Instructions Report

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To: Nancy Myers

From: Andrew Nitchman


Date: May 11, 2020
Subject: APLED 121-Instructions Report
______________________________________________________________________________

MANUAL MILL MACHINING OPERATIONS

A manual mill consists of an adjustable worktable which manually feeds


a workpiece into a rotating, spindle-mounted cutter. This machine can
perform a variety of machining operations. These include milling,
drilling, slot-cutting, and many others. Additional accessories
including rotary tables, indexers and computer-controlled axes can be
used to increase the capability and productivity of this machine. These
steps below will teach you how to perform 3 basic machining
operations on the manual mill.

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• Wear the proper PPE when operating this machine to prevent personal
injury.
• Do not wear loose-fit clothing; it can become caught in the rotating
spindle and moving machine components.
• Completely stop the spindle before making tool changes, machine
adjustments or getting near the cutting area.
• Ensure workpiece and cutting tool are secure. Loose tools can break,
and workpieces can be thrown with deadly force. This can result in
machinery damage or personal injury.

Facing Stock using the Manual Mill

1. Before any operations, ensure the vise is free of debris and that it and the mill head are
aligned properly.
2. Select a parallel set that will permit enough of the workpiece to protrude above the
vise so you can machine material off the top.
3. Select the proper cutting tool for the operation. In this instance, a face mill is the
best choice.
4. Calculate the proper feeds and speeds.
5. Place the cutting tool in the spindle and secure it.
6. Turn on the spindle and move the knee until the cutter barely touches the part surface.
6. Make a pass across the surface. If the surface does not clean up, move knee up a couple
thousandths of an inch and make passes until the surface cleans up.
7. Remove the part from jaws and deburred the edges.
8. Clean any chips in the vise jaws.

Drilling Holes using the Manual Mill

1. Ensure the vise is free of debris and that it and the mill head are aligned properly,
2. Select the cutting tools for this operation. A center-drill and drill will be used here.
3. Calculate the proper feeds and speeds.
4. Locate the hole location with an edgefinder.
5. Set graduated mill dials at Zero.
6. Place a center drill in the spindle, holding it in an R8 Collet or Drill Chuck.
7. Center drill the hole using the quill feed hand lever. Use “pecking” while drilling.
8. Once the hole is center drilled, replace the centerdrill with the proper drill size.
9. Drill a through hole using the same technique in Step 7.
10. Turn off the spindle, remove from the vise, then inspect your workpiece.
Profile Cutting using the Manual Mill

1. Before any operations, ensure the vise is free of debris and that it and the mill head are
aligned properly.
2. Place workpiece in the vise, resting it upon parallels. Ensure there is enough part
clearance from the top of the part to the jaws.
3. Select the proper cutting tool for the operation. In this instance, use an Endmill
4. If necessary, use an edge finder to find the location where you will begin machining.
5. Set graduated mill dials at zero.
6. Place the endmill in the spindle, holding it in an R8 collet.
7. Calculate the proper feeds and speeds.
8. Turn on the spindle and begin feeding into the workpiece using the table traverse
handles1. The cutter should be fed into the workpiece in a counterclockwise
(conventional) direction.
9. After making the first pass, measure the current workpiece dimensions and determine
how much material needs to be removed off the sides of the workpiece.
10. Using the graduated mill dials, continue making passes until you reach the required size.

The manual mill is an extremely versatile machine tool, capable of performing


a variety of machining operations. Every machine shop should be equipped
with a Manual Mill. Make sure you understand how to safely operate the
manual mill to ensure you can create accurate parts.

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You can set the auto-feed to ensure a consistent surface finish.

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