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MetalLab 101


**All participants must sign waiver/policy at front desk before starting class!

Introduction:
  • Names, projects

Basic safety:
  • Fire extinguishers
  • Fire exits
  • First aid kit located at front desk
  • Metal shop appropriate clothing:
    • safety gear required (safety glasses, hearing protection, masks, respirators when needed (dust and fumes))
    • Long sleeved shirt
    • Full length pants which fit over your boots – to stop hot metal/sparks from getting into your footwear 
    • Natural fibers – Do not wear synthetics, they melt into the skin –
    • Closed toed shoes – Preferably leather
    • Long hair, drawstrings and shirt tails/sleeves tucked in/ tied back, safety glasses at all times in shop, hearing protection recommended
    • minors (17 and under) must be accompanied by an adult who’s also taken the class
  • Main causes of injury are: 
    • Sharp metal edges
    • Sparks
    • Heat and flame
    • Arc Flash
    • Electric Shock
    • Welding Gases
    • Fumes

Basic layout of shop:
  • Welding booth
  • Grinding area
  • Communal tables
  • Communal hand tools
  • Communal power tools
  • Metal rack (organized by shape)
Waste streams: 
  • garbage vs. steel/aluminum/other metals all separate 

Tools:

General safety guidelines:
  • safety gear required (safety glasses, closed toed shoes, hearing protection, long pants)
  • hands never close to cutting/drilling/turning mechanisms
  • ALWAYS lockout (unplug and de-energise) a tool before servicing it or changing bits/blades
  • in most cases, blade/bit should reach full speed before touching material

For each tool, explain:
  • Name
  • What it’s used for 
  • Parts: on/off switch, etc
  • Important safety guidelines/WAYS IT CAN HURT YOU
  • Dry demo - show mechanism with tool off
  • True demo on a test piece
  • Everyone in class gives a test run (optional for experienced class members)
  • ---Explain Lockout Procedure---

Manual/mechanical tools:

1. Name: Break (main one)
  • What it’s used for: 
    • forming sheet metal into predetermined angles/profiles
    • 14 gauge max (gauge tool attached to roller)
  • Parts: 
    • Locking castors
    • Blue arms - control clamp
    • die (can be removed for bending boxes, etc), 
    • control arm
    • IMPORTANT: nut to lock heavy yellow counter weights from falling
    • blue know at back to adjust where corner/edge of break sits; distance from the line should reflect thickness of material
  • Important safety guidelines :
    • watch your feet when moving!
    • lock wheels when using
    • Keep fingers clear of ram
    • never let yellow counter weights free-fall!
  • Dry demo - show mechanism with tool off
    • clamp piece
    • loosen counter weight nut and move
    • slowly lower yellow counter weights down
      • always keep a hand on yellow counter weights if nut is loosened
    • bend past angle you want, because metal will spring back a bit
      • can test on scrap piece, measure with protractor, and then set counter weight nut as a stop
    • put counter weight nut back up as high as it will go when not in use
  • True demo on a test piece
    • Note: use a protractor or machinist square to get desired angle
  • Everyone in class gives a test run (optional for experienced class members)


2a. Name: Shear (plus roller & break)
  • What it’s used for: 
    • cutting thin sheet metal (16g Max)
  • Parts: 
    • blades, guide, control arm
  • Important safety guidelines :
    • keep fingers away from blade
  • Dry demo - show mechanism with tool off
    • show 1" marked lines - good to square piece to
    • clamp longer pieces in so they don't shift when cutting
  • True demo on a test piece
  • Everyone in class gives a test run (optional for experienced class members)


2b. Name: Roller
  • What it’s used for: 
    • Forming sheet metal into radiuses 
    • 16 gauge max
  • Parts: 
    • Rollers, adjustment knobs (top and back), control arm, rod benders (may give tighter radius than the bench-top rod bender)
  • Important safety guidelines :
    • Keep fingers away from roller, shear and break when turning the handle, as all move
    • careful when moving - quite top heavy
    • communicate if 2 people using together
    • don't drop anything if you take a roller out (small parts inside), and use 2 ppl
      • might take roller out of you roll a complete circle/tube, etc
    • black knobs (top) adjust gap between rollers to fit thickness of material - material should be sandwiched snug (tighten knob if it doesn't feed in)
    • black knobs (back) adjust for radius
    • thicker metals may need a few passes, starting with larger radius and tightening with each pass
    • reverse piece and put through to bend any parts that have remained flat (ex/ first part)
  • True demo on a test piece
  • Everyone in class gives a test run (optional for experienced class members)

