CEED Wiki - User contributions [en]

The Brunsfield Center/Manufacturing Technologies/Drilling

2025-07-21T15:52:30Z

Benrundle:

[[File:Types-of-Drill-Bits-Black-Oxide-Titanium-Cobalt.jpg|thumb|Standard twist drill bits]]
{{DISPLAYTITLE:Drilling}}
Drilling is a fundamental machining operation used to create round holes in a variety of materials using a rotating cutting tool called a '''drill bit'''. It is performed using tools such as drill presses, milling machines, or lathes with tailstock drills. This page covers drill bit types, material considerations, marking techniques, best practices, and common mistakes to avoid.

== Drill Bit Types ==
There are many types of drill bits, each suited for specific hole geometries or materials.

=== Standard Twist Drills ===

* '''Imperial Sizes''': Measured in inches (e.g., 1/4", 3/8")
* [[File:Types-of-Drill-Bits.webp|thumb|554x554px|Types of drill bits]]'''Metric Sizes''': Measured in millimeters (e.g., 6mm, 10mm)

=== Letter Gauge Bits ===

* Labeled A–Z, commonly used in aerospace and precision applications.
* Example: Size "F" = 0.257" (6.53 mm)

=== Wire Gauge Bits ===

* Numbered #1 (largest) to #80 (smallest).
* Useful for small holes and electronics work.

=== Tapered Shank Bits ===

* Used in drill presses or lathes with matching taper sockets (e.g., Morse taper).
* Provide better concentricity and torque transmission.

=== Reduced Shank Bits ===

* Larger diameter bits with a shank turned down to 1/2" or 3/8"
* Useful when your chuck cannot fit the full-size shank.

=== Hole Saws ===

* Circular cutters for large-diameter holes in sheet material.
* Not suited for high-precision or deep holes.

=== Step Drill Bits ===

* Cone-shaped bits with incrementally larger steps.
* Excellent for enlarging holes in thin sheet metal.

=== Center Drill Bits ===

* Short and stiff bits used to start holes precisely.
* Often used in lathes to create a pilot hole for tailstock drilling.

=== Forstner Bits ===

* Flat-bottomed hole cutters for woodworking.
* Provide clean edges and flat holes.

== Drill Bit Materials ==
Drill bits are made of various materials depending on the application:
{| class="wikitable"
!Material
!Properties & Use
|-
|'''High-Speed Steel (HSS)'''
|General-purpose. Affordable. Good for mild steel, wood, and plastic.
|-
|'''Cobalt Steel (M35/M42)'''
|Withstands higher temps. Better for stainless steel and hard metals.
|-
|'''Carbide'''
|Very hard and brittle. Ideal for production environments or composites.
|-
|'''Titanium Coated'''
|Reduces friction and wear. Not meant to be resharpened.
|-
|'''Black Oxide Coated'''
|Increases lubricity and corrosion resistance.
|}
[[File:DSC01948-min.webp|thumb|Center Punch used for marking hole centers for drilling.]]

== Marking and Starting Holes ==
Accurate hole positioning is critical.

=== Marking Out ===

* Use a '''scribe and steel rule''' or layout dye for precision.
* Mark the hole with a '''center punch''' to guide the drill bit and prevent wandering.
* For very small bits, use a '''spring-loaded automatic center punch'''.

=== Starting Techniques ===

* Always '''spot drill''' or use a '''center drill''' to create a pilot feature before using twist drills, especially in metal.
* When using a large bit (over 1/2"), consider '''pilot drilling''' with a smaller bit first.

== Drilling Techniques ==

=== General Process ===

# Clamp work securely.
# Mark and punch the hole location.
# Use cutting fluid as appropriate for the material.
# Drill at the recommended speed and feed.
# Clear chips frequently (peck drilling if needed).
# Deburr hole edges after drilling.

=== Peck Drilling ===

* Drill in small increments, backing out between each peck to clear chips and reduce heat.
* Essential for '''deep holes''' or materials like aluminum that tend to clog flutes.

=== Backing Material ===

* When drilling through workpieces (especially sheet), place a '''backing board''' underneath to reduce burrs and protect the table.

== Best Practices ==

=== ✅ DO's ===

* Use the correct '''speed and feed''' for your material and bit.
* Always '''clamp the workpiece''' securely.
* Apply '''cutting fluid''' when drilling metal (except cast iron).
* '''Start with a center drill''' or spot drill for accuracy.
* Use '''sharp bits'''—dull tools cause heat and inaccuracy.

=== ❌ DON'Ts ===

* Don’t drill without '''marking or center punching'''.
* Don’t use '''excessive pressure'''—let the bit do the work.
* Don’t use '''wood bits on metal''' or vice versa.
* Don’t '''force a dull or undersized bit''' into a hole to "open it up"—use a reamer or the correct size instead.
* Don’t forget to '''clear chips'''—especially on deep holes.

File:DSC01948-min.webp

2025-07-21T15:52:05Z

Benrundle:

Center Punch

File:Types-of-Drill-Bits.webp

2025-07-21T15:47:54Z

Benrundle:

Types of Drill Bits

File:Types-of-Drill-Bits-Black-Oxide-Titanium-Cobalt.jpg

2025-07-21T15:46:30Z

Benrundle:

Drill Bits

Item:Q32

2025-07-21T15:19:33Z

Benrundle: /* clientsitelink-remove:1||en */ Manufacturing technologies

The Brunsfield Center/Manufacturing Technologies/Mill/Milling Operations

2025-07-21T14:52:31Z

Benrundle:

{{DISPLAYTITLE:Milling Operations}}
There are many different operations that can be done on the mill and with the proper tooling and setup the possibilities are endless.

Coolant is often used when conducting milling operations. See the full [[The Brunsfield Center/Manufacturing Technologies/Coolant|Coolant]] page for info on coolant usage.

=== Climb Milling vs Conventional Milling ===
[[File:Harvey_ConventionalVsClimb_(1).jpg|center|thumb|532x532px]]
Climb vs conventional milling depends on '''which side of the endmill is doing the cutting.''' In climb milling, the cutter rotates against the feed direction, while in conventional milling, the cutter rotates with the feed direction.

Both are valid methods of material removal, however they each have advantages and disadvantages, therefore it is important to understand which is being done for troubleshooting reasons.

==== Climb Milling: ====
The tool enters the cut with a thick chip and gradually reduces chip thickness as it moves through the material.

Benefits: Better surface finish, less vibration, less tool wear, more control over the cutting process.

Considerations: Requires a rigid setup to prevent displacement and poses the potential for the cutter to pull into the workpiece if not properly controlled.

==== Conventional Milling: ====
The tool enters the cut with a thin chip and gradually increases chip thickness as it moves through the material.

Benefits: Easier to control on machines with backlash, can be beneficial for roughing operations.

Considerations: Can lead to more vibration and may result in a rougher surface finish. Can lead to more tool wear.

=== Face Milling ===
[[File:Ijme4680380-fig-0004-m.jpg|thumb]]
Face milling creates a flat surface perpendicular to the spindle axis—typically the top of a part.

'''How It Works:'''

A flat-bottomed cutter (often a large endmill or a shell mill) spins while the table feeds the part beneath it. The wide cutting area allows large surfaces to be machined quickly.

'''Tips:'''

* Use a wide cutter for even finish across the part
* Keep the Z-depth constant and use the X or Y axis to traverse
* Climb milling may give a better surface finish but requires a rigid setup

'''Common Use Cases:'''

* Squaring up stock
* Removing scale or high spots
* Creating reference surfaces

[[File:Diagram-of-side-milling-process.png|thumb|In this drawing, a<sub>r</sub> refers to the depth of cut and a<sub>s</sub> refers to tool engagement length.]]

=== Side Milling ===
Side milling is used to machine vertical faces along the edges of the part, or to clean up the sides after rough cutting.

'''How It Works:'''

The cutting tool (typically an endmill) removes material from the side of the workpiece as it passes by, using the periphery of the tool.

'''Tips:'''

* Always check tool stick-out: the tool should be long enough, but not excessive
* Use a slow, steady feed rate to reduce chatter
* Lock unused axes for a rigid cut
* Leave a small finishing pass for better surface quality

'''Common Use Cases:'''

* Squaring sides of a block
* Cleaning up saw-cut or rough edges
* Cutting shoulders or steps into a part

[[File:Vertm11.gif|thumb]]

=== 3. Drilling (on the Mill) ===
The mill can effectively be used as larger drill presses that provide more accurate measurements for hole location and depth. See the complete [[The Brunsfield Center/Manufacturing Technologies/Drilling|Drilling]] page for info on various types of drilling and drill bits.

'''How It Works:'''

A drill bit is held in a drill chuck or collet in the spindle. The quill is used to plunge the bit into the part.

'''Tips:'''

* Always center-drill first for accuracy
* Use the DRO to position holes precisely
* Start with slower spindle speeds for larger bits
* Clear chips often to avoid binding
* Peck drilling (lifting the drill periodically) helps chip evacuation

'''Common Use Cases:'''

* Accurate bolt patterns
* Pilot holes for tapping
* Starter holes for reaming or boring
*

=== Boring ===
[[File:Image048.jpg|thumb]]
'''Boring''' is the process of enlarging a hole with a single-point cutting tool to achieve a '''precise diameter, roundness, and surface finish'''. It’s typically used when a drilled hole is close to size but needs to be brought to an exact dimension—or when a hole needs to be aligned concentrically to other features.

Unlike drilling, which is limited by the bit size and can leave rough or oversized holes, boring gives the machinist fine control over '''diameter and finish'''.

==== Tools Used for Boring ====

* '''Boring Head -''' A precision-adjustable tool that mounts in the spindle. The head holds a small boring bar off-center and allows you to dial in cut diameter via a fine adjustment screw.
* '''Boring Bar -''' A small, rigid bar with a single cutting tip—often carbide or HSS—that removes material as it swings in a circular path inside the hole.
* '''Drill or Center Drill (Pre-Step) -''' Used to create a starter hole before boring. Typically, you’ll drill a hole slightly under the final size and then use the boring head to finish it.

==== When to Use Boring ====

* You need a '''hole with precise diameter''', especially for bearings or dowel fits
* You want a '''better surface finish''' than a drill can produce
* You need to '''align a hole perfectly''' relative to other features (e.g. from a pre-bored setup)
* You’re '''correcting an out-of-round or misaligned hole'''
* You’re enlarging a casting hole or rough bore that’s uneven

[[File:Types-of-milling-cutter.jpg|thumb]]

=== Shape Cutting with Form Tools ===
'''Form cutting''' is the process of using a cutter with a '''pre-machined profile''' to impart that shape directly into the workpiece. Rather than generating a curve through toolpaths (like in 3D contouring), the cutter itself is shaped to create the desired geometry—like a rounded edge or fillet.

This is often used to:

* Add a '''radius''' to a part edge
* Cut '''chamfers'''
* Machine decorative or ergonomic features
* Match mating surfaces
* Prep a part for welding or assembly

=== Fly cutting ===
[[File:Miller-new4.gif|thumb]]
'''Fly cutting''' is a technique used to produce a very flat and smooth surface using a single-point cutting tool mounted in a fly cutter body. It’s ideal for creating flat reference surfaces on large parts, cleaning up castings, or squaring up stock that's too wide for standard endmills.

A '''fly cutter''' is a tool holder that spins a single cutting bit around the center of the spindle. The cutting edge sweeps across the workpiece, much like a lathe tool on a rotating part—but in reverse. Most fly cutters use a small HSS tool bit that can be ground to a specific shape or radius depending on the finish desired.

==== When to Use Fly cutting ====

* '''Flattening large surfaces''' wider than your largest endmill
* '''Improving surface finish''' on aluminum, brass, or mild steel
* '''Creating reference faces''' before precision machining
* '''Squaring up rough stock''', especially if it came from a bandsaw or casting

It’s not a fast operation, but it delivers excellent flatness and surface quality—especially on manual mills.

==== Setup and Tips ====

* '''Mount securely''': Insert the fly cutter in an R8 collet or endmill holder. Ensure it spins true with no visible wobble.
* '''Set tool height''': Adjust the cutting bit so it’s exactly on the centerline of the spindle. Too high or low can cause uneven surfaces.
* '''Balance matters''': The cutter sweeps a large arc, so imbalance can cause vibration. Keep the cutting edge close to the center and minimize tool stick-out.
* '''Use low RPMs''': Fly cutters have large effective diameters, so keep spindle speed low—usually 300–600 RPM depending on size and material.

* Set the '''depth of cut shallow'''—around 0.005" to 0.010" per pass is typical.
* Use '''slow, steady feed'''. Too fast a feed or deep a cut will cause chatter or poor finish.
* Lock all unused axes, especially the quill and Y-axis.
* For best results, make multiple light passes rather than one aggressive cut.

The Brunsfield Center/Manufacturing Technologies/Mill

2025-07-21T14:25:46Z

Benrundle:

== Intro ==
[[File:1050VS_93596_00296.jpg|thumb|King Turret-Style Knee mill, as seen in the Brunsfield Center]]
The milling machine—commonly referred to as “the mill”—is one of the most versatile and widely used tools in any machine shop. Unlike a drill press, which cuts only in the vertical axis, a mill allows for precise movement in the X (left/right), Y (forward/back), and Z (up/down) directions, enabling complex and accurate machining operations on a wide range of materials.

Mills remove material using a rotating cutting tool held in a spindle, allowing operators to shape metal and plastic parts with high precision. In our shop, we primarily use vertical knee mills equipped with digital readouts (DROs), allowing for repeatable and accurate setups.

Whether you're facing a part flat, drilling a precise hole, cutting a slot, or using a form tool to create complex geometry, the mill is essential for prototype work, part modification, and precision fabrication.

This guide will walk through how mills work, the operations they can perform, how to choose the right tools, proper setup techniques, and what to watch for during machining.

[https://makerepo.com/jboud030/654.fraiseuse-virtuelle-virtual-mill Virtual Mill Tour]

== How the Mill Works ==
A milling machine operates by rotating a cutting tool (such as an endmill) while moving a workpiece against it. Material is removed through the shearing action of the rotating cutter, allowing for precise shaping of metal, plastic, or other materials.

=== Key Components ===

* '''Spindle'''
** The spindle holds and rotates the cutting tool. It's powered by a motor and can run at various speeds, depending on the material and operation.
* '''Table'''
** The flat surface that holds the workpiece. It can move in the '''X-axis (left/right)''' and '''Y-axis (in/out)'''. Movement is controlled by handwheels or power feeds.
* '''Knee & Column'''
** The knee supports the table and moves vertically along the column, giving the '''Z-axis (up/down)''' motion.
* '''Quill'''
** Found on most vertical mills, the quill allows for vertical movement of the spindle—useful for drilling or plunging into material.
* '''Digital Readout (DRO)'''
** A DRO displays the precise position of the table along each axis. It greatly improves accuracy and efficiency, especially for repetitive work.[[File:690174_main_07610.jpg|thumb|224x224px|The X-axis power feed controller (red box) with a control lever to change feed direction.]]

=== Modes of Movement ===

* '''Manual -''' Most shop mills are manual, meaning the operator turns handwheels to control table motion and spindle feed.
* '''Power Feed -''' Our Brunsfield mills have powered X-axis feeds. These are useful for consistent finish during long cuts like face milling.
* '''Locking Mechanisms -''' Axis locks are used to prevent unwanted movement. It's good practice to lock any axis not in use during a cut.

=== How Cutting Happens ===

* The cutter spins at a selected '''RPM''', chosen based on material, tool diameter, and cutter type.
* The workpiece is moved against the spinning cutter, removing material layer by layer.
* Different cutters and operations (face milling, slotting, drilling, etc.) change how the cut engages the workpiece.
* Chip formation and cutting load depend on feed rate, depth of cut, and cutter geometry.[[File:KbvTvAw.gif|thumb|341x341px|Each pass of the tool cuts a chip of metal from the workpiece.]]

=== Feed & Speed ===

* '''Spindle Speed (RPM)''' affects how fast the cutter rotates. Too fast and you'll burn the cutter; too slow and it may chatter or rub instead of cut.
* '''Feed Rate''' is how fast the workpiece moves into the cutter. It must be matched to the material and tool geometry to ensure clean cutting and tool life.

=== [[The Brunsfield Center/Manufacturing Technologies/Coolant|Coolant]] ===

* While machining, always apply coolant to mitigate heat production, minimize tool wear, and improve surface finish. See the coolant page for more info.

== Quick Start Guide ==

=== Mill Controls ===
[[File:Screenshot_2025-06-09_130753.png|thumb|599x599px]]
[[File:Screenshot_2025-06-09_131028.png|thumb|606x606px]]
The following images show the main controls on the milling machine, their functions are listed below:

# '''On/Off switch''' - Activates the motor on the mill.
# '''Speed Adjustment dial''' - Changes the rpm of the spindle while the mill is running.
# '''High/Low Gear Handle''' - Changes the running speed gear of the mill.
# '''Quill Pilot Feed Lever''' - Lowers & raises the spindle, used for drilling.
# '''Quill lock''' - Locks the spindle in the current position.
# '''Quill power feed''' - Used for fine adjustments of the spindle height.

# '''DRO''' - Displays the current X and Y axis position. Can be set to metric or imperial units.
# '''Vise''' - The vise is bolted to the mill table and holds the workpiece during operation.
# '''Y/X axis feed wheels''' - adjust the X & Y position of the table via clockwise or counterclockwise rotation.
# '''Z-axis knee lever''' - Adjusts the height of the table. Used to set proper working height for an operations. Changing this does not change the Z-axis DRO reading.

== [[The Brunsfield Center/Manufacturing Technologies/Mill/Milling Operations|Milling Operations]] ==
Primary operations on the mill are face milling, side milling, and drilling.

See a full run down of all the milling operations:

[[The Brunsfield Center/Manufacturing Technologies/Mill/Milling Operations|Milling Operations]]

== Indicating ==
Before making any cuts, it's critical to establish a '''working zero'''—a reference point from which all other dimensions are measured. On a milling machine with a digital readout (DRO), this is usually done by locating the edge of your part, or the vise, with an '''edge finder''' and then setting the DRO coordinates accordingly.
[[File:1-855-53062.jpg|thumb|153x153px]]

==== What is an Edge Finder? ====
An '''edge finder''' is a precision tool used to locate the exact edge of a workpiece. When used properly, it can help you zero your X and Y axes within a few thousandths of an inch. Most edge finders have a tip that is '''0.200" in diameter''', meaning it has a radius of '''0.100"'''. The tip of the tool is attached with a magnet, allowing it to move when it contacts your piece while spinning.
[[File:Edge-finder-diagram-hoffman-group.webp|thumb]]

==== Step-by-Step Process ====

# '''Mount the Edge Finder''' - Insert the edge finder into a collet (preferably not a drill cuck for accuracy reasons) and snug it up in the spindle. Make sure your mill is set to a low RPM—between '''800 and 1200''' is ideal.
# '''Knock the Edge Finder off center''' - With your finger, push the tip of the edge finder so that it sits out of line with the rest of the tool
# '''Spin the Edge Finder''' - Start the mill and bring the spinning tip near the part edge. As you feed the part slowly toward the tool, you'll notice the tip wobbles eccentrically.
# '''Touch Off the Edge -''' As you get closer, the tip will suddenly "kick" and run true just before it jumps off. That moment of alignment—right before the jump—is your '''edge contact point'''.
# '''Read the DRO -''' At this point, your tool center is still offset from the actual part edge by '''half the diameter of the edge finder''' (typically 0.100").
# '''Set the Zero -''' Subtract the radius from the current DRO reading. For example, if the edge finder touches off and your DRO reads '''0.000"''', your actual part edge is at -'''0.100"'''.

* Set your '''DRO to -0.100"''', then jog the axis until it reads '''0.000"''', and set this as your zero.
* Repeat the same process for both X and Y edges if you're zeroing from a corner. Once both axes are zeroed, jog to any known feature on the part and verify against your print or CAD model.

`

==== Pro Tips ====

* Always approach from the '''same direction''' you plan to cut—this compensates for backlash.
* Use parallels if your part isn’t sitting directly on the vise bed, and indicate the top surface as your Z zero if needed.
* Don’t forget to lock the axis not in use while touching off for added rigidity.
* If your edge finder tip is chipped or the wobble doesn't go away smoothly, replace it—it’s no longer accurate.

[[File:Endmills.jpg|thumb]]

== Endmills ==
Endmills are the workhorses of the milling machine. These rotary cutters remove material using their flutes, and they come in a wide variety of materials, flute counts, and geometries. Selecting the right endmill affects surface finish, tool life, and cutting efficiency.

