MILLING SAFETY

EXPERIMENT # 01 ALIGNING THE TABLE ON A UNIVERSAL MILLING MACHINE Machine/Tools: Procedure:

Clean the table and the face of the column thoroughly. Mount a dial indicator on the table by means of a magnetic base or any suitable mounting device. Milling Machine, Dial Indicator, Magnetic Base

 Move the table toward the column until the dial indicator registers approximately one-quarter of a revolution. Set the indicator bezel to zero (0) by turning the dial. Using the table feed hand wheel, move the table along the width of the column. Note the reading on the dial indicator and compare it to the zero (0) reading at the other end of the column. If there is any movement of the indicator hand, loosen the locking nuts on the swivel table housing. Adjust the table for half the difference of the needle movement and lock the table housing. Recheck the table for alignment and adjust, if necessary, until there is no movement in the indicator as it is moved along the column.

EXPERIMENT # 02 TO MOUNT A CUTTER IN A SOLID COLLET Machine/Tools: Milling Machine, Solid Collet, Milling Cutter, Piece of
Masonite, Draw Bar

Procedure:
Shut off the electric power to the machine. Place the proper cutter, collet, and wrench on a piece of Masonite, wood, or soft plastic on the machine table.

 Slide the draw-bar through the top hole in the spindle. Clean the spindle taper and the taper on the collet. Align the keyway or slots of the collet with the keyway or drive keys in the spindle, and insert the collet into the spindle. Hold the collet up in the spindle and thread the draw-bar clockwise with the other hand. Pull on the brake lever and tighten the draw-bar as tightly as possible with a wrench, using hand pressure only. Insert the end mill into the collet until the flat(s) align with the setscrew(s) of the collet. Tighten the setscrews securely using hand pressure only.

EXPERIMENT # 03 (a) Machine/Tools: TO MOUNT AN ARBOR

Milling Machine, Honing Stone, Arbor, Spanner, Soft

Faced Hammer, Draw Bar

Procedure:
Clean the tapered hole in the spindle and the taper on the arbor using the clean cloth. Check to make sure that there are no cuttings or burrs in the taper that would prevent the arbor from running true. Check the bearing bushing and remove any burrs using a honing stone.

 Place the tapered end of the arbor in the spindle and align the the spindle driving lugs with the arbor slots. Place the right hand on the draw in bar and turn the thread ino the arbor approximately 1 in. Tighten the draw in bar lock nut securely against the back of the spindle.

(b)

TO REMOVE AN ARBOR

Remove the milling machine cutter. Loosen the lock nut on the draw in bar approximately two turns. With a soft faced hammer sharply strike the end of the draw in bar until the arbor tapper is free. With one end hold the arbor unscrew the draw in bar from the arbor with the other hand. Carefully remove the arbor from the tapered spindle to avoid damage to the spindle or arbor tapers. Leave the draw in bar in the spindle for further use. Store the arbor in a suitable rack to prevent it from being damaged or bent.

EXPERIMENT # 04 TO MOUNT A MILLING CUTTER Machine/Tools: Milling Machine, Arbor, Arbor Supports, Milling
Cutter, Piece of Masonite, Spanner Set, Sleeves, Draw Bar

Procedure:

 Remove the arbor nut and collar and place them on a piece of Masonite. Clean the spacing the collar surfaces of cuttings and burs. Set the machine to the slowest spindle speed. Check the direction of the arbor rotation by starting and stopping the machine spindle. Slide the spacing collars on the arbor to the position desired for the cutter. Fit a key into the the arbor keyway at the position where the cuter is to be located. Hold the cutter with a cloth and mount it on the arbor. Make sure that the cutter teeth point in the direction of the arbor rotation. Slide the arbor support in place and to be sure that it is on a bearing bushing on the arbor. Put on additional spacers leaving room for the arbor nut. Tighten the nut by hand. Lock the arbor support in position. Tighten the arbor nut firmly with a wrench using only hand pressure. Lubricate the bearing collar in the arbor support. Make sure that the arbor and arbor support will clear the work.

EXPERIMENT # 05 TO MACHINE A FLAT SURFACE Machine/Tools:

Milling Machine, Milling Cutter, Machine Vise.

