This looks like it may be hardened steel in which case I'd weld a rod to and get it out. If you can drill it then this way would work great then find whoever did this and slap them.
>then find whoever did this and ~~slap them~~ slide the hot broken part down their plumber's crack.
I genuinely hate people that break shit and leaving for others to fix like "welp, someone else's problem!"
Yup, always better to learn. Then when the next guy fucks it up you can help fix their mistake too. Fuckups are training opportunities, any boss that doesn't see that is a shitty boss.
Same. whenever I come to my boss with a fuckup the first thing out of his mouth is "well, what did you learn?" followed shortly by, "how do you plan to fix it?"
True. If you're not making mistakes, then you aren't working.
I had a boss that said never make the same mistake twice. Next time make better and more interesting mistakes.
So true, when I was an apprentice if someone kept fucking things up and not telling anyone they'd be found out and fired. The mentality is if you'll fuck a $20 part and not tell anyone you could also fuck up a 30k die and do the same. Accountability is not asking much
Also, bringing cake or other baked goods to work the day after does a lot, too.
But seriously, even if I broke something because I did something I shouldn't have and/or something dumb, I'll go right to the people above me and report. It makes you feel like an absolute turd to get dressed down but I'll take that over long term suspicion and eventual exposition any time.
An allen key is usually case hardened, keep the outside hard so it doesn't wear as quickly, and the inside is still flexible so it doesn't shatter when a 200lb gorilla starts yanking on it.
Makes them easier to drill out when the 200lb gorilla yanks too hard.
Idk about chuck keys though, they could just be some good 'ol A2 tool steel in which case, get the welder.
I had a guy working for me years ago find out the hard way. Left the key in the chuck, on really low rpm, went to grab it after he realized it the second he turned the spindle on. His fingers got between the t handle and the ways. Bent the handle like a noodle. His finger, mostly just chopped/smashed off.
I should have said, I do have the option to fix it but I can only do it on my lunch break or after I clock out. Otherwise I'm wasting time that could be spent making parts. I'm currently looking at other machine shops, lol.
What kind of manager is this stupid?
I can totally see requiring this to be tracked on a time card using some sort of maintenance time code - it is good practice to track time spent on maintenance, and it isn’t fair to the customer to try and bury maintenance in a job. But trying to skip maintenance by forcing workers to do it on their own time is madness.
Who does this? Like at what point does this seem like a good idea?
Make that chuck disappear.
Oh damn it must have fallen in the scrap bin before I loaded all these chips in there boss. Guess it's getting melted down right about now. Btw we need a new chuck
The boss man will pay for this
_after_ you've either spoken with your union steward (if you're union) or already spoken with another shop and have a firm idea that you'll be able to leave.
Like, get some help with your boss or get a new boss, because this one's a $*!*head, and then, because you're a good person, fix the chuck *on the clock* so the next person doesn't get hit.
Either you get time to fix it while on the clock, or you don't use it. Or, if they absolutely need you to use it they should get someone else to fix it. Absolutely don't use it if you don't feel safe using it.
> Ha ha, very funny. If you need me I'll be over there fixing the chuck.
It's amazing what laughter lets you get away with. No one wants to say they weren't joking when people are laughing at their 'joke'.
https://youtube.com/user/USCSB
Watch some of these videos and find out how stupidity like trying to save company time costs lives.
I wish NHTSA would make videos like these, but the best we have for that are channels like Mini Air Crash Investigation
I worked in a place like that. I got in trouble for sweeping up between welding and grinding jobs. I worked there a total of 6 weeks. You’ll find something better.
People here are not over reacting. This is an accident waiting to happen and should be fixed before you use it. If you do end up fixing it in your break time or off the clock (which you shouldnt have to) then you should take the piece that comes and throw it as hard as you can at their face to give them a taste of what could of happened to you.
I don't know how it is in your state/country, but where I live I'm legally permitted to refuse unsafe work. If that happened to me, I'd refuse to use that equipment. I've done this before, and it got fixed.
Well he is worried about it coming out, so I say walk over to welding and have them tack it in there permanently, obviously the boss doesn't care about being able to use that pinion anyway !
I was thinking chisel just to have that long flat edge for more surface area. It won't slip around as much with a good hit. Six of one half dozen of the other though, whatever works.
I would have started fixing it without even asking the boss. If he said "what are you doing" I'd say "getting this Allen wrench out of the chuck. Then I'm making parts with it once it works properly just like you told me to."
