Fabrication
Machining
Shop safety, precise measurement, and your first manual project.
Machining is the process of using power tools to precisely cut, drill, mill, grind or otherwise remove material from a piece of stock — typically metal or plastic — to create a finished part. It is a subtractive manufacturing process, as opposed to an additive process like 3D printing. In this Tech Crest you will learn shop safety, precise measuring and layout techniques, and use manual machines to complete a small project.
Requirements
What you'll do
Some requirements are independent; others you'll do with your trainer. Check off items as you go — your progress is saved in this browser.
Your progress
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0 of 16 requirements complete
Materials needed (16 items)
- Measuring tape
- Calipers
- Layout fluid
- Machinist square
- Scribe
- Center punch (and hammer, if not an automatic center punch)
- Cutoff saw (chop saw, cold saw, or horizontal band saw)
- Deburring tool or file
- Drill press
- ¼″ drill bit
- 17⁄64″ drill bit
- Countersink
- Sanding station
- Arbor press
- 2″ × ½″ aluminum bar (2″ length per project)
- 0.248–0.250″ diameter aluminum rod (2″ length per project)
Shop Safety
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1. Present yourself to your trainer wearing appropriate shop apparel and explain how your apparel keeps you safe in the shop. You must show appropriate footwear, eye protection, and hearing protection, and explain how you have reduced entanglement risk from hair, clothes, and accessories.
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2. Explain risk factors in the shop:
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2a. Explain the mental conditions that increase risk of error or injury in the shop, including complacency, distraction, and exhaustion. Tell how you will mitigate these risks.
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2b. Explain the environmental conditions that increase risk — distraction, time-pressure, clutter and mess, and deferred maintenance. Tell how you will mitigate these risks.
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3. Explain how you can use your senses of sight, hearing, smell, and touch to monitor whether a machine is operating as it should.
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4. Identify common minor injuries that occur when the machine is off, and explain how you will avoid them.
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5. If your shop or any of its machines have emergency stop buttons, explain when and how to use them, and how to reset them.
Shop Procedures
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6. Explain the procedures in your shop for training to use the machines. Do different machines require different levels of training? What are the supervision requirements as you progress?
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7. Explain shop organization and maintenance:
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7a. Explain the meaning and importance of the mantra "everything has a place and everything in its place."
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7b. Explain the systems in your shop for managing stock inventory, minimizing drop, and disposing of scrap.
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8. Explain the cleanup procedures in your shop. Tell what is expected when you finish using a machine, and at the end of your work session.
Project: Measurement & Layout
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The remaining requirements are designed to be fulfilled as you complete a small machining project. The drawings for the project are included below along with a list of the required tools and materials.
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9. Use the following measurement and layout tools — follow the project drawing to locate part features on the appropriate stock: measuring tape, calipers, layout fluid, square, scribe, and center punch.
- Use measuring tape
- Use calipers
- Apply layout fluid
- Use machinist square
- Scribe layout lines
- Use center punch to mark hole locations
Project: Cutoff Saw
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10. Use a cutoff saw (chop saw, cold saw, or horizontal band saw) to cut stock to length.
- Identify the saw by name and explain its use
- Explain safety precautions specific to that saw
- Demonstrate proper setup, including blade selection and ensuring a square cut
- Demonstrate proper fixturing of the workpiece
- Demonstrate proper operation of the saw
- Demonstrate proper cleanup of the saw and deburring of the part
- Verify the quality and accuracy of the cut
Project: Drill Press
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11. Use a drill press to drill through holes, drill blind holes, and chamfer holes.
- Identify the drill press by name and explain its use
- Explain safety precautions specific to the drill press
- Demonstrate proper setup: drill bit installation, speed selection, table and depth adjustment
- Demonstrate proper operation of the drill press
- Demonstrate proper cleanup and deburring of the part
- Measure the depth accuracy of the blind holes
Project: Sanding & Assembly
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12. Use a sanding station to chamfer the ends of the pins (Part B).
- Identify the sanding station by name and explain its use
- Explain safety precautions specific to the sanding station
- Demonstrate proper setup: grit selection and belt tracking (for a belt sander)
- Demonstrate proper operation of the sanding station
- Demonstrate proper cleanup
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13. Assemble your project by using an arbor press to insert the pins into the blind holes.
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14. Test the quality of your project by mating two copies of the finished assembly together. Hold the two assemblies with the pins on each aligned with the through holes of the other. The pins should nest smoothly.
Ready to start?
Find your trainer. Make a plan.
A trainer is a coach, mentor, or more experienced student with content-area expertise and your coach's approval. Ask your coach to help identify an eligible trainer for Machining.
Process
- 1 Identify your trainer with help from your coach
- 2 Meet to discuss your plan of work and timeline
- 3 Complete requirements; check in periodically
- 4 Present yourself for review at completion
- 5 Trainer submits the Tech Crest completion form
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