Procedure:
Clean the vise and mount the work securely in the vise Check that the vertical head is square with the table. If possible, select a cutter that will just overlap the edges of the work. This will then require only one cut to be taken to machine the surface. If the surface to be machined is fairly narrow, an end mill slightly lighter in diameter than the width of the work should be used. If surface is larger and require several piece, a shell end mill or a suitable fly cutter should be used. NOTE: It is not advisable to use a facing cutter that is too wide, since the head may be thrown out of alignment if the cutter should jam. Set the proper spindle speed for the size and type cutter and material being machined; check cutter rotation. Tighten the quill clamps. Start the machine, and adjust the table until the end of the work is under the edge of the cutter. Raise the table until the work surface just touches the cutter. Move the work clear of the cutter. Raise the table about .030 in.(0.8mm) and take a trial cut of approximately .250in.(6mm). Move the work clear of the cutter, stop the cutter, and measure the work. Raise the table the desired amount, and lock the knee clamp.

 Mill surface to size using the automatic feed, if the machine is so equipped.

EXPERIMENT # 06 TO MACHINE AN ANGULAR SURFACE Machine/Tools:

Square Milling Machine, Machine vise, Protector, Scriber, Tri-

Procedure:
Lay out the angular surface. Clean the vise. Align the vise with the direction of the feed. This is of the utmost importance. Mount the work on parallels in the vise. Swivel the vertical head to the required angle. Tighten the quill clamp.

Start the machine and raise the table until the cutter touches the work. Carefully raise the table until the cut is of the desired depth. Take a trial cut for about .50 in.(13mm). Check the angle with a protector. If the angle is correct, continue the cut.

NOTE: It is always advisable to feed the work into the rotation of cutter, rather than rather than with the cutter, which may draw the work into the cutter and cause damage to the work. The cutter or both. Machine to the required depth, taking several cuts if necessary.

EXPERIMENT # 07 CUTTING SLOTS AND KEYSEATS MACHINE/TOOLS: Milling Machine, End Mills, Scriber, Force Milling
Cutter, Machine Vise, Scale

PROCEDURE:
o Slots and key seats with one or two blind ends may be cut in shafts more easily on vertical milling machine, using two-or threefluted end mill, then with a horizontal mill and a side facing cutter. Lay out the position of the key seat on the shaft, and scribe reference lines on the end of the shaft. Since the work piece in a vice on a parallel. if the shaft is long, it may be clamped directly to the table by placing it in one of the table slots or in Vblocks. Using the layout lines on the end of the shafts, setup the shaft so that the keyseat lay out is in the proper position on top of the shaft.

 Mount a two or three fluted ends mill, of diameter equal to the width of the keyseat, in the milling machine spindle. Note: o If the keyseat has to blind ends , a two or three lip end mill must be used, since they may be used as drill to start the slot. if the slot is at one end of shaft (one blind end only) a four fluted end mill may be used , although a two or three lip end mill will give better chip clearance. Center the work piece by carefully touching the cutter to one side of the shaft. This may also be done by placing a piece of thin paper between the shaft and the cutter. Note : o Paper may made to adhere to shafts or work surfaces by wetting it with coolant or oil before applying it to the surface. This eliminates the necessity of holding paper between the cutter and the work, thus making it a safer operation. Lower the table until the cutter clears the work piece. Move the table over an amount equal to the half the diameter of shaft plus the thickness of the paper. For example, if a 0.250 inch (6 mm) slot is required in a 2 inch (50mm) shaft & the thickness of the paper used is .002 inch(0.05 mm) , the table would be removed over + .125 +.002=1.127 inch (25+3+0.05=28.05)

 If the keyseat being cut has to blind ends , adjust the work until the end of the keyseat is aligned with the edge of the cutter. Feed the cutter down (or the table up) until the cutter just cuts to its full diameter. If the keyseat has one blind end only , the work is adjusted so that this cut is taken at the end of the work. The work would now be moved clear of the cutter. Adjust the depth of cut one half the thickness of the key, and machine the keyseat to the proper length.

