Wickman / Warner & Swasey

Wickman Image The following lesson outline details the tasks needed to be a machinist on a Wickman 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 training system was specifically designed to accommodate both the Wickman or Warner Swasey 6 spindle automatic screw machines commonly found in use today. The instructional technique employed will enable individuals to learn to setup and operate the machines with little difficulty. The first 8 lessons cover the basic setup and operating tasks. The final 6 lessons cover installation and setup of specific attachments. Both existing personnel and new trainees can utilize these training materials to develop or improve their performance.

Lesson 1: Basic Machine Components [ 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. Stock Tubes
    4. Spindles
    5. Collets
    6. Out-of-Stock Mechanism
    7. Indexing
    8. Position Indicator
    9. Cross Slides
    10. Center Tool Slide
    11. Longitudinal Slide
    12. Chip Conveyor
    13. Spindle Drum
    14. Out-of-Stock Light
  2. Identify and explain the following portions of the machining cycle:
    1. Low Point
    2. Feed Portion
    3. High Point
    4. Dwell
    5. Index
    6. Approach Portion
  3. Locate and identify each of the 6 machining positions.

Lesson 2: Basic Machine Controls [ Top ]

After completing this lesson the operator will be able to:

  1. Locate, identify and explain the purpose of the following components:
    1. Front/rear Selector
    2. Main Motor Start Control
    3. Feed Start Control
    4. Main Motor Stop Control
    5. Feed Stop Control
    6. Chip Conveyor Control
    7. Cycle Off Switch
    8. Index Clutch Lever
    9. Hand Crank
    10. Feed Lever
    11. Oil Feed Gauges
    12. Lubricating Oil Dip Stick.Oil Pressure Gauge
  2. Start and stop the Main Motor.
  3. Start and stop machining action.
  4. Jog the Main Motor and Feed.
  5. Hand Crank the machine both forward and reverse.
  6. Use the Cycle Stop switch to stop operations.
  7. Start and stop the chip conveyor.

Lesson 3: The Stock Feed System [ Top ]

After completing this lesson the operator will be able to:

  1. Locate, identify and explain the purpose for the following:
    1. Collet
    2. Collet Tube
    3. Pusher Assembly
    4. Feed Fingers
    5. Stock Feed Slide
    6. Bar Feed Lever
    7. Stock Stop
    8. Collet Slide
    9. Collet Tension Adjusting Nut
    10. Collet Hand Operating Lever
  2. Select and measure bar stock based on setup documentation.
  3. Remove burrs from bar ends and clean bars.
  4. Slide back Stock Reel Tube.
  5. Align and drive bar through Feed Fingers.
  6. Remove bar end from collet.
  7. Advance bar to Stock Stop.
  8. Engage Bar Feed Lever and replace Stock Reel Tube.

Lesson 4: Removal and Replacement of Pushers and Collets [ Top ]

After completing this lesson the operator will be able to:

  1. Disengage and slide back the Stock Reel Tube.
  2. Disengage the Feed Pawl Lever.
  3. Remove a Pusher Assembly.
  4. Clean the Pusher Assembly and Spindle.
  5. Secure the Pusher Assembly and remove the Feed Fingers.
  6. Remove the Stock Guide Bushing.
  7. Select the correct size Feed Fingers and Stock Guide Bushing based on setup documentation.
  8. Replace Feed Fingers.
  9. Replace the Stock Guide Bushing.
  10. Open the Collet and remove the Collet Tension Adjusting Nut.
  11. Remove the Collet Tube from the Spindle and clean both Collet Tube and Spindle.
  12. Secure the Collet Tube and remove the Collet.
  13. Select the correct size Collet and secure to the Collet Tube.
  14. Install the Collet Tube in the Spindle, and replace the Collet Tension Adjusting Nut.
  15. Place the correct size stock in the Collet.
  16. Using the Collet Hand Operating Lever, set Collet tension correctly.
  17. Lock Collet Tension Nut and engage Feed Pawl.

Lesson 5: Setting Feed, Speed, and Stroke [ Top ]

After completing this lesson the operator will be able to:

  1. Read and understand the Gear Chart on the machine.
  2. Identify the Feed and Speed gears required from the setup documentation.
  3. Turn off power and remove the Gear Cover and remove the gears using the pulling collar.
  4. Select the correct gears and mount them in the correct locations.
  5. Locate, identify and explain the position of the Range Gears for various cycle times.
  6. Locate the Positive Stop Screw and Compensating Screw for various slides.
  7. Identify the cross slide, center tool slide, and longitudinal slide stroke for each position from the setup documentation.
  8. Locate and explain the stroke adjustment mechanism for each slide.
  9. Back off Positive Stop screws and jog the machine to high point.
  10. Set the correct stroke for each slide based on setup documentation.

