Warner & Swasey AC / AB

Warner and Swasey Image The following lesson outline details the tasks needed to be a machinist on a Warner Swasey automatic chucker and 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.

Lesson 1: Basic Machine Components [ Top ]

After completing this lesson the operator will be able to locate, identify, and explain the purpose for the following components and machine operations on the machine:

  1. Indexing
  2. Index Control Drum
  3. Main Control Drum
  4. Control Stations
  5. Cam Drum Assembly
  6. Machine Function Control Panel
  7. Trip Dogs
  8. Main Motor
  9. Spindle
  10. Chuck
  11. Turret
  12. Cross Slides
  13. Tool Heads
  14. Cutter Blocks

Lesson 2: Basic Machine Controls [ Top ]

After completing this lesson the operator will be able to identify, locate, and explain:

  1. Main Power Switch
  2. Main Control Switch
  3. Spindle Control Switch
  4. Hand Feed Control Switch
  5. Air Chuck Control Switch
  6. Hand Feed Selector Switch
  7. Coolant Control Switch
  8. Turret Rapid Traverse Reverse
  9. Turret Rapid Traverse Forward
  10. Hand Spindle Speed Selector Switch
  11. Index Switch
  12. Spindle Jog
  13. Cycle Start
  14. Main Motor Stop
  15. Main Motor Start
  16. Air Pressure Gauge
  17. Single Face Switch
  18. Oil Pressure Gauge

Lesson 3: Identifying and Adjusting Basic Tools [ Top ]

After completing this lesson, the operator will be able to identify, locate, and explain:

  1. Multiple Turning Head
  2. Indexable Carbide Insert
  3. Tapered Length Fast Spiral
  4. Tapered Shank Drill
  5. Standard Twist Drill
  6. Carbide Cutter
  7. Adjustable Turning & Boring Heads
  8. Spot Drill
  9. Cutter Blocks
  10. Chip Breaker Drill
  11. Turret Slide Head
  12. Spade Drill
  13. Core Drill

Lesson 4: Controlling the Quality of Parts [ Top ]

After completing this lesson the operator will be able to:

  1. Recognize variations in part dimensions.
  2. Correct problems in part dimensions.
  3. Recognize problems in surface finish.
  4. Correct problems in surface finish including identifying and correcting the most common causes of chatter.

Lesson 5: Chucks and Collets [ Top ]

After completing this lesson the operator will be able to:

  1. Read and identify when a two or three jaw chuck is required from the setup documents.
  2. Mount and adjust Warner & Swasey two jaw chuck.
  3. Mount and adjust a three jaw chuck.
  4. Mount and adjust a collet unit in the machine.

Lesson 6: Machining Chuck Jaws [ Top ]

After completing this lesson the operator will be able to:

  1. Determine the size of the jaw needed for the workpiece holding area.
  2. Machine soft jaws to the correct size and finish.
  3. Check jaws for runout.

Lesson 7: Expandable Arbor [ Top ]

After completing this lesson the operator will be able to:

  1. Determine when an Arbor is needed for a workpiece.
  2. Clean and mount the Arbor to the machine.
  3. Check Arbor operation.
  4. Adjust the Arbor to hold the workpiece.

Lesson 8: Speeds and Feeds [ Top ]

After completing this lesson the operator will be able to:

  1. Read the correct Speed and Feed indicated on the setup documentation.
  2. Locate the Speed and Feed gears and dogs.
  3. Explain the operation of the Speed and Feed Dogs.
  4. Install the proper speed and feed dogs on the main control drum as called for on the layout sheet.

Lesson 9: Basic Machine Setup [ Top ]

After completing this lesson the operator will be able to:

  1. Read the setup document for the W&S Chucker.
  2. Explain the setup requirements.
  3. Read the Setup Kit sheet.
  4. Explain the Setup Kit sheet.
  5. Use a Sample part to setup the chucker.
  6. Complete the setup.

Lesson 10: Late Cross Slide Operations [ Top ]

After completing this lesson the operator will be able to:

  1. Identify when a late cross slide operation may be needed.
  2. Explain a late cross slide cycle of operation.
  3. Locate and explain the dogs which control late cross slide.
  4. Adjust the dogs for late cross slide.
  5. Set up a late cross slide for any face of the turret.

Lesson 11: Die Head Threading [ Top ]

After completing this lesson the operator will be able to:

  1. Locate and identify a self-opening die head and its components.
  2. Locate a die head threading operation on a layout sheet.
  3. Clean and mount the correct chasers.
  4. Clean and mount the die head.
  5. Adjust for proper die head opening and closing.
  6. Check threads with the correct gage.

Lesson 12: The Taper Attachment [ Top ]

After completing this lesson the operator will be able to:

  1. Locate and identify a taper attachment.
  2. Explain the operation of a taper attachment.
  3. Clean and mount the cutting tool.
  4. Clean and mount the attachment to the machine.
  5. Adjust the attachment and timing for the proper taper.

Lesson 13: Adjustable Angle Slide Head [ Top ]

After completing this lesson the operator will be able to:

  1. Identify an Adjustable Angle Slide Head.
  2. Explain the operation of the slide head.
  3. Clean and mount the cutting tool.
  4. Clean and mount the slide head.
  5. Adjust the head for proper operation.

Lesson 14: Setting Up for Tapping [ Top ]

After completing this lesson the operator will be able to:

  1. Identify a tap and tap holder.
  2. Explain the tapping cycle.
  3. Read and explain the tapping requirements from a setup sheet.
  4. Select and mount the correct tap.
  5. Adjust the timing to create an undersize tapped hole.
  6. Measure tap depth and determine adjustment amount.
  7. Adjust for the proper length of thread.
  8. Check thread quality with a go no-go gage.