EXPERIMENT # 08 TO CUT A WOODRUFF KEY SEAT Machine/Tools:

Vise Milling machine, Milling Cutter, Scriber, Machine

Procedure:
Align the spindle of the vertical milling machine 90 degree to the table Lay out the position of the keyseat. Set the shaft in the vise of the milling machine or on V blocks. Be sure the shaft is level (parallel to the table). Mount the cutter of the proper size in the spindle. Start the cutter and touch the bottom of the cutter to the top of the work piece. Set the vertical graduated feed collar to zero and check cutter rotation.

 Move the work clear of the cutter raise the table half the diameter of the work plus half the thickness of the cutter.log the knee at this setting. Position the center of the slot with the center of the cutter. lock the table in this position. Touch the revolving cutter to the work use a strip of paper between the cutter and work if desire. Set the cross field screw collar to zero. Cut the keyseat to the proper depth.

EXPERIMENT # 09
MILLING A T-SLOT

Machine/Tools:
Mills

Milling machine, T-Slot, Scriber, Machine Vise, End

Procedure:
Note: o T-slots are machined in on the tops of machine tables and accessories to receive bolts for clamping work-pieces. They are machined in two operations. Consult a handbook for the T-slot dimensions. Lay out the position of the T-slot. Square the vertical milling machine spindle with the machine table. Mount the work on the milling machine. If the work is to be held in a vise, the vise jaw must be aligned with the table travel. If the work is clamped to the table, the position of the slot must be aligned with the table travel.

 Mount an end mill having a diameter slightly larger than the diameter of the diameter of the bolt body. The size of the end mill to be used is shown in the T-slot tables. Machine the center slot to the proper depth of the T-slot ,using the end mill. Remove the end mill, and mount the proper T-slot cutter. Set the slot cutter depth to the bottom of the slot.

EXPERIMENT # 10 TO PERFORM STRADDLE MILLING Machine/Tools: Procedure:

Select two sharp side milling cutters, preferably staggered-tooth, of suitable size. Mount the cutters, with suitable arbor spacers, as close to column as the work will permit. Mount the arbor support as close to the cutters as possible to provide rigidity for the cutters and arbor. Centre the cutters on the work piece in the proper location. Tighten the saddle lock to prevent any movement during a cut. Set the cutter to the work surface. Move the table so that the cutter clears the end of the work piece. Set the depth of cut required and tighten the knee clamp. Milling Machine, Milling Cutters

 Set the proper speeds and feeds for the cutter size and the type of work material; check cutter rotation. Use the good supply of cutting fluid and complete the straddle milling operation in one cut.

EXPERIMENT # 11 TO PERFORM FACE MILLING Machine/Tools: Procedure:

When face milling a large surface, use an inserted tooth cutter and mount it into the spindle of the machine. When milling small surfaces, the face milling cutter should be about 1 in.(25 mm) larger than the width of the work piece. Set the speeds and feeds for the type of cutter and the material being cut. Set up the work on the milling machine, making sure that the work holding clamps do not interfere with the cutting action. Use cutting fluid if the cutter material or work will allow. Take as large a roughing cut as possible to bring the surface close to within .030 to .060 in.(.08 to 1.5 mm) of finish size. Set the depth of the finish cut and machine the surface to the size. Milling Machine, Milling Cutters

 After completing the operation, clean and store the cutter and clamping equipment in their proper places.

EXPERIMENT # 12 TO MILL A SQUARE BY DIRECT INDEXING Machine/Tools: Procedure:

Disengage the worm and worm shaft by turning the worm disengaging shaft lever if the dividing head is so equipped Adjust the plunger behind the index plate into the 24-hole circle, or slot Mount the workpiece in the dividing head chuck or between centers. Adjust the cutter height and cut the first side. Remove the plunger pin using the plunger pin lever. Turn the plate attached to the dividing head spindle one-half turn (12 holes or slots) and engage the plunger pin. Take the second cut. Measure the work across the flats and adjust the work height if required. Cut the remaining sides by indexing every six holes until all surfaces are cut. Milling Machine, Milling Cutters, Dividing Head, Indexing Plates