Mechanical Engineering Senior Design Lab
SafetyProper PPE: Closed toe shoes and long pants are what they have to bring, we have safety glasses. Safety is number 1 For students with long hair, make sure his/her hair is tied out of the way sufficientlyWrenches should not be left on the draw bar. If a wrench gets left on the drawbar it will be one automatic badge punch Fingers shouldn’t be anywhere near the spindle while it is running for any reason.Toolboss Your unity ID will give you access to the toolbossEvery tool must be returned by the end of classThe lab manager will have a report of students that have not returned toolsOiling Two pumps of the one shot lubricate before operationUse the Mill oil can to oil cups on the head (1-2 pumps per cup)Milling Machine HeadSpindleHigh/Low gears (move only when the spindle is off)CW vs CCW spindle direction (this will be reversed when switching from high to low gear)E-stopSpindle breakSpindle speed (change only when the spindle is on)Quill (quill handle)Manual draw bar (don’t forget wrench on drawbar)Pneumatic draw bar (stop as soon as it ratchets)Saddle X axis (nobody should use the auto feed during the training)Y axisWhen milling lock the axis’ that are not being movedKneeThis moves the table up and downUse the hand crankThe knee also has locks for this axisWhen milling, bring the knee up to the endmill (do not try to mill with the quill all the way down.DRODigital read outThis will tell you where the centerline of your tool is at all timesAll machines have X and Y, not always ZCutter types/ work holding and moreEndmillFacing Side milling (Explain climb vs conventional)Slotting Plunging 2 flute endmills are for aluminum, 4 flute are for steel Center or spot drillUsed to guide a long drillChamfering a hole Face millInsert cutter used only for facing Vise Try to keep material in the middle of the vise Clamp tight but do not over tighten Parallels Used to elevate material in the viseUse rubber bands These parallels are matched together, so do not mix them upDo not drill or mill into the parallels Drill chuckDrills Edge finderTap guideNo Endmills R8 colletEndmillsSingle side edge findersDrills Tap guidesEdge finderMost are .200inch in diameterSpindle runs 1000-1200 RPMWhen you touch the work piece you should move the axis in .100 (if the diameter is .200) to find the center line, then zero out the DRORPMRevolutions per minute Formula for HSS only (SFM *4 / Cutter diameter) = RPMSFM = 200 for aluminum, 120 for steel, 40 for stainlessExample (.500 drill or endmill in aluminum) Rpm = 1600This formula is max. It is okay to run the rpm slower just not faster Climb vs ConventionalConventionalUsed for roughingDoes not leave a good finish Tool profiles on the right side of the work piece ClimbUsed for finishing (.01inch passes)This cutting technique could break your endmill if you cut too deepLeaves a good finishTool profiles on the left side of the work piece Depths of cutEndmillFace milling .025 inchSide milling 25% radial and axial (conventional).01 inch finish (climb)Slotting is using 100% of the cutter so you must treat it as facingFace mill (insert cutter).025 inch passDrillMake sure you break the chip so it doesn’t ball upGet lubrication at the bottom of the hole after a few drill pecksCertification partOperation 1 (slot side)Place parallels in the vise with rubber bands You could set up a vise stop for locating when you flip the part 180 deg or you can just find the X and Y with the edge finder again for op2.Find X,Y with the edge finder, Z with the quillFace the top of the part with a .500 EndmillSet Z 0.0 to this plane Convention mill the step at the end of the part leaving .01in per sideClimb mill the step to finishRough the slot leaving .01Finish the slotDrill the .189 diameter holeOperation 2 (counter bore side)Deburr edges Flip the part 180 degFace to sizeUse a 2 flute 7/16 endmill to counter bore (peck like a drill)Use a 3/4 endmill to spot faceComplete Cleaning Sweep up all the chips (vacuum if needed)Wipe down the machine with a light coat of WD40Return all tools ................
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