Changes

Milling Machine

2,301 bytes added, 09:26, 1 January 2017
Add Accessories, Wishlist/TODO
[[File:mill2.jpg]]
=== Usage & Safety ===
The milling machine is both a precision machine and also powerful enough to seriously hurt you. It needs to be treated with the same respect you would give any precision tool. All members are welcome to use the machine after being shown how to use it properly.
Note that knowing how to use a milling machine is not sufficient - You must be shown by a trained member the intricacies of '''our machine.'''
=== Feeds and Speeds / Feed Direction ===
* Learn about feeds and speeds for the cutter diameter and material you are using. Too fast or slow RPM can damage cutters and make it harder to work.
* There is a chart on the mill cart for calculating the maximum RPM for a given tool bit size and material. The chart was generated using [http://w1n9zr0.github.io/feeds-speeds/mill-chart.html this calculator] ([https://github.com/W1N9Zr0/feeds-speeds source code]).
=== Tips and Advice ===
* Non-metals are okay, but you should use your own tools and be extra careful if you don't know how the material will behave.
* Take the cutter away from the material before turning off the motor.
* Do not use oil on aluminum except for drilling or tapping.
 
== Accessories ==
* [http://www.busybeetools.com/products/vise-milling-5in-kurt-type.html Busy Bee B2251 5" Vise]
* [http://www.busybeetools.com/products/rotary-table-6in-c-w-tail-stock-indexing.html Busy Bee B2485 6" Rotary Table w/ Indexer and Tailstock]
=== Digital Readout ===
The mill is fitted with a [http://www.thedrostore.com/details-promo-3i.htm TDS-3i DRO]. The Z axis scale is not installed on the knee yet, needs brackets made and power switch box relocated.
[[File:DRO.jpg|400px]]
* TODO: Scan the manual and upload it here, there doesn't appear to be a PDF version of it on the internet.
=== Supplies ===
* Busy Bee Tools: http://www.busybeetools.com
* Accusize: http://www.accusizetools.ca/upfile/2014-2015.pdf
* KBC Tools: http://www.kbctools.ca/
 
 
=== Wishlist/TODO ===
* Lubricate spindle (figure out how and what kind of oil/grease it needs and how to do it first)
* Lubricate anything else not fed by the one-shot oiler: leadscrew nuts, etc.
* Install X-axis DRO scale cover
* Install knee (Z-axis) DRO scale
* Make belt cover close completely instead of hanging up on hinge and motor
* Add metering valves to one-shot oiler manifold to prevent oil going all over the place instead of the ways
** Manifold has 1/8-NPT thread, adapters to 5/32" (~4mm) nylon tube
** Option 1 ([https://www.mcmaster.com/#catalog/122/2217/=15o436a McMaster]): 1/8 NPT male to 1/8 NPT male + female-female coupler + existing NPT-quick-connect adapter
*** Metering Valve for Central Lubrication Pump https://www.mcmaster.com/#2293K13
*** High-Pressure Brass Pipe Fitting https://www.mcmaster.com/#50785K91
** Option 2 ([http://www.bijurdelimon.com/fileadmin/products/docs/bdius/Brochures/258_SYS_Single-Line-Resistance_BR.pdf Bijur]): 1/8 NPT male to 5/32 (4mm) tube + compression nut + compression sleeve + tube insert
*** FRA-1 1/8 NPT to 5/16-24 thread, 5/32" OD tube meter unit B3216
*** 5/32 tube 5/16-24 thread compression nut B1095
*** 5/32 nylon tube single-sided sleeve B8272
*** 5/32 tube insert steel 19268 for 5/32 .025 wall nylon tube
** Need to select valve flow ratings to balance amount of oil going to different dovetails, machining forums seem to use a mix of #0 and #1 or all #1 valves
** Problems:
*** Valves can get clogged with wrong type of oil, dirt, etc.
*** Valves are impossible to clean and need to be replaced if that happens
*** Need to unplug tubes to test if valves still flowing. Would a pressure gauge on the manifold show a difference when a valve stops flowing?
*** Expensive! Is squirting oil everywhere cheaper, and good enough to keep the machine lubricated?
* Table covers to prevent dropping things on table
* Cheapo caliper-style DRO for quill travel
* X-axis Power feed