=== HSS vs. Carbide Endmills ===
Endmills are commonly made from either '''high-speed steel (HSS)''' or '''carbide'''. HSS tools are inexpensive, relatively tough, and ideal for general-purpose milling, especially at lower spindle speeds. They’re forgiving if the setup isn’t perfect, making them a good choice for students or roughing operations. Carbide endmills, on the other hand, are harder and more wear-resistant, making them ideal for harder materials and high-speed milling. Carbide also provides better finishes and lasts longer, '''but it's more brittle'''—meaning it can chip or snap if misused or dropped. In most teaching shops, you'll use both: HSS for roughing or learning, and carbide when you need precision, high feed rates, or are cutting tougher materials like steel or aluminum alloys.
[[File:Comparision.jpg|thumb|386x386px]]

=== 2-Flute vs. 4-Flute Endmills ===
Flute count has a major impact on how an endmill performs. '''2-flute endmills''' have wider spaces (gullets) between the cutting edges, which means they can clear chips more easily. This makes them ideal for machining softer materials like aluminum, where chip clogging is a concern, and also for slotting operations where chips have nowhere to escape. '''4-flute endmills''' have more cutting edges in contact with the material at once, leading to faster metal removal and smoother surface finishes, especially in harder materials like steel. However, they don’t clear chips as easily and are less ideal for deep slots unless you adjust feed rates and use coolant or air blast. As a general rule: use 2-flutes for aluminum and slotting, and 4-flutes for steel and side milling.

=== Reground vs. New Endmills ===
In a Brunsfield, you’ll likely come across '''reground''' endmills—cutters that have been resharpened to extend their life. Reground tools are great for roughing passes or when surface finish isn’t critical. They’re cheaper and environmentally friendly, but they may be slightly shorter, have worn coatings, or exhibit minor runout. For high-precision features, smoother finishes, or very tight tolerances, it’s best to use '''new endmills''', which have factory-ground edges and full cutting length.
[[File:104770.jpg|thumb|183x183px]]

=== Ball Nose Endmills ===
A '''ball nose endmill''' has a rounded tip rather than a flat one. This geometry is essential for contouring and 3D profiling, such as in molds or sculpted parts. They’re used when you want to avoid sharp inside corners or need to produce a smooth surface on a curved feature. However, they leave a scalloped finish unless stepovers are very fine, and they’re less rigid at the tip, so they’re not ideal for deep cuts. Use them for finishing passes on 3D surfaces or for parts that require smooth transitions.

== Workpiece Holding and Setup ==
Securing both the '''tool''' and the '''workpiece''' properly is essential to accurate, safe, and efficient milling. A loose setup will lead to poor finishes, chatter, and dangerous tool breakage. Here’s a breakdown of the most common equipment used in the shop for setup and holding.

=== Tool Holding: Collets vs. Drill Chucks ===
[[File:Colletsnchucks.jpg|center|thumb|389x389px|(Left) R8 collets of various sizes. (Right) Jacob's chuck for drill bits.]]

==== R8 Collets ====
R8 collets are the standard tool holders in most manual milling machines. They grip the shank of the cutting tool with good concentricity (low runout), making them ideal for endmills, edge finders, and center drills. Each collet size corresponds to a specific tool diameter—so you’ll need to match the collet to your tool shank.

* '''Pros:''' Accurate, secure, low runout
* '''Cons:''' Requires swapping for different shank sizes

==== Drill Chucks ====
Used for holding drill bits or reamers, drill chucks grip the tool with jaws tightened by a chuck key. They're only suitable for '''axial operations''' like drilling. Never use a drill chuck for side milling—cutting forces can pull the tool out or cause slippage.

* '''Pros:''' Quick tool changes, versatile for drilling
* '''Cons:''' Not secure for milling—can slip or wobble

=== Workpiece holding Tools ===

==== Milling Vise ====
The milling vise is the go-to workpiece holding tool in most shops. It clamps your part securely and aligns it square to the machine’s table. The vice uses a removable handle to open and close the jaws. The handle is stored hanging from the table when not in use.

It’s usually bolted down with T-slot hardware. Always check that your part is sitting flat and square in the vise. Indicating the vise to check if it's sitting square can be done using a '''Dial Indicator.''' See the "Maintenance" section.

'''Pro Tip:''' Use a mallet or dead-blow hammer to "seat" your part after snugging the vise but before final tightening.
[[File:Screenshot_2025-06-10_093432.png|center|thumb|617x617px|The mill machine vise is bolted to the table using T-Head bolts and nuts, allowing it be repositioned, or removed easily.]]
[[File:Slot.jpg|thumb|165x165px]]

==== '''Slot Clamping Kit (T-Slot Clamps)''' ====
Used for clamping irregular or oversized parts directly to the mill table. The kit includes step blocks, strap clamps, nuts, bolts, and T-nuts that fit into the machine’s T-slots.

* '''Good For:''' Holding plates, large parts, or when the vise won’t work
* '''Caution:''' Ensure clamps are level and square—uneven clamping can distort the part

=== Setup Aids and Accessories ===

==== Parallels ====
Parallels are precision-ground bars used to elevate a part inside the vise. They ensure that the part sits flat and level, and allow tool clearance below the part (e.g., for through-holes or full-depth slots). Choose a pair that keeps your part slightly above the vise jaws.

* '''Watch out for:''' Chips under the parallels—this will throw off your Z zero!

[[File:Unnamed.png|center|thumb|The parallels (Red) are used to raise the piece in the vise, while also giving it a level surface to sit on.]]
[[File:123-Supporting-Part-IMG_5489.jpg|thumb|In the image above, a 123 block is used to support the free end of a piece to ensure it doesn't deflect under load.]]

==== 123 Blocks ====
Precision-ground steel blocks sized 1" x 2" x 3". They’re used as reference spacers, squaring aids, or even mini angle plates. Can be clamped together or to the table to help with odd setups.

* '''Common Uses:''' Squaring a part in the vise, setting Z-depths, or elevating parts outside the vise

==== Collet Blocks ====
Collet blocks hold round or hex stock using a standard collet, allowing it to be clamped securely in the mill vise. They’re useful when machining multiple flats on round material or performing indexed operations.

* '''Types:''' Square blocks (for 4 sides), hex blocks (for 6 sides)

[[File:Angle.jpg|thumb|151x151px]]
[[File:J3i84pzrepa81.jpg|thumb|141x141px]]

==== Angle Plates ====
Used to hold parts vertically or at 90° angles to the table. Precision-ground and drilled with mounting holes. Often used in combination with clamps or vises to machine edges or ends of tall parts.

* '''Tip:''' Check squareness with an indicator before cutting

[[File:10inchRotaryTable.jpg|thumb|199x199px]]

==== Rotary Table (Turntable) ====
This allows controlled rotation of the part around a vertical axis. It's useful for machining circular patterns, bolt hole arrays, or radii. The table can be indexed manually in degrees or divided using index plates.

* '''Common Uses:''' Cutting arcs, drilling hole circles, machining gears
* '''Note:''' Always lock the axis you’re not using—these setups require careful planning

=== General Setup Tips ===

* '''Always clean mating surfaces''' (table, vise bottom, parallels) to prevent misalignment. Use brushes instead of your hands as chips can be sharp.
* '''Double-check part squareness''' before cutting—tap it down or into the jaws using a soft mallet
* '''Use the smallest clamp/holder that safely gets the job done'''—fewer things in the way means fewer chances for accidents
* '''Lock unused table axes''' when making a cut for better rigidity
* '''Take time with setup'''—the more precise your setup, the less trouble you’ll have during machining

== Monitoring the cut ==

=== Sound: What You're Hearing ===
'''Smooth, consistent hum -''' Ideal. Indicates proper feed/speed and good tool engagement.

'''Light squealing or whining -''' Usually a sign of rubbing instead of cutting—possibly from dull tools, too low feed, or incorrect RPM.

'''Chatter or rhythmic vibrations -''' A telltale sign of tool deflection, loose setups, or excessive stick-out. You'll hear a high-pitched “buzz” or “hammering” noise that worsens as the cut continues. Stop and address it.

'''Clunking or knocking -''' Indicates serious instability—tool looseness, bad bearings, or a poorly clamped part. Stop immediately and inspect.

'''Screaming or howling -''' Often a sign of way too high spindle speed or aggressive cutting with a brittle cutter (e.g., carbide). Check RPM and tool sharpness.

=== Chip Shape and Color ===
[[File:How-To-Judge-the-Processing-Status-by-the-Chips-Colour.jpg|thumb]]
Chips are your best real-time indicator of whether your cutter is performing well.

* '''Consistent, curled chips -''' Ideal. Suggests good chip evacuation and balanced feed/speed.
* '''Tiny dust-like chips -''' Feed too low or tool rubbing instead of cutting.
* '''Blue or black chips -''' Overheating—too much speed or not enough coolant/air. May damage the tool or workpiece.
* '''Long, stringy chips''' (esp. in aluminum) - Feed might be too low. Also risk of chip wrapping around the cutter—clear frequently.
* '''Powdery chips -''' Could indicate abrasive wear on the tool or surface hardening on the material. Dull tools or the wrong cutter for the job.

[[File:Image003.jpg|thumb|Scalloping finish on a CNC machine from momentary tool acceleration.]]

=== Surface Finish and Vibration ===

* '''Smooth finish with uniform texture -''' You’re doing great! Keep everything the same.
* '''Scalloped or ridged finish -''' Usually from too fast feed or tool chatter. May also mean the spindle is loose or the part is vibrating.
* '''Chatter marks (evenly spaced ripples) -''' Tool deflection or mechanical looseness. Check clamping, tool length, and feed speed.
* '''Random gouges or digs -''' Tool might be loose or broken. Shut down and inspect everything.

----

=== Vibration and Machine Feedback ===

* '''Stable, solid feel -''' Good setup. Axes are locked and the machine is working with you.
* '''Mild vibration through the handwheels or table -''' Not ideal—could be cutting too aggressively, or the setup might be slightly loose.
* '''Visible shaking or movement of the part or tool -''' Serious issue. Stop immediately. Recheck clamping, tool stick-out, and speed/feed.
* '''Tool deflection -''' Especially in longer or smaller-diameter tools, the cutter may bend under load, causing undersize cuts or chatter. Use a more rigid setup or adjust depth of cut.

----

=== Operator Intuition: Know the Signs ===

* '''“This sounds smooth and stable.”''' Keep going.
* '''“Something doesn’t feel right, but I can’t see it yet.”''' Trust that instinct—pause and inspect.
* '''“It’s cutting fine, but my finish looks bad.”''' Try lowering the speed or increasing feed slightly (or both).
* '''“The chips are changing color or shape.”''' Reassess your feed/speed and chip evacuation.

== Safety Considerations ==
The milling machine is one of the most powerful and versatile tools in the shop—but with that comes responsibility. Rotating tools, sharp cutters, and heavy parts can cause serious injuries if proper safety practices are not followed. Whether you're new to the machine or an experienced operator, '''safety always comes first'''.

=== PPE ===

* '''Safety Glasses''': Always required. Protects against flying chips or broken tools.
* '''Hearing Protection''': Recommended, especially during long cuts or when using high RPMs.
* '''Non-Synthetic Clothing''': Avoid synthetics that can melt or ignite. Cotton or natural fiber clothing is best.
* '''Closed-Toe Shoes''': Steel-toes are ideal. Never wear sandals or open footwear.
* '''Gloves''': '''Never wear gloves near rotating tools.''' Gloves can catch and pull your hand into the machine.
* '''Hair and Jewelry''': Tie back long hair and remove rings, watches, and dangling jewelry.

=== General Safety Rules ===

# '''Never leave the machine running unattended.''' Always be present and alert when the spindle is on.
# '''Keep the area clean and free of clutter.''' Chips, tools, and loose rags create tripping and entanglement hazards.
# '''Use a brush or chip hook to remove chips.''' Never use your hands, even with gloves.
# '''Always check for tool tightness.''' Ensure the tool is properly seated and tightened in the collet before starting the spindle.
# '''Double-check your setup.''' Loose vises, parallels, or improperly clamped workpieces are a major hazard.
# '''Know where the emergency stop is.''' Be ready to use it.

=== Machine-Specific Hazards ===

* '''Rotating Spindle and Tooling''': Never reach near the cutter when the machine is running. Even a spinning tool that’s "not cutting" is dangerous.
* '''Kickback and Tool Pullout''': Improper tool holding (like using a drill chuck for an endmill) can result in tools being thrown.
* '''Flying Chips and Debris''': Chips can come off hot and fast—use chip shields if available.
* '''Unexpected Movement''': If power feed or DRO is engaged improperly, the table can move quickly—keep hands clear.

=== Common Safety Mistakes to Avoid ===

* Wearing gloves or long sleeves while operating the machine
* Using a drill chuck to hold an endmill
* Leaving the key in the drill chuck
* Reaching over a spinning tool to brush off chips
* Using damaged or dull tooling
* Forgetting to lock the axes before a cut
* Starting the spindle before securing the part
* Not checking spindle direction—some tools will unscrew themselves or cut incorrectly if running backward.

== Maintenance ==
Before performing any accurate milling operation, it’s important to make sure your '''spindle is perpendicular to the table''' (tramming) and your '''vise is aligned parallel to the machine axes''' (indicating). Without these checks, your cuts can end up angled, off-center, or out of spec—even if everything else seems right.

<youtube>PAoWXnyUZ5M</youtube>

Even if the head is trammed, your cuts won’t be square unless the '''vise jaws are parallel to the X-axis travel'''. This process is called '''indicating the vise'''. This process involved placing a '''parallel''' into the vice, and running a dial indicator along its length while taking not of the change in position at each end. If there is significant deviation along the parallel, it tells you that the vice is not sitting square to the table.

<youtube>9VGu_h8q_cQ</youtube>

'''Tramming''' refers to adjusting the mill head so that the spindle is perfectly perpendicular to the table. On manual mills with tilting heads (like Bridgeport-style mills), this is a common maintenance and setup task—especially if the head has been rotated for a previous job.

This process involves comparing the measurement of each dial indicator on the tramming tool at various points on the mill table. This can tell you if the head of the mill needs to be clocked side to side or front & back.

The Brunsfield Center

2025-07-21T14:25:09Z

Benrundle:

== About ==
[[File:Brunsfield Centre - Header.jpg|thumb|505x505px]]
To gain access to the Brunsfield Centre, uOttawa members (students or staff) must first complete training on the equipment at the Manufacturing Training Centre.

We encourage you to come talk to us about what you are trying to build and we will be happy to point you to the appropriate equipment and will help you get trained.

== [[The Brunsfield Center/Using the Shop|Using the Shop]] ==

=== Shop Rules ===
Some general rules for Brunsfield (STM 129):

* All users must complete the [[Manufacturing Training Center/Shop Trainings/Basic Training|Basic Training]] before using any tools or machines in the shop.
* All users must '''Sign-in''' using their MakerRepo account.
* All users must wear '''safety glasses, long pants, and steel toes boots'''. Toe caps and safety glasses are readily available for those who do not have their own.
* '''Stay within your comfort zone!''' Brunsfield staff (wearing orange) are always there to help to get started or answer your questions.
* Always clean up after yourselves and put tools back in their place.

=== Sign-In Process ===
All Brunsfield and MTC users need to sign in & out of the space using their MakerRepo account. This can be linked with a student/employee card, or can be given manually.

There is a '''Tap-Box''' at the front desk of all of the spaces, simply tap your card on the box and once the light turns green, you're good to go.

A staff can help you link you account to a new card, or sign you in without a card.

It is the user's job to make an account on [https://https//makerepo.com/ MakerRepo] before visiting the spaces.

=== Buying Materials ===
Brunsfield keeps stock of various metals and composites that are left of from projects, and can sell them to shop users.

We also have a selection of '''Scrap Materials''' that are in marked bins in Brunsfield. These materials are '''free to use''' for any users.

Everything that is '''For Sale''' lives on the labelled rack at the back of the shop. All of our pricing is determined by our supplier [https://www.metalpros.com/ Metal Pros.]Simply navigate to their website and identify the geometry of the piece you are looking to purchase. Staff can also assist in determining cost of items.

From there, you will be directed to [https://makerstore.ca/ Makerstore] in order to pay for you material. Simply purchase the item "Brunsfield Bars" at whatever quantity is needed to cover your purchase.

Once a staff has confirmed your order, you're all set!

=== Placing an Order ===
Looking to outsource your project? Our skilled team can help by fabricating your parts for you. Contact us for further information.

=== Design Reviews ===

== [[Manufacturing Training Center/Shop Trainings|Shop Trainings]] ==
The following trainings are offered in MTC or Brunsfield. More info can be found on the trainings page.
* [[Manufacturing Training Center/Shop Trainings/Basic Training|Basic Training]]
* [[Manufacturing Training Center/Shop Trainings/Mill Training|Mill Training]]
* [[Manufacturing Training Center/Shop Trainings/Lathe Training|Lathe Training]]
* [[Manufacturing Training Center/Shop Trainings/Welding Safety & MIG Training|Welding Safety & MIG Training]]
* [[Manufacturing Training Center/Shop Trainings/TIG Training|TIG Training]]
* [[Manufacturing Training Center/Shop Trainings/CNC Training|CNC Training]]

== [[The Brunsfield Center/Our Team|Our Team]] ==

== [[The Brunsfield Center/Manufacturing Technologies|Manufacturing Technologies]] ==
Here is a list of the machines, tools, and processes available through the Brunsfield Center. Click on a specific section to learn more.

* [[The Brunsfield Center/Manufacturing Technologies/Mill|Mill]]
* [[The Brunsfield Center/Manufacturing Technologies/Lathe|Lathe]]
* [[The Brunsfield Center/Manufacturing Technologies/Welding|Welding Area]]
** [[The Brunsfield Center/Manufacturing Technologies/Welding/MIG|MIG]]
** [[The Brunsfield Center/Manufacturing Technologies/Welding/TIG|TIG]]
** [[The Brunsfield Center/Manufacturing Technologies/Welding/Stick Welding|Stick]]
** [[The Brunsfield Center/Manufacturing Technologies/Welding/Plasma Cutting|Plasma cutting]]
** [[The Brunsfield Center/Manufacturing Technologies/Grinders|Grinders]]
** [[The Brunsfield Center/Manufacturing Technologies/Welding/Spot Welding|Spot Welder]]
* [[The Brunsfield Center/Manufacturing Technologies/CNC|CNC machinery]]
** [[Manufacturing Training Center/Manufacturing Technologies/CNC Router|CNC Routers]]
** CNC Mills
** CNC Lathes
* [[The Brunsfield Center/Manufacturing Technologies/Vertical Bandsaw|Vertical Band Saw]]
* [[The Brunsfield Center/Manufacturing Technologies/Horizontal Bandsaw|Horizontal Band Saw]]
* [[The Brunsfield Center/Manufacturing Technologies/Drill Press|Drill press]]
* [[The Brunsfield Center/Manufacturing Technologies/Sheet Metal Brake|Sheet Metal Brake]]
* [[The Brunsfield Center/Manufacturing Technologies/Sheet Metal Shear|Sheet Metal Shear]]
* [[The Brunsfield Center/Manufacturing Technologies/Hand Tools|Hand Tools]]

* [[Manufacturing Training Center/The Wood Room|Wood Room]]
** [[Manufacturing Training Center/The Wood Room/Miter Saw|Miter Saw]]
** [[Manufacturing Training Center/The Wood Room/Panel Saw|Panel Saw]]
** [[Manufacturing Training Center/The Wood Room/Circular Saw|Circular Saw (Skillsaw)]]
** [[Manufacturing Training Center/The Wood Room/Jigsaw|Jigsaw]]
[https://makerepo.com/jboud030/651.formation-de-base-virtuelle-virtual-basic-training Virtual basic training]

[https://labs.makerepo.com/lathe/ Virtual Mill tour:]

[https://labs.makerepo.com/lathe/ Virtual Lathe tour:]

The Brunsfield Center

2025-07-21T14:24:36Z

Benrundle:

The Brunsfield Center

2025-07-21T14:23:37Z

Benrundle:

== About ==
[[File:Brunsfield Centre - Header.jpg|thumb|505x505px]]
To gain access to the Brunsfield Centre, uOttawa members (students or staff) must first complete training on the equipment at the Manufacturing Training Centre.

We encourage you to come talk to us about what you are trying to build and we will be happy to point you to the appropriate equipment and will help you get trained.

== [[The Brunsfield Center/Using the Shop|Using the Shop]] ==

=== Shop Rules ===
Some general rules for Brunsfield (STM 129):

* All users must complete the [[Manufacturing Training Center/Shop Trainings/Basic Training|Basic Training]] before using any tools or machines in the shop.
* All users must '''Sign-in''' using their MakerRepo account.
* All users must wear '''safety glasses, long pants, and steel toes boots'''. Toe caps and safety glasses are readily available for those who do not have their own.
* '''Stay within your comfort zone!''' Brunsfield staff (wearing orange) are always there to help to get started or answer your questions.
* Always clean up after yourselves and put tools back in their place.

=== Sign-In Process ===
All Brunsfield and MTC users need to sign in & out of the space using their MakerRepo account. This can be linked with a student/employee card, or can be given manually.

There is a '''Tap-Box''' at the front desk of all of the spaces, simply tap your card on the box and once the light turns green, you're good to go.

A staff can help you link you account to a new card, or sign you in without a card.

It is the user's job to make an account on [https://https//makerepo.com/ MakerRepo] before visiting the spaces.

=== Buying Materials ===
Brunsfield keeps stock of various metals and composites that are left of from projects, and can sell them to shop users.

We also have a selection of '''Scrap Materials''' that are in marked bins in Brunsfield. These materials are '''free to use''' for any users.

Everything that is '''For Sale''' lives on the labelled rack at the back of the shop. All of our pricing is determined by our supplier [https://www.metalpros.com/ Metal Pros.]Simply navigate to their website and identify the geometry of the piece you are looking to purchase. Staff can also assist in determining cost of items.

