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+++ millsop [2021/04/27 17:39] (current) – furst
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 ====Manual Milling Machine Training SOP====
+Last edited: Furst (10/12/20)
+Instructor:
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+-----
 ====Tool Location====
 Innovation Workshop, Elings 2448
-====Safety====
-  * Untrained or unsupervised operators risk serious injury.
+====Overview:====
-  * Risk of metal splinters and burns from flying chips. Wear safety goggles, closed-toe shoes, long pants.
+PM-25MV Mill
-  * Keep body parts clear of spindle and workpiece while machine is moving
+  - A 3-axis mill with R8 spindle. Spindle speeds varies continuously from 50-2500 rpm.
-  * Take care when handling heavy objects
+  - Weight: 275 lbs
-  * Make sure the part and tool are secured before starting a machining operation
+  - Spindle motor: Brushless DC 750 W (1 HP)
-  * Remove chuck keys and other tools before starting the machine
+  - Travel
+    - X-axis: 20.5”
+    - Y-axis: 7”
+    - Z-axis: 13”
+  - Axis locks
+  - Quill lock
+  - 4” Vice
+    - Hold downs for vice
+    - Indicating vice
+  - DRO
+    - One for table and headstock. A separate DRO for quill.
+    - Functions
+      - Zeroing
+      - Inputting coordinate
+      - Metric/inch interchange
+      - Absolute/incremental coordinates
+      - Automatic half
+      - Calculator
+      - Entering tool offset
 ====Training====
-  - Requirements
+**Safety Hazards**
-    - Machine shop safety test
+  - This machine is designed for milling and drilling operations by experienced users familiar with metal-working hazards.
-    - in-person training
+  - Wear ANSI-approved full-face or eye protection at all times when using the machine (everyday eyeglasses are not reliable protection against flying particles).
-  - Training outline
+  - Wear proper apparel and non-slip footwear – be sure to prevent hair, clothing or jewelry from becoming entangled in moving parts. Gloves – including tight-fitting disposables can be hazardous!
-    - Technical description
+  - Be sure the work area is properly lit.
-      - PM-25MV Mill
+  - Never leave chuck keys, wrenches or other loose tools on the machine.
-        - A 3-axis mill with R8 spindle. Spindle speeds varies continuously from 50-2500 rpm.
+  - Be sure the work piece and machine ways are secure before commencing milling or drilling hold-downs and/or vise fully tightened, X-Y-Z axes locked, cutting tool secured
-        - Weight: 275 lbs
+  - Use moderation: light cuts, low spindle speeds and slow table motion give better, safer results than “hogging”.
-        - Spindle motor: Brushless DC 750 W (1 HP)
+  - Don’t try to stop a moving spindle by hand – allow it to stop on its own.
-        - Travel
+  - Disconnect 110V power from the mill before maintenance operations such as oiling or adjustments
-          - X-axis: 20.5”
+  - Maintain the machine with care – check lubrication and adjustments daily before use.
-          - Y-axis: 7”
+  - Clean the machine routinely – remove chips by brush or vacuum, not compressed air (which can force debris into the ways).
-          - Z-axis: 13”
-        - Axis locks
+**Setup**
-        - Quill lock
+  - Turn on the mill
-      - 4” Vice
+  - Turn on DRO by flipping switch on back
-        - Hold downs for vice
+  - Turn on Quill DRO by pressing power button
-        - Indicating vice
+  - Once part and tool are secure, spindle may be turned on by pressing the green power button on the speed controller panel
-      - DRO
+    - Setting up a vice
-        - One for table and headstock. A separate DRO for quill.
+      - Install the T-bolts and align the vise by eye. With one of the clamp nuts snug, but not tight, tighten the other one just short of fully-tight (but tight enough so the vise won’t budge without a definite tap from a dead-blow mallet). \\ {{:tools:precisionsmillingmachine:indicating_a_vice.png?200|}}
-        - Functions
+      - Adjust the Y-axis to pre-load the indicator to mid range at the tightly-clamped side of the vise, then lock the Y-axis. Do not allow the spindle to rotate during this procedure.
-          - zeroing
+      - Note the indicator reading, then watch the indicator as you traverse the table slowly toward the loosely clamped side. (Also watch for any sign of spindle rotation.) Ideally, there should be no discrepancy between the indicator readings at the two ends — unlikely at the first attempt. Return the table to the starting point, then repeat the process, tapping the vise in as you go. Repeat the process as often as necessary for the desired accuracy, progressively tightening the “looser” nut. Now fully tighten both nuts, and re-check again (tightening a nut can itself introduce significant error).
