Greenlee Automatic Bar Machine

 

The following MasterTask lesson outline indicates the tasks needed to act as a machinist on Greenlee automatic bar machines. Because of the performance-based approach to training utilized within MasterTask systems, the outline below indicates what a trainee will be able to DO after completing each part of a lesson. 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, review The MasterTask Concept and Course Materials.

LESSON #1: BASIC MACHINE COMPONENTS AND CONTROLS

After completing this lesson, the Operator will be able to identify by name, locate, and explain the purpose for the following components:

Spindles

Spindle Carrier

Indexing

Spindle Locations

Cross Slide

Turret Tool Slide

Chip Conveyor

Control Stations

Main Motor Switch

Jog

Run

Feed Control Lever

Hand Crank

Cams:

Approach

Low Point

Feed Portion

High Point

Cam Rise

LESSON #2: STOCK FEED COMPONENTS

After completing this lesson the Operator will be able to:

1. Identify by name, locate, and explain the purpose for each of the following components in the Stock Feed System:

Stock Reel

Stock Feed Shoe

Stock Feed Cam Drum

Stock Stop

Pusher

Feed Tube

Feed Finger

Stock Guide Bushing

2. Explain the function of the Stock Feed System and how the system works.

LESSON #3: CLEANING AND RESTOCKING THE STOCK FEED SYSTEM

After completing this lesson the Operator will be able to:

1. Remove the pushers from the Stock Feed System.

2. Clean the pusher assembly.

3. Remove the feed fingers.

4. Inspect and identify problems with feed fingers.

5. Replace the feed fingers as required by the setup.

6. Replace the pusher assemblies in the machine.

7. Restock the pusher.

8. Adjust the stock stop.

LESSON #4: COLLET LOCKING SYSTEM

After completing this lesson, the operator will be able to:

Identify by name, locate, and explain the purpose for the major components in the Collet Locking System.

Collet.

Collet Sleeve.

Collet tube.

Collet Lever Body.

Spindle Nut.

Locking Plunger.

Collet adjusting nut.

Collet hand operating lever.

LESSON #5: GEAR AND CAM REPLACEMENT

After completing this lesson, the operator will be able to:

1. Identify, locate, and explain the purpose of the speed and feed gears.

2. Remove the speed and feed gears which must be changed for a new setup.

3. Replace the correct speed and feed gears called for by the setup.

4. Remove and replace the Turret Slide gears.

5. Locate and identify the cross slide cams.

6. Remove the cross slide cams called for by the setup.

7. Replace the cross slide cams called for by the setup.

8. Remove and replace the Turret Slide cam called for by the setup.

9. Remove and replace the Auxiliary slide cams as called for by the setup.

10. Correctly adjust the slide stop tension on cross slides and the Turret Slide.

LESSON #6: IDENTIFICATION AND SETTING OF BASIC TOOLING

After completing this lesson, the operator will be able to:

1. Identify the basic tools used in the machine including:

chip breaker drills.

fast spiral drills.

tapered shank drills.

screw machine drills.

spot drills.

cutoff blades.

form tools.

2. Mount the tools in their correct holders.

3. Set the position of the in the holder for adequate tool support.

4. Set the form tools on center.

LESSON #7: CONTROLLING THE QUALITY OF PARTS

After completing this lesson, the operator will be able to:

1. Recognize common problems that cause variations in part dimensions.

2. Recognize problems that cause variations in surface finish.

3. Identify the sound of chatter and chatter marks.

4. Explain the most common causes of chatter and how to correct them.

5. Inspect and identify dull drills, cutoff blades, and form tools.

6. Correctly sharpen drills, cutoff blades, and form tools.

LESSON #8: RECESSING ATTACHMENT

After completing this lesson, the operator will be able to:

1. Explain the operation of the Recessing attachment and the machining cycle.

2. Remove the Recessing Attachment.

3. Clean and mount a Recessing Attachment.

4. Mount a recessing tool and set on center.

5. Mount the pull rod.

6. Set the depth of cut.

7. Set the location of cut.

LESSON #9: ACCELERATED REAMING

After completing this lesson, the operator will be able to:

1. Explain the function and purpose of the components of the accelerated reaming attachment.

2. Mount the reamer, and set reamer position at low point.

3. Jog through a reaming cycle, and set the depth of ream, and check pullback timing.

4. Set positive stop tension.

LESSON #10: SHAVING ATTACHMENT

After completing this lesson, the operator will be able to:

1. Explain the function and purpose of the components of the shaving attachment.

2. Position the shave tool and roller based on part design.

3. Setup shave tool dimensions on the bench.

4. Mount on cross slide, and align shave tool to part both longitudinally and vertically.

5. Adjust cross slide depth of feed.

LESSON #11: DIE HEAD THREADING

After completing this lesson, the operator will be able to:

1. Explain the purpose and function of the components of the combination threading and tapping attachment when used for threading.

2. Mount cam and attachment.

3. Set preliminary thread depth undersize to insure die heads open, and set closing on return stroke.

4. Set return spring pressure.

5. Make final adjustment.

LESSON #12: TAPPING

After completing this lesson, the operator will be able to:

1. Explain the purpose and function of the components of the combination threading and tapping attachment when used for tapping.

2. Mount the attachment and floating tap holder.

3. Set the tap position at high point of the kicker cam to start tap.

4. Set preliminary tap depth and produce first part.

5. Measure tap depth and adjust.

6. Set return spring tension to clear at index without damaging threads.

LESSON 13: THE BOX TOOL.

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. Mount cutting tool and center.

3. Set depth of cut for tool holder under the dimension found on setup documentation.

4. Mount the Box Tool in the correct turret position.

5. Check for indexing clearance.

6. Back off rollers.

7. Disable bar feed, index box tool into cutting position.

8. Jog to highpoint and set length of cut using Cutoff Blade as reference.

9. Feed a short length of bar and manually advance the turret for a trial cut.

10. Check size and adjust until cut is slightly undersize.

11. Adjust rollers to contact cut surface.

12. Back off depth of cut to bring to size.

13. Machine workpiece and make final adjustments.

LESSON #14: THREAD ROLLING

After completing this lesson, the operator will be able to:

1. Mount and setup a Reed type thread roll attachment on the bench for the part required.

2. Mount thread roll cam.

3. Mount thread roll adaptor to cross slide.

4. Set cross slide stroke with setup gauge.

5. Mount head to adaptor.

6. Check blank diameter, and roll first part.

7. Make final adjustments to size.