RB-She-01 Sherline CNC-Ready 3-Axis Milling Machine SHERLINE

RB-She-01 Sherline CNC-Ready 3-Axis Milling Machine SHERLINE
RB-She-01
Sherline CNC-Ready 3-Axis Milling Machine
SHERLINE Lathe and Mill Setup Instructions .................................................................. 3
Getting answers to your questions about machining ...................................................... 3
An introduction to the world of miniature machining .................................................... 3
What new machinists like most and least ................................................................... 3
There are no shortcuts................................................................................................. 4
Anticipation of a tool's limitations is the craftsman's strength ................................... 4
You don't become a machinist by buying a machine.................................................. 4
SAFETY RULES FOR POWER TOOLS .......................................................................... 5
Electrical connections ..................................................................................................... 6
General precautions ........................................................................................................ 8
Avoid overtightening!................................................................................................. 8
Don't overstress the motor! ......................................................................................... 8
Customer's responsibilities ......................................................................................... 8
Learning more about machining ................................................................................. 9
Lubrication...................................................................................................................... 9
Initial assembly of a new machine.................................................................................. 9
Lathe-crosslide mounting procedure............................................................................. 10
Mill-column mounting procedure ................................................................................. 11
Assembly of the model 2000 and related model 8-direction mill columns .................. 12
Check tightness of all bolts ....................................................................................... 12
Mounting the motor and speed control unit to the headstock................................... 13
The advantages of Sherline's DC motor and electronic speed control ......................... 15
What to do if the motor shuts down.......................................................................... 15
Operation of the motor and electronic speed control.................................................... 16
Motors are pre-tested at the factory .......................................................................... 16
Mounting the headstock to the lathe or mill ................................................................. 17
Mounting the mill and lathe to a board ......................................................................... 19
Converting machines from inch to metric or vice versa ............................................... 20
ADJUSTMENTS .............................................................................................................. 21
Two-speed pulley.......................................................................................................... 21
Preload adjustment........................................................................................................ 21
Gib adjustment .............................................................................................................. 22
Backlash adjustment ..................................................................................................... 22
Handwheel adjustment.................................................................................................. 23
Movement of the handwheels ....................................................................................... 23
Aligning the head and tailstock..................................................................................... 24
Use of cutting oils and lubricants.................................................................................. 25
General machining terms .............................................................................................. 25
General rules for feed rates and cutting speeds ............................................................ 26
"If the tool chatters, decrease speed and increase feed." .......................................... 26
VERTICAL MILLING MACHINE OPERATION.......................................................... 28
CAUTION! ............................................................................................................... 28
Read all operating instructions carefully before attempting any machining
operations!................................................................................................................. 28
Review Safety Rules for Power Tools before beginning.......................................... 28
GENERAL DESCRIPTION......................................................................................... 29
HELPFUL TIPS FOR MILLING ................................................................................. 30
SECURING THE WORKPIECE ................................................................................. 31
THINGS TO CONSIDER BEFORE YOU START CUTTING .................................. 32
THREE TYPES OF WORK ......................................................................................... 34
CAUTION! Because the tool spins on a mill, hot chips can be thrown much farther
than when using a lathe. Safety glasses and proper clothing are a must for all milling
operations.................................................................................................................. 34
STANDARD MILLING VS. CLIMB MILLING ........................................................ 35
WORKING TO SCRIBED LAYOUT LINES ............................................................. 36
USE OF A DIAL INDICATOR ................................................................................... 36
LOCATING THE EDGE OF A PART IN RELATION TO THE SPINDLE.............. 40
DETERMINING DEPTH OF CUT.............................................................................. 41
WORK ACCURATELY .............................................................................................. 41
CUTTING SPEEDS FOR MILLING........................................................................... 41
SPEED ADJUSTMENT FORMULA....................................................................... 41
SPEED ADJUSTMENT CHART............................................................................. 42
END MILLS (Slot and side milling) ........................................................................ 42
DRILLS..................................................................................................................... 42
CUTTING TOOLS AND STANDARD ACCESSORIES ........................................... 43
END MILLS ................................................................................................................. 43
RESHARPENING END MILLS.................................................................................. 43
3/8" END MILL HOLDER (P/N 3079)........................................................................ 44
MILL COLLET SET (P/N 3060) ................................................................................. 44
BORING HEAD (P/N 3054) AND BORING TOOLS ................................................ 44
FLYCUTTERS (P/N 3052 and P/N 7620) ................................................................... 46
DRILLS AND DRILL CHUCK (P/N 3072) ................................................................ 47
To drill a 1/8" diameter hole 1" deep:....................................................................... 48
MILL VISE SET (P/N 3551)........................................................................................ 49
4" ROTARY TABLE (P/N 3700)................................................................................. 50
HORIZONTAL MILLING CONVERSION (P/N 6100) ............................................. 51
USE OF ACCESSORIES AND ATTACHMENTS..................................................... 51
MILL EXPLODED VIEW PARTS DIAGRAM.......................................................... 52
PART NUMBERS AND DESCRIPTIONS, SHERLINE LATHES AND MILLS..... 54
SHERLINE Lathe and Mill Setup
Instructions
Getting answers to your questions about machining
Over the years we have found that the majority of our customers are both highly
intelligent and skilled craftsmen. Often they are also new to machining. The instructions
we have included in this book, while far more extensive than anything included with
other machine tools, even ones costing thousands of dollars, still only scratch the surface
when it comes to machining. We have tried to anticipate the most common problems and
questions asked by a new machinist. What we have provided in this book and with each
accessory, when combined with a liberal amount of common sense, is more than enough
to get you started. If you apply what you learn here, you will be well on your way to
making good parts. No doubt you will also have many questions specific to your project
that simply can't be addressed in a booklet of this type.
Answers to questions beyond the scope of this booklet will have to come from your own
research. Book stores and libraries are full of excellent books on machining, and the
Internet is forming some great user groups that can put you in direct contact with others
who share your specific interests. Our own World Wide Web site is a great source of
information as well, as we have published there all the instructions for all our tools and
accessories for you to read and print out for free. We feel we have written the best book
available on miniature machining with Sherline tools. It is called Tabletop Machining by
Sherline's owner and long-time toolmaker Joe Martin. We also sell Doug Briney's Home
Machinist's Handbook as well as a very informative steam engine project video by Rudy
Kouhoupt, both of which are packed with knowledge for new machinists. For the past 35
years I have found Machinery's Handbook to be the source I turn to for answers to my
own questions. May your journey toward becoming a skilled machinist be an enjoyable
one.
An introduction to the world of miniature machining
What new machinists like most and least
If you are new to machining, you may find it to be either one of the most rewarding skills
one can learn or the most frustrating thing you have ever attempted. What makes
machining fun for some is the complexity and challenge. The same thing will drive others
up the wall. One customer may be overjoyed because he can now make parts that were
not available for purchase. Another may wonder why he just spent all day making a part
that is similar to one he could have purchased for two dollars. (The difference is that it is
not the same as the two dollar part-it is exactly the part needed.)
There are no shortcuts
Machining is a slow process if parts are made one at a time. The interesting thing is, a
skilled machinist may take almost as long to make the same part as a novice. Shortcuts
usually end in failure. Unlike some other trades, mistakes cannot be covered up. There
are no erasers, white-out or "putting-on tools" for machinists; you simply start over. To
expand a little on an old rule:
"Think three times, measure twice and cut once!"
Anticipation of a tool's limitations is the craftsman's strength
The skill in machining isn't just "moving the dials". It is a combination of engineering
and craftsmanship. A file is just as useful a tool to a good machinist as a multi-thousand
dollar machine tool. Tools "deflect" or bend under load, and anticipating this bend is
what it is all about. Sharp tools deflect less than dull tools, but with each pass the tool
dulls a little and the deflection becomes greater. If you try to machine a long shaft with a
small diameter, the center will always have a larger diameter than the ends because the
part deflects away from the tool where it has less support. You can go crazy trying to
machine it straight, or you can simply pick up a good flat mill file and file it straight in a
few moments. Machine tools will never replace the "craftsman's touch", and machining is
a combination of both good tools and good technique.
You don't become a machinist by buying a machine
You should strive from the beginning to make better and more accurate parts than you
think you need. Work to closer tolerances than the job demands. Be on the lookout for
ways to make a job easier or better. Having a selection of appropriate materials on hand
and a good cutoff saw to get them to rough size is a good start. Take some time and read
through this instruction book before you try machining anything. We want you to enjoy
the process of creating accurate parts from raw metal. Buying a machine didn't make you
a machinist, but using it along with the skill and knowledge you acquire along the way
eventually will. With the purchase of SHERLINE equipment, you have taken your first
step toward many years of machining satisfaction. We at SHERLINE thank you for
letting us be a part of that.
Joe Martin
President and Owner
SAFETY RULES FOR POWER TOOLS
1. KNOW YOUR POWER TOOL-Read the owner's manual carefully. Learn its
application and limitations as well as the specific potential hazards peculiar to this
tool.
2. GROUND ALL TOOLS-If tool is equipped a with three-prong plug, it should be
plugged into a three-hole receptacle. If an adapter is used to accommodate a twoprong receptacle, the adapter wire must be attached to a KNOWN GROUND.
Never remove third the prong. (See Figure 1.)
3. KEEP GUARDS IN PLACE-and in working order.
4. REMOVE ADJUSTING KEYS AND WRENCHES-Form a habit of checking
to see that keys and adjusting wrenches are removed from tool before turning on
machine.
5. KEEP WORK AREA CLEAN-Cluttered areas and benches invite accidents.
6. AVOID DANGEROUS ENVIRONMENT-Do not use power tools in damp or
wet locations. Keep work area well illuminated.
7. KEEP CHILDREN AWAY-All visitors should be kept a safe distance from the
work area.
8. MAKE WORKSHOP KID PROOF-with padlocks, master switches or by
removing starter keys.
9. DO NOT FORCE TOOL-Do not force tool or attachment to do a job for which
it was not designed. Use the proper tool for the job.