-          - inputting coordinate
+**Change Tooling**
-          - metric/inch interchange
+  - Remove Tooling
-          - Absolute/incremental coordinates
+  - Lock the spindle with the C-wrench, loosen the drawbar one half turn or less, just enough to unseat the taper, then tap the top of the drawbar with a soft hammer to release the R-8 device. Unscrew the drawbar with one hand while supporting the R-8 device with the other hand.
-          - automatic half
+**Install Tooling**
-          - calculator
+  - Install the R-8 device, then hand-thread the drawbar into it until the shoulder on the drawbar bottoms on the splined spindle, diagram above (on the machine this is concealed by the drawbar cap, Figure 3-2). Lock the spindle with the special C-wrench, page 5, while at the same fully tightening the drawbar with an 8 mm wrench.
-          - entering tool offset
+**Securing the part**
-     - Safty
+  - Vice
-       - Precautions
+    - Position part in vice. Vice maximum length is 4”. Use parallels if needed. Press firmly down on part to ensure it is properly seated.
-         - This machine is designed for milling and drilling operations by experienced users familiar with metal-working hazards.
+    - Tighten vice
-         - Wear ANSI-approved full-face or eye protection at all times when using the machine (everyday eyeglasses are not reliable protection against flying particles).
+  - Hold-downs
-         - Wear proper apparel and non-slip footwear – be sure to prevent hair, clothing or jewelry from becoming entangled in moving parts. Gloves – including tight-fitting disposables can be hazardous!
+    - Hold downs can be accessed in the “Milling Supplies Drawer” (See Supplies).
-         - Be sure the work area is properly lit.
+**Moving the Table**
-         - Never leave chuck keys, wrenches or other loose tools on the machine.
+  - Conventionally, left-right movement of the table is said to be along the X-axis (also called “longitudinal travel” or “traversing”). Front-back movement is on the Y-axis, sometimes called “cross travel”.
-         - Be sure the work piece and machine ways are secure before commencing milling or drilling hold-downs and/or vise fully tightened, X-Y-Z axes locked, cutting tool secured
+  - Each axis has a leadscrew with handwheel and graduated dial with 0.001” divisions, 0.1” per revolution.
-         - Use moderation: light cuts, low spindle speeds and slow table motion give better, safer results than “hogging”.
+  - The position of the table is indicated by the digital readout (DRO)
-         - Don’t try to stop a moving spindle by hand – allow it to stop on its own.
+  - Leadscrew backlash
-         - Disconnect 110V power from the mill before maintenance operations such as oiling or adjustments
-         - Maintain the machine with care – check lubrication and adjustments daily before use.
+**Moving headstock**
-         - Clean the machine routinely – remove chips by brush or vacuum, not compressed air (which can force debris into the ways).
+  - For milling
-     - Setup
+    - Z-axis crank. When the headstock is in the desired place, lock it in place.
-       - Turn on the mill
+  - Changing the speed
-         - Turn on DRO by flipping switch on back
+    - Adjust the speed knob one the headstock while the machine is on
-         - Turn on Quill DRO by pressing power button
+  - Quill downfeed \\ {{:tools:precisionsmillingmachine:quill_handle.png?200|}}
-         - Once part and tool are secure, spindle may be turned on by pressing the green power button on the speed controller panel
+    - For drilling operations, loosen knob (4), allowing the lever hub to rotate independently of sleeve (3).
-       - setting up a vice
+      - In the drilling mode, coarse feed, the mill operates like a standard drill press with a 3-lever hub; lever action lowers or raises the quill in the usual way by rack and pinion. Return action is assisted by a compression spring within the quill and spindle assembly.
-         - Install the T-bolts and align the vise by eye. With one of the clamp nuts snug, but not tight, tighten the other one just short of fully-tight (but tight enough so the vise won’t budge without a definite tap from a dead-blow mallet). \\ {{:tools:precisionsmillingmachine:indicating_a_vice.png?200|}}
+    - For fine downfeed
-         - Adjust the Y-axis to pre-load the indicator to mid range at the tightly-clamped side of the vise, then lock the Y-axis. Do not allow the spindle to rotate during this procedure.
+      - For milling operations calling for precise, repeatable control of tool depth, tighten knob (4) to engage hub (1) with the internal taper on sleeve (3). Tighten the Z-axis locks, Figure 3-6.
-         - Note the indicator reading, then watch the indicator as you traverse the table slowly toward the loosely clamped side. (Also watch for any sign of spindle rotation.) Ideally, there should be no discrepancy between the indicator readings at the two ends — unlikely at the first attempt. Return the table to the starting point, then repeat the process, tapping the vise in as you go. Repeat the process as often as necessary for the desired accuracy, progressively tightening the “looser” nut. Now fully tighten both nuts, and re-check again (tightening a nut can itself introduce significant error).