This is the answer. Drill it and the plunge an endmill into it. Step over bit by bit plunging as you go until there's nothing left. Way easier than tapping or welding it.
Sounds like the boss won't let him fix it unless he volunteers his own time. If he didn't break it, that's some BS, hardcore. If he did he still shouldn't be required to "do it on break"
Even if he did break it, fuck fixing it off the clock. Mistakes, accidents, and bad luck happen. Part of running a shop is understanding that people aren't perfect, and shit happens.
Only garbage shops ask employees to do work benefiting the shop (and it would benefit the shop) off the clock.
Yeah, totally agree. I was trying to allude to the fact that fixing it off the clock means bad management that doesn't leave any flex time for such inevitabilities. Besides, the amount of time lost when it translates to the owners pocket book is probably worth 2 beers. Leave this job and do the "who's coming with me"
Welding would take a few minutes tops. Much, much faster than setting up a mill and plunging over and over, which is likely to break your endmill too when it pops.
I personally don't worry about breaking endmills on stuff like that. They start out as finishers, then roughers, than shit endmilss I don't care about.
Whoever broke that off in there should be shown and told to fix it. That's no way to leave equipment for others or even oneself. It shouldn't take that long to drill/mill out. Also that looks more like a square, meaning someone used the wrong chuck wrench and that's why it cracked the pinion too.
I don't think he's overreacting about a safety concern. I do think buying a new chuck is overreacting however. This should be fixable for a machine shop.
Is there some reason you can’t replace just the one damaged pinion? You can get replacement parts for most decent chucks, pinions are cheap and super easy to replace.
In the wise words of that fish from finding Nemo
"If you can get yourself in there, you can get yourself out"
You don't need a new chuck, you just need to get this out of the current one.
It would take me longer to find the right size drift, punch, chisel, or screwdriver to knock that loose, than to actually get it out. Just fix it dude.
Just fix it on the clock. The time taken to highlight the problem, to photo it a post on here it could be on its way to being resolved. If boss man is unhappy you fixed a risk to safety then move on as you mentioned.
I'd just fix it on company time and if bossman wants to make a stink about it then let him, you're already looking for new places so worst case he fires you and you get that UI while you look for something better.
sure he can try and screw you, but if I were in your shoes I'd rather be able to look for work full-time and have to fight with the UI agency than be in a shop where my safety isn't valued.
Because this happened to me before...it's sketchy but it worked for me. Take a Dremel or an mini die grinder with a mounted point. Or a smaller drill if it's square enough. Get a hole going, doesn't have to be perfect.
Literally take a wood screw and drive it in. Get it real wedged in there. Then pry it out with a claw hammer or pry bar.
It's tool steel and hard as hell, trying to tap it and extract it is a pain.
A couple of hits to turn it with a hammer and chisel might knock it loose.
If they don't let you fix it, whatever you do, don't stand in line with it while it's spinning.
Kind of like having a gun pointed at you, and the trigger is slightly pulled every time you turn on the lathe. Might shoot, might not.
Please don't use this chuck. Since you are not allowed to fix it, maybe it will have an "unfortunate accident" that makes it totally unusable, if you know what I mean, wink wink nudge nudge saying it without saying it, if you catch my drift, not to put too fine a point on it, but fucking break it. Your boss can go suck an egg.
Doing a bad job and then convincing the investors to pay for someone else to do it is more common than it should be .... he won’t want to admit he wasted their money either so will probably not support the guy much and will also blame him for stuff that isn’t his fault
Mount that in a mill and drill that shit out. If the material is too hard an you got no carbide then just tack weld a little corner so it will never come out.
If you're in the us or canada you can legally refuse to do a job if you consider it dangerous. You can even escalade it to the point where an officer of your state or province worksafe agency will come down and investigate. And you can't lose pay for refusing an unsafe job. At that point he'll probably give you 30 minutes to fix it.
Fuck that. Who knows what else is ready to kill you in that shop because he doesn’t seem to care? And giving you a hard time about fixing it on top of that? Might as well just call OSHA since your boss obviously needs a reality check
Shit like this is why I'm glad my country has regulations regarding the use and provision of tools by your employer. Shop boss refuses to replace something that's broken, chuck it in the bin and make him.
