Brown & Sharpe

Brown and Sharpe Image The following lesson outline details the tasks needed to be a machinist on a Brown & Sharpe automatic bar machine. Some of these tasks require the trainee to explain how something works to insure they have the required understanding of the processes and are not simply memorizing procedures. All of the tasks listed will be a part of the Performance Test within each lesson. To learn more about these tests and the training process itself, see the Philosophy section.

This MasterTask training system was specifically designed to accommodate the 00, #2 size and Ultramatic Brown & Sharpe cam operated screw machines. The instructional technique employed will enable individuals to learn to set up and operate the machines with little difficulty. The first 8 lessons cover the basic set up and operating tasks. The final 5 lessons cover installation and set up of specific attachments. Both existing personnel and new trainees can utilize these training materials to develop or improve their performance.

Lesson 1: Basic Components and Controls [ Top ]

After completing this lesson the operator will be able to:

  1. Locate, identify by name, and explain the purpose for the following components:
    1. Main Power Switch
    2. Main Motor
    3. Older Model Control Station
    4. Newer Model Control Station
    5. Spindle Start Control
    6. Spindle Stop Control
    7. Drive Shaft Start Control
    8. Drive Shaft Stop Control
    9. Jog Control
    10. Spindle
    11. Spindle Direction Control Switch. Cross Slides
    12. Vertical Slides
    13. Cams and cam shaft
    14. Turret
    15. Turret Slide
    16. Trip Dogs
    17. Dog Carriers for 00 and #2
    18. Trip Levers
    19. Turret Dog Carrier
    20. Spindle Reverse Dog Carrier
    21. Stock Feed Dog Carrier
    22. Hand Wheel
    23. Work Chute for 00 and #2

Lesson 2: The Stock Feeding Cycle [ Top ]

After completing this lesson the operator will be able to:

  1. Locate, identify and explain the purpose of the following components:
    1. Stock Tube
    2. Feed Tube latch
    3. Pusher
    4. Feed Tube
    5. Stock Guide Bushing
    6. Feed Finger
    7. Collet
    8. Stock Stop
    9. Turret Stock Stop
    10. Swing Stock Stop
    11. Feed Adjusting Knob
    12. Feed Scale
    13. Feed Pointer
  2. Identify and explain the following portions of the stock feed cycle:
    1. Indexing
    2. Collet Opening
    3. Feed Stroke Forward
    4. Pusher Stroke
    5. Collet Closing
    6. Pusher Return Stroke

Lesson 3: Pusher Replacement and Restocking [ Top ]

After completing this lesson the operator will be able to:

  1. Stop the machine at the correct point in the machining cycle.
  2. Manually open the Collet using the hand wheel to crank through the cycle.
  3. Move and secure the Stock Tube and remove the Pusher assembly.
  4. Clean and remove the Feed Finger from the end of the Pusher assembly.
  5. Select the correct size Feed Finger and install it on the Feed Tube.
  6. Remove and replace the Stock Guide Bushing with the correct bushing based on setup documentation.
  7. Lubricate and install the Pusher assembly into the back of the collet.
  8. Engage the Feed Tube Latch with the Pusher assembly.
  9. Select, clean, measure and chamfer bar stock as called for in the setup documentation.
  10. Load bars into Stock Tube, through Pusher and out of Collet beyond cutoff.
  11. Manually index Stock Stop into position for feed out of bar.
  12. Manually close Collet by hand cranking machine forward through cycle.
  13. Start spindle, engage feed, then manually spot bar end.

Lesson 4: The Collet Locking System [ Top ]

After completing this lesson the operator will be able to:

  1. Locate, identify and explain the following components:
    1. Collet Jaws
    2. Collet Sleeve
    3. Spindle Nut
    4. Collet Tube
    5. Collet Fork Sleeve
    6. Stock Feed Dog Carrier
    7. Trip Dogs
    8. Feedout Lever
    9. Spindle Alignment Pin
    10. Collet Tension Adjusting Nut
    11. Collet Tension Lock Screw
  2. Locate, identify, and explain the operation of a Collet.
  3. Stop the machine at the correct time in the feed cycle.
  4. Remove the Collet, Collet Sleeve, and clean the Spindle and Collet components.
  5. Burnish a new Collet to remove nicks or burrs.
  6. Lubricate the Collet Sleeve and spindle.
  7. Align and insert Collet Sleeve in spindle.
  8. Assemble Collet and Spindle Nut and install in spindle.
  9. Load bar stock into Collet through Spindle.
  10. Hand crank machine to mid point of Collet stroke.
  11. Correctly adjust collet tension while hand chucking the Collet.
  12. Secure Collet Tension Adjusting Nut and close Collet.

