Manufacturing and the Five Senses.
Being a machinist teaches you fundamentals of common sense. How to use your five senses mechanically and learn to use them as super powers.
Chapter 1: Let's start from the basics
Print Reading
Process creation
Tooling set-up
Work Holding
Programming
Sense 1: The common sense of Sight
Here is where you analyze the part print.
Visually decide which chuck jaws will give you the best grip.(Then test fit).
Which geometries will cut the material efficiently.
Then which process steps you will take based on the dimensions/operations. (Rough or finish)?
Program the speeds and feeds based on the material and set-up rigidity.
Double check your tools, and tool paths to avoid any collision.
Make sure your inserts are new and sharp.
Make sure you have a secure grip on the workpiece.
If you see any potential issues. Fix them before you move to the next process.
Sense 2: The common sense of Touch
Once you get your set-up going you should always keep your hand close to the stop button and rapid very slowly to make sure it's going to plan.
Feel that the workpiece is balanced at the RPM you run.
Then while cutting you must feel if there is any instability
You can feel almost any bumps or vibrations while holding onto the door handles.
If you feel any instability then you may need to speed up or slow down.
Troubleshoot:
Feed higher or feed lower.
Change the depth of cut.
Change insert geometry.
Increase coolant tank volume
Improve chip control.
Sense 3: Common Sense of Hearing
Listening to the harmonics is done mutually with feeling the vibration.
While listening for any instability you must be very in-tune with the machine.
During the cut you want to hear a steady rhythm in order to get the best tool life.
The material sound can vary based on rigidity of tool or workpiece.
Stability is also based on material properties, hardness, and cutting forces.
You need to feel it out for the first couple of passes or even the entire first piece if you are having any troubles.
Sense 4: Sense of Confidence and Wisdom
You must always have a mindset that you can make it happen.
There is no giving up in manufacturing.
Even if you don't get it right the first time you must analyze what went wrong and re-do the process until you find a way.
Sometimes it is luck; But most of the time it is the will power behind the machinist.
Sense 5: Smell
Yes you can smell the oil on your fingertips.
Summary:
You must always learn from experience. but you must also believe in yourself and be confident that you can make it happen.
Anything can be done in a machinist world.
Favian Espino
Listo Group LLC - Publishing Series