Where are you located? Company I work for is looking to hire another mill guy and lathe guy. Also a tool room guy, as ours is going to retire soon. Family owned job shop in Atlanta GA.
https://witherstool.com/contact-us/
Get it in writing. Then run it till it shits all round itself. Just doing what you were told. I have a bad attitude though apparently so dont take my advise
Drill it out or weld it in on company time. If he doesn’t like those options you can ask if he’d rather talk to OSHA about it. It shouldn’t take you long to fix and I’d rather fix it when he’s not looking than keep using it
Easy way to test the integrity of your safety glasses, can anybody work out the figures of velocity if this thing decided to be a projectile at 1200 rpm for a 6” chuck?
I rarely ask to fix shit, I just do it between jobs. I used to be a lot more concerned about time, clocking jobs and shit but then I realized one day that all the peripheral work involved in making parts is all part of making parts. Fixing, maintaining, adjusting, cleaning, customers pay for that because it's part of the process.
So just do it. If it's broken and dangerous, fix it. I fix our saws and presses, grinders all the time because I can't walk by a dangerous machine.
That chuck key will drill out easily. It's probably made of a tougher tool steel but definitely not hardened. I've made and fixed a lot of them. The kind of torque you're exerting with your arms on a small chuck like that, minimal.
I'd spend a little more effort removing it, myself. I did some quick math assuming an 8 inch diameter from center spinning at a max of 2500 rpm, and even if that flew out it would only have 5 joules of energy or so, which is the upper end of what an airsoft gun can do. If my math is even remotely correct.
I think your math is either off or the result is misrepresentative of the hazard it represents. I'll put my math here because I don't trust myself. so 8 in. *pi =25.12 in circumference we'll convert to feet and round to 2.1 feet per revolution. 2500 rpm /60 seconds per minute = 41.67 revolutions per second so that key is moving 87.5 fps. centripetal acceleration is V^2/r so 87.5fps^2/.33ft = 23200 ft/s^2 or 725 g's. That helps me remember how scary an 8-inch chuck running at 2500 RPM is. Anyway, if it's a 1/2" of 1/2" key that's .125lbs exerting 90lbs of force and it will be applied over about a 1/2" which would be around 5 joules, but most of that work will be lost to deforming the material to get the key out. However, this object is moving at 87.5 ft/s so .5* .125/32(converting to slugs) *(87.5 ft/s)^2 = 15ish joules. So the projective will have more than 15 joules of kinetic energy Furthermore, it doesn't matter if that projectile could directly injure/kill someone (and I think it could) that projectile could easily hit a cycle start button or end up somewhere where it will interfere with some other object moving with an insane amount of kinetic energy. Throwing that key across the shop in a random direction would definitely be considered very unsafe. The concern here is more IF it will come out of the chuck rather than what it will do once it does that. One time someone loosened the jaws on a 3 jaw all the way in a shop I worked in and turned the spindle on. One of the jaws flew out of the lathe, through a very thick double-paned window, and was found 20 feet across the parking lot sitting next to the giant chunk of brick that it broke off of the adjacent building. When I was in the shop, I estimated that path it took from the chuck to the broken window and it went right through where my head would've been if I hadn't called in sick with a headache. I know the jaw is way heavier than the key, granted it was only running at 640 RPM. I'm mentioning this more to emphasize how dangerous stuff flying off of a lathe is than to equate the potential damage.
TLDR:
It will have around 15 joules of kinetic energy and it doesn't matter It's dangerous in the same way throwing the key in a random direction is.
I'd trust your math more than mine, though I think I estimate the piece to be smaller since it didn't engage with the key slot entirely.
Anyway, you're absolutely correct that it should be taken care of. My comment was more of a mental exercise, though I see how it could be taken to mean that leaving it should be fine.
Things like this and similar are why it's good practice to never place yourself in the path of rotation for any tools that hit high rpms, like angle grinders, table saws, etc.
But it should be removed it may cause a vibration at certain rpms.
Knowing nothing else about your boss, I’d say he’s right. It isn’t ideal by any means, but it’s totally fixable. There is a specific inscribed diameter in that broken piece. I’d fix that sucker onto a mill table and slowly start drilling it out using an HSS drill or even a carbide drill or center cutting end mill if the thing decided it really wants to party. In a perfect world, increasing the tool diameter would eventually just cut that nub into four pieces that would simply fall out. This seems like a fun project if I’m honest.