From there, you will be directed to [https://makerstore.ca/ Makerstore] in order to pay for you material. Simply purchase the item "Brunsfield Bars" at whatever quantity is needed to cover your purchase.

Once a staff has confirmed your order, you're all set!

=== Placing an Order ===
Looking to outsource your project? Our skilled team can help by fabricating your parts for you. Contact us for further information.

=== Design Reviews ===

== [[Manufacturing Training Center/Shop Trainings|Shop Trainings]] ==
The following trainings are offered in MTC or Brunsfield. More info can be found on the trainings page.
* [[Manufacturing Training Center/Shop Trainings/Basic Training|Basic Training]]
* [[Manufacturing Training Center/Shop Trainings/Mill Training|Mill Training]]
* [[Manufacturing Training Center/Shop Trainings/Lathe Training|Lathe Training]]
* [[Manufacturing Training Center/Shop Trainings/Welding Safety & MIG Training|Welding Safety & MIG Training]]
* [[Manufacturing Training Center/Shop Trainings/TIG Training|TIG Training]]
* [[Manufacturing Training Center/Shop Trainings/CNC Training|CNC Training]]

== [[The Brunsfield Center/Our Team|Our Team]] ==

== [[The Brunsfield Center/Manufacturing Technologies|Manufacturing Technologies]] ==
Here is a list of the machines, tools, and processes available through the Brunsfield Center. Click on a specific section to learn more.

* [[The Brunsfield Center/Manufacturing Technologies/Mill|Mill]]
* [[The Brunsfield Center/Manufacturing Technologies/Lathe|Lathe]]
* [[The Brunsfield Center/Manufacturing Technologies/Welding|Welding Area]]
** [[The Brunsfield Center/Manufacturing Technologies/Welding/MIG|MIG]]
** [[The Brunsfield Center/Manufacturing Technologies/Welding/TIG|TIG]]
** [[The Brunsfield Center/Manufacturing Technologies/Welding/Stick Welding|Stick]]
** [[The Brunsfield Center/Manufacturing Technologies/Welding/Plasma Cutting|Plasma cutting]]
** [[The Brunsfield Center/Manufacturing Technologies/Grinders|Grinders]]
** [[The Brunsfield Center/Manufacturing Technologies/Welding/Spot Welding|Spot Welder]]
* [[The Brunsfield Center/Manufacturing Technologies/CNC|CNC machinery]]
** [[Manufacturing Training Center/Manufacturing Technologies/CNC Router|CNC Routers]]
** CNC Mills
** CNC Lathes
* [[The Brunsfield Center/Manufacturing Technologies/Vertical Bandsaw|Vertical Band Saw]]
* [[The Brunsfield Center/Manufacturing Technologies/Horizontal Bandsaw|Horizontal Band Saw]]
* [[The Brunsfield Center/Manufacturing Technologies/Drill Press|Drill press]]
* [[The Brunsfield Center/Manufacturing Technologies/Sheet Metal Brake|Sheet Metal Brake]]
* [[The Brunsfield Center/Manufacturing Technologies/Sheet Metal Shear|Sheet Metal Shear]]
* [[The Brunsfield Center/Manufacturing Technologies/Hand Tools|Hand Tools]]

* [[Manufacturing Training Center/The Wood Room|Wood Room]]
** [[Manufacturing Training Center/The Wood Room/Miter Saw|Miter Saw]]
** [[Manufacturing Training Center/The Wood Room/Panel Saw|Panel Saw]]
** [[Manufacturing Training Center/The Wood Room/Circular Saw|Circular Saw (Skillsaw)]]
** [[Manufacturing Training Center/The Wood Room/Jigsaw|Jigsaw]]
[https://makerepo.com/jboud030/651.formation-de-base-virtuelle-virtual-basic-training Virtual basic training]

[https://labs.makerepo.com/mill/ Virtual Mill tour:]

[https://makerepo.com/jboud030/655.tour-virtuel-virtual-lathe Virtual Lathe tour:]

The Brunsfield Center/Manufacturing Technologies/Mill

2025-07-21T14:22:45Z

Benrundle:

== Intro ==
[[File:1050VS_93596_00296.jpg|thumb|King Turret-Style Knee mill, as seen in the Brunsfield Center]]
The milling machine—commonly referred to as “the mill”—is one of the most versatile and widely used tools in any machine shop. Unlike a drill press, which cuts only in the vertical axis, a mill allows for precise movement in the X (left/right), Y (forward/back), and Z (up/down) directions, enabling complex and accurate machining operations on a wide range of materials.

Mills remove material using a rotating cutting tool held in a spindle, allowing operators to shape metal and plastic parts with high precision. In our shop, we primarily use vertical knee mills equipped with digital readouts (DROs), allowing for repeatable and accurate setups.

Whether you're facing a part flat, drilling a precise hole, cutting a slot, or using a form tool to create complex geometry, the mill is essential for prototype work, part modification, and precision fabrication.

This guide will walk through how mills work, the operations they can perform, how to choose the right tools, proper setup techniques, and what to watch for during machining.

[https://labs.makerepo.com/mill/ Virtual Mill Tour]

== How the Mill Works ==
A milling machine operates by rotating a cutting tool (such as an endmill) while moving a workpiece against it. Material is removed through the shearing action of the rotating cutter, allowing for precise shaping of metal, plastic, or other materials.

=== Key Components ===

* '''Spindle'''
** The spindle holds and rotates the cutting tool. It's powered by a motor and can run at various speeds, depending on the material and operation.
* '''Table'''
** The flat surface that holds the workpiece. It can move in the '''X-axis (left/right)''' and '''Y-axis (in/out)'''. Movement is controlled by handwheels or power feeds.
* '''Knee & Column'''
** The knee supports the table and moves vertically along the column, giving the '''Z-axis (up/down)''' motion.
* '''Quill'''
** Found on most vertical mills, the quill allows for vertical movement of the spindle—useful for drilling or plunging into material.
* '''Digital Readout (DRO)'''
** A DRO displays the precise position of the table along each axis. It greatly improves accuracy and efficiency, especially for repetitive work.[[File:690174_main_07610.jpg|thumb|224x224px|The X-axis power feed controller (red box) with a control lever to change feed direction.]]

=== Modes of Movement ===

* '''Manual -''' Most shop mills are manual, meaning the operator turns handwheels to control table motion and spindle feed.
* '''Power Feed -''' Our Brunsfield mills have powered X-axis feeds. These are useful for consistent finish during long cuts like face milling.
* '''Locking Mechanisms -''' Axis locks are used to prevent unwanted movement. It's good practice to lock any axis not in use during a cut.

=== How Cutting Happens ===

* The cutter spins at a selected '''RPM''', chosen based on material, tool diameter, and cutter type.
* The workpiece is moved against the spinning cutter, removing material layer by layer.
* Different cutters and operations (face milling, slotting, drilling, etc.) change how the cut engages the workpiece.
* Chip formation and cutting load depend on feed rate, depth of cut, and cutter geometry.[[File:KbvTvAw.gif|thumb|341x341px|Each pass of the tool cuts a chip of metal from the workpiece.]]

=== Feed & Speed ===

* '''Spindle Speed (RPM)''' affects how fast the cutter rotates. Too fast and you'll burn the cutter; too slow and it may chatter or rub instead of cut.
* '''Feed Rate''' is how fast the workpiece moves into the cutter. It must be matched to the material and tool geometry to ensure clean cutting and tool life.

=== [[The Brunsfield Center/Manufacturing Technologies/Coolant|Coolant]] ===

* While machining, always apply coolant to mitigate heat production, minimize tool wear, and improve surface finish. See the coolant page for more info.

== Quick Start Guide ==

=== Mill Controls ===
[[File:Screenshot_2025-06-09_130753.png|thumb|599x599px]]
[[File:Screenshot_2025-06-09_131028.png|thumb|606x606px]]
The following images show the main controls on the milling machine, their functions are listed below:

# '''On/Off switch''' - Activates the motor on the mill.
# '''Speed Adjustment dial''' - Changes the rpm of the spindle while the mill is running.
# '''High/Low Gear Handle''' - Changes the running speed gear of the mill.
# '''Quill Pilot Feed Lever''' - Lowers & raises the spindle, used for drilling.
# '''Quill lock''' - Locks the spindle in the current position.
# '''Quill power feed''' - Used for fine adjustments of the spindle height.

# '''DRO''' - Displays the current X and Y axis position. Can be set to metric or imperial units.
# '''Vise''' - The vise is bolted to the mill table and holds the workpiece during operation.
# '''Y/X axis feed wheels''' - adjust the X & Y position of the table via clockwise or counterclockwise rotation.
# '''Z-axis knee lever''' - Adjusts the height of the table. Used to set proper working height for an operations. Changing this does not change the Z-axis DRO reading.

== [[The Brunsfield Center/Manufacturing Technologies/Mill/Milling Operations|Milling Operations]] ==
Primary operations on the mill are face milling, side milling, and drilling.

See a full run down of all the milling operations:

[[The Brunsfield Center/Manufacturing Technologies/Mill/Milling Operations|Milling Operations]]

== Indicating ==
Before making any cuts, it's critical to establish a '''working zero'''—a reference point from which all other dimensions are measured. On a milling machine with a digital readout (DRO), this is usually done by locating the edge of your part, or the vise, with an '''edge finder''' and then setting the DRO coordinates accordingly.
[[File:1-855-53062.jpg|thumb|153x153px]]

==== What is an Edge Finder? ====
An '''edge finder''' is a precision tool used to locate the exact edge of a workpiece. When used properly, it can help you zero your X and Y axes within a few thousandths of an inch. Most edge finders have a tip that is '''0.200" in diameter''', meaning it has a radius of '''0.100"'''. The tip of the tool is attached with a magnet, allowing it to move when it contacts your piece while spinning.
[[File:Edge-finder-diagram-hoffman-group.webp|thumb]]

==== Step-by-Step Process ====

# '''Mount the Edge Finder''' - Insert the edge finder into a collet (preferably not a drill cuck for accuracy reasons) and snug it up in the spindle. Make sure your mill is set to a low RPM—between '''800 and 1200''' is ideal.
# '''Knock the Edge Finder off center''' - With your finger, push the tip of the edge finder so that it sits out of line with the rest of the tool
# '''Spin the Edge Finder''' - Start the mill and bring the spinning tip near the part edge. As you feed the part slowly toward the tool, you'll notice the tip wobbles eccentrically.
# '''Touch Off the Edge -''' As you get closer, the tip will suddenly "kick" and run true just before it jumps off. That moment of alignment—right before the jump—is your '''edge contact point'''.
# '''Read the DRO -''' At this point, your tool center is still offset from the actual part edge by '''half the diameter of the edge finder''' (typically 0.100").
# '''Set the Zero -''' Subtract the radius from the current DRO reading. For example, if the edge finder touches off and your DRO reads '''0.000"''', your actual part edge is at -'''0.100"'''.

* Set your '''DRO to -0.100"''', then jog the axis until it reads '''0.000"''', and set this as your zero.
* Repeat the same process for both X and Y edges if you're zeroing from a corner. Once both axes are zeroed, jog to any known feature on the part and verify against your print or CAD model.

`

==== Pro Tips ====

* Always approach from the '''same direction''' you plan to cut—this compensates for backlash.
* Use parallels if your part isn’t sitting directly on the vise bed, and indicate the top surface as your Z zero if needed.
* Don’t forget to lock the axis not in use while touching off for added rigidity.
* If your edge finder tip is chipped or the wobble doesn't go away smoothly, replace it—it’s no longer accurate.

[[File:Endmills.jpg|thumb]]

== Endmills ==
Endmills are the workhorses of the milling machine. These rotary cutters remove material using their flutes, and they come in a wide variety of materials, flute counts, and geometries. Selecting the right endmill affects surface finish, tool life, and cutting efficiency.

=== HSS vs. Carbide Endmills ===
Endmills are commonly made from either '''high-speed steel (HSS)''' or '''carbide'''. HSS tools are inexpensive, relatively tough, and ideal for general-purpose milling, especially at lower spindle speeds. They’re forgiving if the setup isn’t perfect, making them a good choice for students or roughing operations. Carbide endmills, on the other hand, are harder and more wear-resistant, making them ideal for harder materials and high-speed milling. Carbide also provides better finishes and lasts longer, '''but it's more brittle'''—meaning it can chip or snap if misused or dropped. In most teaching shops, you'll use both: HSS for roughing or learning, and carbide when you need precision, high feed rates, or are cutting tougher materials like steel or aluminum alloys.
[[File:Comparision.jpg|thumb|386x386px]]

=== 2-Flute vs. 4-Flute Endmills ===
Flute count has a major impact on how an endmill performs. '''2-flute endmills''' have wider spaces (gullets) between the cutting edges, which means they can clear chips more easily. This makes them ideal for machining softer materials like aluminum, where chip clogging is a concern, and also for slotting operations where chips have nowhere to escape. '''4-flute endmills''' have more cutting edges in contact with the material at once, leading to faster metal removal and smoother surface finishes, especially in harder materials like steel. However, they don’t clear chips as easily and are less ideal for deep slots unless you adjust feed rates and use coolant or air blast. As a general rule: use 2-flutes for aluminum and slotting, and 4-flutes for steel and side milling.

=== Reground vs. New Endmills ===
In a Brunsfield, you’ll likely come across '''reground''' endmills—cutters that have been resharpened to extend their life. Reground tools are great for roughing passes or when surface finish isn’t critical. They’re cheaper and environmentally friendly, but they may be slightly shorter, have worn coatings, or exhibit minor runout. For high-precision features, smoother finishes, or very tight tolerances, it’s best to use '''new endmills''', which have factory-ground edges and full cutting length.
[[File:104770.jpg|thumb|183x183px]]

=== Ball Nose Endmills ===
A '''ball nose endmill''' has a rounded tip rather than a flat one. This geometry is essential for contouring and 3D profiling, such as in molds or sculpted parts. They’re used when you want to avoid sharp inside corners or need to produce a smooth surface on a curved feature. However, they leave a scalloped finish unless stepovers are very fine, and they’re less rigid at the tip, so they’re not ideal for deep cuts. Use them for finishing passes on 3D surfaces or for parts that require smooth transitions.

== Workpiece Holding and Setup ==
Securing both the '''tool''' and the '''workpiece''' properly is essential to accurate, safe, and efficient milling. A loose setup will lead to poor finishes, chatter, and dangerous tool breakage. Here’s a breakdown of the most common equipment used in the shop for setup and holding.

=== Tool Holding: Collets vs. Drill Chucks ===
[[File:Colletsnchucks.jpg|center|thumb|389x389px|(Left) R8 collets of various sizes. (Right) Jacob's chuck for drill bits.]]

==== R8 Collets ====
R8 collets are the standard tool holders in most manual milling machines. They grip the shank of the cutting tool with good concentricity (low runout), making them ideal for endmills, edge finders, and center drills. Each collet size corresponds to a specific tool diameter—so you’ll need to match the collet to your tool shank.

* '''Pros:''' Accurate, secure, low runout
* '''Cons:''' Requires swapping for different shank sizes

==== Drill Chucks ====
Used for holding drill bits or reamers, drill chucks grip the tool with jaws tightened by a chuck key. They're only suitable for '''axial operations''' like drilling. Never use a drill chuck for side milling—cutting forces can pull the tool out or cause slippage.

* '''Pros:''' Quick tool changes, versatile for drilling
* '''Cons:''' Not secure for milling—can slip or wobble

=== Workpiece holding Tools ===

==== Milling Vise ====
The milling vise is the go-to workpiece holding tool in most shops. It clamps your part securely and aligns it square to the machine’s table. The vice uses a removable handle to open and close the jaws. The handle is stored hanging from the table when not in use.

It’s usually bolted down with T-slot hardware. Always check that your part is sitting flat and square in the vise. Indicating the vise to check if it's sitting square can be done using a '''Dial Indicator.''' See the "Maintenance" section.

'''Pro Tip:''' Use a mallet or dead-blow hammer to "seat" your part after snugging the vise but before final tightening.
[[File:Screenshot_2025-06-10_093432.png|center|thumb|617x617px|The mill machine vise is bolted to the table using T-Head bolts and nuts, allowing it be repositioned, or removed easily.]]
[[File:Slot.jpg|thumb|165x165px]]

==== '''Slot Clamping Kit (T-Slot Clamps)''' ====
Used for clamping irregular or oversized parts directly to the mill table. The kit includes step blocks, strap clamps, nuts, bolts, and T-nuts that fit into the machine’s T-slots.

* '''Good For:''' Holding plates, large parts, or when the vise won’t work
* '''Caution:''' Ensure clamps are level and square—uneven clamping can distort the part

=== Setup Aids and Accessories ===

==== Parallels ====
Parallels are precision-ground bars used to elevate a part inside the vise. They ensure that the part sits flat and level, and allow tool clearance below the part (e.g., for through-holes or full-depth slots). Choose a pair that keeps your part slightly above the vise jaws.

* '''Watch out for:''' Chips under the parallels—this will throw off your Z zero!

[[File:Unnamed.png|center|thumb|The parallels (Red) are used to raise the piece in the vise, while also giving it a level surface to sit on.]]
[[File:123-Supporting-Part-IMG_5489.jpg|thumb|In the image above, a 123 block is used to support the free end of a piece to ensure it doesn't deflect under load.]]

==== 123 Blocks ====
Precision-ground steel blocks sized 1" x 2" x 3". They’re used as reference spacers, squaring aids, or even mini angle plates. Can be clamped together or to the table to help with odd setups.

* '''Common Uses:''' Squaring a part in the vise, setting Z-depths, or elevating parts outside the vise

==== Collet Blocks ====
Collet blocks hold round or hex stock using a standard collet, allowing it to be clamped securely in the mill vise. They’re useful when machining multiple flats on round material or performing indexed operations.

* '''Types:''' Square blocks (for 4 sides), hex blocks (for 6 sides)

[[File:Angle.jpg|thumb|151x151px]]
[[File:J3i84pzrepa81.jpg|thumb|141x141px]]

==== Angle Plates ====
Used to hold parts vertically or at 90° angles to the table. Precision-ground and drilled with mounting holes. Often used in combination with clamps or vises to machine edges or ends of tall parts.

* '''Tip:''' Check squareness with an indicator before cutting

[[File:10inchRotaryTable.jpg|thumb|199x199px]]

==== Rotary Table (Turntable) ====
This allows controlled rotation of the part around a vertical axis. It's useful for machining circular patterns, bolt hole arrays, or radii. The table can be indexed manually in degrees or divided using index plates.

* '''Common Uses:''' Cutting arcs, drilling hole circles, machining gears
* '''Note:''' Always lock the axis you’re not using—these setups require careful planning

=== General Setup Tips ===

* '''Always clean mating surfaces''' (table, vise bottom, parallels) to prevent misalignment. Use brushes instead of your hands as chips can be sharp.
* '''Double-check part squareness''' before cutting—tap it down or into the jaws using a soft mallet
* '''Use the smallest clamp/holder that safely gets the job done'''—fewer things in the way means fewer chances for accidents
* '''Lock unused table axes''' when making a cut for better rigidity
* '''Take time with setup'''—the more precise your setup, the less trouble you’ll have during machining

== Monitoring the cut ==

=== Sound: What You're Hearing ===
'''Smooth, consistent hum -''' Ideal. Indicates proper feed/speed and good tool engagement.

'''Light squealing or whining -''' Usually a sign of rubbing instead of cutting—possibly from dull tools, too low feed, or incorrect RPM.

'''Chatter or rhythmic vibrations -''' A telltale sign of tool deflection, loose setups, or excessive stick-out. You'll hear a high-pitched “buzz” or “hammering” noise that worsens as the cut continues. Stop and address it.

'''Clunking or knocking -''' Indicates serious instability—tool looseness, bad bearings, or a poorly clamped part. Stop immediately and inspect.

'''Screaming or howling -''' Often a sign of way too high spindle speed or aggressive cutting with a brittle cutter (e.g., carbide). Check RPM and tool sharpness.

=== Chip Shape and Color ===
[[File:How-To-Judge-the-Processing-Status-by-the-Chips-Colour.jpg|thumb]]
Chips are your best real-time indicator of whether your cutter is performing well.

* '''Consistent, curled chips -''' Ideal. Suggests good chip evacuation and balanced feed/speed.
* '''Tiny dust-like chips -''' Feed too low or tool rubbing instead of cutting.
* '''Blue or black chips -''' Overheating—too much speed or not enough coolant/air. May damage the tool or workpiece.
* '''Long, stringy chips''' (esp. in aluminum) - Feed might be too low. Also risk of chip wrapping around the cutter—clear frequently.
* '''Powdery chips -''' Could indicate abrasive wear on the tool or surface hardening on the material. Dull tools or the wrong cutter for the job.

[[File:Image003.jpg|thumb|Scalloping finish on a CNC machine from momentary tool acceleration.]]

=== Surface Finish and Vibration ===

* '''Smooth finish with uniform texture -''' You’re doing great! Keep everything the same.
* '''Scalloped or ridged finish -''' Usually from too fast feed or tool chatter. May also mean the spindle is loose or the part is vibrating.
* '''Chatter marks (evenly spaced ripples) -''' Tool deflection or mechanical looseness. Check clamping, tool length, and feed speed.
* '''Random gouges or digs -''' Tool might be loose or broken. Shut down and inspect everything.

