Category:Machine Shop

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Committees are voluntary groups, formed by members in order to achieve certain goals.
To join this committee, contact the committee chairperson. See Rules and Policies#Committees for more information.

Contents

About

The Machine Shop Committee covers the machine shop equipment, such as: 

:/machineshop/training/ClausingColchester/ClausingColchester101 2018 with quiz

Governance and Meetings

The committee is a benevolent dictatorship comprised of teams and Special Interest Groups built around the equipment.

The committee routinely meets on the fourth Saturday of each month, typically at 5:00 pm. Meetings will be posted on the calendar. While no formal agenda needs to be posted, advance notice of large purchases or other actionable items that will require full committee vote to approve should be posted at least 48 hours before the committee meeting.

Purpose

  1. Maintain and provide tooling for the Machine Shop equipment
  2. Train people on the safe operation of this equipment
  3. Oversee the usage of all Machine Shop assets

Cameras

https://dallasmakerspace.org/cam/

Committee Meeting Minutes

Machine Shop Committee meeting minutes are primarily maintained on the Committee drive at \machineshop\Meeting Minutes\

2022

2021

2020

2019

2018

2017

Members

  • Chair Tim Bene
  • Vice-Chair: Charles Proctor, Bob Karnaugh
  • Procurement Officers
    • Art Givens
    • Freddy Calvert

Machine Teams

  • Team Leader Clausing Colchester Lathe: Bob Karnaugh
    • Instructors:
      • Bob Karnaugh
      • David Kessinger
      • Malcolm Galland
      • Tails Hartnett
    • Mentors:
      • Jay Phelps (helped with rebuild)
  • Team Leader Bridgeport: David Kessinger
    • Instructors:
      • David Kessinger
      • Tanner Fontenot
      • Malcolm Galland
    • Mentors: David Kessinger
  • Team Leader Sherline Lathes: Nick Silva
    • Mentors:
      • Chris Marlow
      • Richard Meyer (cnc ready lathe)
  • Team Leader Sherline Mill: David Kessinger
    • Instructors: David Kessinger
    • Mentors:
      • David Kessinger
  • Team Leader HAAS Vertical Mill: Nick Silva
    • Mentors:
      • Walter Anderson - created the Fusion 360 Domino class.

General Members

  • Adam Oas
  • David Kessinger
  • Richard Meyer, PE
  • Freddy Calvert
  • Cairenn Day
  • Chris Wischkowsky
  • Art Givens
  • Paul Hunt
  • Charles Procter
  • Tru Robertson
  • Brent Williams
  • Randy Lisbona
  • Leo T. Stout
  • Sam McFadden
  • Patrick Schaider
  • Matthew Maducia
  • David Busch
  • Bob Karnaugh
  • Chris Marlow
  • Todd Caldwell
  • Mike Glass
  • Malcolm Galland
  • Frank Lima
  • Patrick Mulry
  • Kevin Braby
  • Raymond Jett
  • David Steele
  • Bud Farnham
  • Abitamim Bharmal
  • Wayne Hutchinson
  • Tails Hartnett
  • Kevin Oliver
  • [Honorable Walter Anderson, deceased]
  • [Honorable Robert Johnson III, deceased]

Role of the Chair

This has been added here to give any new or incoming Chair a starting point for the things that being the Chair of the Committee will face.

Duties of the Chairman

-Head Janitor: Someone once told me that Chairman in another language means Janitor. He was right - you always seem to be cleaning up after others.

-Keep the conversation going: Constantly looking for content to post that generates interest or fosters conversation. The internet is your best friend.

-Purchasing: The chairman is constantly keeping track of what is needed and ordering replacement stock/parts/consumables.

-Head Cheerleader: there are people that go the extra mile like cleaning up when they see the need, contribute time and supplies, and unselfishly help others. It is the chairman's job to take notice and publicly thank and praise those individuals.

-Keeping everyone informed: TALK is the main method we use and I post as much as is necessary to get feedback on current issues.

