Performing grinding work on machines

TYPES OF WORK PERFORMED ON CIRCULAR GRINDING MACHINES

External cylindrical grinding of workpieces such as bodies of revolution on center grinding machines can be carried out with longitudinal working strokes, plunge-in and combined (Fig.4.10).

When grinding with longitudinal working strokes (Fig.4.10a) the workpiece to be grinded 2, rotating in stationary centers, makes a longitudinal movement

performing, grinding, work, machines

External cylindrical grinding patterns: and. grinding with longitudinal working strokes; b. deep grinding; in. plunge-cut grinding; r. combined grinding; one. grinding wheel; 2. the workpiece to be grinded; Snp. longitudinal feed; Sn. cross feed; t. processing depth.

along its axis. At the end of a double stroke or each stroke, the grinding wheel one move in a direction perpendicular to the axis of the workpiece to be ground 2 to the set grinding depth.

This method is expediently used for grinding workpieces with a cylindrical surface of considerable length. It is recommended to choose the grinding depth no more than 0.05 mm per table stroke. For fine sanding, the sanding depth is even shallower.

Deep grinding (Fig. 4.106) as a type of grinding with a longitudinal feed of the wheel, it is used when processing rigid short workpieces with the removal of an allowance of up to 0.4 mm in one pass. The main cutting work is performed by the conical part of the circle, and its cylindrical part only cleans the workpiece surface to be machined.

Creep grinding can be considered a type of rough grinding. Processing is carried out with great depths (over 5 mm), with low speeds of longitudinal feeds (100-300 mm / min), mainly in one working stroke of the table. Rough grinding is understood as a treatment designed to remove a defective layer of material from a workpiece after casting, forging, stamping, rolling and welding.

Plunge grinding (Figure 4.10c) is used for roughing and finishing grinding of cylindrical workpieces. When finishing grinding, in contrast to rough grinding, the goal is to achieve the required shape and roughness parameter of the ground surface. Grinding is carried out with one wide circle, the width of which is 1.0-1.5 mm more than the length of the surface to be ground. The workpiece has no longitudinal feed movement; the movement of the transverse feed of the grinding wheel to a given depth is performed continuously or periodically. To obtain a surface with a smaller deviation of shape and roughness, the grinding wheel is given an additional axial oscillatory (oscillating) movement (up to 3 mm) to the left and to the right.

This method of machining the workpiece has the following advantages over the longitudinal grinding method:

  • the wheel feed movement is performed continuously;
  • it is possible to grind shaped workpieces with a profiled grinding wheel;
  • two or three grinding wheels can be installed on the machine spindle and several sections of the workpiece can be grinded at the same time.

The disadvantages of plunge grinding include:

  • the grinding wheel and the workpiece heat up more during processing than with conventional grinding, therefore grinding must be carried out with abundant cooling;
  • it is necessary to often correct the circle due to the rapid distortion of its geometric shape.

When combined grinding (Fig. 4. South) grinding with longitudinal strokes and plunge is combined. This method is used when grinding long workpieces. First, one section of the shaft is ground during the movement of the transverse feed of the wheel, then the adjacent section, etc. The edges of the sections during grinding overlap each other by 5-10 mm, but the processed surface is stepped. Therefore, an incomplete allowance is removed at each site. The remaining layer (0.02-0.08 mm) is removed with two or three longitudinal strokes at an increased speed.

4.1. Minimum Logistics Requirements

The implementation of the module program assumes the presence of classrooms:

MDK.04.01

Laboratory of metalworking technology on metal-cutting machine tools with programmed control

Automated workstation of a teacher;

Set of educational furniture

Cabinet for equipment and tools

SINUMERIK 802 D CNC Lathe

CNC milling machine RX 3 S. SIEG

CNC lathe 16A20F3

Cutting tool set

T. FLEX software product

KOMPAS-3D software product

MDK.04.02

Laboratory of metalworking technology on metal-cutting machine tools with programmed control

Automated workstation of a teacher;

Set of educational furniture

Cabinet for equipment and tools

SINUMERIK 802 D CNC Lathe

CNC milling machine RX 3 S. SIEG

CNC lathe 16A20F3

Cutting tool set

T. FLEX software product

KOMPAS-3D software product

Laboratory for computer-aided design of technological processes and programming of CNC systems

EliteBoard interactive whiteboard;

Lenovo B 350 laptop;

Lexmark T 644 printer;

Philips 191 V monitors;

Monitor NEC 175 M;

Machine with PU Reabin;

4.2. Information support of training

Ermolaev V.V. Programming for automated equipment: a textbook for students of secondary vocational schools / V.V. Ermolaev. M.: ITs “Academy”, 2014. (Programming turning, milling)

Bosinzon M.A. Modern CNC systems and their operation: u / p. IC “Academy”, 2013. (Operator’s work on a CNC machine).

