw. Nothing else in the machine shop requires training, however members should not use any equipment without understanding its operational and safety requirements. Manuals and some video tutorials are available on this page. If you require help with using equipment, send an email to [email protected]

Training for the HAAS VF-2 is is offered to members on a regular basis; see the event calendar for details. Once trained, members will be allowed to use the CNC mill only under supervision, until they have demonstrated their proficiency in its operation.
To contact HAAS supervisors, send an email to [email protected]

All mills and lathes require completion of a basic course in their operation. Classes are offered on a regular basis. These classes are typically broken into two sections, an in-classroom session that covers controls, safety, etc. and a second session with some hands-on demonstration. With the Introduction of Online Training at the Makerspace, Machine Shop will attempt to get as much of the classroom portions onto online. These will be a perquisite to taking the "at machine portion". The online portion will have a test that must successfully passed before enrolling. This should significantly reduce the amount of time a class takes and allow more frequent offerings.

  • Additional Info:**
  • Equipment that requires a class prior to use and costs of said classes**
    • Bridgeport Mill - nominal costs for materials ranging from $0 - $10
    • Colchester Lathe - nominal costs for materials ranging from $0 - $10
    • Coldsaw - free. Classes are on demand from a experienced member.
    • HAAS vertical mill: 3 classes for a total of $75
    • Sherline Mill: $5 for materials
    • Sherline Lathe: $5 for materials
  • Cost of using equipment**
    • Free
  • Pricing of provided consumables**
    • None. User supplies their own.

Other training is in development.

Safety and Machine Shop Rules

  • Safety glasses must be worn at all time while in the machine shop area.
  • Loose clothing, jewelry, long hair should be secured before operating any equipment.
  • Gloves may not be worn while machine is running.
  • If you aren't 100% sure that you know how to use the equipment safely and correctly, ask for help ([email protected])
  • Put tools and equipment back where they go when you are done with them.
  • Restore the machine to its standard configuration.
  • Clean up any chips, shavings, oil, or other mess (on the equipment, floor, or elsewhere) before leaving the Machine Shop area
  • If you break a tool, or notice a broken or missing tool, add it to the "Supplies/Replacement Tooling" section of the Machine Shop Tasks page (dallasmakerspace.org/wiki/Machine_Shop_Tasks)
  • Lanyards must be safety "breakaway type" and secured inside a pocket or shirt. If not breakaway type they must be removed from around neck.
  • When using the bandsaw do NOT push overly hard. Let the blade do the work. Pushing wears the blade out.

Disciplinary Actions

DMS has a long tradition of trying to keep its members safe. Certain actions of misbehavior can or will result in a loss of machine shop privileges. Such actions include but are not limited to:

  • Defeating safety equipment or interlocks
  • Arguing with a member who <nicely> points out you are being unsafe. It is for your own good.
  • Deliberate abuse or destruction of machine shop equipment. Remember - you're on camera.
  • Failure to follow machine shop rules - including the need for cleanup.

Resources

Bridgeport Series I

User Manual
DRO User Manual
Motor information
Bridgeport 101 Class Material
BridgeportPoster.jpg

Clausing Drill Press

Manual

Colchester Bantam 2000 Lathe (removed from shop)

The Bantam Lathe has been sold. These pages remain here solely as reference material.

Colchester 101 Class Material

Manual for VFD (HY03D023B, found on committee group)
Bantam 2000 Manual
Colchester thread cutting, feed rates, and worm gear cutting information

CLAUSING-Colchester 13" Lathe

CLAUSING-Colchester 13" Lathe - dedicated page

[Lathe Tool Designations De-mystified]

Carbide Insert Designations

HAAS VF-2

The main HAAS page is here

Programming Manual
Operator Manual
Video Describing HAAS Control Panel

Machinist's Guide to Toolholder Maintenance
Technical / Maintenance information on RFID system

Sherline Micro tools

Help sheets and Instructions

Sherline Lathe page
Sherline mill page

Powermatic Band Saw

Manual for Newer Version
"Nicer" manual is available on Vintage Machinery's web site.

Kalamazoo Cold Saw

Manual


Torrent Parts Washer

The Parts washer is now under the governance of Automotive. This remains here solely for reference.

User Manual

Fusion360 by Autodesk

Communications

Cimco Edit

CNC Programs

The following two short programs reside on the HAAS and should not be deleted.

  • Spindle Warmup
    • This is run everytime the HAAS is powered on to give the spindle time to temperature stabilize at a range of speeds
  • Tool Jogging Program
    • The program should be run at the end of the day. It cycles thru each of the tools to prevent them from sticking due to cutting fluid drying with the tools in the tool crib.