-Keeping everyone safe (despite themselves): we have several UNWAIVERING rules which include the use of safety glasses and proper clothing among other rules. If someone is in violation of that, it is important to remind them and to be hard if needed and ask them to leave if the do not want to comply.

-Keeping the motors running: things break. it is a fact of use. that doesn't mean you have to be the main mechanic for fixing things. But it is the chairs job to find someone to do the fix, and to schedule the work and arrange for the parts to be present and for payment when necesary.

-Making the hard decisions: There is the old addage that 90% of the work is done by 10% of the people. It is simply unreasonable to have to call a meeting of the committee for every decision. except in the case where large amounts of money are at stake, the chair makes on the spot decisions with the understanding they may catch heck for the decision from the small percentage of people who would have been against it no matter what.

-Leadership: Keep members involved, interested and have them be an integral part of the decision making process for what we want Machine Shop to be in terms of: equipment maintenance, purchases, teaching, and rules of Machine Shop.

-I spy with my little eye: The chair generally gains access to the cameras. In cases of damage, theft or malfeasance the chair generally is the one that will search thru the video looking for necessary evidence to specify or recommend a penalty. When posting on TALK and In cooperation with the other committee chairs, it was agreed when necessary to only post a head and face picture of someone that needs a talking to as a first try. We will ask for help in identifying the person. In short, we want to minimize the claim of publicly shaming someone. This is dependent on the severity of the infraction. If necessary, or if no response occurs more data including a picture of a bad act in progress is allowed.

-Cooperate with other committees: The machine shop does not live in a vacuum. It is part of a larger community and as such it is important to get along with other committees and work together to fulfill larger goals. New ideas that work well should be shared with the other committees via the occasional Chair and Vice-Chair roundtable meetings or thru the @Committee_Chairs mailing list on TALK.

-Communicate with the Board of Directors: It is important to keep the BoD up to date on the happenings in the machine shop. This is usually done in person and thru the regular reports for the monthly Regular Membership Meeting.

Role of the Vice-Chair

-The Vice-Chair (VC) is our committee backup for when the Chair is unavailable. He is afforded all of the privileges and trappings afforded to the chair. The VC will also become the acting Chair in the event the current Chair steps down or is removed. The VC will be responsible for calling a special election to select a new Chair.

Training

Minimum Age To Use Tools:

You MUST be a minimum of age of 18 to use any powered tools unsupervised in the Machine Shop.

If between age of 16 and 18 years old and a member (add-on) that has been trained on that machine, they may use it under the close, immediate, and active supervision of the Parent or Guardian that has also received training and qualified to use that machine. "Close, immediate, and active supervision" means the parent/guardian is physically standing next to the minor, observing and supervising so as to be capable of taking immediate action in the event of injury or machine malfunction. Texting, talking on a phone or use of another electronic device while the machine is operating constitutes failure to actively supervise. If you need to use the device, stop the machine and resume when you can resume full attention.

Exception: 16 and 17 year old add-on members. You may take the Bench Top Sherline Mill and Lathe classes concurrently with a parent or guardian or if the parent or guardian has completed the class. This is an exception to the Machine Shop Rule that powered machines may only be used by members 18 or older. 16 or 17 year old that completes these requirements may use the machine unattended by a parent or guardian.

Machine Training and Costs

The HAAS VF-2 requires training, as does the Bridgeport mill, the Colchester lathe, the Shark lathe, the Sherline bench top tools and the Kalamazoo cold cut saw, and EVO aluminum saw. Nothing else in the machine shop requires training, however members should not use any equipment without understanding its operational and safety requirements. Manuals and some video tutorials are available on this page. If you require help with using equipment, send an email to [email protected].