Lesson 6: Setting Stock Feed and Cutoff [ Top ]

After completing this lesson the operator will be able to:

  1. Locate, identify, and explain the purpose for the following:
    1. Circular Cutoff Tool
    2. Blade Cutoff Tool
    3. Cutoff Tool Holders
  2. Identify the positions for each tool from setup documentation.
  3. Clean tool holder and cross slide surfaces.
  4. Align and mount the cross slide tool holder to the cross slide.
  5. Align cutoff tool holder longitudinally to accommodate other tooling positions in setup.
  6. Center the Cutoff Tool to the Spindle centerline.
  7. Calculate the distance from cutoff tool to Stock Stop.
  8. Position the Stock Stop to produce the correct part length.
  9. Measure and calculate stock feed requirement.
  10. Move Guide Ring and Out-of-Stock mechanism back.
  11. Jog machine to move Stock Feed Slide back.
  12. Adjust Bar Feed Lever to dimension calculated.
  13. Load Pushers and Bar stock into spindles.
  14. Position Guide Ring in reference to Pusher Bearings.
  15. Position Out-of-Stock mechanism in reference to Thrust Ring.
  16. Secure clamp bolts for Guide Ring and Out-of-Stock mechanism.

Lesson 7: Identification and Setting of Basic Tooling [ Top ]

After completing this lesson the operator will be able to:

  1. Locate, identify, and explain the purpose of the following:
    1. Screw Machine Drill
    2. Chip-breaker Drill
    3. Tapered Length Fast Spiral Drill
    4. Spot Drill
    5. Center Tool Mounting Bracket
    6. Drill Holder
    7. Drill Holder Coolant Connector
    8. Coolant Holes in Drills
    9. Floating Holder
    10. Circular Form Tool
    11. Locating Pin
    12. Centering Plate
    13. Tool Clamp Bolt
    14. Centering Screw
    15. 1st and 4th position Tool Holders
    16. 2nd, 3rd & 5th Position Tool Holders
  2. Clean and mount a circular form tool to a tool holder.
  3. Clean Cross Slide and mount tool holder to first position cross slide.
  4. Load stock into machine.
  5. Jog machine through index.
  6. Align tool holder in reference to cutoff tool.
  7. Secure tool holder to slide and set form tool on center.
  8. Jog machine to High Point.
  9. Manually advance cross slide to move tool into bar to cut undersize dimension.
  10. Secure Positive Stop screw.
  11. Increase Positive Stop pressure until dimension is to size.
  12. Clean and mount a Center Tool Slide bracket.
  13. Clean and mount a drill holder.
  14. Position drill to produce the correct depth of hole.
  15. Correctly adjust Positive Stop pressure for the Center Tool Slide.

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 10 most common causes of chatter and state their corrective action.
  3. Identify the 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 drill and drill collet and clean.
  6. Correctly sharpen a drill by hand or with a drill grinder.
  7. Identify and replace a correctly sharpened drill.
  8. Measure a cutoff tool position, remove, and correctly sharpen.
  9. Identify and replace a correctly sharpened cutoff tool.
  10. Identify and remove a circular form or cutoff tool.
  11. Mount a form tool for sharpening.
  12. 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 and components.
  2. Explain the use of the eccentric bushing and tool adjustment controls of the attachment.
  3. Stop the machine at the correct point in the machine cycle.
  4. Clean the attachment and center tool slide.
  5. Mount the attachment base to the center tool slide.
  6. Mount the recessing tool slide to the attachment.
  7. Insert pull rod into machine housing and thread into the attachment.
  8. Hand crank to high point and adjust tool height to enter workpiece.
  9. Set location of cut with pull rod locating nuts.
  10. Measure and set depth of cut as referenced to attachment base.
  11. Run workpiece, measure and make final adjustments.

