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Worker Health and Safety Awareness

https://www.labour.gov.on.ca/english/hs/elearn/worker/foursteps.php

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Manufacturing Assignments – October 10-13

Grade 10: Submit/share all completed work with my k12 account

 

  1. Design of “2d Wall Art welding project” – complete a paper sketch of the design that you would like to use for the “2d wall art project”

  2. Create a slideshow (powerpoint or google slides) that describes any piece of shop equipment that has been used in this class so far. Should have at least 10 slides and include at least the following: how it works, what it’s used for, major manufacturers, safety rules. Include pictures and text.

  3. Complete a “Shop Safety Poster” that outlines any of the safety rules that have been covered in class to this point.

  4. Create a slideshow (powerpoint or google slides) that outlines a manufacturing related career. Include: Name of occupation. What somebody who has that job does. Places they might work. Hazards of the job. Educational requirements. Average pay.

 

Grade 11:  Submit/share all completed work with my k12 account

  1. Create a slideshow (powerpoint or google slides) that describes any piece of shop equipment that has been used in this class so far. Should have at least 10 slides and include at least the following: how it works, what it’s used for, major manufacturers, safety rules. Include pictures and text.

  2. Research/design an image/logo/graphic that will be used on an upcoming CNC Plasma project – “Illuminated Sign”. We will be building these in the next few weeks, it will be good to get a headstart on a design that you would like to do. Size will be 12”x12”

  3. Create an informative slideshow presentation on any kind of metal. Describe how the metal is produced, attributes, typical uses and any other relevant information. Include pictures of the metal in all forms – raw, processed and final product.

 

Grade 12: Submit/share all completed work with my k12 account

 

  1. Research/design for the mini bbq/fire pit project. Produce detailed sketches for the design that you have selected for this project.

  2. Create a slideshow (powerpoint or google slides) that describes any piece of machine shop equipment that has been used in this class so far. Should have at least 10 slides and include safety rules, what it is used for, how it works. Include pictures of things that have been created on this machine.

  3. Check out any of the machining videos on this channel: https://www.youtube.com/user/mrpete222/videos

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Lathe Intro

The Lathe
Turning is one of the most common of metal cutting operations. In turning, a workpiece is rotated about its axis as single-point cutting tools are fed into it, shearing away unwanted material and creating the desired part. Turning can occur on both external and internal surfaces to produce an round or symmetrical contoured part.

Parts ranging from pocket watch components to large diameter marine propeller shafts can be turned on a lathe. The capacity of a lathe is expressed in two dimensions. The maximum part diameter, or “swing,” and the maximum part length, or “distance between centers.” The general-purpose engine lathe is the most basic turning machine tool. As with all lathes, the two basic requirements for turning are a means of holding the work while it rotates and a means of holding cutting tools and moving them to the work.

The work may be held on one or by both its ends. Holding the work by one end involves gripping the work in one of several types of chucks or collets. Chucks are mounted on the spindle nose of the lathe, while collets usually seat in the spindle. The spindle is mounted in the lathe’s “headstock,” which contains the motor and gear train that makes rotation possible. Directly across from the headstock on the lathe is the “tailstock.” The tailstock can hold the work by either a live or dead center. Work that is held at both ends is said to be “between centers.” Additionally, longer workpieces may have a “steady rest” mounted between the headstock and tailstock to support the work. Typically workpieces are cylindrical, but square and odd shaped stock can also be turned using special chucks or fixtures.

Lathe cutting tools brought to the work may move in one or more directions. Tool movement on the engine lathe is accomplished using a combination of the lathe’s “carriage”, “cross slide”, and “compound rest”.

The carriage travels along the machine’s bedways, parallel to the workpiece axis. This axis is known as the “Z” axis. Motion perpendicular to the work is called the “X” axis. On an engine lathe this motion is provided by the cross slide mounted on the carriage.

Atop the cross slide is the “compound rest,” which can be rotated to any angle and secured. The compound rest also holds the “tool post,” where tools are mounted. Tools may also be mounted in the tailstock for end-working operations.

External turning can be broken down into a number of basic operations. “Straight turning” reduces the work to a specified diameter equally along the work’s axis. “Taper turning” produces a taper along the axis of the workpiece. Tapers are produced by either offsetting the tailstock from centerline or by using a “taper attachment.” Some short, steep tapers can be obtained by using the compound rest alone. “Contour turning” or “profiling” uses a single-point cutting tool to reproduce a surface contour from a template. This operation has been almost entirely replaced by numerically controlled or “NC” programming. “Forming” uses
a cutting tool ground with the form or geometry of the desired shape. This forming tool is advanced perpendicular to the axis of the work to reproduce its shape on the workpiece.

Other external lathe operations include “chamfering” to remove sharp edges, “grooving” to produce recesses and shoulders, “facing” to finish the ends of a workpiece, “parting” to cut off finished pieces from the stock, and “thread chasing” with tools to produce the desired thread form.