10. WEAR PROPER APPAREL-Avoid loose clothing, neckties, gloves or jewelry
that could become caught in moving parts. Wear protective head gear to keep long
hair styles away from moving parts.
11. USE SAFETY GLASSES-Also use face or dust mask if cutting operation is
dusty.
12. SECURE WORK-Use clamps or a vise to hold work when practicable. It is safer
than using your hand and frees both hands to operate the tool.
13. DO NOT OVERREACH-Keep your proper footing and balance at all times.
14. MAINTAIN TOOLS IN TOP CONDITION-Keep tools sharp and clean for
best and safest performance. Follow instructions for lubrication and changing
accessories.
15. DISCONNECT TOOLS-Unplug tool before servicing and when changing
accessories such as blades, bits or cutters.
16. AVOID ACCIDENTAL STARTING-Make sure switch is "OFF" before
plugging in power cord.
17. USE RECOMMENDED ACCESSORIES-Consult the owner's manual. Use of
improper accessories may be hazardous.
18. TURN SPINDLE BY HAND BEFORE SWITCHING ON MOTOR-This
ensures that the workpiece or chuck jaws will not hit the lathe bed, saddle or
crosslide, and also ensures that they clear the cutting tool.
19. CHECK THAT ALL HOLDING, LOCKING AND DRIVING DEVICES
ARE TIGHTENED-At the same time, be careful not to overtighten these
adjustments. They should be just tight enough to do the job. Overtightening may
damage threads or warp parts, thereby reducing accuracy and effectiveness.
20. It is not recommended that the lathe be used for grinding. The fine dust that
results from the grinding operation is extremely hard on bearings and other
moving parts of your tool. For the same reason, if the lathe or any other precision
tool is kept near an operating grinder, it should be kept covered when not in use.
21. DON'T LET LONG, THIN STOCK PROTRUDE FROM THE BACK OF
THE SPINDLE—Long, thin stock that is unsupported and turned at high RPM
can suddenly bend and whip around.
22. WEAR YOUR SAFETY GLASSES-Foresight is better than NO SIGHT! The
operation of any power tool can result in foreign objects being thrown into the
eyes, which can result in severe eye damage. Always wear safety glasses or eye
shields before commencing power tool operation. We recommend a Wide Vision
Safety Mask for use over spectacles or standard safety glasses.
Electrical connections
The power cord used is equipped with a 3-prong grounding plug which should only be
connected to a properly grounded receptacle for your safety. Should an electrical failure
occur in the motor, the grounded plug and receptacle will protect the user from electrical
shock. If a properly grounded receptacle is not available, use a grounding adapter to adapt
the 3-prong plug to a properly grounded receptacle by attaching the grounding lead from
the adapter to the receptacle cover screw.
FIGURE 1-Always use a properly grounded receptacle.
NOTE: The electrical circuits designed into the speed control of your lathe or mill reads
incoming current from 100 to 240 volts AC and 50 or 60 Hz. and automatically adapts to
supply the correct 90 volts DC to the motor. As long as you have a properly wired,
grounded connector cord for your source, the machine will operate anywhere in the world
without a transformer. This has been true for all SHERLINE machines built since 1994.
Prior to that, we used an AC/DC motor. Use that motor ONLY with the power source for
which it was intended. It will not automatically adapt to any other current and using it
with an improper power source will burn out the motor or speed control. Also, the first
few DC units built did not include the circuits to adapt to other currents. If you have an
early DC model, remove the plastic speed control housing and look for a label on the
aluminum speed control frame. If it has a small metallic label on top of the frame that
lists input voltage as 120VAC, DO NOT ATTEMPT TO CONVERT TO OTHER
CURRENTS. Models that can be used with any current have a paper label on the end of
the speed control frame which lists the model number as KBLC-240DS.
The machines are normally supplied with a USA type plug but can be easily rewired to
accept a European or U.K. type plug by attaching the wires using the color codes
provided below.
WIRE
100/240 V
COMMON
GROUND (EARTH)
USA
EUROPE
BLACK
BROWN
WHITE
BLUE
GREEN GREEN W/YELLOW
FIGURE1a-Wire color codes for USA and European connectors.
General precautions
•
•
•
DO NOT attempt to operate the lathe or mill without first mounting them to a
secure base. (See page 6.)
DO NOT turn on the motor with a 3-jaw chuck mounted if the jaws are not
tightened on themselves or on a part.
A chip guard (P/N 4360) is now available that offers additional protection from
flying chips when working near the spindle. It is not a substitute for wearing
proper eye protection but is an excellent level of additional protection. It will also
contain cutting oil to help keep your work area cleaner.
Avoid overtightening!
One of the problems with designing and manufacturing metal cutting equipment of this
size is that the operator can physically be stronger than the machine, which is not
normally the case with larger tools. For example, a 10-pound force applied a couple of
inches out on a hex key becomes a 650-pound force at the tip of the screw. If you tighten
both screws on the tool post this tight, it becomes approximately 1300 pounds of force on
relatively small parts! Tools and/or parts can become distorted and accuracy will be lost.
Overtightening hold down screws and T-nuts in their slots can distort the crosslide
or mill table. It is not necessary to overtighten parts and tools because loads are smaller
on equipment of this size. Save your equipment and increase accuracy by not
overtightening and by taking light cuts.
Don't overstress the motor!
It is also important to realize that you can overload the motor supplied with this lathe or
mill.* The many variables involved in machining, such as materials being machined, size
of cutter, shape of cutter, diameter of stock, etc., can leave but one rule to
follow...COMMON SENSE!
*The motor is thermally protected, so if it is overloaded it will simply shut down until it
cools. See section on thermal protection.
CAUTION!
Read all operating instructions and safety rules carefully before attempting any
machining operations.
Customer's responsibilities
Always use care when operating the lathe and mill. Follow safety rules for power tools.
Turn off motor before attempting adjustments or maintenance. (Do not simply turn the
speed control down to zero RPM but leave the motor switch on.) Be sure the work piece
is firmly supported on the lathe or mill. Accessories should be mounted and operated
following instructions carefully. Keep your machine clean, lubricated and adjusted as
instructed. Do not leave cleaning rags, tools or other materials on the lathe bed or around
moving parts of the machine.
Learning more about machining
Many fine books have been written on machining techniques and are available at your
local library or book store. Although these books will be referring to machines many
times larger than Sherline's tools, the principle remains the same. For the best reference
that is specific to Sherline tools, see Joe Martin's book, Tabletop Machining.
Lubrication
•
•
•
•
•
•
MACHINE SLIDES-Use a light oil such as sewing machine oil on all points
where there is sliding contact. This should be done immediately after each
cleanup. (We grease the slides at the factory to ensure the lubrication stays in
place during shipping, but light oil will work fine once you begin using the
machine.)
LEAD SCREW, TAILSTOCK SCREW, CROSSLIDE SCREW-Sewing
machine oil should be placed along all threads regularly. At the same time, check
that the threads are free from any metal chips. Use an air hose or paint brush to
keep them clean.
TAILSTOCK SPINDLE-Wind out the spindle as far as it will go and lightly oil
it with sewing machine oil.
HANDWHEEL-A few drops of light oil behind the handwheel will reduce
friction between the surfaces and make operation easier and smoother.
HEADSTOCK BEARINGS-These bearings are lubricated at the factory for the
lifetime of the machine and should not need further lubrication. DO NOT break
the seals.
MOTOR-Sealed ball bearings require no maintenance.
Initial assembly of a new machine
Your new lathe or mill will come packed in a box with some items disassembled for
shipping purposes. On the lathe you will install the crosslide table onto the saddle. On the
mill you will install the "Z" axis column onto the base. On both machines you will need
to install the motor and speed control. The machines are completely assembled and tested
for fit at the factory prior to shipping. They are then disassembled and packaged, so
everything should go together easily when you reassemble it. The motors are "run in" for
approximately one hour to assure proper function and seating of the brushes.
Before you call us and say a part is missing, please look carefully through the packaging.
Some parts are in bags taped to the bottom of cardboard flaps or spacers and you may not
notice them when you open the box and remove the major components.
Lathe-crosslide mounting procedure
Installation of the crosslide requires no tools. First, make sure the bottom of the crosslide
has a light coat of grease on all the sliding surfaces. This will have been applied at the
factory, just make sure it has not been wiped off and that it is evenly distributed.
FIGURE 2
Next, see that the gib is in the proper position on the saddle. (See Figure 2.) It is taped
into position for shipping. Remove the tape holding it in place. If the gib has come off,
position it on the gib lock as shown.
Set the dovetail of the crosslide over the gib and matching dovetail on the saddle. Slide it
onto the saddle about 1/4" (6-7mm) until it stops. (See Figure 3.)
FIGURE 3
Look underneath and align the slide screw with the threads on the brass slide screw insert
on the side of the saddle. (See Figure 4.) Turn the crosslide handwheel clockwise to
engage the threads. Continue to crank the handwheel clockwise until the crosslide is in
the desired position on the saddle.
FIGURE 4
Mill-column mounting procedure
The mill is shipped attached to a piece of plywood to keep it from moving in the box.
Before you begin, remove the screws holding the mill base to the plywood. It was
installed strictly for packing purposes and will need to be removed so that the column can
be installed.
The "Z" axis column is mounted to the base with two 1-3/4" long 1/4-20 socket head
screws. These screws and the hex key tool you will need to tighten them are packaged in
the bag with the motor mounting bracket and drive belt. It is much easier to mount the
column to the base before you mount the motor and speed control to the saddle.
FIGURE 5
Set the column on the base aligned with the mounting holes and hold it in position while
you insert the first screw up from the bottom of the base. Hand turn the first screw part
way in and then start the second screw. This can be done with the machine upright by
letting the base hang over the edge of your table or bench just far enough to expose the
first hole. Using the hex key, snug up both screws lightly first, and then tighten evenly.
Assembly of the model 2000 and related model 8direction mill columns
For specific directions on assembly of the various 8-direction columns and upgrades
introduced in August, 1998, click here. The Model 2000 mill and the related upgrades
that convert standard mills into 8-direction mills offer the ability to drill holes or do
machining operations from an almost infinite number of angles on parts mounted square
to the table.
