Lathe Metal Green - Acraturn GH1440A
| Aliases | Green Lathe, Big Lathe |
| Other References | |
| Official Maintainer | Ben Jackson |
Current Status
Working
Induction
This machine requires induction to use.
To get an induction you must first review these videos. You must do this BEFORE attending the in-person induction (booked via event bright).
Safety: https://www.youtube.com/watch?v=0X1nZwOZH6M
Changing the Chuck: https://www.youtube.com/watch?v=K0pwJzHfJ50
Notes:
- We have only 3 cam locks on out lathes.
- Stoning the chuck is not necessary. Keeping the precisions surfaces free of chis is essential.
- We use plywood instead of a block to protect the ways.
- Waxing of the chuck is not necessary.
Skills - Blondihacks: https://www.youtube.com/watch?v=H6Dnmd3lDzA&list=PLY67-4BrEae9Ad91LPRIhcLJM9fO-HJyN
Only the following videos are mandatory:
- 1: Theory
- 2: Tool Bits
- 3: Facing
- 4: Tail Support
- 5: Turning
It is recommended to watch the entire series.
Once you have reviewed the videos, book an induction on Eventbrite for the lathe induction.
https://www.eventbrite.com/cc/metalshop-inductions-804979
At this in-person induction we will review how our machines work and have you perform a few simple operations on the lathe.
This induction covers both lathes.
Usage
Learning
Recommended learning resources:
Personal Protective Equipment
| Required |  | Always wear AS/NZS 1337.1 compliant safety glasses while operating this machine. |
| Required |  | Enclosed shoes are required, no open sandals, thongs etc |
| Required |  | Restrain hair while operating machine |
| Prohibited |  | Loose clothing and jewellery not to be worn while operating this machine. |
| Recommended |  | We recommend hearing protection. |
| Warning |  | Entanglement hazard present while wearing gloves. |
| Maintenance |  | Disconnect power to the machine before performing maintenance, including wheel changes |
Machine Specifications
| Name | Value |
|---|---|
| Motor Power | 415V, 3 Phase, 2.54kW |
| Speed Range | 16 Speed, 45-1800RPM |
| Thread and feed gearbox | Imperial |
| Change gears | Current installed: 25/127/50. Additional change gears are not currently available. |
| Swing over bed | 356mm (14“) |
| Swing over cross slide | 220mm (8-5/8”) |
| Distance between centres | 1000mm (40“) |
| Number of spindle speeds | 16 |
| Range of spindle speeds | 45 - 1800 RPM |
| Spindle bore size | 38mm (1-1/2”) |
| Spindle nose | D1-4 Camlock |
| Taper of spindle bore | Morse taper 5 |
| Tailstock quill taper | Morse taper 3 |
Documents
Manufacturer
Manufacturer
- Acraturn
Known Issues
| Date | Description | Workaround | Proposed Remediation |
|---|---|---|---|
| 6/4/2022 | Missing change gears for metric threads | Investigate if missing 40 teeth (*2) and 32 teeth gears can be sourced. | |
| 6/4/2022 | No Interlock | Use key to unlock the 'Reset' kill switch | Install interlock. |
| 9/8/2022 | Key missing for E-stop | Use the brake to stop the machine | Replace E-stop when installing the interlock. |
Modifications / Repair History
| Date | Modified By | Description | Remediation | Cost |
|---|---|---|---|---|
| 4/2022 | Ben Jackson | Face plates loose/open | Bolted face plates to headstock. | $0 |
| 4/2022 | Ben Jackson | Power feed lever not disengaging | Spaced out the lever guide block to ensure guide pin remains trapped. | $0 |
| 4/2022 | Ben Jackson | Panels missing over drive pulley | Replaced panel after finding new bolts. | $0 |
| 4/2022 | Ben Jackson | Missing lever for feed direction | Manufactured a new lever | $0 |
| 4/2022 | Ben Jackson | Ill fitting coolant hose mount | Removed the wood and modified the original mount to fit the coolant pipe. | $0 |
| 4/2022 | Ben Jackson | Loose pulley on motor | Re-positioned the pulley and locked it in place. | $0 |
| 10/5/2022 | Ryan Marple | Installed Quick Change Toolpost | $380 |
Accessories
| Image | Category | Accessory Name & Notes | Location | Buy from |
|---|---|---|---|---|
| Workholding | Live Centre | Top right draw in trolley next to green lathe. | ||
| Drilling | Tailstock chuck | Top right draw in trolley next to green lathe. | ||
| Workholding | 4-Jaw Independent Chuck | Bottom of trolley next to Green Lathe. Note: Use the Lathe board to protect the ways. | ||
| Workholding | 3-Jaw Self Centering Chuck | On the machine. | ||
| Workholding | Face Plate | Bottom of trolley next to Green Lathe. Note: Use the Lathe board to protect the ways. | ||
| Cutting | Quick Change Tool Holders | Top right draw in trolley next to green lathe. | ||
| Workholding | Steady Rest | Bottom of Trolley next to Green Lathe. | ||