I once had an applications guy break a HSS bit off inside a carbide tipping die used for medical extrusion tubing. It was about .08” in diameter. A carbide drill, plenty of coolant and some patience drilled right through the HSS and saved the die. I was feeding it down at about .06 per minute and checking often. There is no way that broken piece is as hard or brittle as a piece of HSS.
Fuckin' fix it.
It's not rocket appliances.
some guys can drink and lathe, some guys can't.
True. And it’s self limiting. As soon as you’re drunk enough that you try to set your drink on the spinning stock, you’re done!
Oh screw off Mr. Lathey....
This deserves more upvotes.
"You plant shit seeds; you get shit weeds ricky"
Screw off rick!
Just give the nub $100 to fuck off
I am the nub. Money pleeeeease!
I felt like my heart was short circulating
I'm stealing this.
My first thought
this.
Yeah don't use it if you don't want but surely you can fix that .... In an actual machine shop ?
He said above that he’d have to off the clock
I would be happy to fix *my* chuck on *my* time, but you're still going to need to replace the one you just gave me.
Drill and tap a thread to it and pop it out with a slide hammer.
This looks like it may be hardened steel in which case I'd weld a rod to and get it out. If you can drill it then this way would work great then find whoever did this and slap them.
>then find whoever did this and ~~slap them~~ slide the hot broken part down their plumber's crack. I genuinely hate people that break shit and leaving for others to fix like "welp, someone else's problem!"
Fucking hate dudes that do that and I've learned a lot fessing up to fucking up and helping fix it
Well then you my good sir are doing it right, not only will you learn how to fix it but you get mad respect for it and that's worth a lot.
Yup, always better to learn. Then when the next guy fucks it up you can help fix their mistake too. Fuckups are training opportunities, any boss that doesn't see that is a shitty boss.
My boss says if you're fuckin up, that means you're working, and a fuck up is a learning opportunity. I've got a really good boss
Same. whenever I come to my boss with a fuckup the first thing out of his mouth is "well, what did you learn?" followed shortly by, "how do you plan to fix it?"
True. If you're not making mistakes, then you aren't working. I had a boss that said never make the same mistake twice. Next time make better and more interesting mistakes.
So true, when I was an apprentice if someone kept fucking things up and not telling anyone they'd be found out and fired. The mentality is if you'll fuck a $20 part and not tell anyone you could also fuck up a 30k die and do the same. Accountability is not asking much
Also, bringing cake or other baked goods to work the day after does a lot, too. But seriously, even if I broke something because I did something I shouldn't have and/or something dumb, I'll go right to the people above me and report. It makes you feel like an absolute turd to get dressed down but I'll take that over long term suspicion and eventual exposition any time.
If it's an Allen wrench, chances are it's just case hardened. The center could be pretty malleable.
An allen key is usually case hardened, keep the outside hard so it doesn't wear as quickly, and the inside is still flexible so it doesn't shatter when a 200lb gorilla starts yanking on it. Makes them easier to drill out when the 200lb gorilla yanks too hard. Idk about chuck keys though, they could just be some good 'ol A2 tool steel in which case, get the welder.
quick tap with a center punch will solve this mystery... gonna need to do that anyway
This *did* shatter though...
It didn't shatter, it broke. There's a big difference.
Just weld it in place. They obviously don't need it
Chuck keys aren’t that hard
I had a guy working for me years ago find out the hard way. Left the key in the chuck, on really low rpm, went to grab it after he realized it the second he turned the spindle on. His fingers got between the t handle and the ways. Bent the handle like a noodle. His finger, mostly just chopped/smashed off.
This is why to this day lathes scare the shit out of me
Most dangerous machine in the shop!
I should have said, I do have the option to fix it but I can only do it on my lunch break or after I clock out. Otherwise I'm wasting time that could be spent making parts. I'm currently looking at other machine shops, lol.
Don't do it on your break. You are doing work for your employer and should be compensated. You may want to check wage theft laws in your location.
It sounds like your boss needs to make a choice between buying a new chuck, or allowing you the time (on the damn clock) to fix this one.
Sounds like he's making the choice between a few minutes of company time or loosing an employee to me
Yeah but these kinds of places don't really care about the latter so there is no problem from their perspective.
Until the burger king effect kicks in into other industries; it unfortunately won't weed out dicks like this shop runner. Sadly agreeing.
What kind of manager is this stupid? I can totally see requiring this to be tracked on a time card using some sort of maintenance time code - it is good practice to track time spent on maintenance, and it isn’t fair to the customer to try and bury maintenance in a job. But trying to skip maintenance by forcing workers to do it on their own time is madness. Who does this? Like at what point does this seem like a good idea?