Bosinzon M.A. Modern CNC systems and their operation, “Academy” Moscow 2012. (Operator’s work on a CNC machine).

Bosinzon M.A. Modern CNC systems and their operation.

JRC Academy 7th ed. 2015. (Operator work on a CNC machine).

Kholodkova A.G. General fundamentals of metalworking technology and work on metal-cutting machine tools (PPSSZ). JRC Academy 2nd ed. 2015

Agafonova L.S. Shaping processes and tools Album of posters and posters. JRC Academy 1st ed. 2013

Agafonov L.S. Formation processes and tools. Laboratory and practical work. JRC Academy. 2nd ed. 2014

Andreev S.M., Parsunkin B.N. Development and modeling of simple automation systems taking into account the specifics of technological processes. JRC Academy 1st ed. 2016

Bagdasarova T.A. Performing work in the profession “Turner” Manual for educational practice. JRC Academy 1st ed. 2013

Bosinzon M.A. Modern CNC systems and their operation: u / p. IC “Academy”, 2013. (Maintenance of CNC machines)

Bosinzon M.A. Modern CNC systems and their operation, “Academy” Moscow 2012. (Maintenance of CNC machines)

Bosinzon M.A. Modern CNC systems and their operation.

JRC Academy 7th ed. 2015. (Maintenance of CNC machines)

Bagdasarova T.A. Performing work in the profession “Turner” Manual for educational practice. JRC Academy 1st ed. 2013

Professional information systems CAD CAM / CAPP.

General requirements for the organization of the educational process

The program of the professional module “Performing work in the profession” Operator of CNC machines “is implemented during 2 semesters of the second and second semesters of the third year of study.

The organization of the educational process and the teaching of the professional module in modern conditions should be based on innovative psychological and pedagogical approaches and technologies aimed at increasing the effectiveness of teaching and the quality of training of students.

The mastering of this module should be preceded by disciplines from the general humanitarian and socio-economic, mathematical and natural science, professional cycles, such as : “Mathematics”, “Informatics”, “Engineering Graphics”, “Technological equipment”.

In the learning process, the main forms are: classroom sessions, including lectures and practical exercises, educational practice, as well as independent work of the student. The topic of lectures and practical classes corresponds to the content of the professional module program.

For the successful mastering of the professional module “Performing work in the profession” Operator of CNC machines “, each student is provided with educational and methodological materials (thematic plans of seminars and practical exercises, educational and methodological literature, typical test tasks, situational tasks, tasks and recommendations for independent work).

Lectures form a systematic understanding of the studied sections of the professional module among students, ensure their assimilation of the basic didactic units, readiness to perceive professional technologies and innovations, and also contribute to the development of intellectual abilities.

Practical lessons ensure the acquisition and consolidation of the necessary skills and abilities, the formation of professional competencies, readiness for independent and individual work, making responsible decisions within the framework of professional competence.

Educational practice allows you to form the skills of working on machine tools with numerical control.

Students’ independent work is carried out outside classroom hours, accounting for 1/2 of the total labor intensity of the interdisciplinary course. Independent work includes working with literature, preparing essays on a chosen topic, implementing projects, practicing practical skills, and contributes to the development of cognitive activity, creative thinking of students, instills the skills of independent search for information, and also forms the ability and readiness for self-improvement, self-realization and creative adaptation, the formation of general competencies.

The assessment of theoretical and practical knowledge of students is carried out using test control, solving situational problems, assessing practical skills. At the end of the study of the professional module, an exam is held.

Educational practice is conducted in a dispersed manner, alternating with theoretical studies within the professional module. Educational practice is carried out in the training workshops of the college. Educational practice takes place under the guidance of practitioners.

Industrial practice (according to the profile of the specialty) is carried out as a final (concentrated) practice upon completion of the module. The bases of industrial practice are enterprises and organizations with which the college concludes an agreement on mutual cooperation. The main conditions for passing industrial practice in these enterprises and organizations are the availability of qualified personnel, equipment with modern equipment.

Practice in the profile of the specialty is carried out under the guidance of masters in practice and specialists of the enterprise base of practice. The duties of the head of the practice include: monitoring the implementation of the practice program, providing methodological and practical assistance to students in the development of practical professional skills and gaining practical experience, checking the completion of the diary on industrial practice.

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Heads of practice of students from the enterprise-base of practices are appointed by order of the head of the enterprise before the start of practice, from among specialists with education corresponding to the profile of the taught professional module.

A prerequisite for admission to industrial practice (according to the profile of the specialty) within the framework of this professional module is the development of educational practice of the UE. 02 “Operator of CNC machines” and industrial practice.