----

=== Vibration and Machine Feedback ===

* '''Stable, solid feel -''' Good setup. Axes are locked and the machine is working with you.
* '''Mild vibration through the handwheels or table -''' Not ideal—could be cutting too aggressively, or the setup might be slightly loose.
* '''Visible shaking or movement of the part or tool -''' Serious issue. Stop immediately. Recheck clamping, tool stick-out, and speed/feed.
* '''Tool deflection -''' Especially in longer or smaller-diameter tools, the cutter may bend under load, causing undersize cuts or chatter. Use a more rigid setup or adjust depth of cut.

----

=== Operator Intuition: Know the Signs ===

* '''“This sounds smooth and stable.”''' Keep going.
* '''“Something doesn’t feel right, but I can’t see it yet.”''' Trust that instinct—pause and inspect.
* '''“It’s cutting fine, but my finish looks bad.”''' Try lowering the speed or increasing feed slightly (or both).
* '''“The chips are changing color or shape.”''' Reassess your feed/speed and chip evacuation.

== Safety Considerations ==
The milling machine is one of the most powerful and versatile tools in the shop—but with that comes responsibility. Rotating tools, sharp cutters, and heavy parts can cause serious injuries if proper safety practices are not followed. Whether you're new to the machine or an experienced operator, '''safety always comes first'''.

=== PPE ===

* '''Safety Glasses''': Always required. Protects against flying chips or broken tools.
* '''Hearing Protection''': Recommended, especially during long cuts or when using high RPMs.
* '''Non-Synthetic Clothing''': Avoid synthetics that can melt or ignite. Cotton or natural fiber clothing is best.
* '''Closed-Toe Shoes''': Steel-toes are ideal. Never wear sandals or open footwear.
* '''Gloves''': '''Never wear gloves near rotating tools.''' Gloves can catch and pull your hand into the machine.
* '''Hair and Jewelry''': Tie back long hair and remove rings, watches, and dangling jewelry.

=== General Safety Rules ===

# '''Never leave the machine running unattended.''' Always be present and alert when the spindle is on.
# '''Keep the area clean and free of clutter.''' Chips, tools, and loose rags create tripping and entanglement hazards.
# '''Use a brush or chip hook to remove chips.''' Never use your hands, even with gloves.
# '''Always check for tool tightness.''' Ensure the tool is properly seated and tightened in the collet before starting the spindle.
# '''Double-check your setup.''' Loose vises, parallels, or improperly clamped workpieces are a major hazard.
# '''Know where the emergency stop is.''' Be ready to use it.

=== Machine-Specific Hazards ===

* '''Rotating Spindle and Tooling''': Never reach near the cutter when the machine is running. Even a spinning tool that’s "not cutting" is dangerous.
* '''Kickback and Tool Pullout''': Improper tool holding (like using a drill chuck for an endmill) can result in tools being thrown.
* '''Flying Chips and Debris''': Chips can come off hot and fast—use chip shields if available.
* '''Unexpected Movement''': If power feed or DRO is engaged improperly, the table can move quickly—keep hands clear.

=== Common Safety Mistakes to Avoid ===

* Wearing gloves or long sleeves while operating the machine
* Using a drill chuck to hold an endmill
* Leaving the key in the drill chuck
* Reaching over a spinning tool to brush off chips
* Using damaged or dull tooling
* Forgetting to lock the axes before a cut
* Starting the spindle before securing the part
* Not checking spindle direction—some tools will unscrew themselves or cut incorrectly if running backward.

== Maintenance ==
Before performing any accurate milling operation, it’s important to make sure your '''spindle is perpendicular to the table''' (tramming) and your '''vise is aligned parallel to the machine axes''' (indicating). Without these checks, your cuts can end up angled, off-center, or out of spec—even if everything else seems right.

<youtube>PAoWXnyUZ5M</youtube>

Even if the head is trammed, your cuts won’t be square unless the '''vise jaws are parallel to the X-axis travel'''. This process is called '''indicating the vise'''. This process involved placing a '''parallel''' into the vice, and running a dial indicator along its length while taking not of the change in position at each end. If there is significant deviation along the parallel, it tells you that the vice is not sitting square to the table.

<youtube>9VGu_h8q_cQ</youtube>

'''Tramming''' refers to adjusting the mill head so that the spindle is perfectly perpendicular to the table. On manual mills with tilting heads (like Bridgeport-style mills), this is a common maintenance and setup task—especially if the head has been rotated for a previous job.

This process involves comparing the measurement of each dial indicator on the tramming tool at various points on the mill table. This can tell you if the head of the mill needs to be clocked side to side or front & back.

The Brunsfield Center/Manufacturing Technologies/Mill

2025-07-21T14:21:54Z

Benrundle:

== Intro ==
[[File:1050VS_93596_00296.jpg|thumb|King Turret-Style Knee mill, as seen in the Brunsfield Center]]
The milling machine—commonly referred to as “the mill”—is one of the most versatile and widely used tools in any machine shop. Unlike a drill press, which cuts only in the vertical axis, a mill allows for precise movement in the X (left/right), Y (forward/back), and Z (up/down) directions, enabling complex and accurate machining operations on a wide range of materials.

Mills remove material using a rotating cutting tool held in a spindle, allowing operators to shape metal and plastic parts with high precision. In our shop, we primarily use vertical knee mills equipped with digital readouts (DROs), allowing for repeatable and accurate setups.

Whether you're facing a part flat, drilling a precise hole, cutting a slot, or using a form tool to create complex geometry, the mill is essential for prototype work, part modification, and precision fabrication.

This guide will walk through how mills work, the operations they can perform, how to choose the right tools, proper setup techniques, and what to watch for during machining.

[https://makerepo.com/jboud030/654.fraiseuse-virtuelle-virtual-mill Virtual Mill tour:]

== How the Mill Works ==
A milling machine operates by rotating a cutting tool (such as an endmill) while moving a workpiece against it. Material is removed through the shearing action of the rotating cutter, allowing for precise shaping of metal, plastic, or other materials.

=== Key Components ===

* '''Spindle'''
** The spindle holds and rotates the cutting tool. It's powered by a motor and can run at various speeds, depending on the material and operation.
* '''Table'''
** The flat surface that holds the workpiece. It can move in the '''X-axis (left/right)''' and '''Y-axis (in/out)'''. Movement is controlled by handwheels or power feeds.
* '''Knee & Column'''
** The knee supports the table and moves vertically along the column, giving the '''Z-axis (up/down)''' motion.
* '''Quill'''
** Found on most vertical mills, the quill allows for vertical movement of the spindle—useful for drilling or plunging into material.
* '''Digital Readout (DRO)'''
** A DRO displays the precise position of the table along each axis. It greatly improves accuracy and efficiency, especially for repetitive work.[[File:690174_main_07610.jpg|thumb|224x224px|The X-axis power feed controller (red box) with a control lever to change feed direction.]]

=== Modes of Movement ===

* '''Manual -''' Most shop mills are manual, meaning the operator turns handwheels to control table motion and spindle feed.
* '''Power Feed -''' Our Brunsfield mills have powered X-axis feeds. These are useful for consistent finish during long cuts like face milling.
* '''Locking Mechanisms -''' Axis locks are used to prevent unwanted movement. It's good practice to lock any axis not in use during a cut.

=== How Cutting Happens ===

* The cutter spins at a selected '''RPM''', chosen based on material, tool diameter, and cutter type.
* The workpiece is moved against the spinning cutter, removing material layer by layer.
* Different cutters and operations (face milling, slotting, drilling, etc.) change how the cut engages the workpiece.
* Chip formation and cutting load depend on feed rate, depth of cut, and cutter geometry.[[File:KbvTvAw.gif|thumb|341x341px|Each pass of the tool cuts a chip of metal from the workpiece.]]

=== Feed & Speed ===

* '''Spindle Speed (RPM)''' affects how fast the cutter rotates. Too fast and you'll burn the cutter; too slow and it may chatter or rub instead of cut.
* '''Feed Rate''' is how fast the workpiece moves into the cutter. It must be matched to the material and tool geometry to ensure clean cutting and tool life.

=== [[The Brunsfield Center/Manufacturing Technologies/Coolant|Coolant]] ===

* While machining, always apply coolant to mitigate heat production, minimize tool wear, and improve surface finish. See the coolant page for more info.

== Quick Start Guide ==

=== Mill Controls ===
[[File:Screenshot_2025-06-09_130753.png|thumb|599x599px]]
[[File:Screenshot_2025-06-09_131028.png|thumb|606x606px]]
The following images show the main controls on the milling machine, their functions are listed below:

# '''On/Off switch''' - Activates the motor on the mill.
# '''Speed Adjustment dial''' - Changes the rpm of the spindle while the mill is running.
# '''High/Low Gear Handle''' - Changes the running speed gear of the mill.
# '''Quill Pilot Feed Lever''' - Lowers & raises the spindle, used for drilling.
# '''Quill lock''' - Locks the spindle in the current position.
# '''Quill power feed''' - Used for fine adjustments of the spindle height.

# '''DRO''' - Displays the current X and Y axis position. Can be set to metric or imperial units.
# '''Vise''' - The vise is bolted to the mill table and holds the workpiece during operation.
# '''Y/X axis feed wheels''' - adjust the X & Y position of the table via clockwise or counterclockwise rotation.
# '''Z-axis knee lever''' - Adjusts the height of the table. Used to set proper working height for an operations. Changing this does not change the Z-axis DRO reading.

== [[The Brunsfield Center/Manufacturing Technologies/Mill/Milling Operations|Milling Operations]] ==
Primary operations on the mill are face milling, side milling, and drilling.

See a full run down of all the milling operations:

[[The Brunsfield Center/Manufacturing Technologies/Mill/Milling Operations|Milling Operations]]

== Indicating ==
Before making any cuts, it's critical to establish a '''working zero'''—a reference point from which all other dimensions are measured. On a milling machine with a digital readout (DRO), this is usually done by locating the edge of your part, or the vise, with an '''edge finder''' and then setting the DRO coordinates accordingly.
[[File:1-855-53062.jpg|thumb|153x153px]]

==== What is an Edge Finder? ====
An '''edge finder''' is a precision tool used to locate the exact edge of a workpiece. When used properly, it can help you zero your X and Y axes within a few thousandths of an inch. Most edge finders have a tip that is '''0.200" in diameter''', meaning it has a radius of '''0.100"'''. The tip of the tool is attached with a magnet, allowing it to move when it contacts your piece while spinning.
[[File:Edge-finder-diagram-hoffman-group.webp|thumb]]

==== Step-by-Step Process ====

# '''Mount the Edge Finder''' - Insert the edge finder into a collet (preferably not a drill cuck for accuracy reasons) and snug it up in the spindle. Make sure your mill is set to a low RPM—between '''800 and 1200''' is ideal.
# '''Knock the Edge Finder off center''' - With your finger, push the tip of the edge finder so that it sits out of line with the rest of the tool
# '''Spin the Edge Finder''' - Start the mill and bring the spinning tip near the part edge. As you feed the part slowly toward the tool, you'll notice the tip wobbles eccentrically.
# '''Touch Off the Edge -''' As you get closer, the tip will suddenly "kick" and run true just before it jumps off. That moment of alignment—right before the jump—is your '''edge contact point'''.
# '''Read the DRO -''' At this point, your tool center is still offset from the actual part edge by '''half the diameter of the edge finder''' (typically 0.100").
# '''Set the Zero -''' Subtract the radius from the current DRO reading. For example, if the edge finder touches off and your DRO reads '''0.000"''', your actual part edge is at -'''0.100"'''.

* Set your '''DRO to -0.100"''', then jog the axis until it reads '''0.000"''', and set this as your zero.
* Repeat the same process for both X and Y edges if you're zeroing from a corner. Once both axes are zeroed, jog to any known feature on the part and verify against your print or CAD model.

`

==== Pro Tips ====

* Always approach from the '''same direction''' you plan to cut—this compensates for backlash.
* Use parallels if your part isn’t sitting directly on the vise bed, and indicate the top surface as your Z zero if needed.
* Don’t forget to lock the axis not in use while touching off for added rigidity.
* If your edge finder tip is chipped or the wobble doesn't go away smoothly, replace it—it’s no longer accurate.

[[File:Endmills.jpg|thumb]]

== Endmills ==
Endmills are the workhorses of the milling machine. These rotary cutters remove material using their flutes, and they come in a wide variety of materials, flute counts, and geometries. Selecting the right endmill affects surface finish, tool life, and cutting efficiency.

=== HSS vs. Carbide Endmills ===
Endmills are commonly made from either '''high-speed steel (HSS)''' or '''carbide'''. HSS tools are inexpensive, relatively tough, and ideal for general-purpose milling, especially at lower spindle speeds. They’re forgiving if the setup isn’t perfect, making them a good choice for students or roughing operations. Carbide endmills, on the other hand, are harder and more wear-resistant, making them ideal for harder materials and high-speed milling. Carbide also provides better finishes and lasts longer, '''but it's more brittle'''—meaning it can chip or snap if misused or dropped. In most teaching shops, you'll use both: HSS for roughing or learning, and carbide when you need precision, high feed rates, or are cutting tougher materials like steel or aluminum alloys.
[[File:Comparision.jpg|thumb|386x386px]]

=== 2-Flute vs. 4-Flute Endmills ===
Flute count has a major impact on how an endmill performs. '''2-flute endmills''' have wider spaces (gullets) between the cutting edges, which means they can clear chips more easily. This makes them ideal for machining softer materials like aluminum, where chip clogging is a concern, and also for slotting operations where chips have nowhere to escape. '''4-flute endmills''' have more cutting edges in contact with the material at once, leading to faster metal removal and smoother surface finishes, especially in harder materials like steel. However, they don’t clear chips as easily and are less ideal for deep slots unless you adjust feed rates and use coolant or air blast. As a general rule: use 2-flutes for aluminum and slotting, and 4-flutes for steel and side milling.

=== Reground vs. New Endmills ===
In a Brunsfield, you’ll likely come across '''reground''' endmills—cutters that have been resharpened to extend their life. Reground tools are great for roughing passes or when surface finish isn’t critical. They’re cheaper and environmentally friendly, but they may be slightly shorter, have worn coatings, or exhibit minor runout. For high-precision features, smoother finishes, or very tight tolerances, it’s best to use '''new endmills''', which have factory-ground edges and full cutting length.
[[File:104770.jpg|thumb|183x183px]]

=== Ball Nose Endmills ===
A '''ball nose endmill''' has a rounded tip rather than a flat one. This geometry is essential for contouring and 3D profiling, such as in molds or sculpted parts. They’re used when you want to avoid sharp inside corners or need to produce a smooth surface on a curved feature. However, they leave a scalloped finish unless stepovers are very fine, and they’re less rigid at the tip, so they’re not ideal for deep cuts. Use them for finishing passes on 3D surfaces or for parts that require smooth transitions.

== Workpiece Holding and Setup ==
Securing both the '''tool''' and the '''workpiece''' properly is essential to accurate, safe, and efficient milling. A loose setup will lead to poor finishes, chatter, and dangerous tool breakage. Here’s a breakdown of the most common equipment used in the shop for setup and holding.

=== Tool Holding: Collets vs. Drill Chucks ===
[[File:Colletsnchucks.jpg|center|thumb|389x389px|(Left) R8 collets of various sizes. (Right) Jacob's chuck for drill bits.]]

==== R8 Collets ====
R8 collets are the standard tool holders in most manual milling machines. They grip the shank of the cutting tool with good concentricity (low runout), making them ideal for endmills, edge finders, and center drills. Each collet size corresponds to a specific tool diameter—so you’ll need to match the collet to your tool shank.

* '''Pros:''' Accurate, secure, low runout
* '''Cons:''' Requires swapping for different shank sizes

==== Drill Chucks ====
Used for holding drill bits or reamers, drill chucks grip the tool with jaws tightened by a chuck key. They're only suitable for '''axial operations''' like drilling. Never use a drill chuck for side milling—cutting forces can pull the tool out or cause slippage.

* '''Pros:''' Quick tool changes, versatile for drilling
* '''Cons:''' Not secure for milling—can slip or wobble

=== Workpiece holding Tools ===

==== Milling Vise ====
The milling vise is the go-to workpiece holding tool in most shops. It clamps your part securely and aligns it square to the machine’s table. The vice uses a removable handle to open and close the jaws. The handle is stored hanging from the table when not in use.

It’s usually bolted down with T-slot hardware. Always check that your part is sitting flat and square in the vise. Indicating the vise to check if it's sitting square can be done using a '''Dial Indicator.''' See the "Maintenance" section.

'''Pro Tip:''' Use a mallet or dead-blow hammer to "seat" your part after snugging the vise but before final tightening.
[[File:Screenshot_2025-06-10_093432.png|center|thumb|617x617px|The mill machine vise is bolted to the table using T-Head bolts and nuts, allowing it be repositioned, or removed easily.]]
[[File:Slot.jpg|thumb|165x165px]]

==== '''Slot Clamping Kit (T-Slot Clamps)''' ====
Used for clamping irregular or oversized parts directly to the mill table. The kit includes step blocks, strap clamps, nuts, bolts, and T-nuts that fit into the machine’s T-slots.

* '''Good For:''' Holding plates, large parts, or when the vise won’t work
* '''Caution:''' Ensure clamps are level and square—uneven clamping can distort the part

=== Setup Aids and Accessories ===

==== Parallels ====
Parallels are precision-ground bars used to elevate a part inside the vise. They ensure that the part sits flat and level, and allow tool clearance below the part (e.g., for through-holes or full-depth slots). Choose a pair that keeps your part slightly above the vise jaws.

* '''Watch out for:''' Chips under the parallels—this will throw off your Z zero!

[[File:Unnamed.png|center|thumb|The parallels (Red) are used to raise the piece in the vise, while also giving it a level surface to sit on.]]
[[File:123-Supporting-Part-IMG_5489.jpg|thumb|In the image above, a 123 block is used to support the free end of a piece to ensure it doesn't deflect under load.]]

==== 123 Blocks ====
Precision-ground steel blocks sized 1" x 2" x 3". They’re used as reference spacers, squaring aids, or even mini angle plates. Can be clamped together or to the table to help with odd setups.

* '''Common Uses:''' Squaring a part in the vise, setting Z-depths, or elevating parts outside the vise

==== Collet Blocks ====
Collet blocks hold round or hex stock using a standard collet, allowing it to be clamped securely in the mill vise. They’re useful when machining multiple flats on round material or performing indexed operations.

* '''Types:''' Square blocks (for 4 sides), hex blocks (for 6 sides)

[[File:Angle.jpg|thumb|151x151px]]
[[File:J3i84pzrepa81.jpg|thumb|141x141px]]

==== Angle Plates ====
Used to hold parts vertically or at 90° angles to the table. Precision-ground and drilled with mounting holes. Often used in combination with clamps or vises to machine edges or ends of tall parts.

* '''Tip:''' Check squareness with an indicator before cutting

[[File:10inchRotaryTable.jpg|thumb|199x199px]]

==== Rotary Table (Turntable) ====
This allows controlled rotation of the part around a vertical axis. It's useful for machining circular patterns, bolt hole arrays, or radii. The table can be indexed manually in degrees or divided using index plates.

* '''Common Uses:''' Cutting arcs, drilling hole circles, machining gears
* '''Note:''' Always lock the axis you’re not using—these setups require careful planning

=== General Setup Tips ===

* '''Always clean mating surfaces''' (table, vise bottom, parallels) to prevent misalignment. Use brushes instead of your hands as chips can be sharp.
* '''Double-check part squareness''' before cutting—tap it down or into the jaws using a soft mallet
* '''Use the smallest clamp/holder that safely gets the job done'''—fewer things in the way means fewer chances for accidents
* '''Lock unused table axes''' when making a cut for better rigidity
* '''Take time with setup'''—the more precise your setup, the less trouble you’ll have during machining

== Monitoring the cut ==

=== Sound: What You're Hearing ===
'''Smooth, consistent hum -''' Ideal. Indicates proper feed/speed and good tool engagement.

'''Light squealing or whining -''' Usually a sign of rubbing instead of cutting—possibly from dull tools, too low feed, or incorrect RPM.

'''Chatter or rhythmic vibrations -''' A telltale sign of tool deflection, loose setups, or excessive stick-out. You'll hear a high-pitched “buzz” or “hammering” noise that worsens as the cut continues. Stop and address it.

'''Clunking or knocking -''' Indicates serious instability—tool looseness, bad bearings, or a poorly clamped part. Stop immediately and inspect.

'''Screaming or howling -''' Often a sign of way too high spindle speed or aggressive cutting with a brittle cutter (e.g., carbide). Check RPM and tool sharpness.

=== Chip Shape and Color ===
[[File:How-To-Judge-the-Processing-Status-by-the-Chips-Colour.jpg|thumb]]
Chips are your best real-time indicator of whether your cutter is performing well.

