National Boltmaker or Progressive Header

Boltmaker Image The following lesson outline details the tasks needed to be a machinist on a National Multi-Die cold header. 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.

The instructional technique employed will enable individuals to learn to setup and operate the machines with little difficulty. Both existing personnel and new trainees can utilize these training materials to develop or improve their performance.

Lesson 1: Basic Machine Operation [ Top ]

After completing this lesson the operator will be able to:

  1. Locate and explain the purpose for the major components of the National Boltmaker and Progressive Header.
  2. Explain the following operations:
    1. Drawing
    2. Straightening
    3. Feeding
    4. Cutoff
    5. Kickout
    6. Workpiece Forming
    7. Trimming
    8. Pointing
    9. Transfer
    10. Thread Rolling

Lesson 2: Basic Controls and Operation [ Top ]

After completing this lesson the operator will be able to:

  1. Locate and explain the purpose for all operator controls and lubrication components.
  2. Start a machine which has been correctly setup for a production run after checking all operating systems for the correct pressure and fluids.
  3. Identify the reasons for wire not feeding and for the motor not starting.
  4. Stop a machine which is running at production speed.

Lesson 3: Blank and Thread Terminology and Part Inspection [ Top ]

After completing this lesson the operator will be able to:

  1. Understand upsetting and how heads are formed.
  2. Identify measurable features of a blank.
  3. Read dimensional tolerances from part prints.
  4. Check blanks for dimensional accuracy.
  5. Identify faulty blanks.
  6. Explain basic thread terms.
  7. Properly read and interpret standard thread notation.
  8. Measure threaded blanks.
  9. Identify faulty threaded blanks.
  10. Check threaded blanks using GO/NO-GO gauges.

Lesson 4A: Stock Feed Systems - Wire Drawer - Ajax Hogue [ Top ]

After completing this lesson the operator will be able to:

  1. Locate and explain the purpose of each major component of the Ajax Hogue wire drawer.
  2. Setup the Ajax Hogue wire drawer for the draw diameter required for a new setup.
  3. Weld, start and load a new coil of wire into the drawer.
  4. Jog the machine through the first cutoff, inspect the blank, and adjust wire drawer as required.
  5. Setup an inching grip box and straightener roller slide.
  6. Reload a wire drawer with inching mechanism and power starter attachments. Jog the machine through first cutoff, inspect the blank, and adjust wire drawer as required.
  7. Identify causes of improper feed.

Lesson 4B: Stock Feed Systems - Wire Drawer - Capstan [ Top ]

After completing this lesson the operator will be able to:

  1. Locate and explain the purpose of each major component of the Capstan wire drawer.
  2. Setup the Capstan wire drawer for the draw diameter required for a new setup.
  3. Restock the header from a Capstan drawer wound with the correct wire.
  4. Trial run the first cutoff, inspect the blank, and adjust the wire drawer as required.
  5. Weld the end of the previous coil to the end of a new coil, jog the header through the cycle, and remove the welded cutoff.

Lesson 5: Setup of the Straightener with Power Starter and the Stock Feed
Components
[ Top ]

After completing this lesson the operator will be able to:

  1. Remove and replace straightener rollers, adjust straightener pressure and wire alignment.
  2. Change the feed rolls and wire guides.
  3. Adjust the feed roll pressure on either a spring or air operated model to produce the correct feed roll pressure.
  4. Identify two indicators for incorrect feed roll pressures and the corrective actions.
  5. Identify causes of feed roll slippage and improper feed.

Lesson 6: The Cutter, Quill, Stock Gauge Tip - Operation and Adjustments [ Top ]

After completing this lesson the operator will be able to:

  1. Locate and explain the purpose of the cutter, quill, and stock gauge tip assemblies.
  2. Identify five factors indicating poor cutoff quality and state the appropriate corrective action.
  3. Remove a previous cutter and quill setup.
  4. Install and adjust a new cutter and quill.
  5. Install and adjust the pusher for the correct length of stroke.
  6. Adjust the stock feed length.
  7. Install and adjust the stock gauge tip.
  8. Jog the machine through the cutoff and produce an acceptable cutoff blank.