Check tightness of all bolts
Vibration in shipping can cause some bolts or screws to loosen up. Before using your
new machine, check the tightness of all fasteners. It is also a good idea to check tightness
periodically when using the machine, as vibration from operation may cause some
fasteners to loosen up.
Mounting the motor and speed control unit to the headstock
(Refer to the exploded views and number list for part number references.)
FIGURE 6-DC Motor and Speed Control Assembly
1. Remove motor pulley from motor shaft. Mount the inner belt guard to the motor
using the two standoffs (P/N 4310). Next install the motor pulley (P/N 4336) to
the motor shaft and tighten the set screw. The end of the pulley should be just
about even with the end of the motor shaft with the smaller pulley toward the end
of the shaft.
2. Place drive belt over motor pulley.
3. Place round post on speed control hinge plate in hole on inner belt guard.
4. Set outer belt guard in place locating other post of hinge plate in its pivot hole.
Motor standoff ends will register in holes in outer belt guard. Make sure the drive
belt is routed properly. Then secure the cover with (2) 1-3/8" pan head screws
which go into nuts pressed into the back of the inner belt guard.
5. Attach motor mounting bracket to rear of headstock with two 10-32 x 3/8" socket
head screws. There is enough "play" in the mounting holes to allow you to ensure
the motor is visually mounted parallel with the spindle axis. (Note: If chip guard
is to be mounted, its attachment screw replaces one of these mounting screws. It
can be mounted at this time or after the headstock is in place. See instructions that
come with the chip guard.)
6. Place drive belt over spindle pulley and insert 10-32 x 3/4" socket head screws
(with 2 washers on each) through motor mount slot and into holes in the ends of
the motor standoffs. (These standoff ends should be exposed through locating
holes in the outer belt guard.) NOTE: The normal operating position for the drive
belt is on the large diameter groove on the motor pulley and the small diameter
groove on the spindle pulley. Use of the other (low RPM) position is discussed
elsewhere in these instructions. (See Figure 11.)
7. Tighten motor mount screws, tilt speed control unit out of the way and check the
alignment of the drive belt. It should be perpendicular to the drive pulleys. If it is
not, loosen the set screw on the motor pulley and adjust it in or out on its shaft
until the drive belt is square with the motor.
8. Pull desired tension into drive belt by sliding the motor unit out in the bracket
slot. Tighten mounting screws to hold the motor/speed control unit in place.
NOTE: Do not overtension the drive belt. Just make sure it has enough tension to
drive the spindle pulley without slipping under normal load. By not
overtightening the belt you will not only extend its life, but will also provide a
margin of safety for belt slippage should a tool jam in a part or an accident occur.
The belt must be a little tighter when used in the low speed range because small
diameter pulleys are not as efficient.
9. Set mounting plate into top of belt guard housing so it rests on rails molded onto
inside surfaces of housing. (The pressed-in nut goes down and to the outside.)
Slide the plate toward the outside (toward the spindle pulley) until it stops.
NOTE: The mounting plate was designed to be easily removable so it is out of the
way when changing the drive belt position.
10. Rotate speed control unit into place and insert the single 10-32 x 1/2"* socket
head screw through hole in speed control housing and into nut in mounting plate.
Tighten enough to hold in place. Do not overtighten.
*Changed from 3/8" long screws 1/5/05 for stronger engagement.
NOTE: Those of you who machine a lot of wood or brass may want to purchase and
install a switch cover (P/N 3015) to keep the fine dust out of the power switch. The wood
dust can gum up the switch causing intermittent operation. Brass dust can short out the
switch or cause a risk of electric shock to the operator.
The advantages of Sherline's DC motor and electronic
speed control
Sherline's 90 volt DC motor is very smooth and powerful, particularly at low RPM. The
specially designed electronics package also provides some unique advantages in addition
to smooth speed control with a usable speed range of 70 to 2800 RPM. A special circuit
compensates for load, helping to keep RPM constant. The machines can also be used on
any current world wide from 100 VAC to 240 VAC, 50 or 60 Hz without any further
adjustment other than seeing that the proper wall plug is used. The control reads the
incoming current and automatically adjusts to the proper settings.
We offer the motor and speed control along with the headstock and spindle as a package
to builders of special machinery at a very reasonable price. They are especially popular
for custom tooling in small industrial applications because of the large number of
Sherline accessories that fit the spindle. We use them in our own production facility for a
number of operations.
CAUTION—Motor is thermally protected
Thermal protection means there is a built-in circuit breaker that will shut down the motor
if it gets too hot. This keeps the motor from burning out. The breaker will automatically
reset as soon as the motor cools and you can go back to cutting, but you should be aware
of how it works and what to do if the machine suddenly shuts itself down. If your motor
is shutting down from overheating on a regular basis, it means you are taking too heavy a
cut or operating at too high an RPM for long periods. Slow your speed down, reduce your
cut or feed rate and you should have no further problems.
Due to the nature of miniature machining, overloading the machine is a common
problem. It is often tempting to try to speed up the process by working faster. Keep in
mind this is a small machine and work with patience and precision-don't be in a hurry.
Your parts will come out better and your machine will last much longer if it is not
overstressed.
What to do if the motor shuts down
If your thermal protection circuit shuts down the motor while work is in progress,
immediately shut off the power switch and then back the tool out of the work. It should
only take 10 seconds or less for the circuit breaker to reset, then you can turn the motor
on and start the cut again, this time putting a little less stress on the motor. If you leave
the tool engaged in the part and the power on, when the circuit breaker kicks back on, the
motor must start under load. This can be very hard on your motor.
Remember that the circuit breaker turns the speed control off which turns off the motor.
If power were to be applied to the speed control with the motor disconnected, it could
damage the speed control.
Thermal protection is built into your motor to make sure it is not damaged by
overloading. Use good common sense when operating the motor, and it will provide
many years of trouble free operation.
Operation of the motor and electronic speed control
The lathe is supplied with an electronic speed control that produces a comprehensive
range of speeds suitable for all operations. Special circuitry designed into the DC motor
speed control automatically compensates for speed changes due to increased load. If the
spindle RPM drops noticeably when cutting, you are taking too heavy a cut. The speed
range of the spindle using the speed control is from 70 to 2800 RPM. This is achieved
without the inconvenience of changing belt positions or gear ratios as is often the case
with other designs. A second belt position is offered as an additional feature to provide
extra torque at low RPM for larger diameter parts should your job require it.
To operate the motor, turn the speed control knob counter-clockwise as far as it will go.
Then turn the toggle switch to "ON" and select the speed by turning the speed control
knob clockwise.
Motors are pre-tested at the factory
Your new motor should run smoothly the first time you use it as it has been "run in" for
about an hour before being shipped to you. Despite our secure packaging, there have been
cases where extremely rough handling by a shipper has damaged the magnets in the
motor. If the motor does not run when plugged in, turn the motor by hand. If it does not
turn smoothly, it may have been damaged in shipment. Call Sherline for instructions on
making a damage claim with the shipper. Do not attempt to repair the motor yourself.
Mounting the headstock to the lathe or mill
You may notice that the post onto which the headstock mounts is a loose fit where it
projects from the lathe bed or column saddle. This is normal, and the diagram below will
help you understand how it works.
FIGURE 7-Cross section of headstock showing locking screw.
The screw in the front center of the headstock has a cone point. The pivot pin has a
tapered slot with a corresponding angle. When the screw is tightened, its angled face
engages the groove and, because the pivot pin can not come up, it draws the headstock
down into position, clamping it into place. If the pin were rigid, it could keep the
headstock from pulling down squarely.
FIGURE 8-Headstock and alignment key in position over lathe.
The headstock is aligned with the lathe bed or column saddle with a precision ground key
that fits into keyways in both parts. It is not square in cross section so it will fit in only
one direction. Push the headstock firmly against it as you tighten the hold down screw.
The mill headstock has two keyways milled into it so it can be mounted in conventional
fashion or at a 90° angle for horizontal milling.
CAUTION! Always make sure the key, slot and mating surfaces are free from dirt and
chips before locking down the headstock.
Removing the headstock alignment key allows the headstock to be mounted in positions
other than square. This allows you to mill parts at an angle or turn tapers on the lathe.
When using the lathe or mill without the alignment key, keep cutting loads light.
Mounting the mill and lathe to a board
FIGURE 9-Machines mounted to a base board for stability.
Mounting the lathe to a board is necessary because of the narrow base. This keeps the
machine from tipping. We recommend mounting the lathe on a piece of pre-finished shelf
material which should be available from your local hardware store. (See below for sizes.)
The machine can be secured to the board using four 10-32 screws with washers and nuts.
Lengths should be 1-1/2" for short bed lathes and 1-7/8" for long bed lathes. Rubber feet
should be attached at each corner on the bottom of the mounting boards. They are also
readily available in hardware stores.
This arrangement gives the machines a stable platform for operation yet still allows for
easy storage. The rubber feet help minimize the noise and vibration from the motor.
Mounting the tool directly to the workbench can cause vibration of the bench itself which
acts as a "speaker" and actually amplifies the motor noise. Bench mounting also
eliminates one of the best features of Sherline machines...the ability to easily be put away
for storage.
FIGURE 10-Plans for mounting board hole patterns. Confirm actual dimensions from
your lathe or mill before drilling. The newly added model 2000 multi-direction mill can
be mounted to a board 12" x 18" in a similar fashion.
The mill may be mounted in a similar manner on a 10" x 12" to 12" x 24" pre-finished
shelf board with rubber feet using 10-32 x 1" screws to attach the mill to the board.
To keep your Sherline tools clean, soft plastic dust covers are available. The lathe cover
is P/N 4150 for the Model 4000/4100 and 4500/4530 short bed lathes and P/N 4151 for
the Model 4400/4410 long bed lathe. A mill dust cover is available as P/N 5150.