* '''Consistent, curled chips -''' Ideal. Suggests good chip evacuation and balanced feed/speed.
* '''Tiny dust-like chips -''' Feed too low or tool rubbing instead of cutting.
* '''Blue or black chips -''' Overheating—too much speed or not enough coolant/air. May damage the tool or workpiece.
* '''Long, stringy chips''' (esp. in aluminum) - Feed might be too low. Also risk of chip wrapping around the cutter—clear frequently.
* '''Powdery chips -''' Could indicate abrasive wear on the tool or surface hardening on the material. Dull tools or the wrong cutter for the job.

[[File:Image003.jpg|thumb|Scalloping finish on a CNC machine from momentary tool acceleration.]]

=== Surface Finish and Vibration ===

* '''Smooth finish with uniform texture -''' You’re doing great! Keep everything the same.
* '''Scalloped or ridged finish -''' Usually from too fast feed or tool chatter. May also mean the spindle is loose or the part is vibrating.
* '''Chatter marks (evenly spaced ripples) -''' Tool deflection or mechanical looseness. Check clamping, tool length, and feed speed.
* '''Random gouges or digs -''' Tool might be loose or broken. Shut down and inspect everything.

----

=== Vibration and Machine Feedback ===

* '''Stable, solid feel -''' Good setup. Axes are locked and the machine is working with you.
* '''Mild vibration through the handwheels or table -''' Not ideal—could be cutting too aggressively, or the setup might be slightly loose.
* '''Visible shaking or movement of the part or tool -''' Serious issue. Stop immediately. Recheck clamping, tool stick-out, and speed/feed.
* '''Tool deflection -''' Especially in longer or smaller-diameter tools, the cutter may bend under load, causing undersize cuts or chatter. Use a more rigid setup or adjust depth of cut.

----

=== Operator Intuition: Know the Signs ===

* '''“This sounds smooth and stable.”''' Keep going.
* '''“Something doesn’t feel right, but I can’t see it yet.”''' Trust that instinct—pause and inspect.
* '''“It’s cutting fine, but my finish looks bad.”''' Try lowering the speed or increasing feed slightly (or both).
* '''“The chips are changing color or shape.”''' Reassess your feed/speed and chip evacuation.

== Safety Considerations ==
The milling machine is one of the most powerful and versatile tools in the shop—but with that comes responsibility. Rotating tools, sharp cutters, and heavy parts can cause serious injuries if proper safety practices are not followed. Whether you're new to the machine or an experienced operator, '''safety always comes first'''.

=== PPE ===

* '''Safety Glasses''': Always required. Protects against flying chips or broken tools.
* '''Hearing Protection''': Recommended, especially during long cuts or when using high RPMs.
* '''Non-Synthetic Clothing''': Avoid synthetics that can melt or ignite. Cotton or natural fiber clothing is best.
* '''Closed-Toe Shoes''': Steel-toes are ideal. Never wear sandals or open footwear.
* '''Gloves''': '''Never wear gloves near rotating tools.''' Gloves can catch and pull your hand into the machine.
* '''Hair and Jewelry''': Tie back long hair and remove rings, watches, and dangling jewelry.

=== General Safety Rules ===

# '''Never leave the machine running unattended.''' Always be present and alert when the spindle is on.
# '''Keep the area clean and free of clutter.''' Chips, tools, and loose rags create tripping and entanglement hazards.
# '''Use a brush or chip hook to remove chips.''' Never use your hands, even with gloves.
# '''Always check for tool tightness.''' Ensure the tool is properly seated and tightened in the collet before starting the spindle.
# '''Double-check your setup.''' Loose vises, parallels, or improperly clamped workpieces are a major hazard.
# '''Know where the emergency stop is.''' Be ready to use it.

=== Machine-Specific Hazards ===

* '''Rotating Spindle and Tooling''': Never reach near the cutter when the machine is running. Even a spinning tool that’s "not cutting" is dangerous.
* '''Kickback and Tool Pullout''': Improper tool holding (like using a drill chuck for an endmill) can result in tools being thrown.
* '''Flying Chips and Debris''': Chips can come off hot and fast—use chip shields if available.
* '''Unexpected Movement''': If power feed or DRO is engaged improperly, the table can move quickly—keep hands clear.

=== Common Safety Mistakes to Avoid ===

* Wearing gloves or long sleeves while operating the machine
* Using a drill chuck to hold an endmill
* Leaving the key in the drill chuck
* Reaching over a spinning tool to brush off chips
* Using damaged or dull tooling
* Forgetting to lock the axes before a cut
* Starting the spindle before securing the part
* Not checking spindle direction—some tools will unscrew themselves or cut incorrectly if running backward.

== Maintenance ==
Before performing any accurate milling operation, it’s important to make sure your '''spindle is perpendicular to the table''' (tramming) and your '''vise is aligned parallel to the machine axes''' (indicating). Without these checks, your cuts can end up angled, off-center, or out of spec—even if everything else seems right.

<youtube>PAoWXnyUZ5M</youtube>

Even if the head is trammed, your cuts won’t be square unless the '''vise jaws are parallel to the X-axis travel'''. This process is called '''indicating the vise'''. This process involved placing a '''parallel''' into the vice, and running a dial indicator along its length while taking not of the change in position at each end. If there is significant deviation along the parallel, it tells you that the vice is not sitting square to the table.

<youtube>9VGu_h8q_cQ</youtube>

'''Tramming''' refers to adjusting the mill head so that the spindle is perfectly perpendicular to the table. On manual mills with tilting heads (like Bridgeport-style mills), this is a common maintenance and setup task—especially if the head has been rotated for a previous job.

This process involves comparing the measurement of each dial indicator on the tramming tool at various points on the mill table. This can tell you if the head of the mill needs to be clocked side to side or front & back.

The Brunsfield Center

2025-07-21T14:21:21Z

Benrundle:

== About ==
[[File:Brunsfield Centre - Header.jpg|thumb|505x505px]]
To gain access to the Brunsfield Centre, uOttawa members (students or staff) must first complete training on the equipment at the Manufacturing Training Centre.

We encourage you to come talk to us about what you are trying to build and we will be happy to point you to the appropriate equipment and will help you get trained.

== [[The Brunsfield Center/Using the Shop|Using the Shop]] ==

=== Shop Rules ===
Some general rules for Brunsfield (STM 129):

* All users must complete the [[Manufacturing Training Center/Shop Trainings/Basic Training|Basic Training]] before using any tools or machines in the shop.
* All users must '''Sign-in''' using their MakerRepo account.
* All users must wear '''safety glasses, long pants, and steel toes boots'''. Toe caps and safety glasses are readily available for those who do not have their own.
* '''Stay within your comfort zone!''' Brunsfield staff (wearing orange) are always there to help to get started or answer your questions.
* Always clean up after yourselves and put tools back in their place.

=== Sign-In Process ===
All Brunsfield and MTC users need to sign in & out of the space using their MakerRepo account. This can be linked with a student/employee card, or can be given manually.

There is a '''Tap-Box''' at the front desk of all of the spaces, simply tap your card on the box and once the light turns green, you're good to go.

A staff can help you link you account to a new card, or sign you in without a card.

It is the user's job to make an account on [https://https//makerepo.com/ MakerRepo] before visiting the spaces.

=== Buying Materials ===
Brunsfield keeps stock of various metals and composites that are left of from projects, and can sell them to shop users.

We also have a selection of '''Scrap Materials''' that are in marked bins in Brunsfield. These materials are '''free to use''' for any users.

Everything that is '''For Sale''' lives on the labelled rack at the back of the shop. All of our pricing is determined by our supplier [https://www.metalpros.com/ Metal Pros.]Simply navigate to their website and identify the geometry of the piece you are looking to purchase. Staff can also assist in determining cost of items.

From there, you will be directed to [https://makerstore.ca/ Makerstore] in order to pay for you material. Simply purchase the item "Brunsfield Bars" at whatever quantity is needed to cover your purchase.

Once a staff has confirmed your order, you're all set!

=== Placing an Order ===
Looking to outsource your project? Our skilled team can help by fabricating your parts for you. Contact us for further information.

=== Design Reviews ===

== [[Manufacturing Training Center/Shop Trainings|Shop Trainings]] ==
The following trainings are offered in MTC or Brunsfield. More info can be found on the trainings page.
* [[Manufacturing Training Center/Shop Trainings/Basic Training|Basic Training]]
* [[Manufacturing Training Center/Shop Trainings/Mill Training|Mill Training]]
* [[Manufacturing Training Center/Shop Trainings/Lathe Training|Lathe Training]]
* [[Manufacturing Training Center/Shop Trainings/Welding Safety & MIG Training|Welding Safety & MIG Training]]
* [[Manufacturing Training Center/Shop Trainings/TIG Training|TIG Training]]
* [[Manufacturing Training Center/Shop Trainings/CNC Training|CNC Training]]

== [[The Brunsfield Center/Our Team|Our Team]] ==

== [[The Brunsfield Center/Manufacturing Technologies|Manufacturing Technologies]] ==
Here is a list of the machines, tools, and processes available through the Brunsfield Center. Click on a specific section to learn more.

* [[The Brunsfield Center/Manufacturing Technologies/Mill|Mill]]
* [[The Brunsfield Center/Manufacturing Technologies/Lathe|Lathe]]
* [[The Brunsfield Center/Manufacturing Technologies/Welding|Welding Area]]
** [[The Brunsfield Center/Manufacturing Technologies/Welding/MIG|MIG]]
** [[The Brunsfield Center/Manufacturing Technologies/Welding/TIG|TIG]]
** [[The Brunsfield Center/Manufacturing Technologies/Welding/Stick Welding|Stick]]
** [[The Brunsfield Center/Manufacturing Technologies/Welding/Plasma Cutting|Plasma cutting]]
** [[The Brunsfield Center/Manufacturing Technologies/Grinders|Grinders]]
** [[The Brunsfield Center/Manufacturing Technologies/Welding/Spot Welding|Spot Welder]]
* [[The Brunsfield Center/Manufacturing Technologies/CNC|CNC machinery]]
** [[Manufacturing Training Center/Manufacturing Technologies/CNC Router|CNC Routers]]
** CNC Mills
** CNC Lathes
* [[The Brunsfield Center/Manufacturing Technologies/Vertical Bandsaw|Vertical Band Saw]]
* [[The Brunsfield Center/Manufacturing Technologies/Horizontal Bandsaw|Horizontal Band Saw]]
* [[The Brunsfield Center/Manufacturing Technologies/Drill Press|Drill press]]
* [[The Brunsfield Center/Manufacturing Technologies/Sheet Metal Brake|Sheet Metal Brake]]
* [[The Brunsfield Center/Manufacturing Technologies/Sheet Metal Shear|Sheet Metal Shear]]
* [[The Brunsfield Center/Manufacturing Technologies/Hand Tools|Hand Tools]]

* [[Manufacturing Training Center/The Wood Room|Wood Room]]
** [[Manufacturing Training Center/The Wood Room/Miter Saw|Miter Saw]]
** [[Manufacturing Training Center/The Wood Room/Panel Saw|Panel Saw]]
** [[Manufacturing Training Center/The Wood Room/Circular Saw|Circular Saw (Skillsaw)]]
** [[Manufacturing Training Center/The Wood Room/Jigsaw|Jigsaw]]
[https://makerepo.com/jboud030/651.formation-de-base-virtuelle-virtual-basic-training Virtual basic training]

[https://makerepo.com/jboud030/654.fraiseuse-virtuelle-virtual-mill Virtual Mill tour:]

[https://makerepo.com/jboud030/655.tour-virtuel-virtual-lathe Virtual Lathe tour:]

The Brunsfield Center/Manufacturing Technologies

2025-07-21T14:21:04Z

Benrundle:

Here is a list of the machines, tools, and processes available through the Brunsfield Center. Click on a specific section to learn more.

* [[The Brunsfield Center/Manufacturing Technologies/Mill|Mill]]
* [[The Brunsfield Center/Manufacturing Technologies/Lathe|Lathe]]
* [[The Brunsfield Center/Manufacturing Technologies/Welding|Welding Area]]
** [[The Brunsfield Center/Manufacturing Technologies/Welding/MIG|MIG]]
** [[The Brunsfield Center/Manufacturing Technologies/Welding/TIG|TIG]]
** [[The Brunsfield Center/Manufacturing Technologies/Welding/Stick Welding|Stick]]
** [[The Brunsfield Center/Manufacturing Technologies/Welding/Plasma Cutting|Plasma cutting]]
** [[The Brunsfield Center/Manufacturing Technologies/Grinders|Grinders]]
** [[The Brunsfield Center/Manufacturing Technologies/Welding/Spot Welding|Spot Welder]]
* [[The Brunsfield Center/Manufacturing Technologies/CNC|CNC machinery]]
** [[Manufacturing Training Center/Manufacturing Technologies/CNC Router|CNC Routers]]
** CNC Mills
** CNC Lathes
* [[The Brunsfield Center/Manufacturing Technologies/Vertical Bandsaw|Vertical Band Saw]]
* [[The Brunsfield Center/Manufacturing Technologies/Horizontal Bandsaw|Horizontal Band Saw]]
* [[The Brunsfield Center/Manufacturing Technologies/Drill Press|Drill press]]
* [[The Brunsfield Center/Manufacturing Technologies/Sheet Metal Brake|Sheet Metal Brake]]
* [[The Brunsfield Center/Manufacturing Technologies/Sheet Metal Shear|Sheet Metal Shear]]
* [[The Brunsfield Center/Manufacturing Technologies/Hand Tools|Hand Tools]]

* [[Manufacturing Training Center/The Wood Room|Wood Room]]
** [[Manufacturing Training Center/The Wood Room/Miter Saw|Miter Saw]]
** [[Manufacturing Training Center/The Wood Room/Panel Saw|Panel Saw]]
** [[Manufacturing Training Center/The Wood Room/Circular Saw|Circular Saw (Skillsaw)]]
** [[Manufacturing Training Center/The Wood Room/Jigsaw|Jigsaw]]

[https://makerepo.com/jboud030/651.formation-de-base-virtuelle-virtual-basic-training Virtual basic training]

[https://makerepo.com/jboud030/654.fraiseuse-virtuelle-virtual-mill Virtual Mill tour:]

[https://makerepo.com/jboud030/655.tour-virtuel-virtual-lathe Virtual Lathe tour:]

The Brunsfield Center/Manufacturing Technologies/Welding/TIG

2025-07-21T14:15:52Z

Benrundle:

{{DISPLAYTITLE:TIG}}

== About ==
Tungsten Inert Gas (TIG) welding, also known as Gas Tungsten Arc Welding (GTAW), is a precise welding process that uses a non-consumable tungsten electrode to produce the weld. Known for its high-quality, clean welds, TIG welding is commonly used on thin materials such as stainless steel and aluminum in industries requiring strong, visually appealing joints.

=== The TIG torch ===
[[File:TIG_torch.png|thumb|A disassembled TIG torch]]

==== Assembly ====

* Collet body screws into the front of the torch body
** Gas lens does the same thing, creates laminar flow for getting into tight spots

* Collet goes into the back of the collet body
** Notice slits on collet, acts like springs
** Inside of collet body is tapered, pinches the collet closed

* Ceramic gas cup screws on top of collet body

* Sharpened electrode goes in through the back of torch
** Grey paint: 2% ceriated is a good all-purpose electrode, ideal for low- and medium-current welding on all metals
** “rule of thumb” for stickout, half the width of your thumb from the cup to the tip of the elctrode

* Tail cap screws onto back of torch body, seals the collet and electrode

==== Spare parts ====
All internal parts are made of copper for its conductivity. Copper is very soft so be careful to never over-tighten anything when assembling the torche. All these parts get worn out over time, they will tarnish due to the heat, slowly losing its conductivity. Brand new parts are very shiny, bright red and conduct electricity very well; you will notice a more stable arc when you replace an old part with a new one.

There are also different sized parts for different applications. Thicker material requires more heat to weld, meaning a thicker electrode to conduct more current, thus needing larger collet and collet body, and more gas to shield, meaning a larger cup. On the other hand, thinner material requires less amperage, and when an electrode is too big for the amount of amperage the arc becomes unstable and difficult to start. Therefore, a smaller electrode, collet, and collet body should be installed, along with a smaller gas cup to concentrate the gas on the smaller weld pool.

==== Electrode ====
TIG welding uses a tungsten as an electrode. Tungsten has an extremely high melting point (3422C, 6191F), so when you weld the electrode gets hot but it doesn't melt. This means the electrode is non-consummable, it won’t last forever but it doesn’t melt and become part of the weld (unlike MIG where the electrode melts and becomes filler metal. This is a consumable electrode process)

The color of the electrode indicates the type of tungsten alloy. Some of the more common alloys include:

* Grey is 2% ceriated, good choice for all types of welding; providing good arc start and restart characteristics with no spitting. It is ideal for low- and medium-current welding on all metals.

* 2% lanthanated tungsten (color-coded blue) is a true all-purpose electrode, with excellent arc starting characteristics and the ability to transmit high current without spitting. It provides a stable arc at both high and low current, and works very well on all metals.

* Rare earth tungsten (chartreuse) has the very best low-current arc starting characteristics, and it can be used on all metals. This type is often preferred for automated welding.

* Zirconiated tungsten (white) is good for welding aluminum and magnesium alloys. It has high current-carrying capacity, and it provides better arc starts and stability than pure tungsten.

[[File:Electrode_prep.png|thumb]]
[[File:W_angle.png|thumb]]

==== Sharpening your tungsten ====

* Make sure to use the left of the two small wheels, labeled for tungsten

* Wear gloves, it’ll get toasty

* Don't use pliers, not enough grip

* Hold the electrode in line with the wheel, pointing up against the rotation

* Want grind lines running towards the point to direct the current

* If it grabs the wheel, it’ll just push you away

* Holding it downward will pull you into the wheel and revoke your finger privileges

* Spin it slowly and constantly in your fingers

* Looking for a uniform cone, don’t want flat spots

* Aim for 30 degrees

* Break off the point

* Don't want any burrs to throw off our arc

* The flat end helps a little with penetration

==== Machine Setup ====
===== Starting the machine =====

* Plug in, flip power switch

* Open gas valve, set flow to 15-20CFH

* Need to have gas flowing to read flowmeter, press the pedal down

* Connect the ground clamp

* Set the pedal and torch in a comfortable position

===== Settings =====
====== Amperage ======
As a general rule of thumb, start by setting the amperage equivalent to the thickness of your part in thousandths of an inch, ie. 1A = 0.001". So for a 1/8" practice coupon, start out at 125A.

However, with more experience you will learn to play around with this setting to suit your particular style. For example, some people might set their amperage to 140A for 1/8" Aluminum to get an extra kick when starting their weld, even though they'll only use 50% of the pedal (70-80A) for the rest of the weld after it's started.
[[File:AC_welding.png|thumb]]

====== Polarity ======

* AC for Aluminum and Magnesium
** Electrode positive phase, electrons flowing from workpiece to electrode, blows through the back of the oxide layer
** Electrode negative phase, electrons flowing from the electrode to the workpiece, actually melts the pure aluminum inside to make a weld

* DC for all other metals

====== Process ======
This setting controls how the arc starts.

* HF impulse allows to press the pedal and start the arc without needing to touch the workpiece to start the flow of electricity, using high-voltage high-frequency electric pulses

* Lift start requires you to touch the tungsten to the workpiece, press the pedal down, then lift off to start the arc

* Stick (scratch start) is when the electrode stays live at all times so the arc starts as soon as you make contact

[[File:Pulse-004_RESIZED.jpg|thumb|Miller Dynasty front control panel layout. (TIG machines in Brunsfield)]]

====== Output ======
This setting determines what activates the arc.

* Remote allows you to use a foot pedal or hand remote

* 2T hold acts like a toggle function

====== Pulser ======
Use this setting to periodically decrease the heat for smaller parts.

* PPS stands for pulses per second

* Peak time is how long each pulse is at max amperage as a percentage of the PPS

* Background amperage is the minimum amperage in between pulses

====== Sequence ======
Use this setting in conjunction with the 2T hold setting for when a remote (foot pedal) isn’t available or practical.

* Initial amperage is the amount of amps used to initiate the arc, usually based on electrode size

* Initial slope is how long it will take to go from initial A to your working amperage

* Final slope is how long it will take to decrease from working A to final A

* Final A is the amperage right before the arc cuts out

====== Adjust ======

* Preflow is how long the gas will flow before the weld starts, to clear out any impurities for the start

* Postflow is gas flow after the weld, to protect the weld and the electrode as they cool

* DIG is used for stick welding, prevents the electrode from sticking to the workpiece

====== AC Waveshape ======

* Balance changes how much cleaning actions happens to remove the Al oxide. Lower balance has more cleaning action

* Frequency changes the width of the AC arc. Higher frequency will have a tighter arc with more penetration

===== Starting Recipes =====
{| class="wikitable"
|+
!Material
!0.125" AISI 1018 plate
!0.065" AISI 4130 tube
!0.125" 6061-T6 plate
|-
|Amperage
|130A
|67A
|150A
|-
|Polarity
|DC
|DC
|AC
|-
|Process
|HF Impulse
|HF Impulse
|HF Impulse
|-
|Output
|RMT STD
|RMT STD
|RMT STD
|-
|Pulser
|off
|0.8 PPS, 40% peak t, 25A bkgnd A
|off
|-
|Sequence
|off
|off
|off
|-
|Adjust
|0.2s pre-flow, 4s post-flow
|0.5s pre-flow, 5s post-flow
|0.8s pre-flow, 6s post-flow
|-
|AC Waveshape
|off
|off
|70% balance, 80Hz
|}
Start with these settings and play around with them as you practice. Only change one setting at a time until you understand what each one does, that way you can notice the effect of each one.