Lesson 7: Dies and Kickout - Installation and Adjustments [ Top ]

After completing this lesson the operator will be able to:

  1. Locate and explain the purpose for the various components of the dies and the kickout mechanism.
  2. Remove the dies from a previous setup.
  3. Remove the punches from the previous job.
  4. Prepare and install the die stacks and kickout pins for a new setup and adjust kickout.
  5. Remove and replace the kickout rods for long or short parts.
  6. Identify causes and solutions for broken kickout pins and breaker bolts.

Lesson 8: Punches and Knockout in Punches [ Top ]

After completing this lesson the operator will be able to:

  1. Locate and explain the purpose for the various components of the punches.
  2. Correctly identify by name and explain the purpose of the various punches.
  3. Remove a previous setup of punches.
  4. Prepare the punches and punch holders for a new setup.
  5. Install new punches in the punch holders on the heading slide.
  6. Align, center, and adjust the punches using the vertical, horizontal adjustments, and the punch wedge.
  7. Change punch knockout to another station.

Lesson 9: Trim Station - Operation and Adjustments [ Top ]

After completing this lesson the operator will be able to:

  1. Locate and explain the purpose of the trim die, trim punch, and kickout mechanism and their components.
  2. Prepare and install the trim punch in the die block.
  3. Prepare and install the trim die in the heading slide tool holder.
  4. Adjust and align the trim die and the trim punch for proper clearance.
  5. Change the kickout cam inserts for the trim station.
  6. Adjust the trim station kickout.
  7. Identify trimming operation problems and explain causes and solutions.

Lesson 10: Transfer Setup and Adjustment [ Top ]

After completing this lesson the operator will be able to perform the tasks necessary to setup and adjust any of three types of transfer assemblies commonly found on either Boltmakers or Progressive Headers including:

  1. Raise the transfer assembly.
  2. Remove the transfer assembly.
  3. Mount transfer assembly on setup fixture.
  4. Remove and replace finger.
  5. Remove and replace alignment pins.
  6. Adjust keyway arms in the correct sequence on each size machine.
  7. Adjust roller arms.
  8. Adjust arm operating rollers.
  9. Reinstall transfer assembly.
  10. Check and adjust open timing.
  11. Check and adjust close timing.
  12. Explain the common causes for dropped blanks and bent or broken transfer fingers.

Lesson 11: Pointer Operation, Setup, Adjustment and Troubleshooting [ Top ]

After completing this lesson the operator will be able to:

  1. Locate and explain the purpose of the major pointer components and assemblies.
  2. Replace the feed chute tracks, swivel, entrance cam, grip jaws, and cutter plate or insert for the new setup.
  3. Replace the pointer feed tube.
  4. Properly adjust the head grip and shank grip mechanism.
  5. Remove the cutter cover plate.
  6. Replace and rotate the cutter inserts for the new setup.
  7. Align the pointer cutters for the new setup.
  8. Adjust the cutter housing alignment using vertical, front and back, left and right adjustments.
  9. Align the pointer grip jaws with the feed chute and discharge tracks for the new setup.
  10. Adjust the pointer bolt injector for the new setup.
  11. Identify pointing operation problems and explain the possible causes and corrective actions.
  12. Replace discharge chute tracks and adjust bolt stop.

Lesson 12: Roll Thread Operation, Setup and Adjustment [ Top ]

After completing this lesson the operator will be able to:

  1. Locate and explain the purpose of the major components and assemblies of the roll thread.
  2. Remove, setup, install and adjust the feed chute, injector, pusher, and feed tracks.
  3. Remove and replace the dies.
  4. Calculate die shim thickness.
  5. Adjust die squeeze.
  6. Adjust die match.
  7. Eliminate taper.