121.1.1 - Manual Machining

Overview of Manual Mills

What is a "Mill"?

A Mill (AKA a "Milling Machine" or "Bridgeport") is a type of machine tool that is used for cutting and shaping metal and other materials.
- It typically uses a rotary cutting tool to remove material from a workpiece, which is moved by a variety of different motions to achieve the desired shape.
- Milling machines can be used for a wide range of applications, from simple, one-off parts to complex, precision-machined components.
There are several reasons why a milling machine may be used. Some of the most common reasons include:
- Cutting and shaping metal and other materials: Milling machines are often used for cutting and shaping metal and other materials, such as wood or plastic. They can be used to create a wide range of different parts and components with precise dimensions and shapes.
- Creating complex shapes: Milling machines can be used to create complex shapes that would be difficult or impossible to produce using other methods. For example, they can be used to create intricate contours, grooves, and other features on a workpiece.
- Producing high-precision parts: Milling machines are capable of producing parts with very tight tolerances, which is why they are often used in industries such as aerospace, automotive, and medical device manufacturing.
- Mass production: Milling machines can be used to produce large numbers of identical parts quickly and efficiently, making them well-suited for use in mass production settings.
Overall, the use of a milling machine allows for the precise cutting and shaping of a wide range of materials, making it an essential tool in many manufacturing and production settings.

Types of Milling Machines

There are several types of milling machines, including:
- Vertical milling machines - These machines have a vertical orientation, and use a spindle that moves in a vertical direction to remove material from the workpiece. The spindle can move up and down, and is typically equipped with cutting tools that can be rotated to cut in different directions.
- Horizontal milling machines - These machines have a horizontal orientation, and use a spindle that moves in a horizontal direction to remove material from the workpiece. The spindle can move left and right, and is typically equipped with cutting tools that can be rotated to cut in different directions.
- Universal milling machines - These machines can be used to perform a wide range of operations, including both vertical and horizontal milling. They are typically equipped with multiple cutting tools that can be rotated and used for a variety of different operations.
- Bed milling machines - These are milling machines that are designed for large, heavy workpieces. They have a fixed bed, and the spindle moves along the bed to perform the milling operation.
- Planer-style milling machines - These are similar to bed milling machines, but have a movable bed that can be adjusted to accommodate different-sized workpieces.
- Tracer milling machines - These are specialized milling machines that are used to reproduce patterns or designs on workpieces. They use a stylus or tracing device to follow a pattern, and the cutting tools are automatically adjusted to reproduce the pattern on the workpiece.

Manual Mill Safety

There are several safety considerations that should be followed when operating a manual milling machine:
- Always wear appropriate personal protective equipment, including safety glasses, gloves, and hearing protection.
- Ensure that the work area is well-lit and free of clutter.
- Keep the floor around the milling machine free of oil and grease to prevent slipping.
- Secure the workpiece properly before starting the machine.
- Use the correct cutting tools for the material being machined.
- Never reach under or around the moving parts of the milling machine while it is in operation.
- Never attempt to remove cuttings or chips while the machine is in operation.
- Keep your hands and clothing away from the moving parts of the milling machine.
- Never leave the machine running unattended.
- Shut off the machine and wait for all moving parts to come to a complete stop before attempting to clean or perform maintenance on the machine.

Manual Mill Controls

A vertical knee mill like the one you will use for this course typically consists of the following parts:
- Base: The base of the mill is where the machine is mounted and provides support for all of the other parts.
- Saddle: The saddle is mounted on the base and provides a way for the table to move left and right.
- Knee: The knee is mounted on the saddle and provides a way for the table to move up and down.
- Table: The table is mounted on the knee and provides a platform for the workpiece.
- Head: The head is mounted on the top of the knee and contains the spindle, motor, and other components that drive the cutting tools.
- Cutting tools: These are the tools, such as end mills and drill bits, that are used to shape the workpiece.
- Control panel: The control panel is where the user can input instructions and control the movement of the cutting tools.

1.1✔ CHECKPOINT

Mill Safety/Operation Walkthrough

With instructor supervision, do an in-person Manual Mill Safety/Operation Walkthrough on a Manual Mill in the Lab, going over & demonstrating the following competencies:
- Manual Mill Safety Standards, PPE, & Rules
- Safe Shut-Down & Power-Off of a Manual Mill
- Safe Start-Up of a Manual Mill
- Safe unloading & loading of a tool in the spindle
- Safe & precise, manual & powered movement of all axes (X, Y, & Z)

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