==== Troubleshooting ====

* Amperage: The weld bead should be about twice as wide as the thickness of the material. If the bead is wider than that, turn the amperage down. Turn the amperage up if the bead is smaller.
* Process: If the arc won't start when you press the foot pedal, check your process setting. If you're in lift arc or stick, the machine expects you to touch the electrode to the workpiece in order to start the flow of current. Use HF Impulse instead for most TIG operations.
* Pulser: If you feel like you don't have enough time to reposition between pulses, decrease the PPS value. If you don't have time to add filler and connect the bead during the pulse, increase the peak t value. If the arc is flickering or dying in between pulses, turn up the background amperage.
* Adjust: if the weld has any porosity or oxidation, check that the gas flow rate is set correctly on the regulator. If the regulator is set correctly and the issue still arises, increase the post-flow value
* AC Waveshape: If the bead is too narrow, decrease the frequency. If it's too narrow AND has poor penetration, increase the amperage instead. If there's too much etching, turn up the balance. If the oxide layer won't break, turn the balance down.

==== Technique ====

===== Before starting =====

* Make sure your tungsten is sharp and your filler rod is a decent length

* Stick your electrode out the same amount as the width of the cup

* Most joints will use about twice the length of filler as the length of the joint, make sure you have enough

* Find a comfortable position. Being comfy is the fastest way to improve your welds

* Trace your path to make sure you can reach and see everything you need to

[[File:Torch_angle.png|thumb|Travel angle is as seen from the side of the weld, work angle is as seen from the end of the weld]]

===== Starting the weld =====

* Position your torch so the tip of the electrode is ~1/8” from the surface of the workpiece. Never exceed ¼" (long arcing, poor gas coverage)

* Hold the torch at the correct angle

* 5-15deg lead angle in the plane parallel to the weld, meaning handle tilted back, electrode point in the direction of travel

* 90deg to the face of the weld, meaning vertical for flat welds or butt joints, 45deg from vertical for lap or T joints

* Apply the pedal slowly, develop the puddle

* Look for how the heat input affects the width of the puddle

* For joints, make a tack weld first. Start the arc in the middle of the gap to create a puddle on either side, increase the heat until they connect

* Use filler sparingly at first, make sure the base material fuses fully.

[[File:Weave-vs-stringer-bead-1.webp|thumb|Common weave patterns]]

===== Make a bead =====

* Look for how filler input affects the height of the puddle

* Make sure to tie in to your tack or last bead, ie start with some overlap

* For joints, use a back-and-forth motion to connect the two pieces

* Use enough filler to avoid undercut (where the surface dips down)

===== Finishing the weld =====

* Finish the last ~¼" without filler to avoid a big glob at the end

* Make sure to go all the way over your tack or next bead

* Avoid pinholes, lack of fusion

* Slowly lift off pedal, hold torch over the weld

* Maintains gas coverage while the weld and electrode cool

Manufacturing Training Center/Shop Trainings

2025-07-21T14:11:31Z

Benrundle: /* TIG Training */

{{DISPLAYTITLE:Shop Trainings}}
Trainings are offered via MTC or Brunsfield. All trainings can be found on the [https://simpli.events/u/uottawaceed Simpli website] when they are posted each week. Each training is required in order to operate the associated machines on your own.

== [[Manufacturing Training Center/Shop Trainings/Basic Training|Basic Training]] ==
=== About ===
Basic Training is the first training that all users should take. It grants you access to all manufacturing spaces and reassures staff that you are comfortable handling basic hand tools.

Basic training takes place in MTC and a session is run roughly every other week during the fall and winter semesters. The training takes 2 to 3 hours, during which users will listen to a brief safety presentation, then take part in a workshop where they will make a sheet metal box.

'''Basic Training is required before any other training can be taken.'''
[[File:Basic_-_Basic_-_Box-1.png|thumb|398x398px|Technical Drawing for the sheet metal box that is made during the basic training.]]

=== Preparation ===
Brunsfield staff will provide necessary PPE for the training.

In order to take the training, you must sign-up via a link in the CEED Newsletter or via QR code. This will take you to the [https://simpli.events/manage/events ''Simpli'' page] where you can register for a particular session.

It is also the user's responsibility to create a Makerepo account before taking the training. This is done when taking GNG courses, or can be done manually at [https://makerepo.com/ Makerepo.com]. This will allow to sign-in/out of all the CEED spaces and is necessary to take all trainings.

There are no prerequisite trainings to take the basic training. There is an optional '''pre-lab''' that can be completed ahead of time virtually.

=== Tools Used ===
During the training users will use a variety of tools and machines:

* [[The Brunsfield Center/Manufacturing Technologies/Hand Tools|Hand Tools]]
** Files
** Cutters/Tin Snips
** Marking Tools
** Pliers
** Hammers
* [[The Brunsfield Center/Manufacturing Technologies/Drill Press|Drill Press]]
* [[Manufacturing Training Center/Manufacturing Technologies/Corner Notcher|Corner Notcher]]
* [[The Brunsfield Center/Manufacturing Technologies/Sheet Metal Brake|Sheet Metal Brake]]
* [[The Brunsfield Center/Manufacturing Technologies/Welding/Spot Welding|Spot Welder]]

Click on a tool or machine to go to its page and learn more.

== [[Manufacturing Training Center/Shop Trainings/Lathe Training|Lathe Training]] ==

=== About ===
Lathe training takes place in MTC and teaches safe operation of the lathe. The training will consist of a briefing of the machines, and the guided production of a simple plastic part.

Making the part required three operations: Facing, Turning, and Drilling, all of which are instructed before hand.

=== Preparation ===

* Brunsfield staff will provide necessary PPE for the training.
* Basic training must be taken prior to taking lathe training.
* In order to take the training, you must sign-up via a link in the CEED Newsletter or via QR code. This will take you to the ''Simpli'' page where you can register for a particular session.
* There is an optional prelab available.

== [[Manufacturing Training Center/Shop Trainings/Mill Training|Mill Training]] ==

== [[Manufacturing Training Center/Shop Trainings/Welding Safety & MIG Training|Welding Safety & MIG Training]] ==

=== About ===
Welding Safety & MIG is an entry-level welding course offered in Brunsfield. The training can host up to 6 people and take roughly 3 hours.
[[File:Maxresdefault_(1).jpg|thumb|334x334px|MIG weld on a T-joint]]
It is designed to teach users the basics of welding in the shop, from machine setup, shop use and safety, basic welding science, and MIG welding technique.

=== Requirements ===

* All users need to have a [https://makerepo.com/ Makerepo] account to sign in the space and be accredited with the training certification.
* All users need to arrive wearing the propper PPE
** Long hair tied back
** No hand jewelry such as watches, bracelets, or large rings.
** Closed-toed sturdy shoes
** Long pants made of a natural material like cotton or denim (synthetic materials like leggings will melt with sparks.
** All other PPE will be provided
* All users must have completed the [[Manufacturing Training Center/Shop Trainings/Basic Training|Basic Training]]

[[File:Step_2.webp|thumb|MIG torch internals]]

=== Material Covered ===

* Shop Safety
** E-stops, First Aid Kit, Fire extinguisher, Brun Kit, Safety Shower, etc.
** Operation of the fume extractor.
** Basic Shop PPE
* Welding Area
** Special Flame-Rated area to be used for any operation producing fire or sparks.
** PPE Cabinet
** Welding Tables
** Gas Cylinders
* Grinders
** Pedestal and Hand-held grinders
*** different wheels, techniques and safety
* Welding PPE (Red Cabinet)
** Helmets
** Jackets
** Gloves
** Beanies
** Helmets
* Different metals and their weldability
* Machine Setup
** Gas
*** Propper setup, operation, and safety.
** Machine Settings (Feed rate and Voltage)
** Grounding, & Powering the Machine
* MIG machine internals
* Torch Internals
* Welding accessories
** Clamps
** Cutters
** Magnets

[[File:018-mig-welder-set-up.jpg|thumb|390x390px|Internals of the MIG machine]]

=== How to Sign-Up ===
All of the training sessions are posted on the [https://simpli.events/u/uottawaceed Simpli] website. You can sign up for the CEED newsletter on [https://makerepo.com/ Makerepo] to stay up to date on the schedule. We try to change the times of trainings each week to accommodate everyone's schedules.

== [[Manufacturing Training Center/Shop Trainings/TIG Training|TIG Training]] ==
TIG is a form of welding that is taught to users who have '''already competed the Welding Safety & MIG training.''' TIG is a more complex form of welding that is used to achieve more controlled, visually pleasing results.

TIG also allows you to weld very thin metal, as well as easily switch between material types such as stainless steel, and aluminum.
[[File:TIG Welding 9044211.jpg|thumb|TIG Welding]]
Read more about TIG [[The Brunsfield Center/Manufacturing Technologies/Welding/TIG|here]].

=== Training requirements ===

* All users need to have a Makerepo account to sign in the space and be accredited with the training certification.
* All users need to arrive wearing the propper PPE:
** Long hair tied back
** No hand jewelry such as watches, bracelets, or large rings.
** Closed-toed sturdy shoes
** Long pants made of a natural material like cotton or denim (synthetic materials like leggings will melt with sparks.
** All other PPE will be provided
* All users must have completed the [[Manufacturing Training Center/Shop Trainings/Basic Training|Basic Training]], as well as the [[Manufacturing Training Center/Shop Trainings/Welding Safety & MIG Training|Welding Safety & MIG]] training.

=== How to sign up ===
All of the training sessions are posted on the Simpli website. You can sign up for the CEED newsletter on Makerepo to stay up to date on the schedule. We try to change the times of trainings each week to accommodate everyone's schedules.

=== What's covered ===
TIG Basics

* Grounding, the pedal, filler rod

Machine Settings

* Amps, DC/AC, Balance, Pre-flow/Post-flow

TIG Torch

* Cup, Collet, Torch body, Tail, Tungsten
* Tungsten Sharpening

[[File:Types of welding joint 600x600.webp|thumb|Various Welding joint types.]]
PPE

* Gloves, Helmets, Jackets, Beanies, etc.

Basic TIG Technique

* Making a puddle
* Moving the puddle
* Adding filler
* Working on rhythm and consistency.
* Different joint types and welding positions

== [[Manufacturing Training Center/Shop Trainings/CNC Training|CNC Training]] ==

=== What is CNC? ===
CNC (Computer Numerical Control) is a manufacturing method where machines like mills, lathes, routers, 3D printers, laser cutters, and more are controlled using computer codes—primarily G-code, a language that tells machines what movements to make and actions to perform. These codes are interpreted by a controller, which converts them into signals that operate various machine components. While different machines may use different variations of G-code, the underlying principles remain the same. CNC machining offers high precision, speed, and the ability to produce complex parts with tight tolerances, making it ideal for large-scale production and detailed work. However, due to its time-consuming setup and need for specialized programming knowledge, it is less suitable for simple or low-volume projects.

For more information on CNC machining, including G-code, CAM, and speeds and feeds, visit the following YouTube channels:

Haas Automation

NYC CNC

=== About CNC Training ===
The CNC Training Course offered by CEED is a two-part course that covers the basics of G-Code and writing machine programs, a brief overview of feeds and speeds, basic functions in the Fusion 360 CAM workspace, and the operating procedures for the CNC routers in the Wood Room. After completing both parts of the training, students should be able to create a program for a simple part with one setup using common materials like MDF, plastic, or aluminum.

Manufacturing Training Center/Shop Trainings/TIG Training

2025-07-21T14:08:41Z

Benrundle:

[[File:TIG Welding 9044211.jpg|thumb|360x360px]]
{{DISPLAYTITLE: TIG Training}}
== TIG Training ==
TIG is a form of welding that is taught to users who have '''already competed the Welding Safety & MIG training.''' TIG is a more complex form of welding that is used to achieve more controlled, visually pleasing results.

TIG also allows you to weld very thin metal, as well as easily switch between material types such as stainless steel, and aluminum.

Read more about TIG [[The Brunsfield Center/Manufacturing Technologies/Welding/TIG|here]].

== Training requirements ==

* All users need to have a [https://makerepo.com/ Makerepo] account to sign in the space and be accredited with the training certification.
* All users need to arrive wearing the propper PPE:
** Long hair tied back
** No hand jewelry such as watches, bracelets, or large rings.
** Closed-toed sturdy shoes
** Long pants made of a natural material like cotton or denim (synthetic materials like leggings will melt with sparks.
** All other PPE will be provided
* All users must have completed the [[Manufacturing Training Center/Shop Trainings/Basic Training|Basic Training]], as well as the [[Manufacturing Training Center/Shop Trainings/Welding Safety & MIG Training|Welding Safety & MIG]] training.

== How to sign up ==
All of the training sessions are posted on the [https://simpli.events/manage/events Simpli] website. You can sign up for the CEED newsletter on [https://makerepo.com/ Makerepo] to stay up to date on the schedule. We try to change the times of trainings each week to accommodate everyone's schedules.

== What's covered ==
[[File:Types of welding joint 600x600.webp|thumb|425x425px|Various welding joint types.]]
TIG Basics

* Grounding, the pedal, filler rod

Machine Settings

* Amps, DC/AC, Balance, Pre-flow/Post-flow

TIG Torch

* Cup, Collet, Torch body, Tail, Tungsten
* Tungsten Sharpening

PPE

* Gloves, Helmets, Jackets, Beanies, etc.

Basic TIG Technique

* Making a puddle
* Moving the puddle
* Adding filler
* Working on rhythm and consistency.
* Different joint types and welding positions

Manufacturing Training Center/Shop Trainings/TIG Training

2025-07-21T14:08:19Z

Benrundle:

[[File:TIG Welding 9044211.jpg|thumb|360x360px]]

== TIG Training ==
TIG is a form of welding that is taught to users who have '''already competed the Welding Safety & MIG training.''' TIG is a more complex form of welding that is used to achieve more controlled, visually pleasing results.

TIG also allows you to weld very thin metal, as well as easily switch between material types such as stainless steel, and aluminum.

Read more about TIG [[The Brunsfield Center/Manufacturing Technologies/Welding/TIG|here]].

== Training requirements ==

* All users need to have a [https://makerepo.com/ Makerepo] account to sign in the space and be accredited with the training certification.
* All users need to arrive wearing the propper PPE:
** Long hair tied back
** No hand jewelry such as watches, bracelets, or large rings.
** Closed-toed sturdy shoes
** Long pants made of a natural material like cotton or denim (synthetic materials like leggings will melt with sparks.
** All other PPE will be provided
* All users must have completed the [[Manufacturing Training Center/Shop Trainings/Basic Training|Basic Training]], as well as the [[Manufacturing Training Center/Shop Trainings/Welding Safety & MIG Training|Welding Safety & MIG]] training.

== How to sign up ==
All of the training sessions are posted on the [https://simpli.events/manage/events Simpli] website. You can sign up for the CEED newsletter on [https://makerepo.com/ Makerepo] to stay up to date on the schedule. We try to change the times of trainings each week to accommodate everyone's schedules.

== What's covered ==
[[File:Types of welding joint 600x600.webp|thumb|425x425px|Various welding joint types.]]
TIG Basics

* Grounding, the pedal, filler rod

Machine Settings

* Amps, DC/AC, Balance, Pre-flow/Post-flow

TIG Torch

* Cup, Collet, Torch body, Tail, Tungsten
* Tungsten Sharpening

PPE

* Gloves, Helmets, Jackets, Beanies, etc.

Basic TIG Technique

* Making a puddle
* Moving the puddle
* Adding filler
* Working on rhythm and consistency.
* Different joint types and welding positions

File:TIG Welding 9044211.jpg

2025-07-21T13:46:04Z

Benrundle:

TIG Photo

Manufacturing Training Center/Shop Trainings/TIG Training

2025-07-21T13:41:45Z

Benrundle:

== TIG Training ==
TIG is a form of welding that is taught to users who have '''already competed the Welding Safety & MIG training.''' TIG is a more complex form of welding that is used to achieve more controlled, visually pleasing results.

TIG also allows you to weld very thin metal, as well as easily switch between material types such as stainless steel, and aluminum.

Read more about TIG [[The Brunsfield Center/Manufacturing Technologies/Welding/TIG|here]].

== Training requirements ==

* All users need to have a [https://makerepo.com/ Makerepo] account to sign in the space and be accredited with the training certification.
* All users need to arrive wearing the propper PPE:
** Long hair tied back
** No hand jewelry such as watches, bracelets, or large rings.
** Closed-toed sturdy shoes
** Long pants made of a natural material like cotton or denim (synthetic materials like leggings will melt with sparks.
** All other PPE will be provided
* All users must have completed the [[Manufacturing Training Center/Shop Trainings/Basic Training|Basic Training]], as well as the [[Manufacturing Training Center/Shop Trainings/Welding Safety & MIG Training|Welding Safety & MIG]] training.

== How to sign up ==

== What's covered ==

Manufacturing Training Center/Shop Trainings/TIG Training

2025-07-21T13:39:51Z

Benrundle:

The Brunsfield Center/Manufacturing Technologies/Hand Tools

2025-07-18T17:33:15Z

Benrundle: /* Surface Preparation & Finishing */

{{DISPLAYTITLE: Hand Tools}}
== Marking & Layout tools ==

=== Scribe ===
Used to scratch fine lines into metal or plastic surfaces for layout work.

''Tip:'' Best used with a straightedge or square for precision.

=== Combination Square ===
A multipurpose measuring and layout tool used to:

* Check 90° and 45°angles
* Measure depths and short distances
* Scribe lines parallel to edges using its built-in ruler

=== Center Punch ===
Creates a small dimple to guide drill bits and prevent slipping. This is done by holding it straight on the area you want dented, and pressing down.

=== Deburring Tool ===
Removes sharp edges and burrs after cutting metal and plastic.

== Cutting Tools ==

=== X-Acto Knives ===
Used for precision trimming of tape, decals, soft plastics, and foils.

* Keep the cap on/keep blade in when not in use
* Replace dull blades using pliers to avoid cuts

=== Tin Snips ===
Used to cut sheet metal

'''Red:''' Left cuts | '''Green:''' Right cuts | '''Yellow:''' Straight cuts

=== Hand Saws ===

* Use proper blade for material
* Avoid twisting during cuts

=== Dremel Rotary Tool ===
Handheld tool with attachments for cutting, sanding, grinding, polishing.

* ''Requires training and eye protection''
* Clamp small parts before use

== Fastening & Adjustment Tools ==

=== Allen Keys ===
For tightening or loosening hex-socket fasteners.

* Available in metric and SAE sizes
* Use full-depth engagement to avoid stripping

=== Pliers ===
Includes:

* Needle-nose pliers

* Slip-joint pliers

Do not substitute pliers for wrenches on bolts.

=== Socket Set ===

=== Hammers ===

=== Wrenches ===
Adjustable and open-end wrenches

=== Screw Drivers ===

* Phillips, Slotted, Torx, and Robinson heads.
* Available in all sizes and lengths

== Surface Preparation & Finishing ==

=== Scotch-Brite Pads ===
Nonwoven abrasive pads for cleaning, deburring, and blending.

* Used dry or wet
* Wear gloves to avoid fiber irritation

=== Sandpaper ===
Used for smoothing or prepping surfaces.

* Coarse to fine grit available (60–400+)

=== Files ===
Used to round sharp edges, debur surfaces, and smooth sharp corners

* Come in a range of grits/abrasiveness
* Work in one direction only (push not pull)

=== Vice Grips ===

=== F-Clamps & C-Clamps ===

The Brunsfield Center/Manufacturing Technologies/Mill

2025-07-18T17:25:15Z

Benrundle:

== Intro ==
[[File:1050VS_93596_00296.jpg|thumb|King Turret-Style Knee mill, as seen in the Brunsfield Center]]
The milling machine—commonly referred to as “the mill”—is one of the most versatile and widely used tools in any machine shop. Unlike a drill press, which cuts only in the vertical axis, a mill allows for precise movement in the X (left/right), Y (forward/back), and Z (up/down) directions, enabling complex and accurate machining operations on a wide range of materials.

Mills remove material using a rotating cutting tool held in a spindle, allowing operators to shape metal and plastic parts with high precision. In our shop, we primarily use vertical knee mills equipped with digital readouts (DROs), allowing for repeatable and accurate setups.

Whether you're facing a part flat, drilling a precise hole, cutting a slot, or using a form tool to create complex geometry, the mill is essential for prototype work, part modification, and precision fabrication.

This guide will walk through how mills work, the operations they can perform, how to choose the right tools, proper setup techniques, and what to watch for during machining.

== How the Mill Works ==
A milling machine operates by rotating a cutting tool (such as an endmill) while moving a workpiece against it. Material is removed through the shearing action of the rotating cutter, allowing for precise shaping of metal, plastic, or other materials.