Lesson 10: The Pick-Off Attachment [ Top ]

After completing this lesson the operator will be able to:

  1. Identify and explain the purpose of pick-off attachment operations and components.
  2. Identify a pick-off stock stop and back-machining arm.
  3. Locate and explain the operation of the Pick-off Collet Cam Drum.
  4. Locate and explain the purpose of the Stop Rod and Location Clamp.
  5. Locate and explain the purpose of the back-machining positive stop.
  6. Locate and explain the purpose of the Auxiliary Lever and Auxiliary Lever Cam Drum.
  7. Set the stroke of the Auxiliary Lever.
  8. Install the Pick-off Collet Ejector Rod.
  9. Mount and align the Pick-off Collet and Spindle Nose Nut.
  10. Set Pick-off collet gripping pressure.
  11. With bar in position, hand crank to first rise of Auxiliary Cam.
  12. Set collet position to grip workpiece.
  13. Set the Pick-off Collet closing mechanism.
  14. Start spindles and manually cutoff workpiece by advancing cross slide.
  15. Install the back-machining tool and set depth of cut.
  16. Hand crank to retracted position and set collet opening mechanism.
  17. Position Ejector Rod to eject workpiece.
  18. Center back-machining tool to workpiece.
  19. Set positive stop tension on pick-off mechanism.

Lesson 11: The Tapping Attachment [ Top ]

After completing this lesson the operator will be able to:

  1. Locate, identify, and explain the components and operations of a tapping cycle.
  2. Explain the speed changes required for right and left hand threads.
  3. Check the setup documentation to determine the position to be used for tapping.
  4. Check the clutch operation for setup for tapping.
  5. Check the Longitudinal Slide for installation of the threading cam.
  6. Set the stroke of the threading attachment.
  7. Clean and mount the Attachment Slide to the Longitudinal Slide.
  8. Connect the attachment to the threading drive shaft and adjust the Attachment Base.
  9. Mount the operating rods and trip rods, and connect to Lever Mechanism.
  10. Install clutch rod tension spring.
  11. Install Tap and Tap Holder.
  12. Hand crank to set tap to start into workpiece at high point of thread cam.
  13. Set the tap return spring tension.
  14. Set undersize tapping depth initially.
  15. Set the Thread Clutch Reset Clamp.
  16. Run a workpiece, measure, and adjust.

Lesson 12: Die Head Threading [ Top ]

After completing this lesson the operator will be able to:

  1. Locate, identify, and explain Die Head machining operations and components.
  2. Identify the positions in which the threading attachment may be mounted.
  3. Identify and explain the operation of the Starting Spring and Return Spring.
  4. From the setup documentation, determine the position for threading and confirm the thread drive is available.
  5. Lock the threading clutch in low speed.
  6. Check for installation of the proper threading cam.
  7. Set the stroke of the slide.
  8. Mount the chasers and set rough thread depth.
  9. Check threading spindle operation, clean and mount to slide.
  10. Connect drive shaft to threading spindle.
  11. Mount the die head and secure to the threading spindle.
  12. Clean and mount the operating mechanism to the attachment.
  13. Jog to low point and place attachment to contact workpiece.
  14. Set starting spring and return spring pressure.
  15. With die head open, set yoke opening clamp to open head early.
  16. In retracted position, set closing clamp and clutch shift rod.
  17. With die head open, start spindles and hand crank through cycle to check operation.
  18. Run a workpiece and adjust thread depth and attachment timing as required.

Lesson 13: 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. Stop the machine at high point, clean the attachment and slide.
  3. Mount the attachment to the slide.
  4. Mount the cutting tool in the attachment.
  5. Center the cutting tool.
  6. Back tool and rollers away.
  7. Position box tool near bar end and position tool to cut slightly.
  8. Hand crank back and set box tool forward.
  9. Complete trial cut, adjust depth until cut is slightly undersize.
  10. Adjust rollers down to contact bar with equal pressure.
  11. Adjust tool out to bring part to size.
  12. Machine a workpiece and complete final depth and length adjustments.

Lesson 14: The Thread Chasing Attachment [ Top ]

After completing this lesson the operator will be able to:

  1. Locate, identify, and explain the operations and components of the thread chasing attachment.
  2. Open the chasing attachment cover locate and remove the Lead Cam.
  3. Replace the Lead Cam as required in the setup documentation.
  4. Install the Relief Spring.
  5. Remove and replace the Drive Gears.
  6. Fill the unit gear oiler and set oiling rate.
  7. Clean attachment and slide, mount the attachment and connect to drive shaft.
  8. Level attachment with taper screws.
  9. Back off slide and set the stroke for the chasing operation.
  10. Clean and mount chaser, centering bolt, and centering gear.
  11. Center chaser with centering gauge.
  12. Jog to high point, position chaser for correct thread length.
  13. Start spindles, adjust slide in to cut thread.
  14. Set positive stop and adjust thread to size.