OSE Metal Fabrication Certificate: Difference between revisions

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=Methodology=
#Redirect [[OSE Metal Fabrication Certification]]
The OSE Metal Fabrication Certificate is the first in OSE's line of certification based on well-defined criteria and testing. The basic test involves MIG welding, torching, grinding, drilling, marking, tool selection skills, and others. These skills are based on a generalized skill set indispensible to effective functioning in OSE build events.
 
The method of certification involves: (1) skills presentation by instructor; (2) hands-on practice by individuals; (3) Self-exam and documentation on wiki (see [[Fabrication Exams]]; (4) instructor-verified checklist of approved fabrication tasks.
 
Grading is based not on pass/fail basis, but on a method that fosters continuous improvement. As such, an Exam is simply a documentation of someone's skill set - and involves taking pictures and notes of a person's results based on well-defined tasks. These are documented on the wiki as the category [[Category:Certification Exams]].
 
=Tool Selection=
What tools to use for cutting, drilling, holes, severing, measuring, bending, forming. Limits to bending metal. Limits to heat bending. Bending with a shop press. Deciding what tool to use for cutting shaft, thin tube, rebar, flats based on weight, length, precision requirement, speed of cut, temperature of cut, and purpose. Tolerancing of tubing holes. Cutting holes based on diameter, thickness of material, and speed.
 
=Holemaking=
Drill press. Hand Drill. Mag Drill. Punch(see [http://opensourceecology.org/wiki/OSE_Metal_Fabrication_Certificate#Ironworker_machine:_Metal_Shear.2C_Punch.2C_and_Angle_Cutter ironworker])Mill (see [http://opensourceecology.org/wiki/OSE_Metal_Fabrication_Certificate#Using_a_Milling_Machine Milling Machine]).  Holesaws
=Safety=
Eyewear. Gloves. Steel-toed boots. Welding helmets. Hard hats. Excess welding wire. Sharp corners. Heavy objects. Use of hoist. Fire extinguisher. First aid kit. Eyewash. Grinding safety. Welding fumes. Zinc plating and galvanized steel. Sound cues: metal squeaks and gas leaks. [[Safety Exam]].
 
=MIG Welding=
Ability to weld from sheet steel to 1/2" steel. Understanding wire feed speed and power settings, both high and low. Proper tension on MIG wire. Knowing when liner is clean. Understanding shielding gas flow. Keeping guard clean. Replacing tips. Keeping work area clean. Protective clothing. Turn-on and shutoff. [[Welding Exam]].
 
=Torching=
Understanding proper gas pressure. Uderstanding tip size. Cutting straight lines. Cutting circles. Cutting 1" stock. Cutting sheet stock. [[Torching Exam]]
 
=Brazing=
Understanding when metal is hot enough. Range of applications for brazing. [[Brazing Exam]].
 
=Abrasive Cutting and Grinding=
Using an abrasive cutoff saw. Cutting small diameter rounds rapidly. Cutting large-diameter rounds. Mounting new grinding wheels. Distinguishing when material gets cut-hardened. Grinder basics. Using cutoff wheels and grinding wheels. 5 and 15 amp grinders. Locking in a grinding wheel. Replacing motor brushes. Repairing a broken cord. [[Abrasive Tools Exam]].
 
=Measuring=
Using a correct reference point. Transfer punching. Using tracing paper to mark patterns. Using a speed square, level, carpenter's square, tape, and ruler. Match drilling. [[Measuring Exam]].
 
=Using a Milling Machine=
X, Y, Z motion of slides. Using a milling bit. Milling keyways. Locating the top of a shaft. Using a mill as a drill. Feed rate. Cutting fluids. Proper workpiece fixation. Using a Digital Readout for distance measurement. Centering a hole on a shaft using the digital readout. Boring a hole to a precise diameter on a mill. Flycutting. Cutter diameter selection. [[Milling Exam]].
 
=Precision=
Using calipers. Using a dial indicator.
 
=Ironworker machine: Metal Shear, Punch, and Angle Cutter=
Procedure for punching holes. Replacing dies. Understanding die size. Open center bidirectional hydraulic valves. Workpiece hold-down. Force amplification from blade gap and safety. Power Cube operation. [[Ironworker Exam]].
 
=Bandsaw=
Cutting fluids. Feed rate. Blade alignment procedure. Throat thickness adjustment. Understanding Teeth Per Inch. Blade Selection. Clampgin a work piece. Clamping work pieces that are too short. Angled cuts. Cutting seam tubing. Number of teeth on metal. [[Bandsaw Exam]].
 
=Lathe=
At least a basic understanding of the Lathe's role in a manufacturing setting
*how chucks and collets function
*basic understanding of how speeds are selected depending on the work and the operation
*Leadscrew function and when it is used
*Filing and sanding in a lathe
*Drilling a hole
*Manual tapping & threading with a die using tailstock as center
*Turning&boring a diameter
*Use of DRO and/or Dial Indicators
*Coolant
More advanced topics that may not fit in the OSE Spectrum
*Threading with a leadscrew - internal and external
*Setting stops
*Turning Eccentrics
*Four-Jaw chuck
*Turning a Taper
*Turning between centers(not actually advanced, just superfluous)
*Turning over your life to jesus
*Steadyrest/follower rest

Latest revision as of 02:44, 31 July 2015

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