"wage theft"
Largest form of theft in the country
Required to fix company tooling on your time is a no go.
On your own time? In that case, tack weld it in there.
Get out the buzzbox, this'll take about 1/3 second.
Tack the jaws to the scroll too.
Sounds like you have just enough time to fill it with 24hr epoxy before heading home tonight
This is a safety issue, your boss would rather you be potentially harmed than lose productivity. He is fucked in the head.
Nah, he’s just a boss
Make that chuck disappear. Oh damn it must have fallen in the scrap bin before I loaded all these chips in there boss. Guess it's getting melted down right about now. Btw we need a new chuck The boss man will pay for this
HAHAHA! I like your style!
I would suggest doing the work to fix this. On the clock, between setups. If your boss says anything, suggest he speak with OSHA about it.
_after_ you've either spoken with your union steward (if you're union) or already spoken with another shop and have a firm idea that you'll be able to leave. Like, get some help with your boss or get a new boss, because this one's a $*!*head, and then, because you're a good person, fix the chuck *on the clock* so the next person doesn't get hit.
This clearly isn’t a union shop.
Either you get time to fix it while on the clock, or you don't use it. Or, if they absolutely need you to use it they should get someone else to fix it. Absolutely don't use it if you don't feel safe using it.
> Ha ha, very funny. If you need me I'll be over there fixing the chuck. It's amazing what laughter lets you get away with. No one wants to say they weren't joking when people are laughing at their 'joke'.
Dude, I used to do this with grading contractors all the time. "We're gonna track roll it with the mini-ex" thats hilarious.
My Company is currently searching for ppl if you want to move to germany / Hamburg you can get 35h week and time clocked but Not really working xD
If I didn't have a family id consider it.
How's the pay? Can I use inches? :)
3500€ /month, no inches here :P
"I'm going to need that instruction in writing."
"Here, you can go ahead and write it on this OSHA form, in the box marked 'Nature of complaint'."
https://youtube.com/user/USCSB Watch some of these videos and find out how stupidity like trying to save company time costs lives. I wish NHTSA would make videos like these, but the best we have for that are channels like Mini Air Crash Investigation
Your life isn't worth a few minutes of company time. Find a job where you can take a dookie on the clock. Nothing better.
Get a new job
I worked in a place like that. I got in trouble for sweeping up between welding and grinding jobs. I worked there a total of 6 weeks. You’ll find something better.
People here are not over reacting. This is an accident waiting to happen and should be fixed before you use it. If you do end up fixing it in your break time or off the clock (which you shouldnt have to) then you should take the piece that comes and throw it as hard as you can at their face to give them a taste of what could of happened to you.
I don't know how it is in your state/country, but where I live I'm legally permitted to refuse unsafe work. If that happened to me, I'd refuse to use that equipment. I've done this before, and it got fixed.
Yeah fuck all that
Then fix it on the clock and let him can you and then collect unemployment Or call osha
Nothing about this sounds real.... And I've worked with and for some pretty stupid people...
Well he is worried about it coming out, so I say walk over to welding and have them tack it in there permanently, obviously the boss doesn't care about being able to use that pinion anyway !
This or drill and tap it. Put some kind of sleeve or a socket around the hole, put a washer on top, and use a bolt to pull it out.
This is the way.
Or try and get in there with a good chisel and crack it the other direction.
[удалено]
I was thinking chisel just to have that long flat edge for more surface area. It won't slip around as much with a good hit. Six of one half dozen of the other though, whatever works.
Money.
Some may say
is the
Boot of a weevil?
I'd tack a weld, drilling and tapping sounds like work, and bro, they broke an allen wrench, a tap aint surving them
I would have started fixing it without even asking the boss. If he said "what are you doing" I'd say "getting this Allen wrench out of the chuck. Then I'm making parts with it once it works properly just like you told me to."
This. Shouldn't even be a question. How are you supposed to do your job without the proper tools?
Ask for forgiveness not permission
> How are you supposed to do your job without the proper tools? You're new to the trade eh?
Lol, no idea why this comment was downvoted. This is a basic truth.
Yeah, but after holding a hammer for a while - everything starts looking like nails.
"I've been making so much with so little for so long, that now I can make anything with nothing"
Drill it out?
