Operating a Milling Machine - Revision history

Bsboggs: /* Basic Milling Project */

2019-05-10T17:20:22Z

Basic Milling Project

← Older revision		Revision as of 17:20, 10 May 2019
Line 45:		Line 45:
	# ''Face mill'' the other faces such that all faces are 1.000" +- 0.003" from their opposites (use edge finder to precisely locate faces). Get instructor or TA approval before making first side mill operation.		# ''Face mill'' the other faces such that all faces are 1.000" +- 0.003" from their opposites (use edge finder to precisely locate faces). Get instructor or TA approval before making first side mill operation.
	# Use dial indicator to verify that the faces are parallel to within 3 mils (a mil is one thousandth of an inch).		# Use dial indicator to verify that the faces are parallel to within 3 mils (a mil is one thousandth of an inch).
	# ''Drill and tap'' 4 8-32 screw holes at the corners of one face (1/8" in from both faces). Use this [http://www.americanfastener.com/tap-and-drill-size-chart/ drill and tap chart]. Discuss this procedure with instructor or TA before attempting.		# ''Drill and tap'' 4 8-32 screw holes at the corners of one face (3/16" in from both faces). Use this [http://www.americanfastener.com/tap-and-drill-size-chart/ drill and tap chart]. Discuss this procedure with instructor or TA before attempting.
	# ''Hog out'' the face opposite to the tapped holes. Leave 1/8" border and hog to 1/4" depth (make the process easier with a pattern of material-removing drilled holes). Discuss this operation with the instructor or TA before attempting.		# ''Hog out'' the face opposite to the tapped holes. Leave 1/8" border and hog to 1/4" depth (make the process easier with a pattern of material-removing drilled holes). Discuss this operation with the instructor or TA before attempting.
	# Put all tools back into storage and clean up area.		# Put all tools back into storage and clean up area.

Bsboggs: /* Basic Milling Project */

2018-06-08T22:46:33Z

Basic Milling Project

← Older revision		Revision as of 22:46, 8 June 2018
Line 25:		Line 25:
	one face hogged out.		one face hogged out.

	'''CLEAN UP AREA AFTER EACH LAB SESSION'''		'''CLEAN UP AREA AFTER EACH LAB SESSION''' <br>
			'''DO NOT PUT METAL SHAVINGS OR BROKEN GLASS IN TRASH BINS - USE SPECIALLY-MARKED CONTAINERS''' <br>

	'''NOTE:''' Use the low "L" speed range for most operations (and make slow cuts). The motor has more torque in the low range. Also, don't operate the mill at max speed for more than a few minutes at a time in order to avoid overheating the motor. If you want to operate the mill at high speeds (for finishing purposes), use the high "H" range and turn down the variable speed dial from max (maybe 80% of max value).		'''NOTE:''' Use the low "L" speed range for most operations (and make slow cuts). The motor has more torque in the low range. Also, don't operate the mill at max speed for more than a few minutes at a time in order to avoid overheating the motor. If you want to operate the mill at high speeds (for finishing purposes), use the high "H" range and turn down the variable speed dial from max (maybe 80% of max value).

Bsboggs: /* Activities */

2018-06-08T17:06:25Z

Activities

← Older revision		Revision as of 17:06, 8 June 2018
Line 19:		Line 19:

	== Activities ==		== Activities ==

			=== Basic Milling Project ===

	Basic Idea: Make a small 1" Al cube with tapped holes and		Basic Idea: Make a small 1" Al cube with tapped holes and
Line 45:		Line 47:
	# ''Hog out'' the face opposite to the tapped holes. Leave 1/8" border and hog to 1/4" depth (make the process easier with a pattern of material-removing drilled holes). Discuss this operation with the instructor or TA before attempting.		# ''Hog out'' the face opposite to the tapped holes. Leave 1/8" border and hog to 1/4" depth (make the process easier with a pattern of material-removing drilled holes). Discuss this operation with the instructor or TA before attempting.
	# Put all tools back into storage and clean up area.		# Put all tools back into storage and clean up area.

			=== Advanced Milling Project ===
			coming soon...