4.4. Staffing of the educational process

Engineering and teaching staff: graduates with higher education in the specialty. teachers of interdisciplinary courses, as well as general professional disciplines: “Technological equipment”; “Technology of mechanical engineering”; “Technological equipment”; “Programming for automated equipment”; “Information technology in professional activity”.

PM.04 Execution of work on machine tools with programmed control

For preschoolers and pupils of grades 1-11

Record low registration fee 25 R.

WORKING PROGRAM OF THE PROFESSIONAL MODULE

PM.04 Execution of work on machine tools with programmed control

GBPOU “Pavlovsk Automotive Technical School named after I.I. Lepse “

Shchegolev A.V., lecturer, GBPOU PAMT them. I.I. Lepse

Belykh A.V., master of industrial training, GBPOU PAMT them. I.I. Lepse

Passport of the professional module program

Results of mastering the professional module

Structure and professional module

Conditions for the implementation of the professional module program

Monitoring and evaluation of the results of mastering the professional module (type of professional activity)

PROGRAM PASSPORT

professional module

PM 04 Performance of work by profession Operator of machine tools with programmed control

1.1. Scope of the program

The program of the professional module is part of the main professional educational program for the training of skilled workers, employees (FSES SPO PPKRS) by profession 16045 Operator of machine tools with programmed control in terms of mastering the main area of ​​professional activity (OPD): Programmed control of metal-cutting machines and processing of metal products and parts on metal-cutting machines of various types and types and relevant professional competencies (PC):

PC 1 Carry out the processing of parts on machine tools with programmed control using the control panel.

PC 2 Perform readjustment of individual units and mechanisms during operation.

PC 3 Carry out maintenance of numerical control machines and manipulators (robots).

PC 4 Check the quality of surface treatment of parts.

The professional module program can be used in additional vocational education and vocational training of workers in the field of mechanical engineering and metalworking in the presence of secondary general education.

1.2. Goals and objectives of the module. requirements for the results of mastering the module

In order to master the main area of ​​professional activity and the corresponding professional competencies, the student in the course of mastering the professional module must:

have practical experience:

P1 processing of parts on metal-cutting machine tools with program control (for processing the outer contour on two-coordinate lathes);

P2 turning of screws, cylindrical bushings, nuts, stops, flanges, rings, handles;

P3 milling of the outer and inner contours, edges along the butt on three-axis machines of brackets, fittings, boxes, covers, casings, couplings, flanges of shaped parts with butt and support planes located at different angles, with ribs and holes for fastening, shaped boring contour;

P4 drilling, countering, countersinking, tapping in through and blind holes;

P 5 cutting of rectangular and round windows in pipes;

P6 drilling, boring, counter boring, countersinking through and blind holes with coordinates in parts of medium and large dimensions from extruded profiles, hot-stamped blanks of open or annular contour from various metals;

P7 processing of end surfaces, smooth and stepped holes and planes;

P8 processing of external and internal contours on three-coordinate lathes of complex-spatial parts;

P9 adjustment of individual units and mechanisms in the process of work;

P10 maintenance of numerically controlled machine tools and manipulators (robots);

P11 checking the quality of surface treatment of parts;

U1 determine the cutting mode according to the manual and the passport of the machine;

U2 prepare technical documentation;

U3 calculate cutting conditions according to formulas, find requirements for modes according to reference books for different types of processing;

U4 to compose the technological process of processing parts, products on metal-cutting machine tools with programmed control;

U5 to carry out the process of processing from the control panel of parts according to quality on machine tools with programmed control;

U6 install and remove parts after processing;

U7 to control the exit of the tool to the starting point and its correction;

U8 to replace blocks with a tool;

U9 carry out the installation of the tool in the tool blocks;

U10 monitor the operation of the systems of the serviced machines according to the indications of digital displays and signal lamps;

U11 to carry out maintenance of multipurpose machine tools with numerical control (CNC) and manipulators (robots) for mechanical feeding of workpieces to the workplace;

U12. to manage a group of programmable machine tools;

U13 to eliminate minor malfunctions in the operation of tools and devices;

Z1 basic concepts and definitions of technological processes for the manufacture of parts and processing modes;

Z2 fundamentals of the theory of cutting metals within the work performed;

З3 basing principle;

Z4 general information about the design of technological processes;

Z5 the procedure for registration of technical documentation;

Z6 basic information about mechanisms, machines and machine parts;

З7 name, purpose and conditions of use of the most common universal and special devices;

Z8 device, kinematic diagrams and principle of operation, rules for adjusting metal-working machine tools with programmed control;

Z9 the purpose and rules for the use of cutting tools;

З10 angles, rules for sharpening and setting cutters and drills;