+  - Quill DRO indicates quill position
-     - Change Tooling
-       - Remove Tooling
+**Using DRO**
-         - Lock the spindle with the C-wrench, loosen the drawbar one half turn or less, just enough to unseat the taper, then tap the top of the drawbar with a soft hammer to release the R-8 device. Unscrew the drawbar with one hand while supporting the R-8 device with the other hand.
+  - Seroing
-       - install Tooling
+    - Move the table to the desired position. Zero an axis by pressing X0, y0, or Z0.
-         - Install the R-8 device, then hand-thread the drawbar into it until the shoulder on the drawbar bottoms on the splined spindle, diagram above (on the machine this is concealed by the drawbar cap, Figure 3-2). Lock the spindle with the special C-wrench, page 5, while at the same fully tightening the drawbar with an 8 mm wrench.
+  - inputting coordinate
-     - Securing the part
+    - Press X, Y, or Z
-       - vice
+    - Enter the position using the keypad
-         - Position part in vice. Vice maximum length is 4”. Use parallels if needed. Press firmly down on part to ensure it is properly seated.
+    - Press ENT
-         - Tighten vice
+  - Metric/inch interchange
-       - Hold-downs
+     - Press MM/INCH
-         - Hold downs can be accessed in the “Milling Supplies Drawer” (See Supplies).
+  - Absolute/incremental coordinates
-     - Moving the Table
+    - There are two sets of basic coordinates display, ABS (absolute) and INC (incremental) displays.
-       - Conventionally, left-right movement of the table is said to be along the X-axis (also called “longitudinal travel” or “traversing”). Front-back movement is on the Y-axis, sometimes called “cross travel”.
+    - Toggle by pressing ABS/INC
-       - Each axis has a leadscrew with handwheel and graduated dial with 0.001” divisions, 0.1” per revolution.
+  - Automatic half function
-       - The position of the table is indicated by the digital readout (DRO)
+     - Touch one side of the workpiece with the tool. Zero the axis.
-       - Leadscrew backlash
+     - Touch the tool to the other side of the workpiece.
-     - Z-axis
+     - Press X or Y, then press 1/2
-       - Moving headstock
+  - Calculator
-         - for milling
+    - Calculations can be done once the calculator button is pressed.
-         - Z-axis crank. When the headstock is in the desired place, lock it in place.
+  - Edgefinding
-       - Changing the speed
+    - Load edge finder in the spindle.
-         - Adjust the speed knob one the headstock while the machine is on
+    - Turn RPM to 1300.
-       - Quill downfeed \\ {{:tools:precisionsmillingmachine:quill_handle.png?200|}}
+    - Lower the quill so that the edge finder probe can collide with the edge whose position you want to measure.
-         - coarse downfeed
+    - Move the table so that the probe touches the edge of the part, causing the probe to become offset with the shank. At this point, the edge has been found.
-           - For drilling operations, loosen knob (4), allowing the lever hub to rotate independently of sleeve (3).
+    - Raise the quill. Offset the table position by half the edge finder diameter. Zero the axis.
-           - In the drilling mode, coarse feed, the mill operates like a standard drill press with a 3-lever hub; lever action lowers or raises the quill in the usual way by rack and pinion. Return action is assisted by a compression spring within the quill and spindle assembly.
+  - Zeroing Z
-         - fine downfeed
+    - Find a dowel pin (See Supplies). Lower the tool so it is slightly above the dowel pin
-           - For milling operations calling for precise, repeatable control of tool depth, tighten knob (4) to engage hub (1) with the internal taper on sleeve (3). Tighten the Z-axis locks, Figure 3-6.
+    - Slide the dowel pin under the tool, gradually lower the Z-axis until the dowel pin rubs the bottom of the tool but can still pass through underneath.
-         - Quill DRO indicates quill position
+    - Remove the dowel pin. Raise the table by the diameter of the dowel pin.
-     - Using DRO
+  - Drilling
-       - zeroing
+    - Look up proper RPM for tool and material
-         - Move the table to the desired position. Zero an axis by pressing X0, y0, or Z0.
+    - locate XY position, use quill to downfeed
-       - inputting coordinate
+    - Center drill followed by peck drilling the hole
-         - Press X, Y, or Z
+    - Peck drilling
-         - Enter the position using the keypad
+      - periodically remove drill from hole to clear chips
-         - Press ENT
+  - Milling
-       - metric/inch interchange
+    - Consult resources for appropriate tool RPM and feed speed.
-         - Press MM/INCH
+    - Fully retract the quill and lock it with the lever on the left of the headstock
-       - Absolute/incremental coordinates
+    -Facing
-         - There are two sets of basic coordinates display, ABS (absolute) and INC (incremental) displays.
