Machine a replacement pump shaft on the lathe

You are a machinist at the Wodonga machining centre.

Simulated workplaceIntermediate missionCAQA Ironbark Engineering

What is going on

Kestrel Water Corporation have a split case pump out of service and have ordered a replacement shaft under job card JC-26-0415 to drawing KW-P17-03 rev A. The 4140 grade round bar arrived under receipt REC-26-0882 with its certificate on file. The shaft has two bearing journals with close tolerances, a keyway, a thread at the drive end and specified surface finishes. The horizontal borer is tagged out of service, so all work must be planned for the CNC lathe and the mill. Tan Nguyen, the Machine Shop Supervisor, wants the shaft finished, measured and reported by 22 September so the customer's fitters can rebuild the pump.

Tan Nguyen, Machine Shop Supervisor
Subject: Kestrel pump shaft, drawing KW-P17-03

Kestrel need the replacement pump shaft by 22 September and the 4140 bar has arrived under receipt REC-26-0882. Plan the machining sequence from the drawing, set up the lathe, and measure every toleranced dimension with the calibrated equipment. The keyway and the bearing journals are the critical features. Record the results on an inspection report, book your hours to JC-26-0415 and move the job card to Awaiting inspection when done. Check the equipment register first, the horizontal borer is tagged out.

Your brief

Plan the machining sequence from the drawing, set up and operate the lathe and mill safely, hold the drawing tolerances on the journals, thread and keyway, measure with calibrated equipment and produce an inspection report so the shaft can be released to the customer.

Work through it

You do not need to do it all. Doing a few of these will show you what the work is like. Your ticks and notes stay on this device.

Open JC-26-0415 in the Job Card Register, confirm the drawing revision and required date, and check the Plant and Equipment Register for the status and calibration of the lathe, mill and measuring equipment you will use.
Interpret drawing KW-P17-03 rev A and write a machining sequence: stock preparation, roughing, finishing of journals, thread cutting, keyway milling and deburring, with the tooling and speeds and feeds for 4140 grade.
Prepare a Job Safety Analysis for the lathe and mill work covering guarding, swarf handling, coolant, chuck keys and lifting the bar into the machine.
Confirm in the Materials and Certificate Register that the bar under REC-26-0882 is the correct grade and size and record the heat number on the job card.
Set up the lathe, machine the shaft to the sequence and measure each toleranced dimension with micrometers and gauges, recording actual readings against the drawing limits.
Machine the keyway on the mill, check it with the gauge, then complete the inspection report listing every dimension, its tolerance, the measured value and the instrument used.
Record any hazard or near miss, such as coolant on the floor, in the WHS Incident and Hazard Register.
Book hours to JC-26-0415, change the status to Awaiting inspection and give the shaft, drawing and inspection report to the supervisor.

My notes: what did I enjoy, and what surprised me?

What someone in this role would produce

Written machining sequence with tooling and speeds and feeds
Job Safety Analysis for the lathe and mill work
Inspection report with measured values against every toleranced dimension
Updated job card JC-26-0415 with hours and status

Printing this is a record of what you explored. It is not a certificate or a qualification.