Equipment:
Drill Press
Twist Drills
Drill Chuck
Cutting Fluid
collet
Edge finding
Edge finder
Mount the edge finder into the mounting using a drill chuck or approximately
sized collet.
Once mounted correctly ; start the spindle rotating at a moderate speed and
bring the rotating edge finder close to the part
NOTICE - the tip of the edge finder should be running offset f not given it a
flick with your finger.
Slowly feed the tip of the tool against the work piece . the tip of will begin
to become center of the shank
NOTICE – the tip of the edge finder should be running offset , if not give ita
flick with your finger
Slowly feed the tip of the tool against the work piece the tip will begin to be
centered
On the shank
When the tips becomes perfectly centered with the shank the tip will
abruptly jump sideways
At this point is we zero the position in the x axis
And picth over the part by 0.1’’ which is half the diameter of the edge finder
tip
NOTE- in order to complete edge finding you must report all the step for the
y – co-ordinates
If the mill you are using does not have a digital read out the edge finding
process remain the same. All mills have dials that have incremental marking
around the perimeter
Instead of punching the Zero button on the readout we loosen the locking
ring and set the dial 0.1” or 100
We then re-engage the locking ring and turn the dial to zero.
Note - When setting the zero using the dial method it is important that the
dial be oriented in the direction of travel . this eliminates any back lash
Speed gears
The front dial indicates spindle speed for both high and low gear
You must first select the gear range you wish to be in (hi OR low range)
Precaution :Also this handle for high and low range should never be handled when
spindle is in motion
Note: you must gently push the handle inwards to switch gear . you may also need
to spin the spindle by hand in order for the internal gears to align.
Next turn on/off switch to correspond with gear you have chosen to run
Note: if switch doesn’t match gear then spindle will run in
reverse.
The spindle speed is then adjust by way of this handle
found on the right side of the machine.
Attention never turn this handle unless the spindle is in
motion
Tool change
Ensure the spindle is completely up and lock in place.
To help hold the spindle in place during tool change the mill should be in
low gear
Now its time to loosen the draw bar , grab a wrench
Push away from you to loosen you may be required to give it a a few healthy
wacks to overcome the friction
Just loosen it enough to turn by hand then tap the top of the draw bar with
srass hammer to break the compression in the collet
To finish removing the tool just undo the remaining threads
Be sure to have your free hand holding the tool . it tends to drop quickly
when it becomes free.
Next step is tool installation
Insert the cutting tool in appropriate holder ( drill chuck , collet,etc.)
Slide your collet/ chuck onto the spindle on some mills you may need to allign
key/keyways.
Begin tightening the draw bar by rotating clockwise (towards you ), continue
until snug by hand
Wrench must be used now to finish tightening
You may need to apply break to stop rotation while tightening
Tool Changing
1. Stop the Machine: Ensure the milling machine is turned off and the spindle has come to
a complete stop.
2. Select Tools: Choose the appropriate cutting tool based on the material and operation.
3. Precaution: Wear appropriate personal protective equipment (PPE), such as safety
glasses and gloves, to protect against sharp edges and potential debris.
4. Loosen Tool Holder: Use the correct wrenches to loosen the tool holder. Be cautious not
to damage the holder or spindle taper.
5. Remove Current Tool: Carefully extract the current tool from the spindle taper,
ensuring it is secure.
6. Insert New Tool: Insert the new tool into the spindle taper, aligning it correctly.
7. Precaution: Ensure the new tool is securely seated in the spindle taper before tightening
the drawbar.
8. Tighten Tool Holder: Firmly tighten the drawbar to secure the new tool. Use the
manufacturer's torque specifications to prevent overtightening or undertightening.
9. Check Alignment: Optionally, use a dial indicator to verify tool runout. Adjust if
necessary to ensure concentricity.
10. Verify Setup: Confirm that all tools are securely fastened and there are no loose parts
that could interfere with operation.
Speed Setting / High Low Gears
1. Consult Machine Manual: Refer to the manufacturer's recommendations for optimal
speed settings based on cutter size, material type, and operation.
2. Precaution: Always ensure the machine is in the lowest gear when starting the spindle to
prevent sudden movements or accidents.
3. Select Speed Range: Choose the appropriate speed range (high or low gear) for the
operation.
4. Adjust Speed: Adjust the machine's speed using the control mechanisms provided (e.g.,
pulleys, speed selector switch).
5. Precaution: Monitor the machine during operation for unusual vibrations or noises,
which may indicate improper speed settings or other issues.
Use of Edge Finder - Setting Zero
1. Prepare Edge Finder: Insert the edge finder into the spindle and secure it properly.
2. Position Workpiece: Place the workpiece on the milling table, ensuring it is securely
clamped to prevent movement during the operation.
3. Precaution: Avoid placing fingers near moving parts and ensure all guards are in place to
prevent accidental contact with rotating tools.
4. Touch Off: Carefully bring the edge finder into contact with the edge of the workpiece
using the machine's handwheels.
5. Set Zero: Use the digital readout (DRO) or graduated dial to set the zero position
accurately.
6. Precaution: Move the edge finder slowly to prevent damaging the tool or workpiece.
Pitching to a Length Using the Graduated Collar
1. Identify Graduations: Locate the graduated collar on the machine's handwheel that
controls movement in the desired axis.
2. Calculate Pitch: Determine the distance required to move based on the collar's
graduations (e.g., 0.001 inch per graduation).
3. Precaution: Make sure the machine's power feed is disengaged when using manual
handwheels to prevent sudden movements.
4. Adjust Position: Turn the handwheel in the correct direction, counting the number of
graduations moved.
5. Verify Position: Use a precision measuring tool (e.g., micrometer, caliper) to verify the
machine has moved to the correct position.
6. Precaution: Avoid over-tightening handwheel movements to prevent excessive wear and
potential damage to the machine.
Backlash Compensation
1. Identify Backlash: Determine the amount of backlash in the machine's axes by
observing any play or clearance when reversing direction.
2. Compensation Method: Enter backlash compensation values into the machine's control
system if available, or manually adjust by approaching positions consistently from the
same direction.
3. Precaution: Regularly inspect machine backlash and compensate as necessary to
maintain accuracy. Follow manufacturer guidelines for adjustments.
4. Test and Adjust: Perform test movements and checks to ensure the machine accurately
positions tools or workpieces without excessive play.
5. Precaution: Perform backlash adjustments with the machine powered off to prevent
accidental movement.
General Precautions for Milling Operations:
Machine Condition: Regularly inspect and maintain the milling machine to ensure all
components are in good working condition.
Tool Inspection: Always inspect cutting tools for damage or wear before use.
Chip Management: Use appropriate chip management techniques to prevent chips from
becoming entangled in moving parts.
Secure Workpiece: Ensure the workpiece is securely clamped to the table or fixture to
prevent movement during machining.
Operator Safety: Wear appropriate PPE at all times, including safety glasses, hearing
protection, and gloves, to protect against hazards.
Emergency Procedures: Be familiar with emergency stop procedures and the location of
emergency stops on the machine.
Training: Ensure operators are properly trained on the specific milling machine model
and procedures.