Bsboggs: /* Activities */

2018-06-08T17:04:54Z

Activities

← Older revision		Revision as of 17:04, 8 June 2018
Line 39:		Line 39:
	'''Do not take more than 0.020 inches off in any single face or side milling operation.'''		'''Do not take more than 0.020 inches off in any single face or side milling operation.'''

	# ''~~Face~~ mill'' the rough sides so that they are 1.000" +- 0.003" from ~~its~~ opposite ~~face~~.		# ''Side mill'' the rough sides so that they are 1.000" +- 0.003" from their opposite faces.
	# ''~~Side~~ mill'' the other faces such that all faces are 1.000" +- 0.003" from their opposites (use edge finder to precisely locate faces). Get instructor or TA approval before making first side mill operation.		# ''Face mill'' the other faces such that all faces are 1.000" +- 0.003" from their opposites (use edge finder to precisely locate faces). Get instructor or TA approval before making first side mill operation.
	# Use dial indicator to verify that the faces are parallel to within 3 mils (a mil is one thousandth of an inch).		# Use dial indicator to verify that the faces are parallel to within 3 mils (a mil is one thousandth of an inch).
	# ''Drill and tap'' 4 8-32 screw holes at the corners of one face (1/8" in from both faces). Use this [http://www.americanfastener.com/tap-and-drill-size-chart/ drill and tap chart]. Discuss this procedure with instructor or TA before attempting.		# ''Drill and tap'' 4 8-32 screw holes at the corners of one face (1/8" in from both faces). Use this [http://www.americanfastener.com/tap-and-drill-size-chart/ drill and tap chart]. Discuss this procedure with instructor or TA before attempting.
	# ''Hog out'' the face opposite to the tapped holes. Leave 1/8" border and hog to 1/4" depth (make the process easier with a pattern of material-removing drilled holes). Discuss this operation with the instructor or TA before attempting.		# ''Hog out'' the face opposite to the tapped holes. Leave 1/8" border and hog to 1/4" depth (make the process easier with a pattern of material-removing drilled holes). Discuss this operation with the instructor or TA before attempting.
	# Put all tools back into storage and clean up area.		# Put all tools back into storage and clean up area.

Bsboggs: /* Activities */

2018-06-07T22:55:18Z

Activities

← Older revision		Revision as of 22:55, 7 June 2018
Line 36:		Line 36:
	# Lubricate the head stock vertical column with a few drops of oil (on each side).		# Lubricate the head stock vertical column with a few drops of oil (on each side).
	# Mount the rough block in the milling vise using parallel bars (rough side face up) - Get instructor or TA approval before milling.		# Mount the rough block in the milling vise using parallel bars (rough side face up) - Get instructor or TA approval before milling.
	# ''Face mill'' the rough ~~side~~ so that ~~it's~~ 1.000" +- 0.003" from its opposite face.		'''Do not push work piece into bit (in any direction) when machine is stopped.'''
			'''Do not take more than 0.020 inches off in any single face or side milling operation.'''

			# ''Face mill'' the rough sides so that they are 1.000" +- 0.003" from its opposite face.
	# ''Side mill'' the other faces such that all faces are 1.000" +- 0.003" from their opposites (use edge finder to precisely locate faces). Get instructor or TA approval before making first side mill operation.		# ''Side mill'' the other faces such that all faces are 1.000" +- 0.003" from their opposites (use edge finder to precisely locate faces). Get instructor or TA approval before making first side mill operation.
	# Use dial indicator to verify that the faces are parallel to within 3 mils (a mil is one thousandth of an inch).		# Use dial indicator to verify that the faces are parallel to within 3 mils (a mil is one thousandth of an inch).