| Workholding | Follow Rest | Bottom of Trolley next to Green Lathe. | ||
| Cutting | Tailstock die holder | Top right draw in trolley next to green lathe. |
Consumables & Running Costs
| Image | Category | Accessory Name & Notes | Location | Buy from |
|---|
Maintenance
| Interval | Task |
|---|---|
| Each Use/Daily | General lubrication via the oiler points on the carriage and tailstock. See image below. |
| Monthly | Check oil levels in headstock, gearbox and apron. Refer to manual page 24. |
| Monthly | Grease gear train. |
| Monthly | Inspect and adjust the drive belt. Refer to manual page 22. |
| Annually | Adjust Slide Ways and Cross-Slide nut. Refer to manual page 23. |
| Annually | Change the oil in the headstock, gearbox and apron. Refer to manual page 24. |
RACI
| Task / Action | Executive | Cause Leader Cause Team | Named Maintainer | Trainers | Cause | Membership | Implementer |
|---|---|---|---|---|---|---|---|
| Modification and Repairs | - | AC | C | I | I | I | R |
| Induction changes | C | RACI | RC | I | I | I | R |
Risk Matrix and Mitigation
PLACEHOLDER: Risk assessment is important to ensure we are making tools available to members in a responsible fashion. Please make every effort to do a reasonable risk assessment. If there is a safety incident with the tool, please redo a risk assessment and add it to the table.
| Ref / ID | Pre-Mitigation | Mitigations / Warnings / Remedies | Post Mitigation | ||||||
|---|---|---|---|---|---|---|---|---|---|
| Risk | Risk Severity | Risk Likelyhood | Risk Level | Risk Severity | Risk Likelyhood | Risk Level | Acceptable to Proceed | ||
| 0001 | Death | Severe | Possible | 15 | Induction to train users in correct usage. | Severe | Very Unlikely | 5 | Yes |
| 0002 | Electric Shock | Major | Unlikely | 8 | Induction to train users in correct usage. Ensure power cables are properly connected and off the floor. Cables are tested and tagged and inspected for damage. | Minor | Very Unlikely | 2 | Yes |
| 0003 | Noise | Moderate | Likely | 12 | Train users to wear hearing protection. | Insignificant | Unlikely | 2 | Yes |
| 0004 | Tripping Hazard | Moderate | Possible | 9 | Train users to maintain a clean working area. Keep all cables off the ground and secured out of the way. | Insignificant | Unlikely | 2 | Yes |
| 0005 | Insufficient Lighting | Minor | Possible | 6 | Turn on shop lights. Open metal-shop doors for natural lighting. | Insignificant | Unlikely | 2 | Yes |
| 0006 | Entanglement | Major | Possible | 12 | Induction to train users in correct usage. Remove any possible entanglement items such as long sleeves, gloves, watches, jewellery, etc. Tie back long hair. | Minor | Unlikely | 4 | Yes |
| 0007 | Impact Injury | Major | Possible | 12 | Induction to train users in correct usage. Train users in correct use of the chuck/fixture plate as per the induction. Train users in chuck key discipline (never leave the chuck key in while performing another task). Train users to remove the chuck key before engaging the spindle motor. Train users in appropriate use of tailstock support. Require use of appropriate PPE. | Minor | Unlikely | 4 | Yes |
| 0008 | Slip | Major | Possible | 12 | Induction to train users in correct usage. Train users in correct use of coolant to avoid spilling on the floor. | Minor | Unlikely | 4 | Yes |
| 0009 | Respiratory/Skin Irritation | Moderate | Unlikely | 6 | Induction to train users in correct usage. Train users in the risks related to metalworking fluids. | Minor | Unlikely | 4 | Yes |
| 0010 | Inhaliation of Fumes | Moderate | Possible | 9 | Induction to train users in correct usage. Open metal-shop door to allow ventilation. Fans are provided top assist in ventilation. Train users to use the appropriate type and volume of coolant. Require use of appropriate PPE. | Minor | Unlikely | 4 | Yes |
| 0011 | Laceration/Dismemberment | Major | Possible | 12 | Induction to train users in correct usage. Train users to keep clear of the cutting tool and the part. Require that the cutting tool is securely fixed (in the quick change tool-post or tail-stock). Require use of appropriate PPE. | Minor | Unlikely | 4 | Yes |
| 0012 | Burn from workpiece | Moderate | Possible | 9 | Induction to train users in correct usage. Allow parts to cool after cutting. Train users to ensure adequate coolant is used. Require assessing workpiece temperature before handling. | Insignificant | Unlikely | 2 | Yes |
Decision Register
| Ref / ID | Decision Details | Impact | Proposed Date | Proposed By | Status | Approved By | Date | Resulting Actions and Comments |
|---|