Lesson 5: Speed and Feed Adjustments [ Top ]

After completing this lesson the operator will be able to:

  1. Locate identify and explain the purpose of the following components:

    1. RPM Chart
    2. Spindle Speed Gears
    3. Low Speed Gear Location Graphic
    4. High Speed Gear location Graphic
    5. Speed Gear Storage Door
    6. 00 Gears
    7. 00 Feed Chart
    8. 00 Gear Mounting Chart
    9. #2 Feed Change Gears
    10. #2 Feed Change Gear Chart
    11. #2 Feed Change Gear Shafts
  2. Locate and identify the speed and feed requirements from a setup document.
  3. Locate and select the correct Speed Gears.
  4. Remove Speed Gears.
  5. Install the correct Speed Gears.
  6. Select the correct Feed Gears for a 00 machine.
  7. Remove and replace the Feed Gears on a 00 machine.
  8. Select the Feed Gears for a #2 machine.
  9. Remove and replace the Feed Gears on a #2 machine.
  10. Close and secure the Gear Box Cover.

Lesson 6: Lead and Cross Slide Cam Replacement [ Top ]

After completing this lesson the operator will be able to:

  1. Locate, identify, and explain the purpose for the following:

    1. Lead Cam
    2. Lead Cam Roller
    3. Lead Cam Approach Portion
    4. Lead Cam Low Point
    5. Lead Cam Feed Portion
    6. Lead Cam High Point
    7. Lead Cam Rise
    8. Lead Cam Locating Hole
    9. Turret Slide Adjusting Screw
    10. Cross Slide Cams
    11. Vertical Slide Cams
    12. Cross Slide Adjusting Nut
    13. Positive Stop Screw
    14. Adjustable Cross Slide Cam Holders
    15. Cam Holder Zero Point
    16. Turret Trip Dogs
    17. Turret Dog Carriers
  2. Select the correct Lead Cam from the setup documentation.
  3. Identify the machining to be performed with each rise of the Lead Cam.
  4. Identify how many hundredths of cam rotation each operation will require.
  5. Loosen and remove a Lead Cam.
  6. Correctly mount a Lead Cam.
  7. Adjust Turret to spindle location based on setup documentation.
  8. Back off cross slide adjusting screws and Positive Stop screw.
  9. Remove Cross Slide Cams and clean assembly.
  10. Align adjustable Cam Holders with new cam segments and secure.
  11. Set the Turret Trip Dogs while hand cranking the Lead Cam through the cycle.
  12. Set Stock Feed Trip Dog for turret mounted stock stops.
  13. Set Spindle Speed and Spindle Reversing Trip Dogs.

Lesson 7: Basic Setup [ Top ]

After completing this lesson the operator will be able to:

  1. Locate, identify, and explain the following components:
    1. Stock Feed Mechanism
    2. Feed Adjusting Knob
    3. Feed Scale
    4. Circular Cutoff Tool
    5. Cutoff Blade
    6. Cutoff Blade Tool Holder
    7. Circular Tool Holder
    8. Tool Clamp Bolt
    9. T Bolt
    10. Form Tool Centering Screw
    11. Taper Adjusting Screws
    12. Riser Block
    13. Standard Twist Drill
    14. Stub Drill
    15. Stepped Drill
    16. Spot Drill
    17. Combined Drill and Countersink
    18. Adjustable Turret Tool Holder
    19. Tool Holder Bushing
    20. Tool Holder Clamp Screw
  2. Properly set Feed Stroke.
  3. Explain the centering of a form or cutoff tool to the spindle centerline.
  4. Clean Cutoff Tool Holder and cross slide, and mount tool holder.
  5. Rough set the tool on center with the Spindle.
  6. Manually cutoff the bar end.
  7. Identify and correct for non-centered conditions for both Front and Rear Cross Slide Tools.
  8. Hand crank to low point and set cross slide position.
  9. Set Stock Stop for correct part length.
  10. Mount riser block and form tool holder to the Front Cross Slide.
  11. Set cross slide horizontal position.
  12. With Cross Slide at highpoint, set depth of cut of Front Cross Slide.
  13. Set Positive Stop Tension to bring part to size.
  14. Correctly select and mount a drill in the drill holder.
  15. Mount a drill holder in the Turret.
  16. Center the drill to the spindle centerline.
  17. Set the depth of a drilled hole at the highpoint of the Lead Cam lobe.