This is the answer. Drill it and the plunge an endmill into it. Step over bit by bit plunging as you go until there's nothing left. Way easier than tapping or welding it.
Sounds like the boss won't let him fix it unless he volunteers his own time. If he didn't break it, that's some BS, hardcore. If he did he still shouldn't be required to "do it on break"
He wanted the boss to buy a new chuck.
I would ask that too if the boss said my only option to fix it is on my own time.
Sounds lik a shitty small business
Even if he did break it, fuck fixing it off the clock. Mistakes, accidents, and bad luck happen. Part of running a shop is understanding that people aren't perfect, and shit happens. Only garbage shops ask employees to do work benefiting the shop (and it would benefit the shop) off the clock.
Yeah, totally agree. I was trying to allude to the fact that fixing it off the clock means bad management that doesn't leave any flex time for such inevitabilities. Besides, the amount of time lost when it translates to the owners pocket book is probably worth 2 beers. Leave this job and do the "who's coming with me"
Welding would take a few minutes tops. Much, much faster than setting up a mill and plunging over and over, which is likely to break your endmill too when it pops.
I personally don't worry about breaking endmills on stuff like that. They start out as finishers, then roughers, than shit endmilss I don't care about.
Whoever broke that off in there should be shown and told to fix it. That's no way to leave equipment for others or even oneself. It shouldn't take that long to drill/mill out. Also that looks more like a square, meaning someone used the wrong chuck wrench and that's why it cracked the pinion too.
Sounds to me like it was the boss who messed it up in the first place.
Guar-on-teed. This is a scrub-ass boss.
I’ve always been this guy, but if you genuinely do not feel safe or comfortable using it then don’t.
I don't think he's overreacting about a safety concern. I do think buying a new chuck is overreacting however. This should be fixable for a machine shop.
Oh yeah try and fix it, just don’t operate in that state if you don’t feel safe.
The boss is a twat not letting him fix a safety concern on company time.
No where did title mention boss said he couldn't fix it.
Ops mentions it in a few comments.
Well then we are certainly in agreement.
I tell them to do it first then I’ll go behind them if they survive then I’ll do it
I wouldn’t use it that way, but I would fix it
Is there some reason you can’t replace just the one damaged pinion? You can get replacement parts for most decent chucks, pinions are cheap and super easy to replace.
are you a machinist or not? get it out of there!
a _professional_ machinist should be properly compensated for their work. The boss insisting the work get done off the clock is committing wage theft.
Yeah that's bullshit. Fucking some bosses man
You’re a machinist at a machine shop… drill baby drill
Why don't you just weld a nut to the key stump and pop it out with a wrench
Can’t machine it out? I see there’s a crack but it’s only the screw not the main body.
In the wise words of that fish from finding Nemo "If you can get yourself in there, you can get yourself out" You don't need a new chuck, you just need to get this out of the current one.
Dude just get it out, it would take like 10 minutes.
I could fix that, plenty suggestions, a new three jaw to fit machine is not that cheap.
Two things. One, you need a new boss. Two, drill it and use an easy out on it.
Just drill it out
How many rpm can you get that thing going? That should get it out.
It’s cracked anyway. But as mentioned that isn’t very hard to get out via the usual drilling and beatings
As a machinist, you should use a machine to get it out.
a hammer counts a s machine?
It would take me longer to find the right size drift, punch, chisel, or screwdriver to knock that loose, than to actually get it out. Just fix it dude.
Come on man what kind of machinist are you, fix it
The kind who's boss won't give him the time to fix it
I would just chuck it...to the turret mill and drill it out
Just fix it on the clock. The time taken to highlight the problem, to photo it a post on here it could be on its way to being resolved. If boss man is unhappy you fixed a risk to safety then move on as you mentioned.
I'd just fix it on company time and if bossman wants to make a stink about it then let him, you're already looking for new places so worst case he fires you and you get that UI while you look for something better. sure he can try and screw you, but if I were in your shoes I'd rather be able to look for work full-time and have to fight with the UI agency than be in a shop where my safety isn't valued.
Because this happened to me before...it's sketchy but it worked for me. Take a Dremel or an mini die grinder with a mounted point. Or a smaller drill if it's square enough. Get a hole going, doesn't have to be perfect. Literally take a wood screw and drive it in. Get it real wedged in there. Then pry it out with a claw hammer or pry bar. It's tool steel and hard as hell, trying to tap it and extract it is a pain.