З11 purpose and rules of application, rules for heat treatment of cutting tools made of tool steels, with hard alloys or ceramic plates, its main angles and rules for sharpening and setting;

З12 rules for determining cutting modes according to reference books and machine passport;

Z13 lifting equipment used in metalworking shops;

З14 main directions of automation of production processes;

З15 device, principle of operation of the serviced machine tools with programmed control;

З16 rules for managing the serviced equipment;

З17 design features and rules for checking the accuracy of serviced machines of various designs, universal and special devices;

Z18 conventional signaling used at the workplace;

З19 assignment of conventional symbols on the machine control panel;

Z20 software control systems for machine tools;

Z21 rules for installing punched tapes into the reader;

Z22 ways to return the software to the first frame;

З23 basic methods of preparing the program;

Z24 code and rules for reading the program for printing and punched tape;

Z25 the order of machine operation in automatic mode and in manual control mode;

Z26 design of devices for mounting and fixing parts on programmable machine tools;

Z27 technological process of parts processing;

Z28 organization of work in multi-station maintenance of programmable machine tools;

Z29 starting from a different main frame;

causes of malfunctions of machine tools with programmed control and Z30 methods of their detection and prevention;

Z31 correction of cutting conditions based on the results of the machine;

332 ways of installing the tool in tool blocks;

Z33 methods of installing devices and adjusting them;

Z34 techniques to ensure the specified precision in the manufacture of parts;

З35 device and kinematic diagrams of various machine tools with programmed control and rules for their adjustment;

Z36 rules for setting and adjusting control and measuring instruments and devices;

Z37 the procedure for the use of instrumentation and instruments;

Z38 methods of installation and alignment of parts;

1.3. The number of hours for mastering the program of the professional module:

Total. 736 hours, including:

compulsory classroom teaching load of the student. 412 hours;

training practice. 180 hours

industrial practice (according to the profile of the specialty)- 144 hours

RESULTS OF LEARNING THE PROFESSIONAL MODULE

The result of mastering the program of the professional module is the mastering by the students of the area of ​​professional activity:

Programmed control of metal-cutting machines and processing of metal products and parts on metal-cutting machines of various types and types

Structure and professional module

3.1. Thematic plan of the professional module

MDK 04.01 Metalworking technology on metal-cutting machine tools with programmed control

Maintenance of programmed machine tools

3.2. professional module training

MDK 04.01. Technology of metalworking on metal-cutting machine tools with programmed control

Maintenance of programmed machine tools

Topic 1 Operation of CNC machines

Topic 1.1 Machine tools with numerical control

Historical development of numerical control (CNC)

Comparative analysis of universal machine tools and CNC machines. Design, operation algorithm, efficiency of using CNC machines.

Controlled movements of the executive bodies of the machine. Feed drive. Displacement measuring systems for machine tool executive bodies.

Main movement drive and spindle assembly. Clamping devices for workpieces. Automatic tool changers. Safety measures when working on CNC machines

Workshops

Studying the structure of a CNC lathe

Study of the virtual control panel of the machine. Performing machine start-up

Lathe CC. D 6000 E.

Entering control commands from the remote control.

Topic 1.2 Geometric foundations of working on CNC machines

Coordinate systems of CNC machine tools. Types of coordinate systems. Coordinate systems and directions of movement of the executive bodies of a CNC machine.

Part profile coordinates. Basics of calculating coordinates. Calculation of coordinates for CNC machines Zero and origin points of CNC machines

Numerical control of machine tools. Classification of CNC systems. Classification of CNC systems by technological purpose

Tool offset for CNC machining. Measuring and setting the tool with a measuring fixture

Workshops

Studying the principles of constructing a coordinate system of a CNC lathe

Determination of the zero and origin points of the coordinate system of CNC lathes

Performing geometric coordinate calculations for turning on CNC machines

Topic 1.3 Technological foundations of work on CNC machines

Turning and milling tool blocks for CNC machines. Cutting materials for turning and milling tools

Turning tools for CNC machines. Classification. Geometry. Wear and durability of turning tools. Cutting parameters for turning. Features of determining cutting conditions for CNC lathes

Milling tools for CNC machines. Classification. Geometry. Wear and durability of cutters. Cutting parameters for milling. Features of determining cutting conditions for CNC milling machines

Calculation of technological parameters for processing on CNC machines

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Machine tools for CNC machines. Classification of machine tools. Machine tools for CNC lathes. Machine accessories for CNC milling machines

Workshops

Calculations of technological parameters for processing on CNC machines

Topic 1.4 Introduction to programming machining on CNC machines

Organization of work when manually entering programs.

Features of technological preparation of production when processing on CNC machines

The procedure for manual compilation of control programs.

Workshops

Study of the composition of the control program

Introduction to programming.

Exploring helper functions.

Introduction to programming.