Converting machines from inch to metric or vice versa
All Sherline tools and accessories are manufactured in your choice of inch or metric
calibrations. Converting a lathe or mill from one measurement system to the other is
possible, but it takes more than changing the handwheels. The leadscrews, nuts and
inserts must also be changed. A look at the exploded views of the machines on pages 27
and 28 will show which parts need to be purchased. (Look for parts that have both a
metric and inch version in the parts listing.) Conversion kits with all the necessary parts
are available. If you are a good mechanic, you can do the conversion yourself, or you can
return your machine to the factory for conversion.
ADJUSTMENTS
Two-speed pulley
The normal pulley position, which is placing the belt on the larger motor pulley and
smaller headstock pulley, will suffice for most of your machining work. Moving the belt
to the other position (smaller motor pulley, larger headstock pulley) will provide
additional torque at lower RPM. It is particularly useful when turning larger diameter
parts with the optional riser block in place.
FIGURE 11-The two pulley positions. Position A is the conventional setting, position B
offers more torque at low RPM. (Seen from pulley end of headstock.)
To change the pulley position, remove the speed control hold down screw and pivot the
speed control housing up out of the way. Remove the mounting plate from its position on
the rails of the two halves of the belt guard housing. Loosen the two nuts that hold the
motor to the motor mounting bracket and take the tension off the belt. With your finger,
push the belt off the larger groove of the pulley and into the smaller one. (Depending on
which way you are changing it, this could be either the motor or spindle pulley.) Then
move the belt to the larger diameter groove on the other pulley and rotate the headstock
by hand to get it to seat. Push the motor outward on the motor mounting bracket to put
the proper tension on the belt and retighten the two motor mounting screws. Now you can
replace the mounting plate, pivot the speed control back down and refasten it. Moving the
belt back to the other position is simply a reverse of the above procedure.
Preload adjustment
SPINDLE ADJUSTMENT-If any end play develops in the main spindle, it can be easily
eliminated by readjusting the preload nut. (See part number 4016 in the exploded view.)
When the headstocks are assembled at the factory, the preload nut is adjusted to .0002"
(.005mm) of end play. This is controlled by the outer races of the bearing being held
apart by the headstock case and the inner races being pulled together by the preload nut.
This setting was determined through experience and, like everything in engineering, it is
a compromise. If the machine is only to be run at high speed, this setting may be too
"tight". The headstock will run fairly warm to the touch normally, but extended periods
of high speed operation may bring about excessive temperature. If this is your case, the
preload may be reduced slightly.
To change the adjustment, remove the spindle pulley, loosen the set screw in the preload
nut and back the preload nut off four degrees of rotation (counter clockwise). The
bearings are lightly pressed into the case, so the inner race will not move without a sharp
tap with a plastic mallet to the end of the spindle where the pulley is attached.
If you find your bearings are set too loose, you may want to take up on the end play. You
can check them with an indicator or by spinning the spindle without the motor belt
engaged. If the spindle spins freely with a chuck or faceplate on it, it is too loose for
normal work. Adjust the preload nut until it turns approximately one and a half
revolutions when spun by hand.
Gib adjustment
Gibs (tapered synthetic adjustment shims) are fitted to the mill headstock, saddle and
table and to the lathe saddle and crosslide. Correct adjustment of the gibs will ensure
smooth and steady operation of the slides. The gib is effectively a taper with an angle
corresponding to the one machined into the saddle. It is held in place by an "L" wire gib
lock which is secured with a locking screw. It is adjusted by loosening the gib locking
screw and pushing the gib in until "play" is removed. After adjusting, retighten the
locking screw. Milling operations require a tighter adjustment of the gibs than lathe
operations.
Backlash adjustment
Backlash is the amount the handwheel can turn before the slide starts to move when
changing directions. This is a fact of life on any machine tool and on machines of this
type it should be about .003" to .005" (.08mm to .12mm).
Backlash must be allowed for by feeding in one direction only. Example: You are turning
a bar to .600" diameter. The bar now measures .622" which requires a cut of .011" to
bring it to a finished diameter of .600". If the user inadvertently turns the handwheel
.012" instead of .011", he couldn't reverse the handwheel just .001" to correct the error.
The handwheel would have to be reversed for an amount greater than the backlash in the
feed screws before resetting the handwheel to its proper position.
Backlash on the "X" and "Y" axes of the mill may be reduced to a minimum by
adjustment on the anti-backlash nuts. These nuts are located on the handwheel ends of the
mill saddle. The nuts are secured by slotted pan head screws which hold a pointed
locking plate that interlocks with teeth on the nut.
To adjust backlash, simply loosen the pan head screw and slide the locking plate to one
side. Rotate the anti-backlash nut clockwise on the "X" axis and counterclockwise on the
"Y" axis until snug. Replace the locking plate and tighten the pan head screw. With the
anti-backlash nuts properly adjusted, the lead screws will turn smoothly and have no
more than the proper .003" to .005" of backlash.
FIGURE 12-Backlash Adjustment. NOTE: A new lock now uses a star gear rather than
the pointer to locate the anti-backlash nut, and a button head socket screw locks it in
place. This system is easier to use, but the function is essentially the same. (The hole
centers are different, which means the star gear cannot be used to replace the pointer on
older models.)
Handwheel adjustment
The handwheels are secured to their corresponding leadscrew shafts by a small set screw
in the side of the handwheel base. Check them periodically to make sure they have not
been loosened by vibration. On the "zero" adjustable handwheels, you must first release
the rotating collar by loosening the locking wheel. Then rotate the collar until you can see
the set screw through the small hole in the side of the collar and adjust the screw as
necessary.
If excessive backlash develops at the handwheel and thrust collar junctions, adjust by first
loosening the handwheel set screw. Index (rotate) the handwheel so the set screw tightens
on a different part of the shaft. (If you don't, it may tend to keep picking up the previous
tightening indentation and returning to the same spot.) Push the handwheel in tightly
while holding the mill saddle and retighten the handwheel set screw.
Movement of the handwheels
Turning the appropriate handwheel moves the saddle, crosslide and tailstock spindle. For
the inch version, one complete turn of the handwheel gives a movement of .050". For the
metric model, one complete turn of the handwheel gives a movement of 1mm.
Handwheels are calibrated in .001" (1/1000") for inch models and .01mm (1/100mm) for
metric models. Keep the screws clean, oiled and free from chips. The handwheels are
quite accurate and should be used accordingly.
Aligning the head and tailstock
The versatile feature of Sherline machines that allows the headstock to be removed or
rotated for taper turning and angle milling keeps us from being able to lock the headstock
in perfect alignment. Precision ground alignment keys and accurate adjustment at the
factory, however, make the machines highly accurate. In standard form, alignment should
be within .003" (.08mm). This should be more than acceptable for most jobs you will
attempt.
Only someone new to machining would talk about "perfect" alignment. Machinists speak
instead in terms of "tolerances", because no method of measurement is totally without
error. We believe the tolerances of your machine are close enough for the work for which
it was intended, however, for those searching for maximum accuracy, here are some tips
for maximizing the accuracy of your machine.
Loosen the headstock, push it back evenly against the alignment key and retighten. This
will maximize the accuracy of the factory setting. To achieve greater accuracy, you will
have to be willing to sacrifice one of the better features of your lathe or mill; that is, its
ability to turn tapers and mill angles in such a simple manner.
HEADSTOCK-If you choose total accuracy over versatility or need it for a particular job,
proceed as follows. Remove the headstock and clean any oil from the alignment key and
slot and from the area of contact between bed and headstock. Replace the headstock,
pushing squarely against the key and retighten. Take a light test cut on a piece of 1/2" to
3/4" diameter by 3" long aluminum stock held in a 3-jaw chuck. Use a sharp pointed tool
to keep cutting loads low so as not to cause any deflection of the part. Measure the
diameter of both machined ends. If there is a difference, the headstock is not perfectly
square. Now, without removing the key, tap the headstock on the left front side if the part
is larger at the outer end. (Tap on the right side if the part is larger at the headstock end.)
You are trying to rotate the headstock ever so slightly when viewed from the top until the
machine cuts as straight as you can measure. There should be enough movement
available without removing the key, as its factory placement is quite accurate.
Take another test cut and remeasure. Repeat this procedure until you have achieved the
level of perfection you seek. Then stand the lathe on end with the alignment key pointing
up and put a few drops of LocTite™ on the joint between key and headstock. Capillary
action will draw the sealant in, and when it hardens, the key will be locked in place. We
prefer this method to "pinning" the head with 1/8" dowel pins, because it offers you the
option to change your mind. The headstock can be removed by prying with a screwdriver
blade in the slot between the bottom of the headstock and the lathe bed to break the
LocTite™ loose should you wish to be able to rotate the headstock again.
TAILSTOCK-To maximize the machine's tailstock alignment, first make sure that there
are no chips caught in the dovetail of the bed and no chips or dents in the taper of your
tailstock center. Now put a 6" long piece between centers and take a long, light test cut.
Measurements at either end will tell you if you need to use an adjustable tailstock tool
holder in the tailstock to achieve better tailstock alignment. We manufacture adjustable
tailstock tool holders (P/N 1202 & 1203) and an adjustable live center (P/N 1201) which
can help you attain near perfect alignment at the tailstock should your job require it.
Instructions for their use are included with each item.
Remember that unless you drill very small holes (less than 1/64") or turn a lot of long
shafts, you are giving up a very useful feature to solve a problem which can usually be
handled with a few passes of a good mill file. The inaccuracy inherent in any drill chuck
is such that perfect machine alignment is meaningless unless you use adjustable tailstock
tool holders.
Use of cutting oils and lubricants
Much can be written about the use of lubricants, but they may usually be dispensed with
where production rates are not very important. A small amount of any kind of oil applied
with a small brush will be sufficient. Aluminum and its alloys may require the use of
cutting oils to prevent the chips from welding to the tool's point. Do not use oils with a
low flash point or a bad smell. If desired, a mixture of one part soluble oil to six parts
water may be used on steel to assist in producing a smoother finish and reduce tool
chatter when parting off. Brass and cast iron are always turned dry. Cutting lubricants
should be cleaned off the tools after use.
