I mostly program smaller parts directly off solidworks provided by the engineer in surfcam. They taught me to hand write gcode as well but I’m stronger with CAM than handwriting gcode. I rely on the simulation too much i think.
-Nothing wrong with simulation. it helps prevent a crash from happening. I'm from the days when G&M-coding was done long hand and it was a real PITA sometimes. G&M-coding requires a rather intimate feel for what's going on at the cutter and it's not something you just punch numbers into with expected results. There's a lot more than theory going on at the cutter that isn't always obvious. I don't feel you're sub IQ if you've already learned the skills listed above in 3 years starting with no prior experience in a machine shop. Your boss is knocking you to keep your wage down for various reasons. That's not fair to you.
I setup haas vf-0, vf-0E and the vf-4 a lot because they’re the older CRT equipped controllers so I just have to use the edge finder and manually set tooling
-Using a mechanical edge finder is ok, it's just another tool to be familiar with. Relying only on the Renishaw limits you to using just ONE method of locating the edge. The more tools you're familiar with the better, more knowledgeable you are.
I really dislike setting up the vf-6 and vf-7 here because the cat-50 tool holders are heavy as hell and you have to jog the z axis down to set the tools.
-Yep, CAT 50 can hold some heavy tooling. I wouldn't really like it either if the tool can damage me more than I can damage it. That's a lot of lifting setting up a new job or taking down an old one. The lowest paid guy is doing the heaviest lifting? That's done on purpose IMO.
The auto tool setter on that one is nice, but I don’t like using the renishaw probe because those things are expensive and I don’t want to crash it and be liable for buying one of the new little glass beads because I heard they’re like $4000 each… I’d rather take longer and only risk a $12 edge finder lol
-There is no f'ing way you should be held responsible for damaging anything if you're trying to be careful. Sooner or later a crash happens with all CNC machinery. It's not a matter of IF it will happen it's WHEN it will happen. That's the risk the boss/company takes in assigning a person to any task whether it's sweeping the floor or running expensive machinery. If you're not negligent then mistakes happen to everybody. Making you responsible for the cost of anything involved in an accidental crash is the same as you subsidizing the cost of the company doing business. That's decidedly not right and I believe a labor board would agree with me if the company deducts costs from your paycheck. Even the cost of drill bits, taps, and cutting tools should not be coming out of your pocket. I don't like risking expensive probes/tooling either when I don't have to. If the sides aren't dead square to the top then there's likely an error factor anyway and the added precision of a Renishaw probe is wasted. Why risk when there's no benefit?
I’m getting pretty comfortable on the manual lathe, getting better with finishes and holding tolerances but I’m weak with cutting threads.
-Cutting threads by single-point is not an easily accomplished task for someone that doesn't do it on a regular basis. I've done quite a bit of it and can tell you that there are a number of factors in getting it right. There are even some materials that are more difficult to cut than others. Striving for a Class 3 thread (A or B) when it's isn't called for is useless. Thread finish is dependent upon several factors. The difference between using a carbide insert and HSS makes a difference too. Don't beat yourself up on this one.
I’m really weak on the Bridgeport, can’t hold tolerances can’t get good finishes.
-There are plenty of factors that affect tolerance/finish in a Bridgeport. Speed/feed and depth of cut (DOC) have a much greater effect in a relatively light weight machine like a Bridgeport instead a solid machine like a bed mill Okuma/Haas. Vibration greatly affects tolerance AND finish. How far the quill is extended, length of milling cutter, and how prone to vibration everything is can make a huge difference. The Bridgeport was NOT designed to plow off metal, it isn't capable enough due to design and low mass. It's great at versatility but if the boss is telling you that you're taking too much time and you should increase the feed or cut then he's either leading you out on thin ice or he's trying to make better time on a job to make himself look good. Using a lathe or a milling machine have different rules of operation. Great that you've learned a lot in 3 years but unless you use each machine on a regular basis it's not easy to be proficient in only 3 years, especially if you're bounced around to a different machine every couple of days.