Exploring Preparatory Functions for Programming Linear Interpolation.

Introduction to programming.

Learning the preparatory functions for programming the displacement counting method.

Introduction to programming.

Exploring Preparatory Functions for Circular Interpolation Programming.

Introduction to programming.

Learning the preparatory functions for programming zero and origin travel.

Introduction to programming.

Learning the basics of programming technological cycles.

Topic 1.5 Fundamentals of Programming

Components of the control program

Workshops

Writing NC programs using linear interpolation functions for predefined contours

Writing NC programs using linear and circular interpolation functions for predefined contours

Writing NC programs using linear and circular interpolation functions, PAL geometry for predefined contours

Writing NC programs using linear and circular interpolation functions, PAL geometry for predefined contours

Writing NC programs using linear and circular interpolation functions, PAL geometry. PAL cycles for predefined contours

Creation of contours for operating mode G 1 / G 3 / G 3

Selection of operating modes for setting up

Running the program in the PAL simulator

Training practice UP.04 Training practice in the profession “Operator of machine tools with programmed control”

Conducting the processing process from the control panel of medium complexity and complex parts according to 8-11 grades with a large number of transitions on machine tools with program control and the use of three or more cutting tools. Control of the exit of the tool to the starting point and its correction. Replacing blocks with tools. Control of surface treatment of parts with control and measuring devices and tools. Elimination of minor malfunctions in the operation of the tool and accessories. Adjustment of individual simple and medium-complexity components and mechanisms in the process.

Industrial practice PP 04. Industrial practice in the profession “Operator of machine tools with programmed control”

processing of parts on metal-cutting machine tools with program control (for processing the outer contour on two-coordinate lathes);

turning of screws, cylindrical bushings, nuts, stops, flanges, rings, handles;

milling of the outer and inner contours, edges along the butt on three-axis machines of brackets, fittings, boxes, covers, casings, couplings, flanges of shaped parts with butt and support planes located at different angles, with ribs and holes for fastening, shaped boring contour;

drilling, counterbore, countersinking, tapping in through and blind holes;

cutting down rectangular and round windows in pipes;

drilling, boring, counter boring, countersinking of through and blind holes with coordinates in medium and large parts from extruded profiles, hot-stamped blanks of open or annular contour from various metals;

processing of end surfaces, smooth and stepped holes and planes;

processing of external and internal contours on three-coordinate lathes of complex-spatial parts;

readjustment of individual units and mechanisms during operation;

maintenance of numerically controlled machine tools and manipulators (robots);

To characterize the level of mastering the educational material, the following designations are used:

introductory (recognition of previously studied objects, properties);

reproductive (performing activities according to the model, instructions or under the direction);

productive (planning and independent performance of activities, solving problematic tasks)

TERMS OF IMPLEMENTATION OF THE PROGRAM

PROFESSIONAL MODULE

Masters: the presence of 5-6 qualification categories with compulsory internship in specialized organizations at least once every 3 years. Experience in organizations of the relevant professional field is required.

Higher or secondary education. special according to the profile of the specialty.

CONTROL AND EVALUATION OF THE RESULTS OF THE PROFESSIONAL MODULE DEVELOPMENT

(AREAS OF PROFESSIONAL ACTIVITY)

(mastered professional competencies)

Forms and methods of control and evaluation

PC 1 Carry out the processing of parts on machine tools with programmed control using the control panel.

PC 2 Perform readjustment of individual units and mechanisms during operation.

-expert assessment of the process of performing adjustment of individual units and mechanisms in the process of work when performing trial work

PC 3 Carry out maintenance of numerical control machines and manipulators (robots).

PC 4 Check the quality of surface treatment of parts.

OK 1. Understand the essence and social significance of your future profession, show a steady interest in it

Observation and evaluation of the results of practical work, extracurricular independent work.

OK 2. Organize your own activities based on the goal and ways to achieve it, determined by the head

Grinding a Tapered Machinery Gib using the Surface Grinder – Monarch Lathe Restoration:- Part 21

Assessment of solving situational professional tasks.

Observation and evaluation of the results of practical work.

How Surface Grinding Works – Part 1?

OK 3. Analyze the working situation, carry out current and final control, assessment and correction of their own activities, be responsible for the results of their work

Observation and evaluation of the solution of situational professional tasks.

OK 4. Search for information necessary for the effective performance of professional tasks

Observing ICT skills

Observation and evaluation of the results of practical work, extracurricular independent work

OK 5. Use information and communication technologies in professional activities

Observing ICT skills

Observation and evaluation of the results of practical work, extracurricular independent work

OK 6. Work in a team, communicate effectively with colleagues, management, clients

Observing the behavior and role of the learner in the group

OK 7. Perform military duty, including using the acquired professional knowledge (for young men)

Timeliness of military registration

SAFETY REQUIREMENTS IN EMERGENCY SITUATIONS

4.1. In the event of a breakdown of the machine, failure of the control panel to turn off the machine and inform the foreman about it.

