Manual Vertical Mill Setup

This page will be used to provide details on Manual Vertical Mill Setup Information. The order in which the topics occur is the systemic process that needs to be followed if starting the process from a "blank slate" or on an empty mill table.

Cleaning the Mill Table

Prior to and after completing machining operations on the milling machine, the machine needs to be cleaned thoroughly. The cleanliness of the machine is a critical factor when machining parts to specification. Any foreign materials, dirt, or debris on the machine table will prevent a machinists from being able to secure workpieces parallel to the table surface. The cleanliness of the machine table is a direct reflection of the quality of work completed by a machinist.

When cleaning the table of the milling machine, all chips, fluid, dirt, grease, and other foreign materials need to be removed. We can utilize wet/dry shop vacuums and paint brushes to remove loose large debris from the table surface. We only want to use non-marring materials when cleaning off the table surface. Make sure the shop vacuum hose and attachments being used are plastic and not metal. Never scrape debris off the top surface of the milling machine table with metal tools. We also never want to set metal objects directly on the surface of the table, use a piece of wood or plastic as a buffer. Any metal on metal contact will likely result in nicks or gouges in the surface of the milling machine table. These nicks or gouges cause inaccuracies in the flatness of the surface we rely on to perform precision machining operations.

When cleaning debris from the t-slots we can utilize a t-slot scraper. Care needs to be taken when using the t-slot scarper to avoid contact with the top surface of the milling machine table.

Chips, fluid, dirt, grease, and other foreign materials that are not removed by the vacuum or paint brush need to be wiped with a shop rag. Sometimes it is necessary to utilize solvent or light oil when wiping the remaining debris from the surfaces of the milling machine table. Once all debris is remove from the milling machine table, apply a slight amount of light oil (wd-40 is the most common) to a clean shop rag and wipe down all surfaces of the milling machine table. The a light coat of oil will be deposited on the surface of the table to prevent corrosion.

Stoning the Table

Stoning the table is the process utilized to remove high spots of material from the machines table or from mating surfaces of workholding components.

The high spots of material are most often a result of damage due to peening (nicks or gouges) caused by dropping workpieces, tools, or other items directly on the surface. When a surface on a piece of material is peened some material is pressed into a depression and some material flows above the surface. The material that flows above the surface is removed by stoning.

Watch the video to learn more about stoning a table prior to completing this task in hands-on training. Note that the same stoning process is utilized on both CNC and Manual Milling Machines.

Tramming the Spindle

Our milling machine utilizes the X, Y, Z Cartesian Coordinates system. The spindle of the milling machine for general setups is required to be aligned parallel with the Z axis direction of the knee of the mill. This results in the Z axis being perpendicular to both the X and Y axis of the machine. By having and maintaining this relationship between the Z axis and the X and Y axes, the cartesian coordinates system can be used. If the Z axis is not perpendicular to X and Y axes, Cartesian Coordinates can not be used dependably.

We should continue to adjust the pitch and roll axes on the spindle head until we achieve a Zero reading on the Dial Indicator over an 8" length. An example of an exemption will be given in class.

Watch the video to gain more insight into how we go about tramming the spindle head to ensure the Z axis of the machine is perpendicular to both X and Y axes.

Apprentices will be required to tram in spindles during hands-on training sessions at Auburn. Additional instruction will be provided then.

Tramming the Vise

During Project 1, apprentices will utilize a vise on the milling machine table to provide workholding and locating of the work piece material. The vise needs to be setup such that the master jaw of the vise is parallel with the X axis of the manual mill. If the vise is not parallel to the X axis the machining performed will result in an angular bias in our dimensions. The goal in tramming the vise is to obtain a "Zero" reading on our Dial Indicator along the entire length of the master jaw vise. An example of an exemption will be given in class.

Watch the video to gain insight into the process of tramming the vise prior to performing this step during hands-on training.

Machining operations can begin when all of the items above have been completed to the level required.

Recap:

1) Milling machine table should be cleaned spotless

2) The table surface has been stoned to ensure flatness

3) The spindle of the mill has been trammed in to a maximum of .0005" over a 6" diameter. The ideal value is zero.

4) The vise of the mill has been trammed in to a maximum of .0005" over a 6" master jaw length. The ideal value is zero.

Edge Finders

Starting with Operation 25 of Project 1, apprentices will be required to locate and establish a Cartesian Coordinate Plane on the top surface each work piece. This plane will align the blueprint dimensions and operational sketch setup information with the machines X, Y, and Z coordinate system.

Apprentices should watch the video and familiarize themselves with the Edge Finder and the method of application to locate a rectangular solid shaped piece of material.

Apprentices will receive demonstration and practice using the edge finder during hands-on instruction. Edge finder use is a critical machine setup skill. The skill based assessment for each apprentice is to be able to use the edge finder repeatedly locate a surface to .0005" or better on a Bridgeport mill.

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