The most common method of internal turning on the lathe is to present the rotating end of a workpiece to the point of a non-rotating drill bit mounted in the tailstock. Roughly drilled holes are finished to exact size by using a reamer which also mounts in the tailstock. Large diameter holes are made by boring. A boring bar with a cutting tool attached is moved along the work’s axis as in surface cutting, but inside a previously drilled hole. Internal threads are obtained by using tapping tools mounted in the tailstock.
Turning can produce long chips that may interfere with the work in progress. The right cutting tools and proper lubrication are used to control chip formation.

Very large work with swing dimensions beyond the capacity of a horizontal machine are turned on vertical lathes that can accept work two to six feet in diameter.
Raw stock is brought to the lathe in several ways. Long lengths can be fed through the head stock, short lengths or “slugs” can be manually or automatically chucked. Gantry systems are used to handle large, heavy pieces of stock.

Production lathes bring tools and arrangements of tools to the work by the use of turrets on larger machines and slide mounted “gang tooling” on smaller, more compact lathes.
Regardless of the type of lathe, three key parameters determine productivity and part quality.

These parameters are:

• the cutting speed
• the feed rate
• the depth of cut

The cutting speed is the speed of the work as it rotates past the cutting tool.

The feed rate is the rate at which the tool advances into the work.

The depth of cut is the amount of material removed as the work revolves on its axis.

Other factors include the machinability of the stock, the type and the geometry of the cutting tool, the angle of the tool to the work, and the overall condition and power of the lathe itself.

SAFETY

All lathe operators must be constantly aware of the safety hazards that are associated with using the lathe and must know all safety precautions to avoid accidents and injuries. Carelessness and ignorance are two great menaces to personal safety. Other hazards can be mechanically related to working with the lathe, such as proper machine maintenance and setup. Some important safety precautions to follow when using lathes are:

  • Correct dress is important, remove rings and watches, roll sleeves above elbows.
  • Always stop the lathe before making adjustments.
  • Do not change spindle speeds until the lathe comes to a complete stop.
  • Handle sharp cutters, centers, and drills with care. Remove chuck keys and wrenches before operating Always wear protective eye protection.
  • Handle heavy chucks with care and protect the lathe ways with a block of wood when installing a chuck.
  • Know where the emergency stop is before operating the lathe.
  • Use pliers or a brush to remove chips and swarf, never your hands.
  • Never lean on the lathe.
  • Never lay tools directly on the lathe ways. If a separate table is not available, use a wide board with a cleat on each side to lay on the ways.
  • Keep tools overhang as short as possible.
  • Never attempt to measure work while it is turning.
  • Never file lathe work unless the file has a handle.
  • File left-handed if possible.
  • Protect the lathe ways when grinding or filing.
  • Use two hands when sanding the workpiece.
  • Do not wrap sand paper or emery cloth around the workpiece.

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Shop Safety Poster

October 24th

Grade 10:

Hi! Use the computers to research and complete a “shop safety poster” detailing one shop safety rule that we have covered so far in QUIA material.

Use whatever computer software package you are comfortable with.

Include images and as much information as necessary. You can print out and hand in OR email these to me when complete – mrdarling@mrdarling.com .

If you finish that try this “estimating game”, it helps develop your ability to estimate and “eyeball” dimensions;

http://woodgears.ca/eyeball/

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Video for October 17th

https://www.youtube.com/watch?v=CTGpyYqR32k

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ARC Welding Intro

Start here, there is a series of five videos that will give you practice work to do as you go:

Part 1

Part 2

Part 3

Part 4

Part 5

 

 

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Monday, October 26th

Grade 11

Where would you go to school?

Take a look at any of the following trades and research a school based in Ontario that can provide the training required to enter that field:

Welder
Underwater welder
Automotive Repair
Machinist
Tool and Die Maker
Blacksmith
Millwright
CNC Machinist

Provide an outline with the following information:

Name of School/Location
Length of Program and Cost (if available)
Entry Requirements
Sample of courses you will take in the program
Career Opportunities for graduates.

Enter this information into this assignment posted on the Quia site: http://www.quia.com/quiz/5526835.html

If you have completed this you can work on unfinished work from last week or continue research for “functional CNC” or your personal independent project that will be completed before the christmas break.

Grade 10

Choose a career in the manufacturing field, research it online and gather the following information to be entered on Quia here: http://www.quia.com/quiz/5458365.html

You must include the following information in your finished product:
Job description
Educational Requirements (list at least two places that you could receive the education required for this job)
Skills needed by people who do this job
Wage expectations (for people that do this job in Canada if possible, in Canadian dollars if not)
Where you would work if you had this job (names of companies)
Opportunities for advancement (what else is there that people who do this job can do?)
Picture(s) of somebody doing this job or other relevant graphics

Possible Careers:

Welder
Underwater welder
Automotive Repair
Machinist
Tool and Die Maker
Blacksmith
Millwright
CNC Machinist

Grade 12

Take time today to complete research on post-secondary opportunities in the manufacturing industry (i.e. welding, machining). Try to find information on program name, location, length and cost. Find out what sort of career opportunities exist in the field that your have selected.

