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Overview of Manual Saws
Overview of Manual Saws
A Manual Saw is a cutting device that is both powered and controlled by a person
There are many different types of manually saws, that come in all shapes, sizes, and form factors that all serve different purposes, ranging from medical devices to construction tools and even ones used aboard the ISS in Earth's orbit!Links to an external site.
Even though semi-automatic and fully-automatic saws exist, manual saws still serve their role within manufacturing, so there are both pros and cons depending on the scenario:
Pros of using a manual saw:
Manual saws are generally more affordable than semi-automatic or automatic saws.
They are simpler in design and require less maintenance.
They are lightweight and easy to transport, making them ideal for jobs that require mobility.
They are more versatile and can be used for a wide range of cutting tasks.
They can be used in areas where electricity or power may not be available.
They require less training to use, making them a good option for those who are not experienced with power tools.
They require almost no setup time, so can excel in single/small quantity operations.
Cons of using a manual saw:
Manual saws require more physical effort to use, which can lead to fatigue and injury if proper technique is not used.
They are not as efficient as semi-automatic or automatic saws and may take longer to complete a cutting task.
They may not be able to cut through thick or hard materials as easily as a power saw.
They are not as precise as power saws, which can lead to inaccuracies in the finished cut.
Therefore, when deciding whether to use a manual saw or a semi-automatic or automatic saw, it is important to consider the specific cutting task, the available resources, and the skill level of the operator. In some scenarios, a manual saw may be the best choice, while in others, a power saw may be more appropriate.
Tape Measure Basics
Tape Measure Basics
A Tape Measure is a long, flat ribbon or string with linear-measurement markings. It is used to measure length, width, or height of a variety of raw materials.
There are several different types of tape measures available:
Retractable Tape Measures have a spring-loaded mechanism that allows the tape to be easily pulled out and locked in place at a specific measurement. These are the most common type of tape measure and can be found at most hardware stores.
Locking Tape Measures have a thumb lock that keeps the tape in place while taking a measurement. This type of tape measure is great for taking longer measurements or measurements in tight spaces.
Measuring Wheels are used to measure longer distances, such as the distance around a room or the perimeter of a property.
Laser Tape Measures use a laser beam to accurately measure distances.
Soft Tape Measures are made of flexible material and used to measure circumference of round parts.
Pi Tape Measures are flexible and used to measure diameter of cylindrical parts.
When using a tape measure, it is important to hold the tape securely and keep it level while taking a measurement.
Additionally, at the end of a tape measure is typically a metal hook that
When using a tape measure, it is important to be mindful of the blade, as it can easily become bent, kinked, or corroded.
This can cause the tape measure to give inaccurate measurements.
To avoid this, it is important to keep the blade clean and dry, and to not let it come in contact with sharp edges or other objects that can damage it.
Basic Identification of Metals
Basic Identification of Metals
In an industrial environment, a saw operator typically only interacts with one broad category of materials - either metals, woods, polymers, composites, or other type of material
One of the most common types of materials for saw operators to interact with - particularly in an Industry 4.0 manufacturing environment - are metals
Metals can come in many shapes, sizes, & profiles (more on those later!), as well as many different kinds of alloys
An alloy is a specific mixture/blend of alloying elements that combine together to result in desirable material properties not typically found in totally pure metal elements
Common alloys of metals include:
Steels, which are alloys made primarily of Iron
Stainless Steels alloys, made primarily of Iron with a significant amount of Chromium
Brass alloys, made primarily of Copper and Tin
Bronze alloys, made primarily of Copper and Zinc
There are several key methods you can use to properly identify & distinguish metal alloy types from one another:
Magnetism
Testing a metal's reaction to a magnet is a simple way to identify some alloys. If a metal is attracted to a magnet, it is likely to be an iron-based alloy such as steel.
Color
The color of a metal can give clues to its composition, as some alloys have distinct colors. For example, pure copper has a reddish color, while brass has a yellowish tint.
Density (Weight)
Measuring a metal's density (weight per unit of volume) can help to identify it as different alloys have different densities. This method can be used to distinguish between alloys with similar physical characteristics.
Spark Test
A spark test involves striking a metal with a grinding wheel to observe the sparks it produces. The color and pattern of the sparks can give clues to the metal's composition and help distinguish it from other alloys.
2.2✔ CHECKPOINT
2.2✔ CHECKPOINT
Manual (i1.0) Saw Operator
Manual (i1.0) Saw Operator
For this Checkpoint, you will be performing the role of an Industry 1.0 (i1.0) Manual Saw Operator
Note: If you are physically unable to complete the following tasks for whatever reason, please let the instructor know and we'll have you do something else!
Using a metal hacksaw in the MET Cutting Lab, do the following:
Locate 1" 6061-T6 AL Square Bar
Securely holding the square bar in a bench vise:
Measure and cut off a 1.25" (+/- 1/16") long piece
Inspect the cut quality/dimension to the specified tolerance
Measure and cut off another piece of the same length/tolerance (for a grand total of 2 pieces)
Deburr all sharp edges of the piece
Inspect the cut quality/dimension to the specified tolerance
Record and document:
Setup Time (How long it took you to get ready to cut)
Cycle Time (How long it took you to cut each piece)
Post-Processing Time (How long it took you to inspect & deburr each piece)
Bring the pieces to your instructor to verify quality & be used to make parts for a later module in this course
Once done, upload documentation of your progress (text/pictures/gifs/videos) to your previously-created "Saw Operator" project page on your portfolio website, including:
You performing all operations of making the pieces (ID, setup, measure/layout, cutting, deburring, inspecting)
A table showing your setup, cycle, and post-processing times
Descriptions/summaries of what you did/learned
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