4.2. In the event of a fire, rags, equipment or a fire, immediately turn off the machine, inform other workers of the workshop about the incident and proceed to eliminate the source of ignition.

4.3. In the event of an emergency, danger to your health or the health of people around you, turn off the machine, leave the danger area and report the danger to your immediate supervisor.

SAFETY REQUIREMENTS DURING WORK

3.1. During work, the grinder must:

a) fasten the parts only with special thrust and clamping strips, placing them at equal distances;

b) put all stop strips below the surface to be treated;

c) place the fastening bolts as close as possible to the place where the part is pressed, and the fastening strips. at right angles to the part; the thread of the fasteners must be intact;

d) do not use random unsuitable strips and gaskets for fastening parts;

e) check the correct installation of the part on the machine;

a) prevent an increase in the temperature of the magnetic assemblies, as this can cause combustion of insulation, ejection of parts or an explosion inside the plate;

b) do not install bent parts on the machine;

c) to remove the parts held by the residual magnetism of the electromagnet, switch the current in the opposite direction and at the same time remove the parts or use a demagnetizer;

a) do not use a center with worn out cones;

b) after installing the part in the centers, check the fastening of the tailstock and quill;

a) leaving the machine even for a short time;

b) temporary suspension of work;

c) an interruption in the supply of electricity;

d) cleaning, lubricating, cleaning the machine;

e) detection of any malfunction;

f) tightening bolts, nuts and other fasteners;

3.2. While working on the machine, the grinder is prohibited:

SAFETY REQUIREMENTS BEFORE BEGINNING WORK

2.1. Before starting work, the grinder must:

a) the serviceability of the controls;

b) serviceability of the lubrication and cooling system;

c) serviceability of fixing the engaging and switching levers (make sure that the possibility of spontaneous switching from idle to working is excluded).

Check the passport for testing the strength of circles with a diameter of 150 mm and above.

2.2. The grinder is prohibited from:

GENERAL SAFETY REQUIREMENTS

1.1. Trained personnel are allowed to work independently on grinding machines, having passed a medical examination, instruction on labor protection at the workplace, familiarized with fire safety rules and mastered safe working techniques.

1.2. The grinder is allowed to work only on the machines to which he is allowed, and to perform the work that is entrusted to him by the head of the workshop (section).

1.3. A worker serving grinding machines must have: a cotton suit or semi-overalls, goggles, leather boots.

1.4. If the floor is slippery (doused with oil, emulsion), the worker must demand that he be sprinkled with sawdust, or do it himself.

1.5. The grinder is prohibited from:

1.6. Immediately notify the master of any accident and contact the medical center.

Typical instruction on labor protection when working on grinding machines

The collection of typical instructions contains the requirements for labor protection when working on grinding machines.

RAO “UES of Russia”

COLLECTION
STANDARD INSTRUCTIONS
LABOR PROTECTION
BY DOING

WELDING
AND MACHINE WORKS

RD 153-34.0-03.231-00
RD 153-34.0-03.288-00. RD 153-34.0-03.297-00

E.G. Gologorsky, I.M. Pogozhev, B.M. Uzelkov

Department of General Inspection for the Operation of Power Plants and Networks of RAO “UES of Russia”

First Deputy Chairman of the Management Board O.V. Britvin

Date of introduction 07/01/2000.

This collection of standard instructions contains requirements for labor protection and safe performance of electric and gas welding works, as well as when working on turning, milling, gear cutting, grinding, slotting, drilling, planing, cutting and sharpening machines.

Based on these standard instructions, enterprises and organizations develop and approve instructions taking into account local conditions.

maintenance inspection

power plants and networks

March 14, 2000.

March 15, 2000.

March 17, 2000.

TYPICAL INSTRUCTION
LABOR PROTECTION AT WORK
ON GRINDING MACHINES

RD 153-34.0-03.292-00

Date of introduction 07/01/2000

Work on grinding machines can be accompanied by the presence of a number of harmful and hazardous production factors, including:

When developing a typical instruction, the following labor safety system standards were used: GOST 12.0.003-74 Dangerous and harmful production factors. Classification; GOST 12.1.004-91 Fire safety. General requirements; GOST 12.3.002-75 Production processes. General safety requirements; GOST 12.3.025-80 Metal cutting. Safety requirements, etc.

When performing work in accordance with the existing qualifications, grinders must comply with the safety requirements set out in this manual.

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In case of failure to comply with the provisions of this instruction, employees may be brought to disciplinary, administrative, criminal and material liability in accordance with the legislation of the Russian Federation, depending on the severity of the consequences.

