PEO 005 – Procedure Manual

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Job 1 (Side Bracket)
Job 1 (Side Bracket) 41 Topics
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Session Content
0% Complete 0/41 Steps
A.0 – Setup a Safe Working Environment
A.1 – Check and collect all required tools, materials, documents and equipment
A.2 – Remove burrs from sheet material and check for size using rule/tape.
A.3 – Remove all oil and grease from surfaces.
A.4 – Choose a corner of the sheet material and mark as they datum using the centre punch. File adjacent edges square if required.
A.5 – Apply Engineers blue or permanent marker to the sheet material to offer contrast to the forthcoming marking out.
A.6.0 – Clamp the sheet material to an L-Bracket using 2 x Engineers Toolmaker Clamps.
A.6.1 – Mark out Horizontal features (x1, x2, x3, x4) on the sheet material using a Vernier Height Gauge
A.6.2 – Mark out Vertical features (y1, y2, y3, y4) on the sheet material using a Vernier Height Gauge
A.7 – Remove the sheet material and check marking out with a vernier calliper
A.8 – Centre punch intersection points using a Centre Punch
A.9 – Draw a 4mm radius circle around the hole position to be reamed using a set of Dividers.
A.10 – Place plate in drill vice and clamp to drill table, using a centre drill to pick up on centre punch indents for correct positioning
A.11.1 – Drill all holes in accordance with drawing sizes, centre punch indents, clamp, centre drill then drill to size, pilot hole if necessary.
A.11.2 – Remove all burrs from drilled holes using a De-burring tool / De-burring Rose.
A.12 – Hand ream 8mm hole to H8 fit
A.13 – Check hole positions with Vernier Calliper. Record your findings below.
A.14 – Fit sheet material and product template onto the template block and scribe around the profile.
A.15 – Produce cutting guidelines using a scriber and square.
A.16 – Cut out product profile using a hacksaw with correct blade TPI.
A.17 – File both widths to the given dimensions on drawing 0023 ensuring finish is within the specified tolerance using an external micrometre.
A.18 – File Radii in accordance to drawing sizes
A.19 – Remove all burrs and sharp edges and finish the surfaces.
A.20.0 – Take a photo of your product and upload it to this page. Ensure your name is stamped onto the product.
A.20.1 – Check all sizes and dimensions, recording your findings below – Does your product fit in the Template Block?
A.21 – Check all sizes and dimensions, recording your findings below – Does the Go-No-Go Gauge fit in the 8mm reamed holed?
A.22 – Check all sizes and dimensions, recording your findings below – Is the overall length of Side 1 68mm?
A.23 – Check all sizes and dimensions, recording your findings below – Is the overall length of Side 2 62mm?
A.24 – Check all sizes and dimensions, recording your findings below – Is the overall width of Side 1 20mm?
A.25 – Check all sizes and dimensions, recording your findings below – Is the overall width of Side 2 20mm?
A.26 – Check all sizes and dimensions, recording your findings below – Are the R10 x 5 positions to standard?
A.27 – Check all sizes and dimensions, recording your findings below – Is the product Square and Flat?
A.28 – Check all sizes and dimensions, recording your findings below – Is the finish free from false tool cuts, sharp edges and burrs? Are the surfaces finished to 1.6 Ra?
A.29 – Stop work and present product to your tutor.
Parallel Bars
Boxed / Circled Holes
Scraping
Abrasive Paste
How to correct holes
Setting and Adjusting Spindle Speeds
Adjustment of Drill Table
Job 2 (Tap Wrench Body)
Job 2 (Tap Wrench Body) 40 Topics
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Session Content
0% Complete 0/40 Steps
B.1 – Verify material is correct and that all instructions are understood.
B.2.1 – Remove burrs from Aluminium Bar and check for size using rule/tape.
B.2.2 – Stamp name in the centre of where the product profile will be.
B.3 – Remove all oil and grease from surfaces.
B.4 – File datum edge flat and square to bar sides within surface finish standard.
B.5 – Using micrometre blue and scraper, remove localised high spots on datum edge.
B.6 – Check datum face with engineers square.
B.7 – Indicate datum corner with centre punch mark on front face.
B.8 – Mark off 60mm length from datum edge using Vernier Height Gauge and Vee Block.
B.9 – File end face flat and square to datum edge within tolerance and surface finish standard.
B.10 – Check with engineers square and Vernier Calliper.
B.11 – Blue all faces.
B.12 – Mark out the three hole positions and centre punch each.
B.13 – Check hole positions using a Vernier Calliper.
B.14 – Centre drill 40 x 10 position. Drill 4mm dia pilot hole then drill 6.1mm dia for clearance.
B.15 – Enlarge hole to 6.6mm dia to a depth of 12mm (to accept Counterbore lead).
B.16 – Centre drill 18 x 10 position. Drill 4 mm dia pilot hole then drill 5mm dia through hole (to Tap M6 X 1)
B.17 – Centre drill 10 x 8 position on datum end of the block supporting with Vee Block and Bar. Drill 4 mm dia pilot hole 13mm depth, then reset and drill 6.8mm dia hole 13mm depth.
B.18 – Counterbore 40 x 10 hole 10mm dia 6mm depth.
B.19 – Hand Tap 18 x 10 hole to M6 x 1.
B.20 – Hand Tap 10 x 8 hole M8 x 1.25 x 10mm deep and check with M8 thread gauge.
B.21 – Mark out end 12mm radius using dividers and steel rule.
B.22 – Mark out end chamfer using VHG and combination set.
B.23 – Mark out V cut 4 x 4 x 45 degree angles using Pythagoras, VHG and combination set.
B.24 – File 12mm radius and check to gauge.
B.25 – File end chamfer 45 degrees.
B.26 – File V cut 4 x 4 x 45 degrees
B.27 – Remove all burrs and sharp edges and finish the surfaces.
B.28.0 – Take a photo of your product and upload it to this page. Ensure your name is stamped onto the product.
B.28 – Check all sizes and dimensions, recording your findings below – Is the overall length 60mm +/- 0.25mm?
B.29 – Check all sizes and dimensions, recording your findings below – Is the 10mm x 8mm hole centred to those dimensions?
B.30 – Check all sizes and dimensions, recording your findings below – Is the 42mm x 10mm hole centred to those dimensions?
B.31 – Check all sizes and dimensions, recording your findings below – Is the 20mm x 10mm hole centred to those dimensions?
B.32 – Check all sizes and dimensions, recording your findings below – Is the thread pitch on the 8mm tapped hole 1.25?
B.33 – Check all sizes and dimensions, recording your findings below – Is the radius R12?
B.34 – Check all sizes and dimensions, recording your findings below – Is the Chamfer 4 x 4 x 45 degrees?
B.35 – Check all sizes and dimensions, recording your findings below – Is the Vee Cut 4 x 4 x 45 degrees?
B.36 – Check all sizes and dimensions, recording your findings below – Is the product flat and square?
B.37 – Check all sizes and dimensions, recording your findings below – Is the finish free from false tool cuts, sharp edges and burrs? Are the surfaces finished to 1.6 Ra?
B.38 – Stop work and present product to your tutor.
Job 3 (Tap Wrench Handle)
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