Staff/Student Shop

Physics Staff/Student Shop

Located in Room 1249 Chamberlin Hall

Hours:

Monday-Friday 7 am – 3 pm Provided there’s staff available.

Safety glasses must be worn at all times while in the shop. Please return glasses upon leaving
Proper footwear must be worn; a complete shoe that covers the toes, tennis shoes are allowed. (NO SANDALS)
No loose hanging jewelry, rings, watches, or ties while operating equipment.
Long hair must be tied back, or under a cap or hat.
No cell phone use while running machines. (as a calculator is permissible)
You are not to use any piece of equipment that you have not been trained on or not cleared to run by the supervisor in charge.
All machines and tools are to be used in a safe and appropriate manner.
Machine guards/stops must be in place and in use while equipment is in operation.
All equipment and tools must be cleaned after you are done using them.
All tools are to be used in the manner for which they were designed.
While you are encouraged to use the shop during supervised hours, if however you have been authorized to use the shop after hours another person must be in the shop with you in case of accident.
ALL accidents, including minor cuts or burns must be reported to the supervisor in charge within 24 hours.

Only Authorized Shop Users may utilize the equipment after hours.

Authorized Shop Users are those persons who have either taken and passed the Department’s Machine Shop Class or proven their competency in the use of Machine Tools to the Supervisor in charge.

After Hours

Monday – Friday after 3:00 pm

We currently have 2 part time student staff techs working in the student shop. We will try and set up times during their schedule to accommodate students that want to use the student shop. If that doesn’t work, follow the rules below.

After hours users must adhere to the following rules and regulations:

Main Door to the shop must be left open at all times.
Buddy System is to be used.
Must log into the Student shop app and reserve a machine.

The Buddy System is as follows:

You must sign your name, date, time you arrived, and your shop I.D. # and the name of your “Buddy”.
Your “Buddy” is someone in the shop with you at all times.

Remember:

All Safety Rules must be adhered to ESPECIALLY AFTER HOURS. If you see safety
rules being ignored, please report it to Supervisor A.S.A.P.
Notify the Supervisor in charge A.S.A.P. if equipment is in need of repair.
Always sign out the stock you have used.

Project PDF Files

https://making.engr.wisc.edu/wp-content/uploads/sites/412/2017/12/AlphaPart.pdf

https://making.engr.wisc.edu/wp-content/uploads/sites/412/2017/12/BetaPart.pdf

Training videos

Alpha

http://bit.ly/lathe-alpha

http://bit.ly/mill-alpha

Beta

http://bit.ly/lathe-beta

http://bit.ly/mill-beta

How to Square Up Stock

Standard Drawing Views

Standard drawing views

Undimensioned – Try it yourself! – (Solution)

Cutting Speed and Feeds

Some considerations to your choices:

rigid set up

is your part secure? no-take lighter cuts

is your tool as short as possible to do the job? no-use a lower speed

is the machine rigid? no-use a lower speed and feed

is your tool sharp? no-reduce your speed and feed or get a new cutter

does your material work harden? start in the middle of the range

chip formation & chip evacuation

inner voice-self preservation-if you are not comfortable with the caculated speed and feed, start off on the lower end of the range

Simplified Speeds and Feeds

S= (CS x 4) ÷ D

S= Speed (revolutions per minute) – how fast you spin the part or tool
CS = Cutting Speed of the material (surface feet per minute)
D = Diameter of the rotating tool or part (inches)

CS for typical materials using high speed cutting tools, for carbide tools increase the CS by 1½ -3 times
Aluminum          200-300
Brass                100-200
Copper              60-80
Plastic                200 varies greatly, depending on the type of plastic
Steel                 80-100
Stainless Steel   40-50

FR=Feed Rate (inches per minute) – how fast you cut across the part

FR=CS x # of teeth in tool x chip load

Rule of Thumb
Increase the Feed Rate or Decrease the Speed to remove chatter

For example:
Cutting Aluminum block with a ½” ø high speed end mill with 2 flutes
S = (300 x 4 ) ÷ .5 = 2400 RPM
FR = 2400 x 2 x .001 = 4.8 ipm
this is a good place to start