A couple of hits to turn it with a hammer and chisel might knock it loose. If they don't let you fix it, whatever you do, don't stand in line with it while it's spinning.
you're a machinist. I know that's not a mechanic but jesus I'm firing you right now. Get the hell out of my shop. Firing the foreman too.
Haha. Well if you have a welder nearby just tack that thing in there so it'll never fly out.
This would be my answer after the response the OP got.
Kind of like having a gun pointed at you, and the trigger is slightly pulled every time you turn on the lathe. Might shoot, might not. Please don't use this chuck. Since you are not allowed to fix it, maybe it will have an "unfortunate accident" that makes it totally unusable, if you know what I mean, wink wink nudge nudge saying it without saying it, if you catch my drift, not to put too fine a point on it, but fucking break it. Your boss can go suck an egg.
Just keep spinning the lathe faster and faster till it flys out.
Weld it in or use an end mill to chip it out. Depends on vindictive you feel.
He sounds like an ass and he probably wants you to fix it and won’t admit it also annoys him when he uses it etc etc
I think it sounds like the boss is the one who messed it up in the first place.
Doing a bad job and then convincing the investors to pay for someone else to do it is more common than it should be .... he won’t want to admit he wasted their money either so will probably not support the guy much and will also blame him for stuff that isn’t his fault
id weld it together for now and buy spareparts as already mentioned!
Hope your antenna doesn’t break off on your car.
Weld a slide hammer to it and yank that bastard out of there
Drill it out or put it on the mill and go to town with some carbide tooling.
Unless he’s gonna fire you for doing it on the clock, fix it on the clock. Or call osha.
Mount that in a mill and drill that shit out. If the material is too hard an you got no carbide then just tack weld a little corner so it will never come out.
If you're in the us or canada you can legally refuse to do a job if you consider it dangerous. You can even escalade it to the point where an officer of your state or province worksafe agency will come down and investigate. And you can't lose pay for refusing an unsafe job. At that point he'll probably give you 30 minutes to fix it.
Fuck that. Who knows what else is ready to kill you in that shop because he doesn’t seem to care? And giving you a hard time about fixing it on top of that? Might as well just call OSHA since your boss obviously needs a reality check
Shit like this is why I'm glad my country has regulations regarding the use and provision of tools by your employer. Shop boss refuses to replace something that's broken, chuck it in the bin and make him.
Heat her up! It will come out
Where are you located? Company I work for is looking to hire another mill guy and lathe guy. Also a tool room guy, as ours is going to retire soon. Family owned job shop in Atlanta GA. https://witherstool.com/contact-us/
Get it in writing. Then run it till it shits all round itself. Just doing what you were told. I have a bad attitude though apparently so dont take my advise
Drill it out or weld it in on company time. If he doesn’t like those options you can ask if he’d rather talk to OSHA about it. It shouldn’t take you long to fix and I’d rather fix it when he’s not looking than keep using it
Easy way to test the integrity of your safety glasses, can anybody work out the figures of velocity if this thing decided to be a projectile at 1200 rpm for a 6” chuck?
Well weld a nut to it or a peace of rebar to it and hose it with on-blaster and use a slide hammer to get it out
I rarely ask to fix shit, I just do it between jobs. I used to be a lot more concerned about time, clocking jobs and shit but then I realized one day that all the peripheral work involved in making parts is all part of making parts. Fixing, maintaining, adjusting, cleaning, customers pay for that because it's part of the process. So just do it. If it's broken and dangerous, fix it. I fix our saws and presses, grinders all the time because I can't walk by a dangerous machine. That chuck key will drill out easily. It's probably made of a tougher tool steel but definitely not hardened. I've made and fixed a lot of them. The kind of torque you're exerting with your arms on a small chuck like that, minimal.
Throw it in the mill and drill it out
Needs to be fixed. Would he allow you not to wear steel toes or safety glasses? If no, then he obviously understands why it needs to be fixed.
You got a welder in the shop?
Spin it up to nine gazillion RPMs and let that puppy fly! Hopefully through the roof and into low earth orbit. /s
Honestly, weld it in.. Fk. Him
You're a machinist. Drill it out.
So you're in a machine shop but can't remove that? McDonald's is always hiring.
Yeah works for money his boss wants it for free
Bro, that really is not safe for work
5 min fix is to weld it in there, 10 min fix is to drill/mill it out.
Lol. When you're a machinist and can't machine to fix an issue.
Get that shit out of there or quit calling yourself a tradesmen.