Bsboggs: /* Activities */

2018-06-06T22:29:11Z

Activities

← Older revision		Revision as of 22:29, 6 June 2018
Line 34:		Line 34:
	# Read the Wikipedia page on [https://en.wikipedia.org/wiki/Speeds_and_feeds machining speeds and feeds]. Calculate Spindle Speed with this [https://littlemachineshop.com/mobile/speeds_feeds.php online calculator]. Set the mill's spindle speed to be no more than 3/4 the calculated speed and less than 80% of the maximum G0759's spindle speed.		# Read the Wikipedia page on [https://en.wikipedia.org/wiki/Speeds_and_feeds machining speeds and feeds]. Calculate Spindle Speed with this [https://littlemachineshop.com/mobile/speeds_feeds.php online calculator]. Set the mill's spindle speed to be no more than 3/4 the calculated speed and less than 80% of the maximum G0759's spindle speed.
	# Set up a ''rough cut'' of a ~ 1 1/8 length section from the Al bar stock using the band saw - Get instructor or TA approval before making the cut. Clean up metal shavings and put bandsaw and stock back in storage areas.		# Set up a ''rough cut'' of a ~ 1 1/8 length section from the Al bar stock using the band saw - Get instructor or TA approval before making the cut. Clean up metal shavings and put bandsaw and stock back in storage areas.
			# Lubricate the head stock vertical column with a few drops of oil (on each side).
	# Mount the rough block in the milling vise using parallel bars (rough side face up) - Get instructor or TA approval before milling.		# Mount the rough block in the milling vise using parallel bars (rough side face up) - Get instructor or TA approval before milling.
	# ''Face mill'' the rough side so that it's 1.000" +- 0.003" from its opposite face.		# ''Face mill'' the rough side so that it's 1.000" +- 0.003" from its opposite face.

Bsboggs: /* Activities */

2018-05-01T21:31:35Z

Activities

← Older revision		Revision as of 21:31, 1 May 2018
Line 34:		Line 34:
	# Read the Wikipedia page on [https://en.wikipedia.org/wiki/Speeds_and_feeds machining speeds and feeds]. Calculate Spindle Speed with this [https://littlemachineshop.com/mobile/speeds_feeds.php online calculator]. Set the mill's spindle speed to be no more than 3/4 the calculated speed and less than 80% of the maximum G0759's spindle speed.		# Read the Wikipedia page on [https://en.wikipedia.org/wiki/Speeds_and_feeds machining speeds and feeds]. Calculate Spindle Speed with this [https://littlemachineshop.com/mobile/speeds_feeds.php online calculator]. Set the mill's spindle speed to be no more than 3/4 the calculated speed and less than 80% of the maximum G0759's spindle speed.
	# Set up a ''rough cut'' of a ~ 1 1/8 length section from the Al bar stock using the band saw - Get instructor or TA approval before making the cut. Clean up metal shavings and put bandsaw and stock back in storage areas.		# Set up a ''rough cut'' of a ~ 1 1/8 length section from the Al bar stock using the band saw - Get instructor or TA approval before making the cut. Clean up metal shavings and put bandsaw and stock back in storage areas.
	# Mount the rough block in the milling vise using parallel bars (rough side face up)- Get instructor or TA approval before milling.		# Mount the rough block in the milling vise using parallel bars (rough side face up) - Get instructor or TA approval before milling.
	# ''Face mill'' the rough side so that it's 1.000" +- 0.003" from its opposite face.		# ''Face mill'' the rough side so that it's 1.000" +- 0.003" from its opposite face.
	# ''Side mill'' the other faces such that all faces are 1.000" +- 0.003" from their opposites (use edge finder to precisely locate faces). Get instructor or TA approval before making first side mill operation.		# ''Side mill'' the other faces such that all faces are 1.000" +- 0.003" from their opposites (use edge finder to precisely locate faces). Get instructor or TA approval before making first side mill operation.

