Waterbury Hi-Pro Cold Header Setup Operator Training System

The following MasterTask lesson outline indicates the tasks needed to act as a machinist on Waterbury Hi-Pro headers. 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 OPERATION AND BLANK TERMINOLOGY

After completion of this lesson, the Operator will be able to explain the basic operation of the Waterbury Farrel cold header. He will also become familiar with the process of cold heading. In addition, he will become familiar with the various segments of the cold headed blank including the following:

Head

Radius

Body

Die Point

Shoulder

The Operator will also become familiar with the basic head styles and cross recesses formed by the cold header including the following:

Indented Hex Washer Head

Standard Fillister Head

Indented Hex Head

Phillips Cross Recess

Frearson Cross Recess

Pozi-Drive Cross Recess

Pan Head

Truss Head

Binder Head

Round Head

Oval Head

Flat Head

In addition, the Operator will be shown the correct procedure for checking the dimensional accuracy of the cold headed blank for the following dimensions and angles:

Overall Part Length

Blank Length

Head Height

Head Diameter

Concentricity

Body Diameter

Die Point Diameter

Die Point Angle

Radius

LESSON #2: BASIC HEADER CONTROLS AND FUNCTIONS

This lesson is designed to teach the Operator the location and purpose of the key components and controls on the cold header. After completion of this lesson, he will be able to identify by name, locate, and explain the function for the following components:

Feed Adjusting Handle

Operator's Control Panel

Run-Jog Selector & Button

Disconnect Switch

Wire Feed Knob

Wire Feed Lever

Stop Button

Main Motor

Flywheel

Brake

Brake Pedal

Discharge Chute

Feed Rolls

Oil Sight Gauge

Oil Filter

In addition, the Operator will be able to correctly start and stop the cold header, correctly check the oil level, and clean or replace the filter. He will also be shown some very important safety precautions to be followed when operating and adjusting the header.

LESSON #3: WIRE DRAWER

The Operator will be shown the key components of the wire drawer and the function of each. In addition, he will be shown the components necessary to provide wire to the drawer and their functions. The following components are covered:

Wire Drawer Control Panel

Forward-Off-Reverse Selector

Wire Drawer Capstan

Feed Control Light

Gripper Head & Chain

Compensator Wheel

Wire Drawer Drum

Drawing Compound

Combination Run-Jog Selector

& Push Button

Wire Reel

Wire Carrier

Wire Mill Tag

Draw Box

Vari-Drive

Carbide Draw Die

Compensator Arm

Draw Box Bushings

After completion of this lesson, the Operator will be able to perform the following tasks:

1. Correctly load wire on the wire reel.

2. Correctly grind the wire to be started in the draw die.

3. Correctly remove and replace the carbide draw die.

4. Correctly place the ground end of the wire through the draw die, and connect it to the gripper head.

5. Correctly test the first two feet of drawn wire for dimensional accuracy and score marks.

6. Correctly position the first wrap of wire on the drum.

7. Place the correct number of wire wraps on the drum.

LESSON #4: RESTOCKING THE HEADER

After completion of this lesson, the Operator will be able to correctly perform the following tasks:

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

After completion of this lesson, the Operator will be able to correctly perform the following tasks:

1. Remove and clean the die block and wedge.

2. Correctly identify a header die and its components listed below:

Die Casing

Die Notch

Carbide Insert

Die Packing

Die or Knockout Pin

Pin Guide

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.

When adjusting the knockout mechanism, the Operator will become familiar with the following components of the knockout mechanism:

Backing Screw

Knockout Lever

Knockout Follow Cam

Knockout Roll Arm

Knockout Slide Adjusting Screw

Knockout Cam

Connecting Rod

Knockout Pin

Knockout Slide

LESSON #6: CUTOFF AND TRANSFER

This lesson is designed to teach the Operator the necessary skills needed to assemble, adjust, and mount the cutoff knife and transfer finger. In addition, he will be shown the correct procedure used to align the knife and finger with the header die. Upon completion of this lesson, the Operator will be able to perform the following tasks:

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

After completion of this lesson, the Operator will be able to identify various types of punches and their components. This will include the following types of punches and their components:

First Blow Punch

Finish Punch

Standard First Blow Punch

Sliding First Blow Punch

Forming Cavity

First Blow Pin

First Blow Spring

Packing & Shims

Outer Sleeve

Retaining Pin

Travel Notch

Solid Tee Plug

In addition, the Operator will be able to perform the following tasks on the cold header upon completion of this lesson:

1. Correctly remove and replace the punch holder.

2. Correctly mount the first blow punch.

3. Correctly adjust the transfer finger and knife with the first blow punch.

4. Correctly form the first blow on the sheared wire.

5. Correctly adjust the first blow punch vertically and horizontally.

6. Correctly mount the finish punch.

7. Correctly adjust the finish punch vertically and horizontally.

8. Correctly position the punches closer or further away from the die to produce an acceptable part.

LESSON #8: OPERATION AND PART TROUBLE SHOOTING

This lesson is divided into several parts designed to teach the Operator corrective actions required to correct the most common problems that can occur in the machine operation. The Operator will be able to solve the following common problems:

Short feed.

Dropping of the sheared blank.

Poor quality cutoff.

Breaking the transfer finger and knife.

Broken punches and punch holders.

Bent or damaged finished parts.

Broken knockout pins.

Header becoming frozen.

Broken cutoff breaker plate.