=== Key Components ===

* '''Spindle'''
** The spindle holds and rotates the cutting tool. It's powered by a motor and can run at various speeds, depending on the material and operation.
* '''Table'''
** The flat surface that holds the workpiece. It can move in the '''X-axis (left/right)''' and '''Y-axis (in/out)'''. Movement is controlled by handwheels or power feeds.
* '''Knee & Column'''
** The knee supports the table and moves vertically along the column, giving the '''Z-axis (up/down)''' motion.
* '''Quill'''
** Found on most vertical mills, the quill allows for vertical movement of the spindle—useful for drilling or plunging into material.
* '''Digital Readout (DRO)'''
** A DRO displays the precise position of the table along each axis. It greatly improves accuracy and efficiency, especially for repetitive work.[[File:690174_main_07610.jpg|thumb|224x224px|The X-axis power feed controller (red box) with a control lever to change feed direction.]]

=== Modes of Movement ===

* '''Manual -''' Most shop mills are manual, meaning the operator turns handwheels to control table motion and spindle feed.
* '''Power Feed -''' Our Brunsfield mills have powered X-axis feeds. These are useful for consistent finish during long cuts like face milling.
* '''Locking Mechanisms -''' Axis locks are used to prevent unwanted movement. It's good practice to lock any axis not in use during a cut.

=== How Cutting Happens ===

* The cutter spins at a selected '''RPM''', chosen based on material, tool diameter, and cutter type.
* The workpiece is moved against the spinning cutter, removing material layer by layer.
* Different cutters and operations (face milling, slotting, drilling, etc.) change how the cut engages the workpiece.
* Chip formation and cutting load depend on feed rate, depth of cut, and cutter geometry.[[File:KbvTvAw.gif|thumb|341x341px|Each pass of the tool cuts a chip of metal from the workpiece.]]

=== Feed & Speed ===

* '''Spindle Speed (RPM)''' affects how fast the cutter rotates. Too fast and you'll burn the cutter; too slow and it may chatter or rub instead of cut.
* '''Feed Rate''' is how fast the workpiece moves into the cutter. It must be matched to the material and tool geometry to ensure clean cutting and tool life.

=== [[The Brunsfield Center/Manufacturing Technologies/Coolant|Coolant]] ===

* While machining, always apply coolant to mitigate heat production, minimize tool wear, and improve surface finish. See the coolant page for more info.

== Quick Start Guide ==

=== Mill Controls ===
[[File:Screenshot_2025-06-09_130753.png|thumb|599x599px]]
[[File:Screenshot_2025-06-09_131028.png|thumb|606x606px]]
The following images show the main controls on the milling machine, their functions are listed below:

# '''On/Off switch''' - Activates the motor on the mill.
# '''Speed Adjustment dial''' - Changes the rpm of the spindle while the mill is running.
# '''High/Low Gear Handle''' - Changes the running speed gear of the mill.
# '''Quill Pilot Feed Lever''' - Lowers & raises the spindle, used for drilling.
# '''Quill lock''' - Locks the spindle in the current position.
# '''Quill power feed''' - Used for fine adjustments of the spindle height.

# '''DRO''' - Displays the current X and Y axis position. Can be set to metric or imperial units.
# '''Vise''' - The vise is bolted to the mill table and holds the workpiece during operation.
# '''Y/X axis feed wheels''' - adjust the X & Y position of the table via clockwise or counterclockwise rotation.
# '''Z-axis knee lever''' - Adjusts the height of the table. Used to set proper working height for an operations. Changing this does not change the Z-axis DRO reading.

== [[The Brunsfield Center/Manufacturing Technologies/Mill/Milling Operations|Milling Operations]] ==
Primary operations on the mill are face milling, side milling, and drilling.

See a full run down of all the milling operations:

[[The Brunsfield Center/Manufacturing Technologies/Mill/Milling Operations|Milling Operations]]

== Indicating ==
Before making any cuts, it's critical to establish a '''working zero'''—a reference point from which all other dimensions are measured. On a milling machine with a digital readout (DRO), this is usually done by locating the edge of your part, or the vise, with an '''edge finder''' and then setting the DRO coordinates accordingly.
[[File:1-855-53062.jpg|thumb|153x153px]]

==== What is an Edge Finder? ====
An '''edge finder''' is a precision tool used to locate the exact edge of a workpiece. When used properly, it can help you zero your X and Y axes within a few thousandths of an inch. Most edge finders have a tip that is '''0.200" in diameter''', meaning it has a radius of '''0.100"'''. The tip of the tool is attached with a magnet, allowing it to move when it contacts your piece while spinning.
[[File:Edge-finder-diagram-hoffman-group.webp|thumb]]

==== Step-by-Step Process ====

# '''Mount the Edge Finder''' - Insert the edge finder into a collet (preferably not a drill cuck for accuracy reasons) and snug it up in the spindle. Make sure your mill is set to a low RPM—between '''800 and 1200''' is ideal.
# '''Knock the Edge Finder off center''' - With your finger, push the tip of the edge finder so that it sits out of line with the rest of the tool
# '''Spin the Edge Finder''' - Start the mill and bring the spinning tip near the part edge. As you feed the part slowly toward the tool, you'll notice the tip wobbles eccentrically.
# '''Touch Off the Edge -''' As you get closer, the tip will suddenly "kick" and run true just before it jumps off. That moment of alignment—right before the jump—is your '''edge contact point'''.
# '''Read the DRO -''' At this point, your tool center is still offset from the actual part edge by '''half the diameter of the edge finder''' (typically 0.100").
# '''Set the Zero -''' Subtract the radius from the current DRO reading. For example, if the edge finder touches off and your DRO reads '''0.000"''', your actual part edge is at -'''0.100"'''.

* Set your '''DRO to -0.100"''', then jog the axis until it reads '''0.000"''', and set this as your zero.
* Repeat the same process for both X and Y edges if you're zeroing from a corner. Once both axes are zeroed, jog to any known feature on the part and verify against your print or CAD model.

`

==== Pro Tips ====

* Always approach from the '''same direction''' you plan to cut—this compensates for backlash.
* Use parallels if your part isn’t sitting directly on the vise bed, and indicate the top surface as your Z zero if needed.
* Don’t forget to lock the axis not in use while touching off for added rigidity.
* If your edge finder tip is chipped or the wobble doesn't go away smoothly, replace it—it’s no longer accurate.

[[File:Endmills.jpg|thumb]]

== Endmills ==
Endmills are the workhorses of the milling machine. These rotary cutters remove material using their flutes, and they come in a wide variety of materials, flute counts, and geometries. Selecting the right endmill affects surface finish, tool life, and cutting efficiency.

=== HSS vs. Carbide Endmills ===
Endmills are commonly made from either '''high-speed steel (HSS)''' or '''carbide'''. HSS tools are inexpensive, relatively tough, and ideal for general-purpose milling, especially at lower spindle speeds. They’re forgiving if the setup isn’t perfect, making them a good choice for students or roughing operations. Carbide endmills, on the other hand, are harder and more wear-resistant, making them ideal for harder materials and high-speed milling. Carbide also provides better finishes and lasts longer, '''but it's more brittle'''—meaning it can chip or snap if misused or dropped. In most teaching shops, you'll use both: HSS for roughing or learning, and carbide when you need precision, high feed rates, or are cutting tougher materials like steel or aluminum alloys.
[[File:Comparision.jpg|thumb|386x386px]]

=== 2-Flute vs. 4-Flute Endmills ===
Flute count has a major impact on how an endmill performs. '''2-flute endmills''' have wider spaces (gullets) between the cutting edges, which means they can clear chips more easily. This makes them ideal for machining softer materials like aluminum, where chip clogging is a concern, and also for slotting operations where chips have nowhere to escape. '''4-flute endmills''' have more cutting edges in contact with the material at once, leading to faster metal removal and smoother surface finishes, especially in harder materials like steel. However, they don’t clear chips as easily and are less ideal for deep slots unless you adjust feed rates and use coolant or air blast. As a general rule: use 2-flutes for aluminum and slotting, and 4-flutes for steel and side milling.

=== Reground vs. New Endmills ===
In a Brunsfield, you’ll likely come across '''reground''' endmills—cutters that have been resharpened to extend their life. Reground tools are great for roughing passes or when surface finish isn’t critical. They’re cheaper and environmentally friendly, but they may be slightly shorter, have worn coatings, or exhibit minor runout. For high-precision features, smoother finishes, or very tight tolerances, it’s best to use '''new endmills''', which have factory-ground edges and full cutting length.
[[File:104770.jpg|thumb|183x183px]]

=== Ball Nose Endmills ===
A '''ball nose endmill''' has a rounded tip rather than a flat one. This geometry is essential for contouring and 3D profiling, such as in molds or sculpted parts. They’re used when you want to avoid sharp inside corners or need to produce a smooth surface on a curved feature. However, they leave a scalloped finish unless stepovers are very fine, and they’re less rigid at the tip, so they’re not ideal for deep cuts. Use them for finishing passes on 3D surfaces or for parts that require smooth transitions.

== Workpiece Holding and Setup ==
Securing both the '''tool''' and the '''workpiece''' properly is essential to accurate, safe, and efficient milling. A loose setup will lead to poor finishes, chatter, and dangerous tool breakage. Here’s a breakdown of the most common equipment used in the shop for setup and holding.

=== Tool Holding: Collets vs. Drill Chucks ===
[[File:Colletsnchucks.jpg|center|thumb|389x389px|(Left) R8 collets of various sizes. (Right) Jacob's chuck for drill bits.]]

==== R8 Collets ====
R8 collets are the standard tool holders in most manual milling machines. They grip the shank of the cutting tool with good concentricity (low runout), making them ideal for endmills, edge finders, and center drills. Each collet size corresponds to a specific tool diameter—so you’ll need to match the collet to your tool shank.

* '''Pros:''' Accurate, secure, low runout
* '''Cons:''' Requires swapping for different shank sizes

==== Drill Chucks ====
Used for holding drill bits or reamers, drill chucks grip the tool with jaws tightened by a chuck key. They're only suitable for '''axial operations''' like drilling. Never use a drill chuck for side milling—cutting forces can pull the tool out or cause slippage.

* '''Pros:''' Quick tool changes, versatile for drilling
* '''Cons:''' Not secure for milling—can slip or wobble

=== Workpiece holding Tools ===

==== Milling Vise ====
The milling vise is the go-to workpiece holding tool in most shops. It clamps your part securely and aligns it square to the machine’s table. The vice uses a removable handle to open and close the jaws. The handle is stored hanging from the table when not in use.

It’s usually bolted down with T-slot hardware. Always check that your part is sitting flat and square in the vise. Indicating the vise to check if it's sitting square can be done using a '''Dial Indicator.''' See the "Maintenance" section.

'''Pro Tip:''' Use a mallet or dead-blow hammer to "seat" your part after snugging the vise but before final tightening.
[[File:Screenshot_2025-06-10_093432.png|center|thumb|617x617px|The mill machine vise is bolted to the table using T-Head bolts and nuts, allowing it be repositioned, or removed easily.]]
[[File:Slot.jpg|thumb|165x165px]]

==== '''Slot Clamping Kit (T-Slot Clamps)''' ====
Used for clamping irregular or oversized parts directly to the mill table. The kit includes step blocks, strap clamps, nuts, bolts, and T-nuts that fit into the machine’s T-slots.

* '''Good For:''' Holding plates, large parts, or when the vise won’t work
* '''Caution:''' Ensure clamps are level and square—uneven clamping can distort the part

=== Setup Aids and Accessories ===

==== Parallels ====
Parallels are precision-ground bars used to elevate a part inside the vise. They ensure that the part sits flat and level, and allow tool clearance below the part (e.g., for through-holes or full-depth slots). Choose a pair that keeps your part slightly above the vise jaws.

* '''Watch out for:''' Chips under the parallels—this will throw off your Z zero!

[[File:Unnamed.png|center|thumb|The parallels (Red) are used to raise the piece in the vise, while also giving it a level surface to sit on.]]
[[File:123-Supporting-Part-IMG_5489.jpg|thumb|In the image above, a 123 block is used to support the free end of a piece to ensure it doesn't deflect under load.]]

==== 123 Blocks ====
Precision-ground steel blocks sized 1" x 2" x 3". They’re used as reference spacers, squaring aids, or even mini angle plates. Can be clamped together or to the table to help with odd setups.

* '''Common Uses:''' Squaring a part in the vise, setting Z-depths, or elevating parts outside the vise

==== Collet Blocks ====
Collet blocks hold round or hex stock using a standard collet, allowing it to be clamped securely in the mill vise. They’re useful when machining multiple flats on round material or performing indexed operations.

* '''Types:''' Square blocks (for 4 sides), hex blocks (for 6 sides)

[[File:Angle.jpg|thumb|151x151px]]
[[File:J3i84pzrepa81.jpg|thumb|141x141px]]

==== Angle Plates ====
Used to hold parts vertically or at 90° angles to the table. Precision-ground and drilled with mounting holes. Often used in combination with clamps or vises to machine edges or ends of tall parts.

* '''Tip:''' Check squareness with an indicator before cutting

[[File:10inchRotaryTable.jpg|thumb|199x199px]]

==== Rotary Table (Turntable) ====
This allows controlled rotation of the part around a vertical axis. It's useful for machining circular patterns, bolt hole arrays, or radii. The table can be indexed manually in degrees or divided using index plates.

* '''Common Uses:''' Cutting arcs, drilling hole circles, machining gears
* '''Note:''' Always lock the axis you’re not using—these setups require careful planning

=== General Setup Tips ===

* '''Always clean mating surfaces''' (table, vise bottom, parallels) to prevent misalignment. Use brushes instead of your hands as chips can be sharp.
* '''Double-check part squareness''' before cutting—tap it down or into the jaws using a soft mallet
* '''Use the smallest clamp/holder that safely gets the job done'''—fewer things in the way means fewer chances for accidents
* '''Lock unused table axes''' when making a cut for better rigidity
* '''Take time with setup'''—the more precise your setup, the less trouble you’ll have during machining

== Monitoring the cut ==

=== Sound: What You're Hearing ===
'''Smooth, consistent hum -''' Ideal. Indicates proper feed/speed and good tool engagement.

'''Light squealing or whining -''' Usually a sign of rubbing instead of cutting—possibly from dull tools, too low feed, or incorrect RPM.

'''Chatter or rhythmic vibrations -''' A telltale sign of tool deflection, loose setups, or excessive stick-out. You'll hear a high-pitched “buzz” or “hammering” noise that worsens as the cut continues. Stop and address it.

'''Clunking or knocking -''' Indicates serious instability—tool looseness, bad bearings, or a poorly clamped part. Stop immediately and inspect.

'''Screaming or howling -''' Often a sign of way too high spindle speed or aggressive cutting with a brittle cutter (e.g., carbide). Check RPM and tool sharpness.

=== Chip Shape and Color ===
[[File:How-To-Judge-the-Processing-Status-by-the-Chips-Colour.jpg|thumb]]
Chips are your best real-time indicator of whether your cutter is performing well.

* '''Consistent, curled chips -''' Ideal. Suggests good chip evacuation and balanced feed/speed.
* '''Tiny dust-like chips -''' Feed too low or tool rubbing instead of cutting.
* '''Blue or black chips -''' Overheating—too much speed or not enough coolant/air. May damage the tool or workpiece.
* '''Long, stringy chips''' (esp. in aluminum) - Feed might be too low. Also risk of chip wrapping around the cutter—clear frequently.
* '''Powdery chips -''' Could indicate abrasive wear on the tool or surface hardening on the material. Dull tools or the wrong cutter for the job.

[[File:Image003.jpg|thumb|Scalloping finish on a CNC machine from momentary tool acceleration.]]

=== Surface Finish and Vibration ===

* '''Smooth finish with uniform texture -''' You’re doing great! Keep everything the same.
* '''Scalloped or ridged finish -''' Usually from too fast feed or tool chatter. May also mean the spindle is loose or the part is vibrating.
* '''Chatter marks (evenly spaced ripples) -''' Tool deflection or mechanical looseness. Check clamping, tool length, and feed speed.
* '''Random gouges or digs -''' Tool might be loose or broken. Shut down and inspect everything.

----

=== Vibration and Machine Feedback ===

* '''Stable, solid feel -''' Good setup. Axes are locked and the machine is working with you.
* '''Mild vibration through the handwheels or table -''' Not ideal—could be cutting too aggressively, or the setup might be slightly loose.
* '''Visible shaking or movement of the part or tool -''' Serious issue. Stop immediately. Recheck clamping, tool stick-out, and speed/feed.
* '''Tool deflection -''' Especially in longer or smaller-diameter tools, the cutter may bend under load, causing undersize cuts or chatter. Use a more rigid setup or adjust depth of cut.

----

=== Operator Intuition: Know the Signs ===

* '''“This sounds smooth and stable.”''' Keep going.
* '''“Something doesn’t feel right, but I can’t see it yet.”''' Trust that instinct—pause and inspect.
* '''“It’s cutting fine, but my finish looks bad.”''' Try lowering the speed or increasing feed slightly (or both).
* '''“The chips are changing color or shape.”''' Reassess your feed/speed and chip evacuation.

== Safety Considerations ==
The milling machine is one of the most powerful and versatile tools in the shop—but with that comes responsibility. Rotating tools, sharp cutters, and heavy parts can cause serious injuries if proper safety practices are not followed. Whether you're new to the machine or an experienced operator, '''safety always comes first'''.

=== PPE ===

* '''Safety Glasses''': Always required. Protects against flying chips or broken tools.
* '''Hearing Protection''': Recommended, especially during long cuts or when using high RPMs.
* '''Non-Synthetic Clothing''': Avoid synthetics that can melt or ignite. Cotton or natural fiber clothing is best.
* '''Closed-Toe Shoes''': Steel-toes are ideal. Never wear sandals or open footwear.
* '''Gloves''': '''Never wear gloves near rotating tools.''' Gloves can catch and pull your hand into the machine.
* '''Hair and Jewelry''': Tie back long hair and remove rings, watches, and dangling jewelry.

=== General Safety Rules ===

# '''Never leave the machine running unattended.''' Always be present and alert when the spindle is on.
# '''Keep the area clean and free of clutter.''' Chips, tools, and loose rags create tripping and entanglement hazards.
# '''Use a brush or chip hook to remove chips.''' Never use your hands, even with gloves.
# '''Always check for tool tightness.''' Ensure the tool is properly seated and tightened in the collet before starting the spindle.
# '''Double-check your setup.''' Loose vises, parallels, or improperly clamped workpieces are a major hazard.
# '''Know where the emergency stop is.''' Be ready to use it.

=== Machine-Specific Hazards ===

* '''Rotating Spindle and Tooling''': Never reach near the cutter when the machine is running. Even a spinning tool that’s "not cutting" is dangerous.
* '''Kickback and Tool Pullout''': Improper tool holding (like using a drill chuck for an endmill) can result in tools being thrown.
* '''Flying Chips and Debris''': Chips can come off hot and fast—use chip shields if available.
* '''Unexpected Movement''': If power feed or DRO is engaged improperly, the table can move quickly—keep hands clear.

=== Common Safety Mistakes to Avoid ===

* Wearing gloves or long sleeves while operating the machine
* Using a drill chuck to hold an endmill
* Leaving the key in the drill chuck
* Reaching over a spinning tool to brush off chips
* Using damaged or dull tooling
* Forgetting to lock the axes before a cut
* Starting the spindle before securing the part
* Not checking spindle direction—some tools will unscrew themselves or cut incorrectly if running backward.

== Maintenance ==
Before performing any accurate milling operation, it’s important to make sure your '''spindle is perpendicular to the table''' (tramming) and your '''vise is aligned parallel to the machine axes''' (indicating). Without these checks, your cuts can end up angled, off-center, or out of spec—even if everything else seems right.

<youtube>PAoWXnyUZ5M</youtube>

Even if the head is trammed, your cuts won’t be square unless the '''vise jaws are parallel to the X-axis travel'''. This process is called '''indicating the vise'''. This process involved placing a '''parallel''' into the vice, and running a dial indicator along its length while taking not of the change in position at each end. If there is significant deviation along the parallel, it tells you that the vice is not sitting square to the table.

<youtube>9VGu_h8q_cQ</youtube>

'''Tramming''' refers to adjusting the mill head so that the spindle is perfectly perpendicular to the table. On manual mills with tilting heads (like Bridgeport-style mills), this is a common maintenance and setup task—especially if the head has been rotated for a previous job.

This process involves comparing the measurement of each dial indicator on the tramming tool at various points on the mill table. This can tell you if the head of the mill needs to be clocked side to side or front & back.

The Brunsfield Center/Manufacturing Technologies/Mill

2025-07-18T17:22:15Z

Benrundle:

== Intro ==
[[File:1050VS_93596_00296.jpg|thumb|King Turret-Style Knee mill, as seen in the Brunsfield Center]]
The milling machine—commonly referred to as “the mill”—is one of the most versatile and widely used tools in any machine shop. Unlike a drill press, which cuts only in the vertical axis, a mill allows for precise movement in the X (left/right), Y (forward/back), and Z (up/down) directions, enabling complex and accurate machining operations on a wide range of materials.

Mills remove material using a rotating cutting tool held in a spindle, allowing operators to shape metal and plastic parts with high precision. In our shop, we primarily use vertical knee mills equipped with digital readouts (DROs), allowing for repeatable and accurate setups.