External Sites

CNC Handbook

MIT Machine Shop Instructional Videos - The Gold Standard

  1. Part Layout, Drill Press (Basic), Tapping
  2. Drill Press (Advanced), Bandsaw
  3. Part Finishing (Sanding, Grinding, Deburring, Polishing)
  4. Manual Mill 1
  5. Manual Mill 2
  6. Manual Mill 3
  7. Manual Mill 4
  8. Manual Lathe 1
  9. Manual Lathe 2
  10. Manual Lathe 3


Mr Pete (Machining Videos)
Very good instructor ClickSpring Instructional Videos, very accessible.
Destiny Tool
Engine Turning
G-Code Tutorial
Glossary
Guerrilla Guide to CNC Machining
Learn CNC

Practical Machinist
That Lazy Machinist The Virtual Machine Shop
Tom Lipton (Machining Videos) Author of Metalworking Doing it Better and Metalworking Sink or Swim
University of Idaho Mindworks

Parts and Equipment

Bits and Bits *Makes engraving cutters, wax milling cutters, end mills and has diamond drag engraving bits.
Bridgeport Parts
Brownell's Gunsmithing Supplies (lots of hard to find tools even for non-gunsmithing...)
Discount tools
Fastener Express
Enco (Machining tools, equipment, and accessories)
Little Machine Shop
Maritool (Machine Tooling)
McMaster Carr
MSC Industrial Supply
Precision Balls
Monster Jaws (soft jaws for Kurt Vises)
Sherline Machines
Stock Drive Products *Good source of gears and other machine parts
Travers Tool Company

Metal Suppliers

Metal Suppliers

Equipment List

Mill Tooling

  • Collets (R8)
    • These are used to hold milling cutters (end mills, shell mills, etc...) and are located in a rack attached to the Bridgeport mill.
  • Collets (5C)
    • These are used to hold stock in the Spin Indexer to be milled. Currently we have 0.250", 0.375", 0.500", 0.625", 0.750", 0.825", and 1.000" They are located in in a small labelled laser cut wood holder located on the shelf above the machine shop work bench.
  • Dividing Head
    • We have a Yuasa 550-030 dividing head. We do not own the tail stock or the center with carrier. We do have a 6" three jaw chuck for this dividing head. The standard division plates are; A-15,16,17,18,19,20; B-21,23,27,29,31,33; and C-37,39,41,43,47,49 The dividing head is stored on the second table in the machine shop.
    • User manual
  • Drill Chuck (R8)
    • These are used to hold tools for drilling operations in the mill (countersinks, counterbores, reamers, twist drills, etc...) and is located in a rack attached to the Bridgeport mill.
  • End Mills
    • End mills are consumables (they wear out) so a current list would be too time consuming to maintain; however, our current available supply can be found in a grey cabinet on the machine shop workbench.
  • Gauge Blocks (Jo Blocks)
    • Tutorial on proper use of gauge blocks
    • These are located in the red tool box, in the drawing with the other measuring equipemnt
    • These are expensive precision pieces of equipment and should only be used for calibration of measurement equipment like micrometers, or for layout work like setting up a sine bar. Also, if one block is lost or misplace, the utility of the set is greatly diminished. Please be especially careful if you need to use these.
  • Rotary Table
    • It is located on the hydralic lift cart.
  • Shell Mill
    • The shell mill is located on the workbench in the machine shop area. This uses replaceable inserts, which are located in ...
  • Spin Indexer
    • It is located on the hydralic lift cart.
  • Spot Drills
    • Spot drills are consumables (they wear out) so a current list would be too time consuming to maintain; however, our current available supply can be found in a grey cabinet on the machine shop workbench.
  • Tilt Table
    • This table addition is for use with the Bridgeport mill or HAAS vertical mill. It has a standard t-slot table which can be tilted +/- 45 degrees so that the mill does not have to be taken out of tram to do complex cutting. It is located on the hydralic lift cart.

Set-up and Measurement Tools

  • SPI 4 piece combination square
    • This is in the red tool box with the other measurement equipment
  • 0-6" Dial Calipers
    • In the black tool box
  • 0-6"/0-150mm Dial Calipers
    • Red toolbox, in drawer with other measurement equipment
  • Center Finder
    • Located in the drawer (labeled edge finder) in the end mill cabinet (on the workbench shelf)
  • Dial Indicators
    • Located in the top of the red tool box
  • Dial Test Indicators
    • Located in the black toolbox
  • Edge Finder
    • Located in a drawer (labeled edge finder) in the end mill cabinet (on the workbench shelf)
  • Machinist Jacks
    • A pair of machinist jacks for supporting odd shaped parts during set-up. Located in the top of the red toolbox.
  • 0-1" Micrometer
    • Located in the top of the red tool box
  • Noga Indicator Mount
    • Located attached to the top of the red toolbox.
  • Set of telescoping hole measurement gauges
    • Used to accurate measure the diameter of holes from 5/16" to 6". Located in the red tool box drawer with the other measurement equipment
  • 6" 5R steel rule
    • In red toolbox, in drawer with other measuring equipment
  • 18" 5R steel rule
    • On order
  • 600mm steel rule
    • Located on the workbench shelf

Machinist Information

Reference Materials

Public Domain Books on Machining
English and Metric Tap and Clearance drill sizes
Rake and relief angles for lathe cutting tools
Sharpening Lathe tool bits
Dimensions of standard tapers
End Mill Speeds and Feeds
cnccookbook.com blog

Instructional Information

Maintenance / To Do List

Outstanding Tasks

How To Join

Add your name to the "Members" section of this wiki page or send an e-mail to the chairperson requesting to join. Actively participate in the monthly committee meetings. Meet your fellow committee members and volunteer to help.

Discussion

Discussions are held thru TALK.

Projects

User Projects
Steam Engine #3 The steam engine project has been discontinued