Lesson 8: Controlling the Quality of Parts [ Top ]

After completing this lesson the operator will be able to:

  1. Given machined workpieces, identify those with and without chatter marks.
  2. Identify the 12 most common causes of chatter and state their corrective action.
  3. Identify the 6 most common causes of Short Feed and state their corrective action.
  4. Identify and state the correct angles for each of the following:
    1. Screw machine drill cutting angle
    2. Spot drill cutting angle
    3. Lip Clearance
    4. Cutoff tool rake angle
    5. Cutoff tool relief angle
    6. Cutoff side rake for center-hole workpieces
    7. Cutoff side rake for non center-hole workpieces
  5. Measure a drill position, remove, and correctly sharpen.
  6. Identify and replace a correctly sharpened drill.
  7. Measure a cutoff tool position, remove, and correctly sharpen.
  8. Identify and replace a correctly sharpened cutoff tool.
  9. Identify and remove a circular form or cutoff tool.
  10. Mount a form tool for sharpening.
  11. Correctly grind a form tool with the correct rake and relief angles.

Lesson 9: The Recessing Attachment [ Top ]

After completing this lesson the operator will be able to:

  1. Identify and explain the purpose of recessing operations.
  2. Identify the two types of recessing holders.
  3. Explain the use of the eccentric bushing for forward and revers spindle rotation.
  4. Identify and explain the recessing lobes on the Lead Cam.
  5. Identify and explain the operating movements and component parts of a Swing type recessing attachment.
  6. Stop the machine at the correct point in the machine cycle.
  7. Mount the tool holder in the correct turret location based on setup documentation and lead cam design.
  8. Position and secure the eccentric bushing and recessing tool in the holder.
  9. Index turret and check for bump screw clearance.
  10. Set machine to start of dwell of recess lobe and set location of cut referenced from cutoff blade.
  11. Center the recess tool and secure in holder.
  12. Feed out stock and check for entrance clearance.
  13. Position bump screw to start recess cut.
  14. Run workpiece and adjust for correct depth of recess.

Lesson 10: Knurling Operations [ Top ]

After completing this lesson the operator will be able to:

  1. Locate, identify, and explain the types of knurling surfaces produced.
  2. Identify the knurling tool components.
  3. Select the correct Knurl Rollers based on setup documentation.
  4. Mount the knurl rollers in the Roll Holders.
  5. Secure with the Roll Holders in the Knurl Head with the depth adjusting screws.
  6. Set Roller Angle to match lines.
  7. Locate and identify the Knurling Lobe on a Lead cam.
  8. Mount Knurling Head, hand crank to high point and set length of knurl.
  9. With cam at high point of knurl lobe, set rollers to contact work, set initial depth.
  10. Run workpiece and set final roll depth.

Lesson 11: Die Head Threading [ Top ]

After completing this lesson the operator will be able to:

  1. Locate, identify, and explain Die Head operating sequence and component parts.
  2. Check all components against setup documents.
  3. Clean and mount the correct thread chasers in the Die Head.
  4. Set rough die head thread depth.
  5. Hand crank to low point and set Spindle Speed Trip Dog.
  6. Center Die Head to workpiece.
  7. Position die head in turret to under cut thread length.
  8. Jog through machining cycle and manually reset head.
  9. Adjust die head in turret to increase depth of cut, check thread dimensions.
  10. Set die head closer.
  11. Run at production speeds and check operation.

Lesson 12: The Box Tool [ Top ]

After completing this lesson the operator will be able to:

  1. Locate, identify, and explain a Box Tool, it's operating sequence and component parts.
  2. Mount cutting tool and center.
  3. Set depth of cut for tool holder under the dimension found on setup documentation.
  4. Mount the Box Tool in the correct turret position.
  5. Check for indexing clearance.
  6. Back off rollers.
  7. Disable bar feed, index box tool into cutting position.
  8. Jog to highpoint and set length of cut using Cutoff Blade as reference.
  9. Feed a short length of bar and manually advance the turret for a trial cut.
  10. Check size and adjust until cut is slightly undersize.
  11. Adjust rollers to contact cut surface.
  12. Back off depth of cut to bring to size.
  13. Machine workpiece and make final adjustments.

Lesson 13: Tapping Operations [ Top ]

After completing this lesson the operator will be able to:

  1. Locate, identify, and explain a tapping sequence and component parts.
  2. Mount the Tap and Tap Bushing into the tap holder.
  3. Check for Tap Holder operation, mount holder in correct turret position.
  4. Jog to low point of tap lobe and set trip dog to reverse spindle and slow the spindle speed.
  5. Hand crank to high point and set trip dogs to resume forward spindle rotation and high speed.
  6. Set tap under required depth of cut.
  7. Without stock, check spindle speed and direction changes.
  8. Center the tap with the hole.
  9. Tap a workpiece and make final adjustments.