Cutting oils can be purchased at an industrial supply store. We used to sell cutting oil, but
dropped it from the line because we received so few orders. We assume our customers
prefer to purchase their cutting oil from local sources. Do not use high sulfur pipe thread
cutting oil. It is good for hard to machine materials, but is so dirty to work with we do not
recommend it. We also find some of the tap cutting fluids are too smelly and unpleasant
to use for general machining.
The main purpose of using lubricants is to keep the chips from sticking to the cutting
tool. When used properly, modern high speed tool bits are not likely to be affected by
heat on the type of work usually done on Sherline tools.
General machining terms
Two terms frequently used in machining are "Feed" and "Cut". Reference to the diagrams
below will show what is meant by these terms. Normal turning on a lathe, when used to
reduce the diameter of a work piece, involves advancing the cutting tool perpendicular
to the lathe bed by an appropriate amount (depth of cut) and feeding the tool along
parallel to the lathe bed to remove material over the desired length. (See Figure 13A
below.)
FIGURE 13-Directions of Feed and Cut showing (A) Turning work between centers and
(B) Facing off a work piece.
In normal machining, the depth of cut is set by the crosslide handwheel, and the feed is
provided by the handwheel on the end of the bed. When facing off the end of a work
piece held in a chuck or faceplate, the depth of cut is set by the handwheel on the end of
the bed, and the feed is provided by the crosslide handwheel. (See Figure 13B above.)
When using a mill, cut is determined by the amount of depth the cutter is set to by the
"Z" axis handwheel. Feed is supplied by either or both the "X" or "Y" axis handwheels
depending on the desired direction of the cut.
General rules for feed rates and cutting speeds
Before attempting to machine any metal, please try to remember this simple rule about
machining:
"If the tool chatters, decrease speed and increase feed."
Understanding this simple rule can save you many hours of grief. When the tool
"chatters", it is not cutting in a continuous fashion. Metal likes to be machined in a way
that allows the material to come off in a continuous strip while the tool is in contact with
the metal. If the tool is not fed at a rate that is fast enough, the tool skips along the
surface, occasionally digging in. The surface of the tool that is doing the most cutting will
find a frequency of vibration that is a product of all the variables involved. This can cause
anything from a high pitched whine on light, high speed cuts to a resonating racket that
can rip the work out of the chuck on heavy cuts. If you maintain the same feed rate and
reduce the RPM, the feed will increase because chip will be thicker. (If that sounds
wrong at first, think of it this way: At the same feed rate, if you cut the RPM in half,
twice as much metal must be removed with each rotation to get to the end of the cut in
the same amount of time. The chip is twice as thick, so the feed is GREATER at lower
RPM if the feed RATE stays constant.)
When a tool chatters it gets dull faster because it must keep cutting through the
previously machined surface that has been "work hardened" by machining. As you can
imagine, there are limits to how much you can increase feed rate, so the answer lies in
adjusting both speed and feed to achieve the proper cut.
Proper cutting speed is the rate a particular material can be machined without damaging
the cutting edge of the tool that is machining it. It is based on the surface speed of the
material in relation to the cutter. This speed is a function of both the RPM of the spindle
as well as the diameter of the part or size of the cutter, because, as the part diameter or
cutter size increases, the surface moves a greater distance in a single rotation. If you
exceed this ideal speed, you can damage the cutting tool. In the lathe and mill
instructions, we give some examples of suggested cutting speeds, but what I wanted to
get across here is that it isn't a slow process. A tool can be destroyed in just a few
seconds. It isn't a case of getting only one hour of use instead of two. The cutting edge
actually melts. If you machine tough materials like stainless steel, you will ruin more
tools than you care to buy if you don't pay a lot of attention to cutting speeds. Charts
showing suggested cutting speeds for various materials are included in both the lathe and
mill sections that follow.
VERTICAL MILLING MACHINE
OPERATION
(Reprinted from the Sherline Assembly and Instruction Guide, Fourth Edition (1997)
CLICK HERE to download the complete Assembly and Instruction Guide, Fifth
Edition as a .pdf file.
CAUTION!
Read all operating instructions carefully
before attempting any machining operations!
Review Safety Rules for Power Tools before beginning.
NOTE: See general machine setup section for lubrication and general machining
instructions.
FIGURE 1-Milling Machine part terminology. Note that newer lathes now have an
improved, more positive locking lever on the Z-axis leadscrew that replaces the
Headstock Friction Adjusting Screw shown in this older diagram.
GENERAL DESCRIPTION
At first glance, a vertical mill looks similar to a drill press, but there are some important
design differences; for example, a spindle that can take side loads as well as end loads
and an accurate method of moving work in relation to the spindle on all three axes. It is
wise to memorize these "X", "Y" and "Z" axes, because since the advent of complex
electronically controlled milling machines, these terms have become common "shop
talk", even outside engineering departments. (See Figure 2.) Feed screws with calibrated
handwheels control movements on these three axes. The handwheel calibrations are quite
accurate and should be used whenever possible. Counting handwheel revolutions and/or
the marks on the handwheel is a more accurate way to move from one location to another
than "eyeballing" a cut to a scribed line.
Angles can be machined by removing the headstock alignment key and rotating the
milling head to the appropriate angle to the work or by holding the work at an angle to
the spindle. (Note: Lighter than normal cuts should be taken when the alignment key is
not in place.) The latter method must be used for drilling to keep the drill movement
parallel with the machine slide. All machine slides have an adjustable gib to compensate
for any "play" that may develop. (See section on adjusting gibs in the "Adjustments"
section of the setup instructions.)
In August, 1998, Sherline introduced the Model 2000 mill and related upgrades that
allows for eight directions of adjustment. For instructions specific to this machine, click
here.
It is assumed that anyone purchasing a vertical milling machine has had some experience
working with metal cutting tools; therefore, these instructions are somewhat limited for a
beginner. There is enough information, however, to enable a good craftsman to get
started. Using a vertical mill correctly takes more skill and experience than is required for
lathe operation because of the additional axis (vertical) and the more varied type of work
which can be performed. For those wanting to learn more, we have written a 350-page
color book called Tabletop Machining (P/N 5301) that covers the subject in much greater
detail.
The machine must be well maintained, for it is subject to higher stresses than a lathe. This
particular mill is one of the smallest being manufactured and is an extremely useful tool.
However, it would be unreasonable to clamp a 3-pound piece of stainless steel to the
work table and expect to make a 1-pound part from it. The key point is to work within the
capabilities of the machine, and those limitations can only be determined by the operator.
HELPFUL TIPS FOR MILLING
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This is a small, light duty mill and should not be used to remove large amounts of
stock that could be easily removed with a hacksaw. For efficiency, select a piece
of stock as close to finished size as possible.
Stresses on a mill are quite high when cutting most materials; therefore, gib and
backlash adjustments must be properly maintained. (See "Adjustments" section
beginning on page 6.)
End mills must run true and be sharp. Holding end mills in a drill chuck is a poor
practice. Use collets or an end mill holder instead. The 3/8" end mill holder (P/N
3079) allows you to use a large range of readily available 3/8" end mills with your
machine. (1/4" and 3/16" end mill holders are also available.)
Flycutting is an excellent way of removing stock from flat surfaces and leaves a
good finish.
Normal machine alignment is adequate for most work, but if the work is
exceptionally large or requires extreme accuracy, shims may be employed to
improve machine alignment.
For accurate setups you should have and know how to use a dial indicator.
Often, more time will be spent making fixtures to hold work than doing the actual
machining.
To help save time on many simple setups a good mill vise is a must.
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Always try to have one point from which to measure. Do not machine this point
off part way through the job. This would leave you with no way of measuring the
next operation. Plan ahead.
Remember the basic machining rule that says: "If the tool chatters, reduce speed
and increase feed."
It takes a long time to accumulate the knowledge, tools and fixtures required for
many different types of milling operations. Do not become discouraged by
starting with a job that is too complex or by using materials that are extremely
difficult to machine.
FIGURE 2-- The three axes of movement on a vertical milling machine.
SECURING THE WORKPIECE
The first problem encountered will be holding the work and aligning it to the machine. It
is important for reasons of safety and accuracy that the workpiece be solidly secured.
This may be the most difficult task, since once the work is clamped in position, the
method of doing the entire job has been established. Usually, a rectangular block can be
easily held in a vise. Note that round stock may also be held in a "V" shaped vise slot.
Mill vises are specially designed to pull the movable jaw down as they tighten on it.
Certain objects can be secured with a 4-jaw lathe chuck, which is in turn clamped to the
machine. Some irregular shapes, such as steam engine castings, may present greater
difficulties. Often they may be clamped directly to the table. Very small or irregular
shapes can be secured by epoxying them to a second, more easily held piece of material.
The part is then broken loose from the material after machining. A tooling plate (P/N
3560) offers a drillable surface with a predrilled pattern of holes to help mount parts and
fixtures while also protecting the mill table and adding further stiffness.
THINGS TO CONSIDER BEFORE YOU START
CUTTING
The following steps should be considered before commencing any part:
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Is the material about to be machined best suited for the job, and is it machinable
with available cutting tools and equipment? Work with aluminum, brass, plastic
or cast iron whenever possible. Too often a hobbyist will pick up the first
correctly sized piece of material he finds at his local salvage dealer thinking that if
it is rusty, it's steel, and that all steels are pretty much the same. Not so! Anyone
who has ever tried to machine an old automobile axle can attest to this. If the part
must be steel, grade 12L14, commonly called "lead-loy", is about the best
material for machining. It was developed for screw machine use and is available
in round stock only. However, it works so well that many times it may be
advisable to machine rectangular parts from it. It can also be case hardened. Your
local screw machine shop will usually have scrap pieces available and may be a
good source for obtaining it.
Figure 3-Center drilling a part clamped to the table with the P/N 3012
hold-down set. The newer P/N 3013 step block hold-down set is more
quickly adjustable for height and covers a wider clamping range.
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Avoid exotic materials, such as stainless steel, unless absolutely necessary
because of machining difficulty and poor milling cutter life. (Probably, if each
new mechanical engineer were given a block of stainless steel to mill, drill and
tap upon his graduation, stainless steel sales would drop considerably!)