Training for the HAAS VF-2 is is offered to members on a regular basis and requires Bridgeport training as a pre-requisite; see the event calendar for details. Once trained, members will be allowed to use the CNC mill only under supervision, until they have demonstrated their proficiency in its operation.
To contact HAAS supervisors, send an email to [email protected]

All mills and lathes require completion of a basic course in their operation. Classes are offered on a regular basis. These classes are typically broken into two sections, an in-classroom session that covers controls, safety, etc. and a second session with some hands-on demonstration. With the Introduction of Online Training at the Makerspace, Machine Shop will attempt to get as much of the classroom portions onto online. These will be a prerequisite to taking the "at machine portion". The online portion will have a test that must be successfully passed before enrolling in the machine-side portion. This should significantly reduce the amount of time a class takes and allow more frequent offerings. Links/pointers to self-study material are contained in the Resources section for the relevant tools (specifically Clausing-Colchester lathe as of this writing).

  • Additional Info:**
  • Equipment that requires a class prior to use and costs of said classes**
    • Bridgeport Mill - nominal costs for materials ranging from $0 - $10
    • Colchester Lathe - nominal costs for materials ranging from $0 - $10
    • Coldsaw - free. Classes are on demand from a experienced member.
    • Aluminum Cut-off Saw - Classes are on demand from a experienced member.
    • HAAS vertical mill: 2-3 classes for a total of $75
    • Sherline Mill: $5 for materials
    • Sherline Lathe: $5 for materials
    • Tormach CNC Lathe: $40 for class
    • Shapeoko CNC Router Mill: Free class
  • Cost of using equipment**
    • Free
  • Pricing of provided consumables**
    • None. Machine shop will provide basic tools and common sized items such as drill bits and end mills. For specialty sizes - User supplies their own.
  • There is a fee if you break the blade on the Kalamazoo Cold Cut saw. Details are documented in the Cold Cut saw subsection of Resources below.

Other training is in development.

Safety and Machine Shop Rules

Safety

  • Loose clothing, jewelry, long hair should be secured before operating any equipment. No portion of sleeves may be below the elbow (clarified 12/28/2019).
  • Safety glasses must be worn at all times while in the machine shop area. Safety glasses must be Z87 compliant and of the type that wrap around or have side shields. This means regular glasses are NOT defined as being safety glasses.
  • Only closed toe shoes allowed. Safety shoes recommended.
  • Gloves may not be worn *for any reason* during machine set-up, while running, or tear-down; even nitrile or latex. Gloves may be worn during cleaning or maintenance or for material handling only.
  • Lanyards must be safety "breakaway type" and secured inside a pocket or shirt. If not breakaway type they must be removed from around neck.
  • Compressed air guns may not be used for cleaning machines or blowing chips; except the compressed air gun that is inside the HAAS may be used inside the HAAS. Flying chips are an eye hazard. (Enacted by Committee 03/2017)
  • When the machine is operating you may wear (optional) hearing protection. You may not wear headphones or ear buds as you must listen to the machine to ensure it is operating properly. (Enacted by Committee 03/2017)
  • Keep the aisles clean and clear
  • Running machines may NOT be left unattended.
  • No one may operate the machine shop equipment if they have been drinking or in an inebriated condition due to alcohol, prescription medicines, or nonprescription drugs. The standard for determining this will be the same rules/guidelines outlined by the state of Texas for operating an automobile. If a member is suspected of inebriation, they will be asked to cease and LEAVE the machine shop for the day. If the member does not comply, they will be immediately banned from the machine shop and a formal complaint will be filed with the BoD for expulsion for a safety rule violation. Further – Any and All machine shop members are empowered to enforce this rule. If needed, members should find a DMS officer for help or to ask the member to cease. This is a zero tolerance rule.

Usage

  • No machining firearms or firearms parts (per the Machine Shop rule enacted at the committee meeting 11/9/2017 and the larger DMS rules passed by the BoD)
  • Machines marked as needing to have passed training means exactly that. Anyone caught using the machines that shouldn't will be banned for some period of time.
  • Minimum Age To Use Tools: You MUST be a minimum of age of 18 to use any powered tools unsupervised in the Machine Shop. Special conditions for ages 16 - 18 are detailed at the beginning of the Training section.
  • If you aren't 100% sure that you know how to use the equipment safely and correctly, ask for help ([email protected])
  • Comply with all equipment operating instructions and restrictions posted on individual machines
  • If you break a tool, or notice a broken or missing tool, add it to the "Supplies/Replacement Tooling" section of the Machine Shop Tasks page (Machine Shop Tasks). Please create an Issues and Request message on TALK.
  • Common sense should prevail. If something doesn't seem right - STOP. Ask someone to check before proceeding.

