Difference between revisions of "Operating a Milling Machine"

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[[File:G0759.jpg | 400px |thumb|Grizzly G0759|right]]
 
[[File:G0759.jpg | 400px |thumb|Grizzly G0759|right]]
  
Make a small (Al or brass) cube with tapped holes and  
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== Permanent Materials ==
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- G0759 Milling Machine and Milling Vise<br>
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- Collets<br>
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- HSS Mills<br>
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- Drill Chuck and Drill Bits<br>
 +
- Die and Tap Sets<br>
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- Edge Finder<br>
 +
- Dial Indicator<br>
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- Parallel Bar Set<br>
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- Digital Calipers<br>
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== Consumable Raw Material ==
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- Al 6061 1 1/8" x 1 1/8" Bar Stock
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== Activities ==
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Basic Idea: Make a small 1" Al cube with tapped holes and  
 
one face hogged out.
 
one face hogged out.
  
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'''CLEAN UP AREA AFTER EACH LAB SESSION'''
  
Skills:<br>
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# Get a safety demonstration from the instructor or TA.
- rough cutting stock with bandsaw<br>
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# Read the [[Media:Grizzlyg0759_Milling_Machine.pdf|  G0759 manual]] Introduction and Safety sections (pages 2-10) and the Operations section (pages 22-32).
- side mill<br>
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# 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.
- face mill<br>
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# 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.
- edge find<br>
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# Mount the rough block in the milling vise using parallel bars (rough side face up)- Get instructor or TA approval before milling.
- drill<br>
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# ''Face mill'' the rough side so that it's 1.000" +- 0.005" from its opposite face.
- tap<br>
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# Side mill the other faces such that all faces are 1.000" +- 0.005" from their opposites (use edge finder to precisely locate faces). Get instructor or TA approval before making first side mill operation.
- hog out<br>
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# 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.
 
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# 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.
Idea: To learn machining skills while making a small parallel-faced cube.
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# Put all tools back into storage and clean up area.

Revision as of 14:18, 30 April 2018

Grizzly G0759


Permanent Materials

- G0759 Milling Machine and Milling Vise
- Collets
- HSS Mills
- Drill Chuck and Drill Bits
- Die and Tap Sets
- Edge Finder
- Dial Indicator
- Parallel Bar Set
- Digital Calipers

Consumable Raw Material

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

Activities

Basic Idea: Make a small 1" Al cube with tapped holes and one face hogged out.

CLEAN UP AREA AFTER EACH LAB SESSION

  1. Get a safety demonstration from the instructor or TA.
  2. Read the G0759 manual Introduction and Safety sections (pages 2-10) and the Operations section (pages 22-32).
  3. Calculate Spindle Speed with this 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.
  4. 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.
  5. Mount the rough block in the milling vise using parallel bars (rough side face up)- Get instructor or TA approval before milling.
  6. Face mill the rough side so that it's 1.000" +- 0.005" from its opposite face.
  7. Side mill the other faces such that all faces are 1.000" +- 0.005" from their opposites (use edge finder to precisely locate faces). Get instructor or TA approval before making first side mill operation.
  8. Drill and tap 4 8-32 screw holes at the corners of one face (1/8" in from both faces). Use this drill and tap chart. Discuss this procedure with instructor or TA before attempting.
  9. 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.
  10. Put all tools back into storage and clean up area.