Complete a brief write-up with the above information as well as your perspective on the chosen pathway and email it to me at mrdarling@mrdarling.com

Have a good day and see you on Tuesday.

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Thursday, October 22nd

Grade 10:

Hi! Use the computers to research and complete a “shop safety poster” detailing one shop safety rule.

Use whatever computer software package you are comfortable with.

Include images and as much information as necessary. You can print out and hand in OR email these to me when complete – mrdarling@mrdarling.com .

If you have completed this try to find a lathe instructional video on youtube, especially one that deals with feed rates, speeds and RPM.

See you tomorrow!

Grade 12:

Research and respond to the following statement:

“It should be illegal to throw an aluminum can in the garbage”

Provide reasons why this statement is true (or false, but it’s totally true).

A couple paragraphs would be cool.

See you tomorrow.

Grade 11:

A bit of reading for you today.

Precision Measuring: http://www.jjjtrain.com/vms/measure_fundmentals/measure_fund_00.html

Lathe/Turning: http://www.mfg.mtu.edu/marc/primers/turning/turn.html

Drilling: http://www.mfg.mtu.edu/marc/primers/drilling/nomen.html

Milling: http://www.mfg.mtu.edu/marc/primers/milling/index.html

After you have finished this reading, you can create a safety poster for a machining tool (i.e. lathe, mill, drill press)

Use online research to select a general safety rule and then assemble using images to create a poster.

When you complete this you can email it to me mrdarling@mrdarling.com or print it out and hand it in.

 

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Wednesday, October, 21st

Grade 10:

The teacher has your QUIA password if you do not know what it is.

Read handout as well as information posted here and then complete the QUIA quiz located here: http://www.quia.com/quiz/5513037.html

If you have any safety quizzes not completed, take the time today to complete them.

We will be making metal stools with CNC routed tops of MDF wood. You will need to find a logo or design to place on the top of your stool – take some time today to find a logo to use with your project. Sports logos and motorsport logos have been popular in the past. Save what you find to your profile. Try to get a large image size. Logos work better than pictures – look for things with clean lines and solid colours.

Grade 11:

Read handout as well as information posted here and then complete the QUIA quiz located here: http://www.quia.com/quiz/5513037.html

If you have completed this and all other Quia quizzes, you can do some online research for upcoming project work including:

Functional CNC – We will do some CNC work using Vcarve, I would like us to talk about using CNC to create functional objects. Here are some examples.  (for example, toys, furniture, coasters, art – we will be using MDF to create these, but they might have some metal accents)

Grade 12:

Read handout as well as information posted here and then complete the QUIA quiz located here: http://www.quia.com/quiz/5513037.html

After that there are a few things I would like you to consider:

Tool storage: Please do some online research to help finalize our new tool rack layout. If you find any interesting concepts, save or print them to share with me on Monday.

 

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Tuesday, September 15th

Grade 11

An upcoming project we will complete is designing and building a metal chair.

After you have completed the Quia work take some time to research some of the following:

Optimum chair dimensions (height/seat size/back/etc)

Existing metal/welded chair designs

We will be completing a formal design process for this project so now is the time to gather ideas and begin to think about what sort of metal chair you could build (we can include fabric elements if you are interested in doing so).

There will be material constraints that we work in – essentially the bulk of the material you use will be 1/2″ and 1/4″ round stock.

Save any work/images you find for future reference.

Grade 12

Hi Grade 12’s – take some time today (after you have completed the safety quizzes) to begin some research and design work for one of the four independent projects that you will need to complete this year.

Things to consider:

Design (what am I going to build)

Materials and resources required

Processes required

Of course we will be completing the “shop renewal” projects first before we start on any of the independent projects.

Save your work and I will present you with some more formal framework at a later date.

Some of you had mentioned an interest in TIG Welding – here is a good starting point: https://www.youtube.com/watch?v=LLUXaLT6hIo

 

Grade 10

New and Emerging Technologies

Describe how society is being affected today by various new and emerging technologies (e.g., electronic messaging, Global Positioning System [GPS], smart phones, wireless access, hybrid vehicles, nanotechnology, biotechnology, alternative energy such as solar or wind power, mapping systems such as google maps)

Choose one of the terms above, or select your own (check here for more ideas) and enter the following information into Quia under the “New and Emerging Technology” more: http://www.computerworld.com/category/emerging-technology

Description of the technology (what is it and what does it do)

Short history or timeline of the technology

Use of the technology (who uses it for what)

Innovators – who is in the lead at developing this technology

Impacts – how is this technology affecting the world around us

Future – What is seen as the future of this technology – where is it going?

These assignments are meant to have you do some research into technology and technological change. Although they may not see directly related to the hands-on part of our course, they are curriculum requirements that we need to cover – these assignments will be graded and count as part of your final mark.

 

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