Waterbury Hi-Pro

Waterbury HiPro Image The following lesson outline details the tasks needed to be a machinist on a Waterbury Hi-Pro 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 Operation and Blank Terminology [ Top ]

After completing this lesson the operator will be able to:

  1. Explain the basic operation of the Waterbury Farrel cold header.
  2. Become familiar with the cold heading process.
  3. Locate, identify, and explain various segments of the cold headed blank including:
    1. Head
    2. Radius
    3. Body
    4. Die Point
    5. Shoulder
  4. Locate, identify, and explain the basic head styles and cross recesses formed by the cold header including:
    1. Indented Hex Washer Head
    2. Standard Fillister Head
    3. Indented Hex Head
    4. Phillips Cross Recess
    5. Frearson Cross Recess
    6. Pozi-Drive Cross Recess
    7. Pan Head
    8. Truss Head
    9. Binder Head
    10. Round Head
    11. Oval Head
    12. Flat Head
  5. Check the dimensional accuracy of the cold headed blank for the following dimensions and angles:
    1. Overall Part Length
    2. Blank Length
    3. Head Height
    4. Head Diameter
    5. Concentricity
    6. Body Diameter
    7. Die Point Diameter
    8. Die Point Angle
    9. Radius

Lesson 2: Basic Header Controls and Functions [ Top ]

After completing this lesson the operator will be able to:

  1. Locate, identify, and explain the function for the following components:
    1. Feed Adjusting Handle
    2. Operator's Control Panel
    3. Run-Jog Selector & Button
    4. Disconnect Switch
    5. Wire Feed Knob
    6. Wire Feed Lever
    7. Stop Button
    8. Main Motor
    9. Flywheel
    10. Brake
    11. Brake Pedal
    12. Discharge Chute
    13. Feed Rolls
    14. Oil Sight Gauge
    15. Oil Filter
  2. Correctly start and stop the cold header.
  3. Correctly check the oil level.
  4. Clean or replace the filter.
  5. Follow very important safety precautions when operating and adjusting the header.

Lesson 3: Wire Drawer [ Top ]

After completing this lesson the operator will be able to:

  1. Locate, identify, and explain key components of the wire drawer including:
    1. Wire Drawer Control Panel
    2. Forward-Off-Reverse Selector
    3. Wire Drawer Capstan
    4. Feed Control Light
    5. Gripper Head & Chain
    6. Compensator Wheel
    7. Wire Drawer Drum
    8. Drawing Compound
    9. Combination Run-Jog Selector
    10. & Push Button
    11. Wire Reel
    12. Wire Carrier
    13. Wire Mill Tag
    14. Draw Box
    15. Vari-Drive
    16. Carbide Draw Die
    17. Compensator Arm
    18. Draw Box Bushings
  2. Correctly load wire on the wire reel.
  3. Correctly grind the wire to be started in the draw die.
  4. Correctly remove and replace the carbide draw die.
  5. Correctly place the ground end of the wire through the draw die, and connect it to the gripper head.
  6. Correctly test the first two feet of drawn wire for dimensional accuracy and score marks.
  7. Correctly position the first wrap of wire on the drum.
  8. Place the correct number of wire wraps on the drum.

Lesson 4: Restocking the Header [ Top ]

After completing this lesson the operator will be able to:

  1. Thread the wire coming from the wire drawer to the header.
  2. Adjust and change the stock feed components for a new job.
  3. Disconnect the gripper chain from the drawn wire.
  4. Thread the wire coming from the wire drawer drum around the compensator wheel.
  5. Run wire through the wire straightener.
  6. Run wire through the wire guide.
  7. Run wire between the feed rolls.
  8. Change the feed rolls as required for a new setup or for wear.
  9. Correctly adjust feed roll pressure for a new job.
  10. Remove and replace the cutoff die.
  11. Identify Cutoff Die wear and rotate the cutoff die if it is worn.
  12. Correctly adjust the wire straightener.

Lesson 5: The Header Die and Knockout [ Top ]

After completing this lesson the operator will be able to:

  1. Remove and clean the die block and wedge.
  2. Correctly identify a header die and its components listed below:
    1. Die Casing
    2. Die Notch
    3. Carbide Insert
    4. Die Packing
    5. Die or Knockout Pin
    6. Pin Guide
    7. Die Wafer
  3. Correctly remove the header die.
  4. Correctly install a new header die assembly.
  5. Correctly adjust the knockout mechanism for the retracted position.
  6. Correctly adjust the knockout mechanism for the kicked position.
  7. Locate and identify the components of teh knockout mechanism including:
    1. Backing Screw
    2. Knockout Lever
    3. Knockout Follow Cam
    4. Knockout Roll Arm
    5. Knockout Slide Adjusting Screw
    6. Knockout Cam
    7. Connecting Rod
    8. Knockout Pin
    9. Knockout Slide

Lesson 6: Cutoff and Transfer [ Top ]

After completing this lesson the operator will be able to:

  1. Correctly assemble a cutoff knife and finger.
  2. Correctly grind the correct angles on the transfer finger.
  3. Correctly mount the cutoff knife and finger in the header.
  4. Adjust the wire stop for the required cutoff length.
  5. Correctly align the cutoff knife and finger with the header die.
  6. Correctly adjust the wire feed stroke.

Lesson 7: Setting Punches and Timing [ Top ]

After completing this lesson the operator will be able to:

  1. Identify various types of punches and their components including:
    1. First Blow Punch
    2. Finish Punch
    3. Standard First Blow Punch
    4. Sliding First Blow Punch
    5. Forming Cavity
    6. First Blow Pin
    7. First Blow Spring
    8. Packing & Shims
    9. Outer Sleeve
    10. Retaining Pin
    11. Travel Notch
    12. Solid Tee Plug
  2. Correctly remove and replace the punch holder.
  3. Correctly mount the first blow punch.
  4. Correctly adjust the transfer finger and knife with the first blow punch.
  5. Correctly form the first blow on the sheared wire.
  6. Correctly adjust the first blow punch vertically and horizontally.
  7. Correctly mount the finish punch.
  8. Correctly adjust the finish punch vertically and horizontally.
  9. Correctly position the punches closer or further away from the die to produce an acceptable part.

Lesson 8: Operation and Part Trouble Shooting [ Top ]

After completing this lesson the operator will be able to:

  1. Correct the most common problems that can occur in the machine operation including:
    1. Short feed
    2. Dropping of the sheared blank
    3. Poor quality cutoff
    4. Breaking the transfer finger and knife
    5. Broken punches and punch holders
    6. Bent or damaged finished parts
    7. Broken knockout pins
    8. Header becoming frozen
    9. Broken cutoff breaker plate