+    -Side cutting
-         - Toggle by pressing ABS/INC
+  -Tapping
-       - automatic half
+    - Do not turn the spindle motor on during tapping
-         - Touch one side of the workpiece with the tool. Zero the axis.
+    - Place the tap guide in the spindle
-         - Touch the tool to the other side of the workpiece.
+    - Position hole under the tap
-         - Press X or Y, then press 1/2
+    - Apply tapping fluid
-       - calculator
+    - Turn the tap clockwise to cut threads. Periodically reverse tap direction to clear out chip build up.
-         - Calculations can be done once the calculator button is pressed.
-       - entering tool offset
-     - Machining operations
-       - Edgefinding
-         -  Load edge finder in the spindle.
-         - Turn RPM to 1300.
-         - Lower the quill so that the edge finder probe can collide with the edge whose position you want to measure.
-         - Move the table so that the probe touches the edge of the part, causing the probe to become offset with the shank. At this point, the edge has been found.
-         - Raise the quill. Offset the table position by half the edge finder diameter. Zero the axis.
-       - Zeroing Z
-         - Find a dowel pin (See Supplies). Lower the tool so it is slightly above the dowel pin
-         - Slide the dowel pin under the tool, gradually lower the Z-axis until the dowel pin rubs the bottom of the tool but can still pass through underneath.
-         - Remove the dowel pin. Raise the table by the diameter of the dowel pin.
-       - drilling
-         - Look up proper RPM for tool and material
-         - locate XY position, use quill to downfeed
-         - center drill, then drill the hole
-         - peck drilling
-           - periodically remove drill from hole to clear chips
-       - milling
-         - consult resources for tool RPM and feed speed.
-         - fully retract the quill and lock it with the lever on the left of the headstock
-         -facing
-         -Side cutting
-       -tapping
-         - Do not turn the spindle motor on during tapping
-         - Place the tap guide in the spindle
-         - Position hole under the tap
-         - Apply tapping fluid
-         - Turn the tap clockwise to cut threads. Periodically reverse tap direction to clear out chip build up.
 {{:tools:precisionsmillingmachine:st1r-l2q0wxizo1iu9bou0a.png?400|}}
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     * 3-In-One multi purpose oil
       * Used for drilling and milling
+-----
+====Mill SOP Quick Review====
+Tool Lead:    \\
+Contact: andrewfurst@ucsb.edu      \\
+====Safety Concern====
+  * Untrained or unsupervised operators risk serious injury.
+  * Risk of metal splinters and burns from flying chips. Wear safety goggles, closed-toe shoes, long pants.
+  * Keep body parts clear of spindle and workpiece while machine is moving
+  * Take care when handling heavy objects
+  * Make sure the part and tool are secured before starting a machining operation
+  * Remove chuck keys and other tools before starting the machine
+====Safe Operation Procedures Review====
+  -Install a collet or drill chuck
+    - Select the corresponding size tool holder for the diameter of the tool shank
+    - Align the key in the spindle with the key in the tool holder by spinning the tool holder while maintaining light upward pressure into the spindle
+      - If tool holder is a drill chuck tighten the drawbar with the wrench on the drawbar and large open ended wrench around the spindle flats
+      - If tool holder is a collet, turn the drawbar to retain the tool holder, install the tool shank into the collet, and then tighten the drawbar the remining distance using a wrench on the drawbar and the large open ended wrench on the spindle flats
+    - Be sure to remove all wrenches and drill chuck keys before powering on the machine
+  - Zeroing the machine
+    - Use an edge finder in the spindle at approximately 1000 RPM to set the part zero. Be sure to account for the radius of the edge finder and cutting tool you intend to be using
+    - With the tool in the spindle, Z zero can be set by rolling a dowel pin over the workpiece under the tip of the tool while slowly dialing down the Z axis until the dowel pin catches the tool. Be sure to account for the diameter of the dowel pin
+  - Milling and drilling
+    - Refer to the feeds and speeds chart and select the correct spindle RPM based on on tool diameter, tool material, and workpiece material.
+    - Use DRO to set the correct depth of feed for the tool and workpiece material
+    - Use the hand crank so take smooth consistent cuts, be sure to avoid sudden movements when moving the machine and take passes appropriate to the rigidity of the machine (not very ridged).
+====Post Processing====
+  - Deburr part using a file or deburring tool
+  - Vacuum the mill and table
+  - Remove tool and tool holder from machine
+  - Wipe the clamping surface of the vice with a towel
+====Maintenance====
+  * Periodically insure the vice is square to the table using a dial indicator and sweeping back and forth against the fixed jaw
+  * Periodically oil the machine to prevent corrosion, wear, and binding of axes
+  * After machine is moved or is crashed, insure head remains square to the table by securing a dial indicator in the spindle and indicating the table by rotating the spindle by hand. Indicator should show no consistent pattern