2c. Name: [Box] break (not as good as other one)
  • What it’s used for: 
    • forming sheet metal into angles/profiles
  • Parts: 
    • Fingers, bed, counter weights, control arm
  • Important safety guidelines :
    • Keep fingers clear of pinch points
  • Dry demo - show mechanism with tool off
  • True demo on a test piece
  • Optional, since they just tried the bigger one: everyone in class gives a test run (optional for experienced class members)
3. Name: Universal bender
  • What it’s used for: 
    • bending tubes and rod
  • Parts: 
    • clamps, handle, indexing pin for angles
  • Important safety guidelines :
    • Keep fingers clear of pinch points
    • clamp to work bench
  • Dry demo - show mechanism with tool off
    • clamp to bench
    • adjust black handle/knob at back for material thickness - thicker material needs more room to bend
    • set angle using indexing pin (if incorrect, use scrap piece and measure with protractor)
    • Don't push too hard - if there's a risk of bending the handle, use a diff tool to bend your material
  • True demo on a test piece
  • Optional, since they just tried the bigger one: everyone in class gives a test run (optional for experienced class members)

Hand tools:

1.  Name: Grinder
  • What it’s used for:
    • Cleaning/finishing/removing material
    • There are different disks/wheels for different purposes and materials 
  • Parts: 
    • Wrench, guard, how to change disks
  • Important safety guidelines :
    • Clamp material to work table
    • Be aware of where the sparks are going
    • Do not remove guard
  • Dry demo - show mechanism with tool off
  • True demo on a test piece
  • Everyone in class gives a test run (optional for experienced class members)

2. Name: Bench Grinders (x2)
  • What it’s used for: 
    • Cleaning/finishing/removing material
    • There are different disks/wheels for different purposes and materials 
  • Parts: 

  • Important safety guidelines:
    • pinch points
    • no aluminum (unless wheel says it can take alum.  Currently neither can)
  • Dry demo - show mechanism with tool off
  • True demo on a test piece
  • Everyone in class gives a test run (optional for experienced class members)
3. Name: Disk/Belt Sander
  • What it’s used for: 
    • smoothing/shaping/finishing
  • Parts: 
    • Disk, Belt
  • Important safety guidelines:
    • dust extraction
    • how to avoid piece flying away
    • Metal will get hot
    • Keep hand clear!
    • Hold small pieces with locking pliers
  • Dry demo - show mechanism with tool off
  • True demo on a test piece
  • Everyone in class gives a test run (optional for experienced class members)

Power Tools:

1. Name: Cold Cut Saw
  • What it’s used for: 
    • cutting stock down to size 
  • Parts: 
    • table, blade, vise, guides, how to move guides
  • Important safety guidelines :
    • start saw in up position
    • never cross hands
    • fingers never within 6” of blade
  • Dry demo - show mechanism with tool off
    • Right blade for the right metal
    • how to cut: rectangle, angle, round, square stock
    • Slow medium pressure, sparks = excessive pressure
    • angle cuts
  • True demo on a test piece
  • Everyone in class gives a test run (optional for experienced class members)

2. Name: Drill press
  • What it’s used for: 
    • drilling in metal
  • Parts: 
    • bits (signed out at front desk), chuck, speed adjust, bed/table (how to raise/lower)
  • Important safety guidelines :
    • secure piece to table with clamps
    • keep hand clear of bit!!
    • never start with bit touching piece
    • "peck" in and out of piece
    • go very slow with metal, to keep heat down
    • don't drill into table!
  • Dry demo - show mechanism with tool off
    • Clamp securely
    • Center punch with screw to align start - bit can wander
    • Grease/coolant -wax tube (better than WD40)
    • Pilot hole – move up in 1/8th inch increments to let chips escape and tool cool down
    • let tool do the work - don't push too hard
  • True demo on a test piece
  • Everyone in class gives a test run (optional for experienced class members)

3. Name: [Horizontal] Bandsaw
  • What it’s used for: 
    • cutting stock down to size
  • Parts: 
    • blade, guides, vise, coolant, hydraulic gauge with dial (adjusts feed rate) and lock-off valve (will hold saw/stop from moving), feed rate (2 is a good feed rate; looks like it's barely moving)
  • Important safety guidelines :
    • keep hands far from blade!
    • let saw stop before grabbing anything too close
    • careful not to let it flip over when saw is in top position
    • pay attention to dial before you flip lock-off valve up (make sure saw won't fall quicly!)
    • make sure piece is supported if large
    • watch for coolant flowing out back - put bin under to catch any drips
    • blade still spins when saw is turned off - let it stop completely before putting hands anywhere near
  • Dry demo - show mechanism with tool off
    • how to raise/lower throat
      • can get in the way of the cut if not adjusted for larger material
    • how to clamp material
      • clamp narrowest side
    • Feed rate adjustment (~2 is good, alum. especially needs slower bc it melts/sticks to blade)
    • Coolant (should be just dripping off blade, not pouring)
      • keep switch on all the time - will automatically start when saw starts
      • look at flow tube for bubbles/foam - add a few L of water if low (staff only))
    • Blade tension - don't change (staff only)
    • Blade speed - don't change (staff only)
  • True demo on a test piece
  • Everyone in class gives a test run (optional for experienced class members)



Notes:
Consumables: We have them (screws, drill bits, etc.) but do not assume they will always be available for use/in good condition, as they are shared by everyone.  We have some nicer bits available for $5 rental fee

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