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Harold Hall - The Milling Machine for Home Machinists (Fox Chapel Publishing) Over 150 Color Photos & Diagrams; Learn How to Successfully Choose, Install, & Operate a Milling Machine in Your Home Workshop

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The Milling Machine for Home Machinists (Fox Chapel Publishing) Over 150 Color Photos & Diagrams; Learn How to Successfully Choose, Install, & Operate a Milling Machine in Your Home Workshop: summary, description and annotation

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The home machinists essential guide for choosing and using a milling machine.

  • Over 150 color photos and diagrams illustrate essential accessories and the differences between the options
  • Detailed knowledge to help you successfully choose, install, and operate a milling machine in your home workshop
  • Clear explanations of the usage of each machine and accessory for the vast majority of applications in an active shop
  • Discover your options for holding the many diverse shapes and sizes of work pieces youll need
  • Learn which method is best for any applicationwhether to use a vice or an angle plate, mount the piece directly onto the worktable, or produce a fixture specifically for the task
  • Learn the right ways to cut metal and maintain your milling tools

The Milling Machine for Home Machinists provides the detailed knowledge you need to successfully choose, install, and operate a milling machine in your home workshop. Lavishly illustrated with color photographs and diagrams, it will help you to understand which accessories are essential, and which can be postponed until your activity demands it. The usage of each machine and accessory is explained in detail for the vast majority of applications in an active shop.

The real learning curve begins once your milling machine and its accessories are chosen and installed. Discover your options for holding the many diverse shapes and sizes of work pieces that will inevitably surface during your machines life. This critical task is by far the most important part of learning to use the machine.

Learn how to decide which method is best for any applicationwhether to use a vice or an angle plate, or mount the piece directly onto the worktable, or even produce a fixture specifically for the task.

With the work piece set up and ready for machining, the book goes on to show you the right ways to cut metal and maintain your milling tools

Milling machines are an integral part of any hobbyists workshop, but the huge variety of machine styles and accessories can be overwhelming for beginners. From selecting the right machine and accessories to the finer points of use, The Milling Machine for Home Machinists will help to answer all of your milling machine questions.

The Milling Machine for Home Machinists (Fox Chapel Publishing) Over 150 Color Photos & Diagrams; Learn How to Successfully Choose, Install, & Operate a Milling Machine in Your Home Workshop — read online for free the complete book (whole text) full work