END OF WORK SAFETY REQUIREMENTS

At the end of the work, the grinder must:

a) remove chips and metal dust from the machine;

b) clean the machine from dirt;

c) carefully fold the workpieces and the tool to the designated place;

d) lubricate the rubbing parts of the machine;

TURNING ON MACHINES WITH PROGRAM CONTROL

1 REGIONAL COMPETITION 2014 TURNING ON MACHINES WITH PROGRAM CONTROL COMPETITION TASK

3 Control program (maximum 20 points) The program does not contain errors The program is structured logically (optimal) Work on the machine (maximum 30 points) Compliance with labor protection requirements Handling machine controls Procedure when setting up a tool Control of the machine while executing a machining program Workpiece ( maximum 40 points) Compliance with the dimensions for the dimensions kept during the manufacture of the part according to the 12th grade of accuracy 10 points for the dimensions kept during the manufacture of the part according to the higher quality of accuracy 25 points Actual processing time of the part 5 points Note. 1. For gross violations of labor protection requirements, which led to damage to equipment, tools, injury or the creation of an emergency, the participant is removed from further participation in the competition. 2. In case of an equal number of points based on the results of the assignment, the priority is given to the participant who scored the highest number of points according to the “Workpiece” criterion. 4. MATERIALS, TOOLS AND EQUIPMENT 4.1. To fill in the infrastructure sheet and complete the competition task, the organizer of the regional round of the competition provides (for each participant): lathes with numerical control; billet (rolled Ø40 mm; l = 84 mm, material steel 40X); clamping devices and accessories: three-jaw chuck; tool blocks for cutters and axial tools; bushings for installing axial tools with a tapered tail; a template for controlling the angle at the top of the drill; a set of wrenches and hex keys; template for sharpening and installing a threaded cutter (if necessary); cutting tool: straight cutter (T15K6); thread-cutting cutter (T15K6); grooving cutter (T15K6); boring cutter for blind holes (T15K6); 3

4 drill Ø20 (R6M5); centering drill with tapered shank; control and measuring tool: vernier caliper ШЦ I; vernier caliper ШЦ II-250-0.05; micrometer MK 25-50; internal gauge; gauge rings for thread inspection M20; thread gauge (to control the thread pitch); goniometer; roughness samples Permitted aids, which the participants of the competition are allowed to have with them: catalog of tools; tables of cutting parameters, tolerances and fits; calculator. 5. MINIMUM REQUIREMENTS FOR THE PLANNING OF THE COMPETITION AREA The total area of ​​the competition area depends on the number of jobs for the participants of the competition. The workplace of each participant must be equipped with a lathe with PU and a bedside table for the location of cutting, measuring instruments and devices. When placing the equipment, the convenience and safety of its maintenance, the safety of evacuation of the bidders in the event of emergencies, must be ensured, the impact of dangerous and harmful production factors must be excluded. The width of the passages between the equipment when the equipment is located with the back sides to each other must be at least 1 m; when the equipment is located with the front and back sides to each other at least 1.5 m; when the workplaces are located opposite each other at least 3 m. The workplace of the participant is provided with a three-phase AC 220/380 V source with an installed power of at least 3 kW. The floor of the competition site must be located on a stable foundation, load-bearing structures, with an even relief. The organization of the competition site on temporary, wooden, unstable and uneven structures is not allowed. The training / expert area should accommodate the contestants and a flipchart and be equipped with 4 sockets. Dressing room for participants. A room for storing inventory, consumables for making competition tasks. four

5 6. GENERAL LABOR PROTECTION REQUIREMENTS Participants must know and strictly follow the labor protection requirements and internal regulations at the venue of the competition. In addition, it is necessary to ensure the following requirements: when performing turning work, participants work only in overalls, using personal eye and hearing protection; when examining, checking or working with the project of the participant of the competition, experts are obliged to use appropriate personal protective equipment; all machines must be equipped with protective devices, tools, auxiliary equipment, coolant that meet the technical requirements of the manufacturer. A first aid kit and an eye wash device are required. five

6 INFRASTRUCTURE SHEET WorldSkills BY The infrastructure list lists all equipment, materials and devices, which are presented by the organizer of the competition (per participant): lathes with programmed control; billet (rolled Ø 40 mm; l = 84 mm, material steel 40X); clamping devices and accessories: three-jaw chuck; tool blocks for cutters and axial tools; bushings for installing axial tools with a tapered tail; a template for controlling the angle at the top of the drill; a set of wrenches and hex keys; cutting tool: straight cutter (T15K6); thread-cutting cutter (T15K6); grooving cutter (T15K6); boring cutter for blind holes (T15K6); drill Ø20 (R6M5); centering drill with a tapered shank; control and measuring tool: vernier caliper ШЦ I; vernier caliper ШЦ II-250-0.05; micrometer MK 25-50; internal gauge; gauge rings for thread inspection M20; thread gauge (to control the thread pitch); goniometer; roughness samples. 6