When Finished

  • Restore the machine to its standard configuration.
  • Put tools and equipment back where they go when you are done with them.
  • Clean up any chips, shavings, oil, or other mess (on the equipment, floor, or elsewhere) before leaving the Machine Shop area. In short - leave it the way you found it. OR BETTER.

Consequences

Consequences for violations are described in the Discipline section below.

Disciplinary Actions

DMS has a long tradition of trying to keep its members safe. Certain actions of misbehavior can or will result in a loss of machine shop privileges and/or may require you to retake the training class before you can use the equipment again. Such actions include but are not limited to:

  • Defeating safety equipment or interlocks
  • Arguing with a member who <nicely> points out you are being unsafe. It is for your own good.
  • Doing something specifically prohibited and taught during training.
  • Using a machine that requires training for which you have not had the training or have been approved to use.
  • Deliberate abuse or destruction of machine shop equipment. Remember - you're on camera.
  • Failure to follow machine shop rules - including the need for cleanup.

Resources

Mills

Bridgeport Series I

User Manual
DRO User Manual
Motor information


Bridgeport footprint (floor plan)
BridgeportPoster.jpg

Bridgeport Training Material
Part I - Self-Study

Part I training (self-study) for Bridgeport Mill is required prior to mandatory machine-side training. The quiz must be completed, and the correct answer submitted (to MachineshopTeachers at Dallasmakerspacedotorg) before registration for Part II (Machine Side) will be allowed. Study Material (contains quiz) at this link.

Bridgeport101 for historical reference has been supplanted by the above self-study and quiz.

Part II - Machine-Side-Study

We watch the submissions from Part I to help gauge demand for Part II. Once we see sufficient demand, we will post a class to the calendar.

HAAS VF-2

The main HAAS page is here

Programming Manual
Operator Manual
Video Describing HAAS Control Panel

Machinist's Guide to Toolholder Maintenance
Technical / Maintenance information on RFID system

Lathes

CLAUSING-Colchester 13" Lathe

CLAUSING-Colchester 13" Lathe - dedicated page

[Lathe Tool Designations De-mystified]
Carbide Insert Designations

Clausing-Colchester Training Material

Part I training (self-study) for Clausing-Colchester lathe is required prior to mandatory machine-side training.

Clausing Colchester Lathe Training [1]

SHARK 16x 40 Lathe with DRO

(placeholder - not yet operational)

TORMACH 8L 8 x 10 CNC Lathe

Tormach-8L Lathe - dedicated page

Colchester Bantam 2000 Lathe (removed from shop)

The Bantam Lathe has been sold. These pages remain here solely as reference material.

Colchester 101 Class Material

Manual for VFD (HY03D023B, found on committee group)
Bantam 2000 Manual
Colchester thread cutting, feed rates, and worm gear cutting information

Sherline Micro tools

Help sheets and Instructions

Sherline Lathe page

Sherline mill page

Saws

Powermatic Band Saw

Manual for Newer Version - This is the correct manual this has the right part numbers
"Nicer" manual is available on Vintage Machinery's web site.This manual does not have correct numbers possibly

Kalamazoo Cold Saw

For cutting Brass and Mild steel Only

There is a $75 replacement for breaking the blade.

  • The main reason the cold cut blade has broken has been due to poor clamping which makes it a user issue.
  • Cold cut blades run about $165 each. We realize that there is wear and tear on it from use so if you’re the unlucky person that breaks one we will be requesting a $75 replacement fee.

