Waterbury Flat-Die

Waterbury Image The following lesson outline details the tasks needed to be a machinist on a Waterbury thread roller. 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 Waterbury Thread Roller with little difficulty. The eight lessons will teach the trainee to perform a complete set up of the machine, given a part print and all necessary tooling. The trainee will also learn the measurement techniques needed by thread roll setup operators. Both existing personnel and new trainees can utilize these training materials to develop or improve their performance.

Lesson 1: Basic Machine Components; Lubrication; Operation [ Top ]

After completing this lesson the operator will be able to:

  1. Locate and state the purpose of basic components; locate all machine controls.
  2. Explain the correct level and flow of lubricating oil; explain the correct level of coolant; locate all of the oil cups and grease fittings on the machine.
  3. Start the machine for normal operation, including lubricating the machine and using the machine controls.
  4. Explain which lubrication tasks must be performed halfway through a work shift; correctly stop the machine.
  5. Jog the machine forward or in reverse to certain points in the machine cycle.

Lesson 2: Blank and Thread Terminology and Measuring Techniques [ Top ]

After completing this lesson the operator will be able to:

  1. Identify parts of a blank; read a dimensional tolerance.
  2. Check blanks for dimensional accuracy.
  3. Identify faulty blanks.
  4. Define basic thread terms.
  5. Identify common thread and point types; identify parts of standard thread notation.
  6. Check threaded blanks for dimensional accuracy.
  7. Measure pitch diameter with a pitch micrometer.
  8. Identify faulty threaded blanks.

Lesson 3: Die Installation [ Top ]

After completing this lesson the operator will be able to:

  1. Identify types of dies, and state the types of screws which are made with those dies.
  2. Check dies and the fluting insert for correctness for a setup; identify die wear and damage.
  3. Remove dies and die packing from the machine.
  4. Select die packing for blanks to be threaded to the head.
  5. Select die packing for blanks with an unthreaded section below the head.
  6. Install dies and die packing.
  7. Check and adjust die height.
  8. Make and install a stationary die bridge.
  9. Install die adaptors.

Lesson 3A: Relieving the Dies [ Top ]

After completing this lesson the operator will be able to:

  1. Describe the type of die relief needed for various blank head styles.
  2. Grind flat head relief.
  3. Grind radius relief.
  4. Grind tapered head relief.
  5. Measure, construct, and relieve steel plates for blanks with contoured heads or shoulders.

Lesson 4: The Blank Feed System [ Top ]

After completing this lesson the operator will be able to:

  1. Locate and state the purpose of components of the blank feed system.
  2. Adjust the feed rails, including the feed rail space and the transfer space.
  3. Adjust the feed rail cover.
  4. Adjust the feed bowl rails and feed control lines on a vibrating bowl feed.
  5. Adjust the clearing wheel on a rotor vane feed.

Lesson 5: Starter Finger and Transfer Assembly [ Top ]

After completing this lesson the operator will be able to:

  1. Locate and explain the purpose of starter finger and transfer assembly components.
  2. Select a starter finger and transfer finger.
  3. Determine whether contours, a work stop, and a recess are needed for a particular blank; grind the required contours, work stop, and recess.
  4. Install and position the starter finger.
  5. Install and position the transfer finger.
  6. Install and position the registration finger.
  7. Adjust the registration finger.
  8. Adjust the travel of the starter finger and transfer finger.

Lesson 6: Die Adjustment [ Top ]

After completing this lesson the operator will be able to:

  1. Describe the adjustment terms; locate and describe the purpose of die adjustment machine components.
  2. Initially set die squeeze.
  3. Adjust die squeeze.
  4. Explain the adjustment procedures for incorrect die squeeze conditions.
  5. Set and adjust die squeeze with gimlet point dies.
  6. Check and adjust die match.
  7. Adjust die height after the dies are matched.
  8. Install and adjust a fluting insert.
  9. Adjust knurling dies.

Lesson 7: Controlling the Part Quality and Trouble Shooting [ Top ]

After completing this lesson the operator will be able to:

  1. Describe the correct procedure to efficiently trouble shoot a part problem.
  2. Identify and state the most probable causes of die problem indicators.
  3. Identify and state the most probable causes of part problem indicators.
  4. Adjust a set of dies to roll full threads on tapered blanks.
  5. Determine where additional die relief is needed.
  6. Construct and install a transfer bridge.
  7. Adjust a set of dies to correct an incorrect die helix angle.
  8. Remove a jammed blank from the dies.