7 DRAWING DETAILS 7

9 EVALUATION CARD OF DETAILS Maximum Objects of control point Tool setting chart All data are entered 5 All steps of the technological process are lined up in a structured logical sequence 3 The tools are given the correct names 2 Control program The program does not contain errors 12 The program is built logically (optimal) 8 Operation on the machine Compliance requirements for labor protection 5 Handling the machine controls 5 Observance of the procedure for changeover 10 tools Control of the machine during the execution of the machining program 10 Workpiece Observance of dimensions 35 for the dimensions kept during the manufacture of 10 parts of 12 accuracy grade for the dimensions kept during the manufacture of 25 parts for a higher quality of accuracy Actual processing time of the part 5 Received The received number of points Date Signature of the checking expert / Controlling expert 1 / / Controlling expert 2 / / Controlling expert 3 / / 9

GRINDING MACHINES AND WORKS PERFORMED ON THEM

The main types of grinding machines and their designation

Metal-cutting machines for processing workpieces with abrasive tools form a group consisting of grinding, polishing, lapping and sharpening machines. Grinding machines provide the surface roughness 11a 1.25. 0.02 μm.

Grinding machines receive mainly workpieces after preliminary mechanical and heat treatment with minimal machining allowances.

Depending on the shape of the surface of the workpiece to be ground and the type of grinding, the following are distinguished: cylindrical grinding machines for circular external grinding (center and centerless); internal grinding machines for cylindrical internal grinding (center and centerless); surface grinding machines for processing the periphery and the end face of the grinding wheel. Figure 6.1 shows a general view of the main types of grinding machines.

According to the ENIMS classifier, models of machines working with an abrasive tool are designated by numbers and (if necessary) a letter. The group of grinding machines is designated by number 3 (the first number in the model designation). The second digit indicates the type of machine: 1. cylindrical grinding machines; 2. internal grinding; 3. roughing and grinding; 4. specialized grinding machines; 5. not provided; 6. sharpening; 7. surface grinders with a rectangular or round table; 8. lapping and polishing; 9. special machines working with abrasive tools. When it is necessary to indicate that the considered design of the machine is improved, i.e. belongs to a new generation of machine tools, then a letter is entered into the symbol (for example, ZA64). The third digit indicates the main technical characteristics of the machine.

In addition to mass-produced machines, machine-tool plants produce special machines and, as a rule, assign them conditional serial numbers. the code of the machine, which does not give specific information about it, therefore, additional information is required, set out in the passport of the machine.

Fig. 6.1. General view of grinding machines of the main types: and. flat grinding with rectangular table and horizontal spindle: one. bed; 2 control panel; 3 handwheel for manual movement of the table; four operator console;

  • five table; 6,7. casings; 5. flywheel; 9. rack; ten- grinding headstock; II. grinding wheel; 12. magnetic plate; thirteen. hydroelectric station; 14. SOTS supply pump; b. cylindrical grinding: / electrical cabinet; 2 headstock; 3 COTS feed handle; four lunette,
  • 5. mechanism for automatic wheel dressing; 6. flywheel for lateral feed motion; 7. grinding headstock; 8. cross feed mechanism; 9. control panel; ten. hydroelectric station; II. handle for manual clamping of the headstock quill; 12. tailstock; thirteen. handle for inlet / outlet of the tailstock quill; 14 hydraulic control panel; 15 pedal for hydraulic retraction of the tailstock quill; 16. rail; 17. flywheel; eighteen. bed; 19. top table; 20. lower table; in inside grinding: one. bed; 2. casing; 3. shields; four.

mechanism for the cross feed of the headstock of the product; 5 movable plate; 6 headstock of the product; 7 flywheel for manual transverse feed of the work headstock; 8 blank; 9- wheel for face grinding; ten- wheel displacement handle for face grinding; eleven. grinding wheel for internal processing; 12. face milling device body; thirteen. handle for transverse movement of the grinding support; 14. grinding wheel support; 15. machine control panel; 16. rack; 17. machine table; eighteen. table body; 19. longitudinal handle

table; 20 longitudinal table movement stops

The main cutting movement in grinding machines. rotation of the grinding wheel. Its circumferential speed (speed of the main cutting movement) y = 35.50 m / s, with high-speed grinding y = 80.120 m / s.

test questions

  • 1. What can you tell us about the main types of grinding machines?
  • 2. What are the designations of the different types of grinding machines?
  • 3. What is the usual speed of the main cutting motion in grinding machines?