Manual

Evolution Power Tools RAGE 3-DB - Soft metals saw

For cutting Aluminum, brass, bronze, copper only

10-Inch TCT Multipurpose Cutting Double Bevel Compound Sliding Miter Saw

Manual

Drill Presses

Clausing Drill Press

Manual

Jeweling Drill Press

WEN 4214 12-Inch Variable Speed Drill Press with laser centering device

For engine jeweling and plastics only

Cameron Micro Drill Press Model 164

Maintenance oiling locations
Specifications and Parts list

Other Tools

Turret Punch

Surface Grinder

Harig Hand Feed Super 612 (NOT YET IN SERVICE)

Link to online manual (Also available on Machine Shop committee drive)

Specifications:

  • Chuck Size: 6″ x 12″
  • Longitudinal Travel: 12 3/4″
  • Cross Travel: 6 3/4″
  • Grinding Wheel:
    • 8″ Max.
    • Wheel Width: 1/2″
    • Hole Size: 1 1/4″
  • Max. Distance: 12″ (7″ Diameter Wheel)

Mechanical Specifications:

  • Dimensions: 41″ x 38″ x 77″ H
  • Weight: approx. 725 lbs.

Torrent Parts Washer

The Parts washer is now under the governance of Automotive. This remains here solely for reference.

User Manual

Fusion360 by Autodesk

Communications

Cimco Edit

CNC Programs

The following two short programs reside on the HAAS and should not be deleted.

  • Spindle Warmup
    • This is run everytime the HAAS is powered on to give the spindle time to temperature stabilize at a range of speeds
  • Tool Jogging Program
    • The program should be run at the end of the day. It cycles thru each of the tools to prevent them from sticking due to cutting fluid drying with the tools in the tool crib.

External Sites (Reference and Instructional Videos)

CNC Handbook

MIT Machine Shop Instructional Videos - The Gold Standard

  1. Part Layout, Drill Press (Basic), Tapping
  2. Drill Press (Advanced), Bandsaw
  3. Part Finishing (Sanding, Grinding, Deburring, Polishing)
  4. Manual Mill 1
  5. Manual Mill 2
  6. Manual Mill 3
  7. Manual Mill 4
  8. Manual Lathe 1
  9. Manual Lathe 2
  10. Manual Lathe 3


Mr Pete (Machining Videos)
Very good instructor ClickSpring Instructional Videos, very accessible.
Destiny Tool
Engine Turning
G-Code Tutorial
Glossary
Guerrilla Guide to CNC Machining
Learn CNC

Practical Machinist
That Lazy Machinist The Virtual Machine Shop
Tom Lipton (Machining Videos) Author of Metalworking Doing it Better and Metalworking Sink or Swim
University of Idaho Mindworks

Parts and Equipment

Bits and Bits *Makes engraving cutters, wax milling cutters, end mills and has diamond drag engraving bits.
Bridgeport Parts
Brownell's Gunsmithing Supplies (lots of hard to find tools even for non-gunsmithing...)
Discount tools
Fastener Express
Enco (Machining tools, equipment, and accessories)
Little Machine Shop
Maritool (Machine Tooling)
McMaster Carr
MSC Industrial Supply
Precision Balls
Monster Jaws (soft jaws for Kurt Vises)
Sherline Machines
Stock Drive Products *Good source of gears and other machine parts
Travers Tool Company

Metal Suppliers

Metal Suppliers

Plastics and Composites Special Interest Group

For information on the Plastics and Composites Special Interest Group (PIG SIG) go to this wiki page.

Rules made by the Plastics Sig about prohibited materials extend to the Machine Shop. For details about which plastic/composite materials are allowed or prohibited, see the Plastics SIG rules