Before beginning, carefully study the part to be machined. Select the best surface
from which to work (usually the flattest).
Pick a point from which to measure that will not be machined off part way
through the job.
Decide if work should be "rough cut" to size. Some materials will warp while
being machined. Close tolerance parts can be destroyed by attempting heavy
machining at the end of the job rather than at the beginning.
The method of holding the work is also determined by the type of machining to be
performed. For instance, work that involves only small drilling jobs does not have
to be held as securely as work to be milled.
Lay the job out so that it can be machined with the minimum number of setups.
Be sure to have all needed cutting tools available before beginning a job.
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Do not start off with a job so complex that the odds of success are limited.
Making complex machined parts requires a great deal of intelligence, planning
and skill.
In summary, you should become aware of the fact that milling is difficult, but not
impossible. There are many more considerations than just moving the handwheels, and
you should not start your first step until your last step has been determined.
THREE TYPES OF WORK
There are three basic types of work which can be performed with a vertical milling
machine: milling, drilling and boring. It would be extremely difficult to determine
whether a vertical mill or a lathe would be the most valuable machine in a shop.
Theoretically, most vertical mills are capable of reproducing themselves with standard
milling accessories such as a rotary table and centers. This would be impossible on a
lathe without exotic modifications and attachments. These instructions briefly describe
standard vertical mill work. Many comprehensive books are available on this subject,
and, although the machines they describe are much larger, the principles remain the same.
A good starting point is Tabletop Machining. It is available through Sherline as P/N
5301and uses Sherline tools throughout in all the setups and examples.
CAUTION! Because the tool spins on a mill, hot chips can be thrown much
farther than when using a lathe. Safety glasses and proper clothing are a
must for all milling operations.
Milling on a vertical mill is usually accomplished with end mills. These cutters are
designed to cut with both their side and end. (See Figure 12.) Drilling is accomplished by
raising and lowering the entire milling head with the "Z" axis feed screw. Center drills
must be used before drilling to achieve any degree of accuracy. (See Figure 18.) Note that
subsequent holes may be accurately "dialed in" from the first hole by using the calibrated
handwheels. Each revolution of the wheel will yield .050" of travel on inch machines or 1
mm for metric machines. There is no need to start with the handwheel at "zero", although
this can be easily accomplished with the optional "zero" resettable handwheels to make
calculations easier.
Boring is a method of making accurate holes by rotating a tool with a single cutting edge,
usually in an adjustable holder called a boring head. It is used to open up drilled holes or
tubing to a desired diameter. (See Figure 4.)
Another type of milling is performed with an adjustable flycutter, which may be used for
surfacing. For maximum safety and rigidity, the cutting bit should project from the holder
no further than necessary. A 1-1/2" diameter circle of cut is quite efficient, and multiple
passes over a surface should overlap about 1/3 of the circle size. For machining
aluminum, use a speed of 2000 RPM and remove about .010" (0.25mm) per pass. (See
also the flycutter information in the Sherline Tools & Accessories Catalog.)
FIGURE 4- Boring the inside of a hole to exact size with a boring tool held in a boring
head.
STANDARD MILLING VS. CLIMB MILLING
It is important to understand that the cutting action of a milling cutter varies depending
upon the direction of feed. Study the relationship of cutting edges to the material being
cut as shown in Figure 5. Note that in one case the tool will tend to climb onto the work,
whereas in the other case the tool will tend to move away from the cut. The result is that
climb milling should be avoided except for very light finishing cuts.
FIGURE 5-Standard vs. climb milling. (For clarity, consider the cutter moving, although
it is actually the part that moves while the cutter remains in one place.)
WORKING TO SCRIBED LAYOUT LINES
A common practice when working with a mill is to lay out the hole centers and other key
locations using a height gauge and a surface plate. A coloring (usually deep blue) called
layout fluid or "Dykem" is brushed or sprayed on a clean surface of the part. A thin layer
is best because it dries quicker and won't chip when a line is scribed. The purpose of this
fluid is to highlight the scribed line.
Don't prick punch the scribed crossed lines representing a hole center. Using a center drill
in the mill spindle and a magnifying glass, bring the headstock down until the center drill
just barely touches the scribed cross. Examine the mark left with a magnifying glass and
make any corrections needed to get it perfectly on center. You should be able to locate
the spindle within .002" (.05mm) of the center using this method.
Once the first hole is located in this manner, the additional holes can be located using the
handwheels. (This is where the optional resettable "zero" handwheels are handy.) Now
the scribe marks are used as a double check and the handwheels take care of the
accuracy. Don't forget the rules of backlash and always turn the handwheels in the same
direction as you go from one point to the next.
USE OF A DIAL INDICATOR
The basis of most accurate machining involves the use of a universal dial test indicator; a
small, inexpensive indicator which is calibrated in .001" or .01mm divisions. An
indicator with a large face or one that reads in finer divisions is not necessary for use with
this mill. Three major tasks that can be accomplished with an indicator are:
1. Checking the squareness of a setup.
2. Finding the center of a hole.
3. Aligning the work with the machine.
FIGURE 6-Indicating in the jaws of a vise. Shown is a Starret "Last Word" Indicator.
Starret gauges are available in numerous sizes and types. They are manufactured in
Athol, Massachusetts and can be purchased from most industrial dealers.
FIGURE 7-Indicating in the center of a hole.
A vise can be mounted or a part can be clamped down exactly parallel with the machine
slides by holding the test indicator stationary and moving the slide with which you wish
to align. When "indicating in" a vise, always take the reading on the fixed jaw. To start
with, use approximately .005" indicator deflection from neutral. Remember that
excessive pressure can cause inaccurate readings. Also, try to keep the indicator finger at
a reasonable angle to the indicated part or surface. When the part is properly aligned there
will not be any deflection on the indicator. If you wish to locate the spindle over an
existing hole, place the indicator in the spindle and read the inside surface. Move the "X"
and "Y" axes until there is no deflection when the spindle is rotated. At this point, the
spindle is in perfect alignment with the hole's center.
When aligning the spindle to used bearing holes, remember that the hole may be worn
out-of-round, and it may be impossible to attain zero indicator deflection reading. Boring
out a worn bearing hole to a larger diameter and sleeving it with a simple bushing made
on a lathe is a fairly common machining operation. With the new bushing pressed in, the
bearing will be like new.
FIGURE 8--Indicating in a 30° head tilt using a mill vise and draftsman's triangle.
The squareness of your machine may also be checked with an indicator. For instance,
alignment of the head can be checked by offsetting the indicator in the spindle so the tip
will move on a 5-inch diameter circle. The amount of reading relative to the table is the
amount of error. Don't be discouraged to find a few thousandths of an inch error in your
machine. This machine has been designed to have the most accuracy commensurate with
reasonable cost. In machine tool manufacturing, accuracy and cost run hand in hand. To
increase accuracy only a few percentage points could double the selling price, because
entirely different manufacturing processes would be required. However, you can
personally improve the accuracy of your machine with a few shims if needed by
employing your dial indicator.
The column bed is aligned with the column block at the factory. If you remove it, it will
have to be realigned by mounting a known "square" on the mill table and adjusting
placement of the bed by running an indicator on the square as the headstock is raised and
lowered. The same method can be used to check alignment of the column bed to ensure it
is square with the "Y" axis. To correct any error (which should be small), place a shim
between the column block and the mill base.
LOCATING THE EDGE OF A PART IN RELATION
TO THE SPINDLE
There are two quick methods of "picking up an edge" of a part on a mill. The first is to
put a shaft of known diameter in the spindle and see that it runs perfectly true. Using a
depth micrometer against the edge of the part, measure the distance to the outside
diameter of the shaft. To that dimension add 1/2 the known shaft diameter. You now have
the distance from the edge of the part to the centerline of the spindle. Rotate the
handwheel on the axis being set exactly this distance and you will have the centerline of
the spindle lined up with the edge of the part from which you measured.
The second method is much easier. It involves the use of a clever tool called an "edge
finder". These devices have been around for years and have two lapped surfaces held
together by a spring. One surface is on the end of a shaft which fits in a 3/8" end mill
holder and is held in the spindle. The other is a .200" diameter shaft held to the larger
shaft with a spring so it is free to slide around. With the spindle running at approximately
2000 RPM the shorter shaft will be running way off center. As this shaft is brought into
contact with the edge you are trying to locate in relation to the spindle, the .200" shaft
will be tapped to the center as the spindle rotates. This keeps making the .200" shaft run
continually truer. When the shaft runs perfectly true it makes contact with the part 100%
of the time. This creates a drag on the surface of the shaft that will "kick" it off center.
(See Figure 9.) At this point you know the part is exactly .100" (half the diameter) from
the centerline of the spindle. Advancing the handwheel on a Sherline mill two revolutions
(.050" per revolution) will bring the edge of the part into alignment with the spindle.
FIGURE 9--Using an "edge finder" to accurately locate the edge of a part.
It is important to use a high quality edge finder such as the Starrett 827A shown in the
drawing. It must have a 3/8" shaft to fit the end mill holder on the Sherline mill. Metric
sized edge finders are also available which work in the same manner.
DETERMINING DEPTH OF CUT
There are no firm rules other than common sense for determining depth of cut. A .030"
cut depth with a 3/16" end mill in aluminum could be considered light, but .003" cut
depth in steel with a 1/32" diameter end mill would break to cutter. Start with very light
cuts and gradually increase the depth until satisfactory results are achieved. Try to
develop the skill of knowing how much cut is satisfactory without breaking the cutter or
damaging the work.
Note that regular end mills should not be used for drilling; however, they may be
employed to enlarge an existing hole. The cutting edges deserve more respect than those
of drills even though similar in appearance; they are designed to cut with the sides.
WORK ACCURATELY
It should be remembered that a good machinist is capable of making a part to much closer
tolerances than those of the machine with which he is working. The accuracy of the parts
you make is limited only by your skill as a craftsman and the quality of your
measurement equipment. Accuracy should be the ultimate goal of every machinist!
