Machine Shop 3 - Milling Operations

Step#	Location	Description	Initials	Date
10	Instructor	Secure stock from instructor. You will do the majority of the machining with the blocks as one piece.	*
20	Vertical or Horizontal Milling Machine	Set Rpm and Feed rate. Remember, this is 1045 steel.
30	Vertcal or Horizontal Milling Machine	Square and size both blocks, but just clean up the ends. Leave the overall length as long as possible. Check for Parallel and perpendicularity after each cut.
40	Horizontal Mill	Set up the vise for machining the .38 slots. Indicate the vise so it is parallel with the X axis.
50	Horizontal Mill	Set up a "B" style arbor with a 3/8 staggered tooth-side milling cutter.
60	Instructor	Have instructor check your setup. Be prepared to answer questions on climb milling Vs conventional milling directions.	*
70	Horizontal Mill	Place the part in the vise with Datum surface C against the solid jaw of the vise. Make sure the part is setting down on the parallels.
80	Horizontal Mill	Calculate and set the RPM and Feed rate for 1045 steel. CS = 60, Chip load = .005 per tooth.
90	Horizontal Mill	Using a long piece of paper, have the Instructor show you how to touch off and locate the cutter location for the first slot.	*
100	Horizontal Mill	Lock the appropriate table locks and take a 0.02 deep trial cut.
110	Horizontal Mill	Check the slot for location, width and parallelism to Datum C. Make adjustments if necessary.
120	Horizontal Mill	Lock the appropriate table locks and take a 0.15 roughing cut.
130	Horizontal Mill	Check the slot depth.
140	Horizontal Mill	Take the Slot to finish depth. Shoot for the shallow side because of tool deflection on the roughing cut.
150	Horizontal Mill	Flip the block maintaining Datum C against the solid jaw of the vise.
160	Horizontal Mill	Repeat step 100 through 140.
170	Vertical Mill	Set up the mill for drilling the 0.50 hole. Set up a vise stop against Datum surface B.
180	Vertical Mill	Drill the 0.50 hole.
190	Vertical Mill	Flip the block end for end.
200	Vertical Mill	Drill the other 0.50 hole.
210	Layout	Layout both Vees on the block.
220	Horizontal Mill	Set up the fixture for milling the V in the blocks.
225	Horizontal Mill	Place your part in the fixture so as to cut the small V first. Indicate the part parallel with the X axis of the machine.
230	Horizontal Mill	Set up a "B" style arbor with a 3/4 staggered tooth -side milling cutter. Make sure to set up the cutter and spindle rotation so as to cut toward the solid stop on the fixture.
240	Horizontal Mill	Have Instructor check the setup. Be ready to answer questions concerning how to locate the cutter to the part. How as your RPM and Feedrate changed?	*
250	Horizontal Mill	Cut the V in the block.
260	Horizontal Mill	Flip the block.
270	Horizontal Mill	Cut the second V in the block
280	Layout	Layout the 1/8 recess in the bottom of both Vees .
290	Horizontal Mill	Set up the Vise and Indicate solid Jaw within 0.002.
300	Horizontal Mill	Set up a 1/8 inch slitting saw to cut the recess
310	Horizontal Mill	Align the cutter to the part using the paper touch off alignment method used previously.
320	Horizontal Mill	Have Instructor check the setup. Be ready to answer questions concerning how to locate the cutter to the part. How has your RPM and Feedrate changed?
330	Instructor	Cut the slots on both sides, in both Vees.	*
340	Layout	Layout the overall length of the blocks from each end. There should be a gap in the middle of the blocks between the layout lines.
350	Horizontal Band Cutoff saw	Place the part in the saw and cut the block between the layout lines.
360	Vertical or Horizontal Milling Machine	Square and size both blocks. Check for Parallel and perpendicularity after each cut.
370	Vertical Mill	Center drill, drill, and tap the (9)1/4-20 threaded holes. Think ahead about the best use of the vise stop.
380	Vertical Mill	Set up to mill the chamfers on the edges. Use the vise stop to enhance the speed of your setup.
390	Bench	Stamp your Initials in the 0.38 slot on both blocks.
400	Bench	Deburr and Inspect both blocks.
410	Instructor	Turn in both parts for grading.	*