Equipment List

Mill Tooling

  • Collets (R8)
    • These are used to hold milling cutters (end mills, shell mills, etc...) and are located in a rack attached to the Bridgeport mill.
  • Collets (5C)
    • These are used to hold stock in the Spin Indexer to be milled. Currently we have 0.250", 0.375", 0.500", 0.625", 0.750", 0.825", and 1.000" They are located in in a small labelled laser cut wood holder located on the shelf above the machine shop work bench.
  • Dividing Head
    • We have a Yuasa 550-030 dividing head. We do not own the tail stock or the center with carrier. We do have a 6" three jaw chuck for this dividing head. The standard division plates are; A-15,16,17,18,19,20; B-21,23,27,29,31,33; and C-37,39,41,43,47,49 The dividing head is stored on the second table in the machine shop.
    • User manual
  • Drill Chuck (R8)
    • These are used to hold tools for drilling operations in the mill (countersinks, counterbores, reamers, twist drills, etc...) and is located in a rack attached to the Bridgeport mill.
  • End Mills
    • End mills are consumables (they wear out) so a current list would be too time consuming to maintain; however, our current available supply can be found in a grey cabinet on the machine shop workbench.
  • Gauge Blocks (Jo Blocks)
    • Tutorial on proper use of gauge blocks
    • These are located in the red tool box, in the drawing with the other measuring equipemnt
    • These are expensive precision pieces of equipment and should only be used for calibration of measurement equipment like micrometers, or for layout work like setting up a sine bar. Also, if one block is lost or misplace, the utility of the set is greatly diminished. Please be especially careful if you need to use these.
  • Rotary Table
    • It is located on the hydralic lift cart.
  • Shell Mill
    • The shell mill is located on the workbench in the machine shop area. This uses replaceable inserts, which are located in ...
  • Spin Indexer
    • It is located on the hydralic lift cart.
  • Spot Drills
    • Spot drills are consumables (they wear out) so a current list would be too time consuming to maintain; however, our current available supply can be found in a grey cabinet on the machine shop workbench.
  • Tilt Table
    • This table addition is for use with the Bridgeport mill or HAAS vertical mill. It has a standard t-slot table which can be tilted +/- 45 degrees so that the mill does not have to be taken out of tram to do complex cutting. It is located on the hydralic lift cart.

Set-up and Measurement Tools

  • SPI 4 piece combination square
    • This is in the red tool box with the other measurement equipment
  • 0-6" Dial Calipers
    • In the black tool box
  • 0-6"/0-150mm Dial Calipers
    • Red toolbox, in drawer with other measurement equipment
  • Center Finder
    • Located in the drawer (labeled edge finder) in the end mill cabinet (on the workbench shelf)
  • Dial Indicators
    • Located in the top of the red tool box
  • Dial Test Indicators
    • Located in the black toolbox
  • Edge Finder
    • Located in a drawer (labeled edge finder) in the end mill cabinet (on the workbench shelf)
  • Machinist Jacks
    • A pair of machinist jacks for supporting odd shaped parts during set-up. Located in the top of the red toolbox.
  • 0-1" Micrometer
    • Located in the top of the red tool box
  • Noga Indicator Mount
    • Located attached to the top of the red toolbox.
  • Set of telescoping hole measurement gauges
    • Used to accurate measure the diameter of holes from 5/16" to 6". Located in the red tool box drawer with the other measurement equipment
  • 6" 5R steel rule
    • In red toolbox, in drawer with other measuring equipment
  • 18" 5R steel rule
    • On order
  • 600mm steel rule
    • Located on the workbench shelf

Machinist Information

Reference Materials

Public Domain Books on Machining
English and Metric Tap and Clearance drill sizes
Rake and relief angles for lathe cutting tools
Sharpening Lathe tool bits
Dimensions of standard tapers
End Mill Speeds and Feeds
cnccookbook.com blog

Government and Military Specifications and Training Manuals When you enter the website, select the “Library” button at the top and it will list all the document categories. Just searching for the term “soldering” will bring up 100’s of other documents.

Instructional Information

Maintenance / To Do List

Outstanding Tasks

How To Join

Add your name to the "Members" section of this wiki page or send an e-mail to the chairperson requesting to join. Actively participate in the monthly committee meetings. Meet your fellow committee members and volunteer to help.

Interest Groups

The Plastics and Composites Interest Group is a sub-group under the Machine Shop committee.

Discussion

Discussions are held thru TALK.

Projects

User Projects
Steam Engine #3 The steam engine project has been discontinued
All pages related to the Machine Shop Committee.

Subcategories

This category has the following 2 subcategories, out of 2 total.

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Pages in category "Machine Shop"

The following 60 pages are in this category, out of 60 total.

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