Bsboggs: /* Consumable Raw Material */

2018-05-01T19:07:41Z

Consumable Raw Material

← Older revision		Revision as of 19:07, 1 May 2018
Line 14:		Line 14:
	- Digital Calipers<br>		- Digital Calipers<br>

	== Consumable Raw ~~Material~~ ==		== Consumable Raw Materials ==

	- Al 6061 1 1/8" x 1 1/8" Bar Stock		- Al 6061 1 1/8" x 1 1/8" Bar Stock

Bsboggs: /* Activities */

2018-05-01T02:23:23Z

Activities

← Older revision		Revision as of 02:23, 1 May 2018
Line 26:		Line 26:

	'''NOTE:''' Use the low "L" speed range for most operations (and make slow cuts). The motor has more torque in the low range. Also, don't operate the mill at max speed for more than a few minutes at a time in order to avoid overheating the motor. If you want to operate the mill at high speeds (for finishing purposes), use the high "H" range and turn down the variable speed dial from max (maybe 80% of max value).		'''NOTE:''' Use the low "L" speed range for most operations (and make slow cuts). The motor has more torque in the low range. Also, don't operate the mill at max speed for more than a few minutes at a time in order to avoid overheating the motor. If you want to operate the mill at high speeds (for finishing purposes), use the high "H" range and turn down the variable speed dial from max (maybe 80% of max value).

			'''NOTE:''' Only change speed ranges (between "L" and "H") with the machine off.

	# Get a safety demonstration from the instructor or TA.		# Get a safety demonstration from the instructor or TA.

Bsboggs: /* Activities */

2018-05-01T02:20:05Z

Activities

← Older revision		Revision as of 02:20, 1 May 2018
Line 30:		Line 30:
	# Read the [[Media:Grizzlyg0759_Milling_Machine.pdf\| G0759 manual]] Introduction and Safety sections (pages 2-10) and the Operations section (pages 22-32). You can also view a few of the many good [https://www.youtube.com/results?search_query=how+to+mill how-to-mill videos on YouTube].		# Read the [[Media:Grizzlyg0759_Milling_Machine.pdf\| G0759 manual]] Introduction and Safety sections (pages 2-10) and the Operations section (pages 22-32). You can also view a few of the many good [https://www.youtube.com/results?search_query=how+to+mill how-to-mill videos on YouTube].
	# Use [https://en.wikipedia.org/wiki/AutoCAD AutoCAD] (on virtual machine on mother in APL) to make a technical drawing of a 1" Al cube with four 8-32 (0.5" deep) tapped holes in the corner of one face (holes positioned 1/8" from edges) and a 1/4" hogged out squarish hole (1/8" border) on the opposite face. If you're new to AutoCAD you can view a few of the many good AutoCAD-for-beginners [https://www.youtube.com/results?search_query=autocad tutorials on YouTube]. Show drawing to Instructor or TA before moving on.		# Use [https://en.wikipedia.org/wiki/AutoCAD AutoCAD] (on virtual machine on mother in APL) to make a technical drawing of a 1" Al cube with four 8-32 (0.5" deep) tapped holes in the corner of one face (holes positioned 1/8" from edges) and a 1/4" hogged out squarish hole (1/8" border) on the opposite face. If you're new to AutoCAD you can view a few of the many good AutoCAD-for-beginners [https://www.youtube.com/results?search_query=autocad tutorials on YouTube]. Show drawing to Instructor or TA before moving on.
	# Calculate Spindle Speed with this [https://littlemachineshop.com/mobile/speeds_feeds.php online calculator]. Set the mill's spindle speed to be no more than 3/4 the calculated speed and less than 80% of the maximum G0759's spindle speed.		# Read the Wikipedia page on [https://en.wikipedia.org/wiki/Speeds_and_feeds machining speeds and feeds]. Calculate Spindle Speed with this [https://littlemachineshop.com/mobile/speeds_feeds.php online calculator]. Set the mill's spindle speed to be no more than 3/4 the calculated speed and less than 80% of the maximum G0759's spindle speed.
	# Set up a ''rough cut'' of a ~ 1 1/8 length section from the Al bar stock using the band saw - Get instructor or TA approval before making the cut. Clean up metal shavings and put bandsaw and stock back in storage areas.		# Set up a ''rough cut'' of a ~ 1 1/8 length section from the Al bar stock using the band saw - Get instructor or TA approval before making the cut. Clean up metal shavings and put bandsaw and stock back in storage areas.
	# Mount the rough block in the milling vise using parallel bars (rough side face up)- Get instructor or TA approval before milling.		# Mount the rough block in the milling vise using parallel bars (rough side face up)- Get instructor or TA approval before milling.