CUTTING SPEEDS FOR MILLING
SPEED ADJUSTMENT FORMULA
SPINDLE RPM = (3.82 x S.F.M. ) ÷ D
S.F.M. = The rated Surface Feet for Milling. For drilling, use 60% of the rated
surface feet.
RPM = The rated spindle speed in Revolutions Per Minute
D = The diameter of work in inches
FIGURE 10-Formula for adjusting spindle speed for cutting a given diameter.
NOTE: To estimate RPM, remember that the speed range of your vertical mill is from 0
to 2800 RPM. (The lowest usable speed is about 70 RPM, so we use that in our
specifications. To obtain much more torque at the lower speed ranges, the drive belt can
be switched to the smaller diameter positions on the spindle and drive pulleys.)
Therefore, in the normal belt position, half speed is approximately 1450 RPM and so on.
You can estimate these speeds by a combination of the setting on the speed control knob
and the sound of the motor itself.
SPEED ADJUSTMENT CHART
END MILLS (Slot and side milling)
MATERIAL
CUT SPEED
(S.F.M.)
1/8"
DIA.
1/4"
DIA.
3/8"
DIA.
Stainless Steel, 303
40
Stainless Steel, 304
36
1100
500
350
Stainless Steel, 316
30
900
450
300
Steel, 12L14
67
2000
1000
650
Steel, 1018
34
1000
500
350
Steel, 4130
27
800
400
250
Gray Cast Iron
34
1000
500
350
Aluminum, 7075
300
2800
2500
2000
Aluminum, 6061
280
2800
2500
2000
Aluminum, 2024
200
2800
2500
2000
Aluminum, Cast
134
2800
2000
1300
Brass
400
2800
2800
2800
1200 RPM 600 RPM 400 RPM
DRILLS
MATERIAL
CUT SPEED
1/16" DIA. 1/4" DIA.
(S.F.M.)
Carbon Steel
36
2000 RPM
550 RPM
Cast Iron, Soft
30
1800
450
Stainless Steel
24
1400
360
Copper
72
2000
1100
Aluminum, Bar
240
2000
2000
Aluminum, Cast
120
2000
2000
FIGURE 11-End mill and drill speed adjustment chart.
CUTTING TOOLS AND STANDARD ACCESSORIES
END MILLS
End mills are the standard vertical mill cutting tools. We recommend 3/8" shank end
mills held in the 3/8" end mill holder P/N 3079. One of the benefits of 3/8" end mills is
they are available in a large range of sizes. The end mill is held with a set screw on its flat
surface and it can be easily changed. They are also lower in price than miniature cutters
because of their popularity. You can also use miniature series end mills having 3/16" or
1/4" shank sizes which should be held in collets. (End mills held in collets must be single
ended, while end mills held in our end mill holders may be double ended.) We
recommend using 2-flute, high-speed steel end mills for aluminum because the flutes are
less prone to clog with chips. Use 4-flute cutters for cutting steels with lower RPM. The
solid carbide tools are not suggested since they are very expensive and the cutting edges
will chip unless used with heavy duty production equipment.
FIGURE 12-A typical end mill
As a convenience to our customers, SHERLINE keeps in inventory many of the popular
sizes of end mills which are appropriate for use on our machines. See tooling price list for
selection. End mills may also be purchased from your local industrial machine shop
supply outlet (see yellow pages under "Machine Shop Supplies") or from mail order
industrial suppliers.
Because small diameter cutters (less than 1/8") are quite fragile, the largest diameter
cutter possible for the job requirements should be employed. Be certain that the RPM is
appropriate before attempting to remove any metal. An end mill can be instantly damaged
if a cut is attempted at excessive RPM. Like all cutting tools, end mills will have a short
lifespan when used for machining steel or other exotic materials. Save new cutters for
finish work. Do not use small diameter end mills with long flutes unless absolutely
necessary because of excessive cutter deflection (bending).
RESHARPENING END MILLS
End mills can be resharpened by your local tool and cutter grinding shop. End mills lose
their cutting edge clearance after a couple of sharpenings and should no longer be reused.
FIGURE 13-3/8" End Mill Holder
3/8" END MILL HOLDER (P/N 3079)
The 3/8" end mill holder makes it easy to use the popular (and less expensive) 3/8" end
mills. Using double ended end mills is economical and easy with this holder as tools are
changed by simply loosening a set screw and changing the tool. The holder is now also
available to hold smaller size tools in the same manner. The 3/16" end mill holder is P/N
6080 and the 1/4" end mill holder is P/N 6079.
FIGURE 14-3/8" End Mill Holder
MILL COLLET SET (P/N 3060)
The main purpose of the mill collet set is to hold end mills. The spindle nose has an
internal Morse No. 1 taper, which closes the collet as the drawbolt is tightened. Morse
tapers are approximately 5/8" per foot and are self-locking. Therefore, to loosen a collet,
the drawbolt must be loosened a few turns and given a few light taps with a hammer.
BORING HEAD (P/N 3054) AND BORING TOOLS
The main purpose of the boring head is to eliminate the need for a large inventory of
drills and reamers. A small milling machine would not have the power or rigidity to turn
a one-inch diameter drill even if one could be obtained that would fit. However, holes of
even larger diameters can be accurately bored to size with a little patience and care.
FIGURE 15-Boring Head and Boring Tool. P/N 3061 is for 1/4" (6.4mm) min.
diameter by .60" (15.2mm) max. depth hole. P/N 3063 is for 5/16" (7.0mm) min. dia. by
1.0"(25mm) max. depth hole. Both have a 3/8" diameter shaft.
Boring heads work on the same cutting principle as lathe boring, except that the cutting
tool turns while the work remains stationary. (In the case of a lathe, the work turns and
the cutter remains stationary.) The boring head is designed to employ cutting tools with a
3/8" shank. SHERLINE offers two boring tools with lengths appropriate for the
SHERLINE mill. It is sometimes advisable to remove excessive tool shank length from
standard (non-SHERLINE) 3/8" boring tools in order to improve rigidity. (See Figure 4
for a boring tool in use.)
Tool sizes are listed indicating the smallest diameter hole that can be bored and the
maximum depth that can be cut. For best results, use the largest diameter possible with
the shortest lengths. A .010" cut represents a good starting point.
If boring a hole where a flat bottom is required, it is advisable to stop the down feed at
about .002" above the desired depth, turn off the motor and cut the remaining distance by
hand turning the spindle to eliminate any possibility of chatter.
FIGURE 16-Standard flycutter (left) and inserted tip flycutter (rigit) with their drawbolts.
FLYCUTTERS (P/N 3052 and P/N 7620)
For machining flat surfaces, the flycutter shown in the SHERLINE Tool & Accessory
Catalog is recommended. It is imperative that the tool be used with utmost care. EYE
PROTECTION IS A MUST, and the work as well as the cutting tool must be properly
held. The big advantage of a flycutter is its ability to take light cuts up to 2" wide and to
give an excellent surface finish. It is ideal for squaring up work. Also, the machining
stresses are lower than one might imagine, because very little crushing action takes place
at the cutting edge, unlike an end mill. Flycutting tools look like left-hand lathe tools, and
although the fly cutter (P/N 3052) comes with a brazed carbide tool, high speed tools
work quite well and can be sharpened on any grinder.
FIGURE 17-A typical setup for flycutting.
For those who prefer the advantages of working with inserted carbide tip tools, the P/N
7620 flycutter is available. It uses replaceable carbide cutting inserts which last longer
than steel tools without sharpening, plus they provide an excellent finish on hard to
machine materials like cold rolled and stainless steels. The cutter shape allows it to cut a
straight shoulder on a part, something not possible with a standard flycutter. Included is
the toolholder, a drawbolt, a 2-edged carbide insert and Torx T-15 driver and mounting
screw. Additional inserts are available (P/N 7622).
DRILLS AND DRILL CHUCK (P/N 3072)
The 1/4" drill chuck available for this vertical mill is supplied complete with a Morse No.
1 arbor and a drawbolt to hold it securely in place. Drilling can be accomplished by
raising and lowering the entire head with the vertical feed handwheel. This allows for
very accurate control of feed rate and hole depth. For accurately located holes we again
stress the importance of using center drills.
Drills should be kept in excellent condition, either by replacement or proper
resharpening. Good quality high speed steel drills should be employed. A dull or
improperly sharpened drill can cut oversize by as much as 10%. When you start to drill,
the initial penetration should be no more than twice the diameter of the hole before you
retract the drill, clear the chips and add coolant with the tip of a small brush. From then
on, do not try to drill deeper than the diameter of the drill without clearing the chips and
adding coolant. For example:
To drill a 1/8" diameter hole 1" deep:
OPERATION
TOTAL
DEPTH
1st Pass: 2 times diameter or 1/4"
1/4"
2nd Pass: 1 times diameter or 1/8"
3/8"
3rd Pass: 1 times diameter or 1/8"
1/2"
Etc.
Etc.
You may encounter recommendations exceeding these figures, but they are meant for
automatic equipment with pressurized coolant systems.
It is difficult to maintain tolerances of better than +.003"-.000" with a drill. If tolerances
closer than these are required, a reamer must be employed. Try to use fractional size
reamers whenever possible rather than decimal sizes, because the cost difference can
amount to 2 or 3 times higher. (The length of reamers may prevent their use for some
operations on machines of this size.)
FIGURE 18-Typical Center Drill
To accurately start holes, center drills must be used. They have a small tip which
accurately starts the hole, and then the shaft widens with a 60° cutting face to the final
diameter. Care must be taken to employ cutting oil and to clear the drill frequently. If this
is not done, the fragile tip may load up and twist off even in soft materials. Center drills
are available in a variety of sizes, but for general work we recommend No.1.
SIZE
000
BODY DRILL DRILL
LENGTH
DIA.