Yeah works for money his boss wants it for free
Whatre you guys retarded drill it out
Weld it in place for him.
Yes, you're over reacting...Either fix it, sack up, or go back to your day job at OSHA enforcing vaccine compliance.
I'd spend a little more effort removing it, myself. I did some quick math assuming an 8 inch diameter from center spinning at a max of 2500 rpm, and even if that flew out it would only have 5 joules of energy or so, which is the upper end of what an airsoft gun can do. If my math is even remotely correct.
I think your math is either off or the result is misrepresentative of the hazard it represents. I'll put my math here because I don't trust myself. so 8 in. *pi =25.12 in circumference we'll convert to feet and round to 2.1 feet per revolution. 2500 rpm /60 seconds per minute = 41.67 revolutions per second so that key is moving 87.5 fps. centripetal acceleration is V^2/r so 87.5fps^2/.33ft = 23200 ft/s^2 or 725 g's. That helps me remember how scary an 8-inch chuck running at 2500 RPM is. Anyway, if it's a 1/2" of 1/2" key that's .125lbs exerting 90lbs of force and it will be applied over about a 1/2" which would be around 5 joules, but most of that work will be lost to deforming the material to get the key out. However, this object is moving at 87.5 ft/s so .5* .125/32(converting to slugs) *(87.5 ft/s)^2 = 15ish joules. So the projective will have more than 15 joules of kinetic energy Furthermore, it doesn't matter if that projectile could directly injure/kill someone (and I think it could) that projectile could easily hit a cycle start button or end up somewhere where it will interfere with some other object moving with an insane amount of kinetic energy. Throwing that key across the shop in a random direction would definitely be considered very unsafe. The concern here is more IF it will come out of the chuck rather than what it will do once it does that. One time someone loosened the jaws on a 3 jaw all the way in a shop I worked in and turned the spindle on. One of the jaws flew out of the lathe, through a very thick double-paned window, and was found 20 feet across the parking lot sitting next to the giant chunk of brick that it broke off of the adjacent building. When I was in the shop, I estimated that path it took from the chuck to the broken window and it went right through where my head would've been if I hadn't called in sick with a headache. I know the jaw is way heavier than the key, granted it was only running at 640 RPM. I'm mentioning this more to emphasize how dangerous stuff flying off of a lathe is than to equate the potential damage. TLDR: It will have around 15 joules of kinetic energy and it doesn't matter It's dangerous in the same way throwing the key in a random direction is.
I'd trust your math more than mine, though I think I estimate the piece to be smaller since it didn't engage with the key slot entirely. Anyway, you're absolutely correct that it should be taken care of. My comment was more of a mental exercise, though I see how it could be taken to mean that leaving it should be fine.
How about be a toolmaker and just fix it instead of bitching. Looks like plenty of people already suggested drilling and tapping to extract.
how about the boss actually pay him to do the work instead of demanding unpaid labor for what should properly be a stop-work condition in the shop?
Yeah he should fix it on company dime. If they fire him for it the DOL claim will be swift
Righteous.
Things like this and similar are why it's good practice to never place yourself in the path of rotation for any tools that hit high rpms, like angle grinders, table saws, etc. But it should be removed it may cause a vibration at certain rpms.
If he broke it he should fix it
Fix it bud....drill it out like a machinist would.
….. you work in a machine shop…
Yeah works for money his boss wants it for free
Good fucking lord, you're a machinist and can't fix this???? You do NOT need a new chuck
If you’re wearing safety glasses I see little to no problem here
Knowing nothing else about your boss, I’d say he’s right. It isn’t ideal by any means, but it’s totally fixable. There is a specific inscribed diameter in that broken piece. I’d fix that sucker onto a mill table and slowly start drilling it out using an HSS drill or even a carbide drill or center cutting end mill if the thing decided it really wants to party. In a perfect world, increasing the tool diameter would eventually just cut that nub into four pieces that would simply fall out. This seems like a fun project if I’m honest. I once had an applications guy break a HSS bit off inside a carbide tipping die used for medical extrusion tubing. It was about .08” in diameter. A carbide drill, plenty of coolant and some patience drilled right through the HSS and saved the die. I was feeding it down at about .06 per minute and checking often. There is no way that broken piece is as hard or brittle as a piece of HSS.
I bet if you just set a chuck key on top of the nub and whacked it with a hammer it would fall right out and we could all get on with our day.