Also with programming, I’m very weak on fixturing/work holding. I’ve scrapped parts because my fixturing/ work holding wasn’t up to snuff and the part moved in my fixture on more than one occasion.
-That could very well be that the part moved because there was too much metal being removed in a cut or too high a feed rate. Any machining has what's called "cutting force" and that is proportionate to how much metal is being removed and how quickly this is happening. What works for a piece held solidly in a vise may not work well for a piece held on an angle plate with a C-clamp. Knowing how much and how fast is a matter of experience, ruining a part because it moved has happened to ALL machinists. Even squeezing a part as tight as possible in a vise isn't always a good thing either as the vise can deform a part from over-clamping forces. Proper fixturing and work holding is critical for machining and ALL machinists have had to learn this by scrapping parts. It's not a fun way to learn but there are no substitutes for learning by failure. Somebody should have been helping you to learn this until you were ready to solo, not throwing you into the deep end of the pool.
Im not worth more than minimum wage yet because my scrap rate is still pretty high. On a part run of 10 I might mess up one or two of them
-Uh-huh, I still cut an extra piece of stock now and then so I can test out an iffy process. Lots of machinists do this unless it's really expensive stock or a casting. The boss is holding the scrap rate over your head to keep your wage rate down. After 30+ years of metal working I'd still scrap a piece now and then. Being perfect every hour of every day is a ridiculous expectation. Yes we strive to not make mistakes but learning from your mistakes is part and parcel of the trade. Sometimes the wrong expectation is the problem. I once worked at a company that expected +/- .0005 from a milled external slots on a 10 pound block of 4140. It would have been simple to finish grind them in on a surface grinder but the boss insisted it be done on a Bridgeport. They also had me bore a precision hole in a plate that required cranking the entire usable length of the table. This would have been ok except there was no DRO and the lead screw error multiplied with every inch of travel. They insisted the lead screw error factor didn't matter but it clearly did after getting the same amount of error on the second attempt. Sometimes the boss is just flatly wrong because he's capable of making mistakes too.
Chips on my taper, or chip between the part and the part jaw scraps the part.
-Well that is something to watch for when changing parts, cleanliness is important and is something you learn to follow. It's happened to ALL machinists too and will again, if not careful, regardless of experience. Some methods have to become habits, clean jaws is one of them.
I’m trying to get better. We’re slow a lot here months between jobs and stuff so a lot of sump cleaning and floor sweeping until we have something to program, setup
And cut..
-Slow in between jobs? Boss browbeats you to avoid rising shop costs? Sounds fairly consistent that money is tight at the company and either the front office is telling the boss to hold costs down or the boss is just gaslighting you. You may not have a great deal of experience but I believe you have enough for another company to invest in you by hiring you and increasing your learning. This would be done by pairing you with a more experienced worker to oversee your set-up/programming until there's enough confidence to let you go solo. Your pay at $18 per hour may be ok for a Day 1 beginner but that's not what you are now.
You're being taken advantage of IMO by playing on your low regard for your own experience/abilities. I wouldn't mention this at all to your current job, find another company willing to take you on for your potential (which you DO have) before trying to negotiate at your current job. Your current boss may just fire you or try to make you pay for something that's not your responsibility to pay for. Don't give them a chance to screw you over, they already have for long enough.
-You are still cordially invited to ask questions to answers you can't find or don't understand. Machining is a deep rabbit hole and the knowledge/skill required is not easily obtained. A better forum for questions would be at a devoted site like Practical Machinist but they're sometimes a cranky bunch that doesn't tolerate newbies very well. There are several members here that probably wouldn't mind helping you because ALL of us that are experienced machinists were helped in the beginning and some of us still remember how it was for us. Chin up, you'll do fine to persist and persevere in the face of obstacles and discouragement.