DIA. LENGTH OVERALL
1/8"
.020"
3/64"
1-1-4"</TD
00
1/8
.025
1/16
1-1/4
0
1/8
.031
1/16
1-1/4
1
3/16
.046
3/64
1-1/4
2
3/16
.078
5/64
1-7/8
3
1/4
.109
7/64
2
FIGURE 19-Table of commonly available center drill sizes
FIGURE 20-The SHERLINE Mill vise
MILL VISE SET (P/N 3551)
The vise shown here and in figures 42 and 44 is furnished with special clamps that allow
it to be clamped in any position on the mill table. The vise capacity is 2 inches. It has a
movable jaw which is pulled down while clamping, eliminating any chance for the jaw to
lift. It is the most convenient way to hold small parts for milling.
FIGURE 21-SHERLINE's 4" Rotary Table
4" ROTARY TABLE (P/N 3700)
The rotary table mounts to the mill table and provides a rotary axis for milling. Each
increment on the handwheel represents 1/10° of rotation, so a circle can be divided into
3600 segments without interpolation. 72 handwheel revolutions rotate the table one time.
It can be used to mill a radius on a part, cut a circular slot or drill precision circular hole
patterns. Used with the right angle attachment (P/N 3701) and right angle tailstock (P/N
3702) it can also be used to cut gear teeth. A rotary table used with a mill allows a
machinist to produce virtually any part he can design. The only limits are size, not
complexity. The compact size of this high quality rotary table also make it a good choice
for use on larger machines where its size would offer an advantage in working with small
parts.
FIGURE 22-The Horizontal Milling Conversion turns the standard SHERLINE vertical
mill into a horizontal mill. This greatly expands the operations that can be completed on
the mill.
HORIZONTAL MILLING CONVERSION (P/N 6100)
A number of milling operations require the application of the cutting tool from the side
rather than from the top. A 3/4" thick aluminum base 10.5" x 12.5" allows the mill
column to be mounted separately from the base for a variety of milling configurations.
The headstock is rotated 90° and work is machined from the side, allowing larger
surfaces to be worked on without having to reclamp the work.
The black anodized mounting plate is predrilled to mount the base and column in several
possible locations. Alignment bars and a selection of appropriate bolts are included to
make it easy to accurately relocate the column. Rubber feet insulate the table for quiet,
vibration free operation. (Note: the column base should be shortened by 2" for best
operation. Instructions are provided or we will shorten your column for you. The
modification is listed as P/N 6101.)
USE OF ACCESSORIES AND ATTACHMENTS
Your mill can be made more versatile with the addition of suitable attachments and
accessories. These include various chucks and collets, a thread cutting attachment,
vertical milling column, knurling tool, a live center and many others. Remember that
accessories and attachments must be cared for in the same way as the lathe. Always make
sure that threads are free from metal chips and dirt. Chucks should be lightly oiled
frequently so that they continue to function smoothly and accurately. Gears in the thread
cutting attachment should be lightly greased when in operation. Some attachments have
moving slides and these should be lubricated in the same way as the slides in your lathe.
Each accessory comes with complete instructions for its use when it is purchased.
MILL EXPLODED VIEW PARTS DIAGRAM
Refer to part number list below drawing for part number name and material.
EXPLODED VIEW ONLY: To view and print out just the exploded view and part
numbers for reference, CLICK HERE for exploded view only. (Note: Requires Acrobat
Reader program to view.)
PART NUMBERS AND DESCRIPTIONS, SHERLINE
LATHES AND MILLS
KEY TO MATERIALS: A=Aluminum, B=Brass, C=Composite, DC=Die Cast,
P=Plastic, U=Urethane, S=Steel
PART NO.
DESCRIPTION
MATERIAL
12970
Headstock Spacer Block (Deluxe Mill)
30220
Toggle Switch Retaining Ring
S
30230
Toggle Switch
--
31080
10-32 x 3/8" Flat Pt. Set Screw
S
Oversize Handwheel, Inch (Metric)
A
34000
(34100)
34060
34200
(34300)
A/S
Thrust Bearing Washer Set
Ball
2" Zero Adjust. Hndwhl. Asby., Inch (Metric)
A/S
34210
2" handwheel Body
A
34220
Handwheel ocking Nut
S
Y Axis/Crosslide Collar, Inch (Metric)
A
6-32 x 7/8" Pan Hd. Screw
S
34260
(34270)
X, Z Axis and Leadscrew Collar, Inch (Metric)
A
34400
(34500)
2-1/2" Zero Adjust. Hndwhl. Asby., Inch (Metric)
34230
(34240)
34250
A/S
34410
2-1/2" Handwheel Body
40010
15" Lathe Bed
DC
40020
Motor Bracket
Diecast
40040
Drive Belt
40050
(41050)
1-5/8" Handwheel, Y Axis/Crosslide, Inch (Metric)
A
Urethane
A
40070
40080
(41040)
Faceplate
1-5/8" Handwheel, X Axis/Leadscrew, Inch (Metric)
Diecast
A
40090
Drive Dog
40100
Headstock Casing
A
40120
15" Lathe Bed
S
40160
Preload Nut
S
Saddle Nut, Inch (Metric)
B
Tool Post
A
40200
(41200)
Leadscrew, Inch (Metric)
S
40220
(41220)
Feed Screw, Inch (Metric)
S
40230
Headstock Spindle
S
40240
Headstock Pivot Pin, Lathe
S
40250
Tool Post Tee Nut
S
40260
Head Key
S
Tailstock Spindle, Inch (Metric)
S
40280
Thrust Collar
S
40300
Leadscrew Thrust
S
40320
Bearing Washer
S
40330
10-32 x 5/8" Skt. Hd. Cap Screw
S
40340
110-32 x 1" Skt. Hd. Cap Screw
S
40370
Leadscrew Support
S
40380
#1 Morse Center
S
40390
#0 Morse Center
S
40400
Plug Button
P
40170
(41170)
40180
40270
(41270)
Diecast
40420
Headstock Bearing
Ball
40440
Self Tapping Screw
S
40500
10-24 x 7/8" Skt. hd. Cap Screw
S
40510
10-32 x 3/8" Skt. Hd. Cap Screw
S
40520
10-32 x 3/16" Cup Pt. Set Screw
S
40530
5-40 x 3/8" Skt. Hd. Cap Screw
S
40540
5/16-18 x 3/4" Cone Pt. Set Screw
S
40550
5/32" Hex Key
S
40560
3/16" Hex Key
S
40570
3/32" Hex Key
S
40580
Spindle Bar
S
40590
1/4" I.D. Washer
S
40600
10-32 x 1/4" Flat Pt. Set Screw
S
40620
Power Cord, USA
--
40630
Power Cord, UK
--
40640
Power Cord, Europe
--
40660
3/16" I.D. Washer
S
40670
10-32 x 1/2" Skt. Hd. Cap Screw
S
40690
10-32 x 3/4" Skt. Hd. Cap Scrw
S
40760
10-32 x 5/8" Thumbscrew
S
40820
Gib Lock
S
40860
Tailstock Locking Screw Grommet
P
40870
Tailstock Spindle Locking Screw
S
40890
(41890)
Slide Screw Insert, Inch (Metric)
B
40900
10-32 x 3/8" Flat Hd. Skt. Screw
S
40910
Saddle
A
40980
Crosslide Gib
Composite
40990
Saddle Gib
Composite
41080
6-32 Hex Nut
S
41110
Tailstock Casing
A
41130
DC Speed Control Knob and Set Screw
43100
DC Motor Standoff
A
43110
DC Speed Control Case
P
43120
DC Speed Control Hinge Plate
P
43130
DC Speed Control Cover Mounting Plate
P
43140
DC Speed Control Tab, Small
P
43150
DC Speed Control Tab, Large
P
43160
Belt Guard, Outer
P
43170
6-32 x 1-3/8" Pan Hd. Screw
S
43180
Belt Guard, Inner
P
43190
#2 x 1/4" Flat Hd. Sheet Metal Screw
S
43200
DC Speed Control Foil Label
Foil
43230
Stepped Main Spindle Pulley
A
43360
Stepped Motor Pulley
A
43460
DC Speed Control Electronics
--
44010
24" Lathe Base
DC
44120
24" Lathe Bed
S
44200
(44230)
24" Leadscrew, Inch (Metric)
S
44210
(44220)
Slide Screw, Inch (Metric)
S
Crosslide
A
Leadscrew, Z Axis, Inch (Metric)
S
44880
45010
(45160)
P/S
45030
Column Bed
S
45040
Saddle, Z Axis
A
45070
Lock, Teflon
P
45170
Column Saddle Lock
P
45180
3/16" Ball Bearing
S
45190
#10 Type B Washer
S
45200
Leadscrew Thrust, Bored
S
45450
or
45460
45450=DC Motor with externally replaceable brushes
(Leeson)
45460=DC Motor with externally replaceable brushes (Hill
House)
(NOTE: We purchase motors from two different
manufacturers to keep pricing competitive. Specifications on
both are the same, but replacement motors should be ordered
with the same part number as the original. Part number is
printed on motor.)
50010
10" Mill Base
A
50050
Column Base
A
50120
Backlash Lock
S
50130
(51130)
Backlash Nut, X Axis, Inch (Metric)
S
50140
(51140)
Backlash Nut, Y Axis, Inch (Metric)
S
50160
(51160)
Leadscrew, Y Axis, Inch (Metric)
S
50170
(51170)
Leadscrew, X Axis, Inch (Metric)
S
50180
Mill Table
A
50190
X Axis Lock
S
50200
(51200)
Nut, Y Axis, Inch (Metric)
B
50210
8-32 x 1/4" Pan Hd. Screw
S
Motor
50220
1/4-20 x 1-3/4" Skt. Hd. Cap Screw
S
50240
Headstock Pivot Pin, Mill
S
50280
Thrust Collar, Mill
S
50910
Saddle
A
50980
Gib, X Axis
C
50990
Gib, Y Axis
C
54020
(54120)
12" Mill Base, Deluxe Engraved, Inch (Metric)
A
54160
(54170)
Leadscrew, Y Axis, Deluxe Mill, Inch (Metric)
S
54180
(54190)
Mill Table, Deluxe Engraved, Inch (Metric)
A
90060
DC Speed Control 5K Potentiometer
--
90080
3/8-32 Hex Nut
S
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