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Parts of this book were updated for todays American reader with regard to new - photo 1
Parts of this book were updated for todays American reader with regard to new - photo 2
Parts of this book were updated for todays American reader with regard to new - photo 3
Parts of this book were updated for todays American reader with regard to new techniques and tools. These updates were graciously provided by George Bulliss of The Home Shop Machinist, Machinists and Digital Machinist magazines.
2013 by Harold Hall and Fox Chapel Publishing Company, Inc., East Petersburg, PA.
First published in the United Kingdom by Special Interest Model Books, 2011. First published in North America in 2013 by Fox Chapel Publishing, 1970 Broad Street, East Petersburg, PA 17520.
All rights reserved. No part of this publication may be reproduced, stored in a retrieval system, or transmitted, in any form or by any means, electronic, mechanical, photocopying, recording or otherwise, without prior permission of the copyright holder.
ISBN 9781565237698
eISBN: 978-1-63741-093-6
Library of Congress Cataloging-in-Publication Data
Hall, Harold, 1933-
The milling machine for home machinists.
pages cm
Includes index.
ISBN 978-1-56523-769-8
Milling (Metal-work)--Amateurs manuals. I. Title.
TT209.H355 2013
671.35--dc23
2012042876
To learn more about the other great books from Fox Chapel Publishing, or to find a retailer near you, call toll-free 800-457-9112 or visit us at
Note to Authors: We are always looking for talented authors to write new books. Please send a brief letter describing your idea to Acquisition Editor, 1970 Broad Street, East Petersburg, PA 17520.
CONTENTS
PREFACE
INTRODUCTION
CHOOSING
CHAPTER
THE MILLING MACHINE
CHAPTER
THE CUTTERS
CHAPTER
CUTTER HOLDING DEVICES
CHAPTER
METHODS FOR SECURING THE WORKPIECE
CHAPTER
OTHER ESSENTIAL ACCESSORIES
CHAPTER
OTHER ACCESSORIES
INSTALLATION
CHAPTER
INSTALLATION
USING
CHAPTER
GETTING STARTED
CHAPTER
USING THE VISE
CHAPTER
USING THE ANGLE PLATE
CHAPTER
USING THE WORKTABLE
CHAPTER
USING A DIVIDING HEAD
CHAPTER
USING THE ROTARY TABLE
CHAPTER
USING OTHER ACCESSORIES
CHAPTER
POSITIONING THE WORKPIECE
MACHINING
CHAPTER
MAKING THE FIRST CUT
FINALLY
CHAPTER
MAINTAINING YOUR CUTTERS
CHAPTER
FINAL COMMENTS
PREFACE
Having provided the book Milling, A Complete Course, Workshop Practice Series number 35, it became apparent that many workshop owners were looking for a more theoretical book on the subject rather than the hands-on approach of that published. This book therefore attempts to fill the gap, going into much greater detail regarding the choice of machine and the accessories that can be used with it.
There are chapters covering which accessories should be considered essential from the early stages and those which can be delayed until a need arises. This includes such accessories as dividing heads, rotary tables and boring heads. Within this detail, different versions of an accessory are discussed and their plus and minus points are examined.
The book then looks at the subject of installation, although this is relatively easy compared to the requirements for most lathes.
Having covered the subject regarding which machine and accessories to obtain, the following chapters discuss the methods of holding the workpiece, and in the case of active accessories (such as dividing heads and rotary tables) give sufficient detail regarding their use for all but the most complex applications.
Having the workpiece then ready for machining, the machining operation is covered in depth. The book concludes with a simple device for sharpening the end cutting edges of a high-speed steel end mill.
INTRODUCTION
For many years the milling machine was a rarity in the home workshop, with milling carried out on the lathe, some still using this as their only method. More cheaply available machines, though, and in a much larger range of types and sizes particularly smaller ones coupled I feel with greater wealth, has resulted them being much more common.
While some of this book will apply equally to both methods, it is mainly aimed at the workshop that possesses a conventional milling machine. I say conventional although there are two types available: horizontal and vertical. Again, the horizontal machine is rare in the home workshop, so the book only deals with the vertical machine in depth.
Even having limited the choice to a vertical machine, there are still many decisions to be made size, speed range, drive type, etc. All these considerations are discussed throughout the book.
While new machines are often supplied with a small number of accessories, these are rarely adequate, a major omission invariably being a cutter holding chuck. The accessories are therefore considered fully, from those that are essential, typically a cutter chuck, through to those that many will work without, such as a dividing head.
On the basis that an accessory is something that you may or may not need, then one item that is not an accessory, and one that cannot be done without, is a cutter. The range of these is vast, but mostly applicable to their use in industry. Even so, the number that may find a use in the home workshop is still quite large; which cutter to choose is, as a result, an essential part of equipping the workshop with a milling facility.
Having acquired your machine, together with the initial set of accessories, it will need installing. Fortunately this is simpler than with a lathe, but there are factors that must be taken into account; some are easily overlooked, such as whether there is enough headroom to remove the draw bar.
With the machine and all its accessories ready to be put through their paces, it is now that the real learning curve starts. The reason for this is the multitude of shapes and sizes of workpieces that will invariably surface during the machines life. After many years using a milling machine, you will still probably find yourself looking at something quite unlike any workpiece you have attempted previously. In simple terms, the decisions to be made are: do I use a vise or an angle plate or mount the workpiece directly onto the worktable, or perhaps even produce a fixture specifically for the task? Even then, how is the part positioned suitably for machining? This aspect of the milling machine is a major part of the books content, and for the machine owner the only way to gain the vital experience.
With the workpiece mounted and the chosen cutter in place, the next task is to start the machining operation. For this, such items as traverse direction, effect of the machine spindle not being at to the machine table, speed and feed rates are covered.
The process of removing metal is not as simple as it may appear, but once the requirements are understood it will very quickly be mastered. However, choosing the method of mounting the workpiece and the order in which surfaces should be machined is a continuous learning process in view of the large number of workpiece shapes that will occur. Therefore, in terms of the time taken for machining a complete part, the process will typically be 40% deciding the method, 40% setting it up and only 20% actual machining often even less machining time than that.
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