Whether you're facing a part flat, drilling a precise hole, cutting a slot, or using a form tool to create complex geometry, the mill is essential for prototype work, part modification, and precision fabrication.

This guide will walk through how mills work, the operations they can perform, how to choose the right tools, proper setup techniques, and what to watch for during machining.

== How the Mill Works ==
A milling machine operates by rotating a cutting tool (such as an endmill) while moving a workpiece against it. Material is removed through the shearing action of the rotating cutter, allowing for precise shaping of metal, plastic, or other materials.

=== Key Components ===

* '''Spindle'''
** The spindle holds and rotates the cutting tool. It's powered by a motor and can run at various speeds, depending on the material and operation.
* '''Table'''
** The flat surface that holds the workpiece. It can move in the '''X-axis (left/right)''' and '''Y-axis (in/out)'''. Movement is controlled by handwheels or power feeds.
* '''Knee & Column'''
** The knee supports the table and moves vertically along the column, giving the '''Z-axis (up/down)''' motion.
* '''Quill'''
** Found on most vertical mills, the quill allows for vertical movement of the spindle—useful for drilling or plunging into material.
* '''Digital Readout (DRO)'''
** A DRO displays the precise position of the table along each axis. It greatly improves accuracy and efficiency, especially for repetitive work.[[File:690174_main_07610.jpg|thumb|224x224px|The X-axis power feed controller (red box) with a control lever to change feed direction.]]

=== Modes of Movement ===

* '''Manual -''' Most shop mills are manual, meaning the operator turns handwheels to control table motion and spindle feed.
* '''Power Feed -''' Our Brunsfield mills have powered X-axis feeds. These are useful for consistent finish during long cuts like face milling.
* '''Locking Mechanisms -''' Axis locks are used to prevent unwanted movement. It's good practice to lock any axis not in use during a cut.

=== How Cutting Happens ===

* The cutter spins at a selected '''RPM''', chosen based on material, tool diameter, and cutter type.
* The workpiece is moved against the spinning cutter, removing material layer by layer.
* Different cutters and operations (face milling, slotting, drilling, etc.) change how the cut engages the workpiece.
* Chip formation and cutting load depend on feed rate, depth of cut, and cutter geometry.[[File:KbvTvAw.gif|thumb|341x341px|Each pass of the tool cuts a chip of metal from the workpiece.]]

=== Feed & Speed ===

* '''Spindle Speed (RPM)''' affects how fast the cutter rotates. Too fast and you'll burn the cutter; too slow and it may chatter or rub instead of cut.
* '''Feed Rate''' is how fast the workpiece moves into the cutter. It must be matched to the material and tool geometry to ensure clean cutting and tool life.

=== [[The Brunsfield Center/Manufacturing Technologies/Coolant|Coolant]] ===

* While machining, always apply coolant to mitigate heat production, minimize tool wear, and improve surface finish. See the coolant page for more info.

== Quick Start Guide ==

=== Mill Controls ===
[[File:Screenshot_2025-06-09_130753.png|thumb|599x599px]]
[[File:Screenshot_2025-06-09_131028.png|thumb|606x606px]]
The following images show the main controls on the milling machine, their functions are listed below:

# '''On/Off switch''' - Activates the motor on the mill.
# '''Speed Adjustment dial''' - Changes the rpm of the spindle while the mill is running.
# '''High/Low Gear Handle''' - Changes the running speed gear of the mill.
# '''Quill Pilot Feed Lever''' - Lowers & raises the spindle, used for drilling.
# '''Quill lock''' - Locks the spindle in the current position.
# '''Quill power feed''' - Used for fine adjustments of the spindle height.

# '''DRO''' - Displays the current X and Y axis position. Can be set to metric or imperial units.
# '''Vise''' - The vise is bolted to the mill table and holds the workpiece during operation.
# '''Y/X axis feed wheels''' - adjust the X & Y position of the table via clockwise or counterclockwise rotation.
# '''Z-axis knee lever''' - Adjusts the height of the table. Used to set proper working height for an operations. Changing this does not change the Z-axis DRO reading.

== [[The Brunsfield Center/Manufacturing Technologies/Mill/Milling Operations|Milling Operations]] ==
Primary operations on the mill are face milling, side milling, and drilling.

See a full run down of all the milling operations:

[[The Brunsfield Center/Manufacturing Technologies/Mill/Milling Operations|Milling Operations]]

== Indicating ==
Before making any cuts, it's critical to establish a '''working zero'''—a reference point from which all other dimensions are measured. On a milling machine with a digital readout (DRO), this is usually done by locating the edge of your part, or the vise, with an '''edge finder''' and then setting the DRO coordinates accordingly.
[[File:1-855-53062.jpg|thumb|153x153px]]

==== What is an Edge Finder? ====
An '''edge finder''' is a precision tool used to locate the exact edge of a workpiece. When used properly, it can help you zero your X and Y axes within a few thousandths of an inch. Most edge finders have a tip that is '''0.200" in diameter''', meaning it has a radius of '''0.100"'''. The tip of the tool is attached with a magnet, allowing it to move when it contacts your piece while spinning.
[[File:Edge-finder-diagram-hoffman-group.webp|thumb]]

==== Step-by-Step Process ====

# '''Mount the Edge Finder''' - Insert the edge finder into a collet (preferably not a drill cuck for accuracy reasons) and snug it up in the spindle. Make sure your mill is set to a low RPM—between '''800 and 1200''' is ideal.
# '''Knock the Edge Finder off center''' - With your finger, push the tip of the edge finder so that it sits out of line with the rest of the tool
# '''Spin the Edge Finder''' - Start the mill and bring the spinning tip near the part edge. As you feed the part slowly toward the tool, you'll notice the tip wobbles eccentrically.
# '''Touch Off the Edge -''' As you get closer, the tip will suddenly "kick" and run true just before it jumps off. That moment of alignment—right before the jump—is your '''edge contact point'''.
# '''Read the DRO -''' At this point, your tool center is still offset from the actual part edge by '''half the diameter of the edge finder''' (typically 0.100").
# '''Set the Zero -''' Subtract the radius from the current DRO reading. For example, if the edge finder touches off and your DRO reads '''0.000"''', your actual part edge is at -'''0.100"'''.

* Set your '''DRO to -0.100"''', then jog the axis until it reads '''0.000"''', and set this as your zero.
* Repeat the same process for both X and Y edges if you're zeroing from a corner. Once both axes are zeroed, jog to any known feature on the part and verify against your print or CAD model.

`

==== Pro Tips ====

* Always approach from the '''same direction''' you plan to cut—this compensates for backlash.
* Use parallels if your part isn’t sitting directly on the vise bed, and indicate the top surface as your Z zero if needed.
* Don’t forget to lock the axis not in use while touching off for added rigidity.
* If your edge finder tip is chipped or the wobble doesn't go away smoothly, replace it—it’s no longer accurate.

[[File:Endmills.jpg|thumb]]

== Endmills ==
Endmills are the workhorses of the milling machine. These rotary cutters remove material using their flutes, and they come in a wide variety of materials, flute counts, and geometries. Selecting the right endmill affects surface finish, tool life, and cutting efficiency.

=== HSS vs. Carbide Endmills ===
Endmills are commonly made from either '''high-speed steel (HSS)''' or '''carbide'''. HSS tools are inexpensive, relatively tough, and ideal for general-purpose milling, especially at lower spindle speeds. They’re forgiving if the setup isn’t perfect, making them a good choice for students or roughing operations. Carbide endmills, on the other hand, are harder and more wear-resistant, making them ideal for harder materials and high-speed milling. Carbide also provides better finishes and lasts longer, '''but it's more brittle'''—meaning it can chip or snap if misused or dropped. In most teaching shops, you'll use both: HSS for roughing or learning, and carbide when you need precision, high feed rates, or are cutting tougher materials like steel or aluminum alloys.
[[File:Comparision.jpg|thumb|386x386px]]

=== 2-Flute vs. 4-Flute Endmills ===
Flute count has a major impact on how an endmill performs. '''2-flute endmills''' have wider spaces (gullets) between the cutting edges, which means they can clear chips more easily. This makes them ideal for machining softer materials like aluminum, where chip clogging is a concern, and also for slotting operations where chips have nowhere to escape. '''4-flute endmills''' have more cutting edges in contact with the material at once, leading to faster metal removal and smoother surface finishes, especially in harder materials like steel. However, they don’t clear chips as easily and are less ideal for deep slots unless you adjust feed rates and use coolant or air blast. As a general rule: use 2-flutes for aluminum and slotting, and 4-flutes for steel and side milling.

=== Reground vs. New Endmills ===
In a Brunsfield, you’ll likely come across '''reground''' endmills—cutters that have been resharpened to extend their life. Reground tools are great for roughing passes or when surface finish isn’t critical. They’re cheaper and environmentally friendly, but they may be slightly shorter, have worn coatings, or exhibit minor runout. For high-precision features, smoother finishes, or very tight tolerances, it’s best to use '''new endmills''', which have factory-ground edges and full cutting length.
[[File:104770.jpg|thumb|183x183px]]

=== Ball Nose Endmills ===
A '''ball nose endmill''' has a rounded tip rather than a flat one. This geometry is essential for contouring and 3D profiling, such as in molds or sculpted parts. They’re used when you want to avoid sharp inside corners or need to produce a smooth surface on a curved feature. However, they leave a scalloped finish unless stepovers are very fine, and they’re less rigid at the tip, so they’re not ideal for deep cuts. Use them for finishing passes on 3D surfaces or for parts that require smooth transitions.

== Workpiece Holding and Setup ==
Securing both the '''tool''' and the '''workpiece''' properly is essential to accurate, safe, and efficient milling. A loose setup will lead to poor finishes, chatter, and dangerous tool breakage. Here’s a breakdown of the most common equipment used in the shop for setup and holding.

=== Tool Holding: Collets vs. Drill Chucks ===
[[File:Colletsnchucks.jpg|center|thumb|389x389px|(Left) R8 collets of various sizes. (Right) Jacob's chuck for drill bits.]]

==== R8 Collets ====
R8 collets are the standard tool holders in most manual milling machines. They grip the shank of the cutting tool with good concentricity (low runout), making them ideal for endmills, edge finders, and center drills. Each collet size corresponds to a specific tool diameter—so you’ll need to match the collet to your tool shank.

* '''Pros:''' Accurate, secure, low runout
* '''Cons:''' Requires swapping for different shank sizes

==== Drill Chucks ====
Used for holding drill bits or reamers, drill chucks grip the tool with jaws tightened by a chuck key. They're only suitable for '''axial operations''' like drilling. Never use a drill chuck for side milling—cutting forces can pull the tool out or cause slippage.

* '''Pros:''' Quick tool changes, versatile for drilling
* '''Cons:''' Not secure for milling—can slip or wobble

=== Workpiece holding Tools ===

==== Milling Vise ====
The milling vise is the go-to workpiece holding tool in most shops. It clamps your part securely and aligns it square to the machine’s table. The vice uses a removable handle to open and close the jaws. The handle is stored hanging from the table when not in use.

It’s usually bolted down with T-slot hardware. Always check that your part is sitting flat and square in the vise. Indicating the vise to check if it's sitting square can be done using a '''Dial Indicator.''' See the "Maintenance" section.

'''Pro Tip:''' Use a mallet or dead-blow hammer to "seat" your part after snugging the vise but before final tightening.
[[File:Screenshot_2025-06-10_093432.png|center|thumb|617x617px|The mill machine vise is bolted to the table using T-Head bolts and nuts, allowing it be repositioned, or removed easily.]]
[[File:Slot.jpg|thumb|165x165px]]

==== '''Slot Clamping Kit (T-Slot Clamps)''' ====
Used for clamping irregular or oversized parts directly to the mill table. The kit includes step blocks, strap clamps, nuts, bolts, and T-nuts that fit into the machine’s T-slots.

* '''Good For:''' Holding plates, large parts, or when the vise won’t work
* '''Caution:''' Ensure clamps are level and square—uneven clamping can distort the part

=== Setup Aids and Accessories ===

==== Parallels ====
Parallels are precision-ground bars used to elevate a part inside the vise. They ensure that the part sits flat and level, and allow tool clearance below the part (e.g., for through-holes or full-depth slots). Choose a pair that keeps your part slightly above the vise jaws.

* '''Watch out for:''' Chips under the parallels—this will throw off your Z zero!

[[File:Unnamed.png|center|thumb|The parallels (Red) are used to raise the piece in the vise, while also giving it a level surface to sit on.]]
[[File:123-Supporting-Part-IMG_5489.jpg|thumb|In the image above, a 123 block is used to support the free end of a piece to ensure it doesn't deflect under load.]]

==== 123 Blocks ====
Precision-ground steel blocks sized 1" x 2" x 3". They’re used as reference spacers, squaring aids, or even mini angle plates. Can be clamped together or to the table to help with odd setups.

* '''Common Uses:''' Squaring a part in the vise, setting Z-depths, or elevating parts outside the vise

==== Collet Blocks ====
Collet blocks hold round or hex stock using a standard collet, allowing it to be clamped securely in the mill vise. They’re useful when machining multiple flats on round material or performing indexed operations.

* '''Types:''' Square blocks (for 4 sides), hex blocks (for 6 sides)

[[File:Angle.jpg|thumb|151x151px]]
[[File:J3i84pzrepa81.jpg|thumb|141x141px]]

==== Angle Plates ====
Used to hold parts vertically or at 90° angles to the table. Precision-ground and drilled with mounting holes. Often used in combination with clamps or vises to machine edges or ends of tall parts.

* '''Tip:''' Check squareness with an indicator before cutting

[[File:10inchRotaryTable.jpg|thumb|199x199px]]

==== Rotary Table (Turntable) ====
This allows controlled rotation of the part around a vertical axis. It's useful for machining circular patterns, bolt hole arrays, or radii. The table can be indexed manually in degrees or divided using index plates.

* '''Common Uses:''' Cutting arcs, drilling hole circles, machining gears
* '''Note:''' Always lock the axis you’re not using—these setups require careful planning

=== General Setup Tips ===

* '''Always clean mating surfaces''' (table, vise bottom, parallels) to prevent misalignment. Use brushes instead of your hands as chips can be sharp.
* '''Double-check part squareness''' before cutting—tap it down or into the jaws using a soft mallet
* '''Use the smallest clamp/holder that safely gets the job done'''—fewer things in the way means fewer chances for accidents
* '''Lock unused table axes''' when making a cut for better rigidity
* '''Take time with setup'''—the more precise your setup, the less trouble you’ll have during machining

== Monitoring the cut ==

=== Sound: What You're Hearing ===
'''Smooth, consistent hum -''' Ideal. Indicates proper feed/speed and good tool engagement.

'''Light squealing or whining -''' Usually a sign of rubbing instead of cutting—possibly from dull tools, too low feed, or incorrect RPM.

'''Chatter or rhythmic vibrations -''' A telltale sign of tool deflection, loose setups, or excessive stick-out. You'll hear a high-pitched “buzz” or “hammering” noise that worsens as the cut continues. Stop and address it.

'''Clunking or knocking -''' Indicates serious instability—tool looseness, bad bearings, or a poorly clamped part. Stop immediately and inspect.

'''Screaming or howling -''' Often a sign of way too high spindle speed or aggressive cutting with a brittle cutter (e.g., carbide). Check RPM and tool sharpness.

=== Chip Shape and Color ===
[[File:How-To-Judge-the-Processing-Status-by-the-Chips-Colour.jpg|thumb]]
Chips are your best real-time indicator of whether your cutter is performing well.

* '''Consistent, curled chips -''' Ideal. Suggests good chip evacuation and balanced feed/speed.
* '''Tiny dust-like chips -''' Feed too low or tool rubbing instead of cutting.
* '''Blue or black chips -''' Overheating—too much speed or not enough coolant/air. May damage the tool or workpiece.
* '''Long, stringy chips''' (esp. in aluminum) - Feed might be too low. Also risk of chip wrapping around the cutter—clear frequently.
* '''Powdery chips -''' Could indicate abrasive wear on the tool or surface hardening on the material. Dull tools or the wrong cutter for the job.

[[File:Image003.jpg|thumb|Scalloping finish on a CNC machine from momentary tool acceleration.]]

=== Surface Finish and Vibration ===

* '''Smooth finish with uniform texture -''' You’re doing great! Keep everything the same.
* '''Scalloped or ridged finish -''' Usually from too fast feed or tool chatter. May also mean the spindle is loose or the part is vibrating.
* '''Chatter marks (evenly spaced ripples) -''' Tool deflection or mechanical looseness. Check clamping, tool length, and feed speed.
* '''Random gouges or digs -''' Tool might be loose or broken. Shut down and inspect everything.

----

=== Vibration and Machine Feedback ===

* '''Stable, solid feel -''' Good setup. Axes are locked and the machine is working with you.
* '''Mild vibration through the handwheels or table -''' Not ideal—could be cutting too aggressively, or the setup might be slightly loose.
* '''Visible shaking or movement of the part or tool -''' Serious issue. Stop immediately. Recheck clamping, tool stick-out, and speed/feed.
* '''Tool deflection -''' Especially in longer or smaller-diameter tools, the cutter may bend under load, causing undersize cuts or chatter. Use a more rigid setup or adjust depth of cut.

----

=== Operator Intuition: Know the Signs ===

* '''“This sounds smooth and stable.”''' Keep going.
* '''“Something doesn’t feel right, but I can’t see it yet.”''' Trust that instinct—pause and inspect.
* '''“It’s cutting fine, but my finish looks bad.”''' Try lowering the speed or increasing feed slightly (or both).
* '''“The chips are changing color or shape.”''' Reassess your feed/speed and chip evacuation.

== Safety Considerations ==
The milling machine is one of the most powerful and versatile tools in the shop—but with that comes responsibility. Rotating tools, sharp cutters, and heavy parts can cause serious injuries if proper safety practices are not followed. Whether you're new to the machine or an experienced operator, '''safety always comes first'''.

=== PPE ===

* '''Safety Glasses''': Always required. Protects against flying chips or broken tools.
* '''Hearing Protection''': Recommended, especially during long cuts or when using high RPMs.
* '''Non-Synthetic Clothing''': Avoid synthetics that can melt or ignite. Cotton or natural fiber clothing is best.
* '''Closed-Toe Shoes''': Steel-toes are ideal. Never wear sandals or open footwear.
* '''Gloves''': '''Never wear gloves near rotating tools.''' Gloves can catch and pull your hand into the machine.
* '''Hair and Jewelry''': Tie back long hair and remove rings, watches, and dangling jewelry.

=== General Safety Rules ===

# '''Never leave the machine running unattended.''' Always be present and alert when the spindle is on.
# '''Keep the area clean and free of clutter.''' Chips, tools, and loose rags create tripping and entanglement hazards.
# '''Use a brush or chip hook to remove chips.''' Never use your hands, even with gloves.
# '''Always check for tool tightness.''' Ensure the tool is properly seated and tightened in the collet before starting the spindle.
# '''Double-check your setup.''' Loose vises, parallels, or improperly clamped workpieces are a major hazard.
# '''Know where the emergency stop is.''' Be ready to use it.

=== Machine-Specific Hazards ===

* '''Rotating Spindle and Tooling''': Never reach near the cutter when the machine is running. Even a spinning tool that’s "not cutting" is dangerous.
* '''Kickback and Tool Pullout''': Improper tool holding (like using a drill chuck for an endmill) can result in tools being thrown.
* '''Flying Chips and Debris''': Chips can come off hot and fast—use chip shields if available.
* '''Unexpected Movement''': If power feed or DRO is engaged improperly, the table can move quickly—keep hands clear.

=== Common Safety Mistakes to Avoid ===

* Wearing gloves or long sleeves while operating the machine
* Using a drill chuck to hold an endmill
* Leaving the key in the drill chuck
* Reaching over a spinning tool to brush off chips
* Using damaged or dull tooling
* Forgetting to lock the axes before a cut
* Starting the spindle before securing the part
* Not checking spindle direction—some tools will unscrew themselves or cut incorrectly if running backward.

== Maintenance ==
Before performing any accurate milling operation, it’s important to make sure your '''spindle is perpendicular to the table''' (tramming) and your '''vise is aligned parallel to the machine axes''' (indicating). Without these checks, your cuts can end up angled, off-center, or out of spec—even if everything else seems right.

https://youtu.be/PAoWXnyUZ5M

Even if the head is trammed, your cuts won’t be square unless the '''vise jaws are parallel to the X-axis travel'''. This process is called '''indicating the vise'''. This process involved placing a '''parallel''' into the vice, and running a dial indicator along its length while taking not of the change in position at each end. If there is significant deviation along the parallel, it tells you that the vice is not sitting square to the table.

https://youtu.be/9VGu_h8q_cQ

'''Tramming''' refers to adjusting the mill head so that the spindle is perfectly perpendicular to the table. On manual mills with tilting heads (like Bridgeport-style mills), this is a common maintenance and setup task—especially if the head has been rotated for a previous job.

This process involves comparing the measurement of each dial indicator on the tramming tool at various points on the mill table. This can tell you if the head of the mill needs to be clocked side to side or front & back.

Manufacturing Training Center/Shop Trainings

2025-07-18T16:19:53Z

Benrundle:

{{DISPLAYTITLE:Shop Trainings}}
Trainings are offered via MTC or Brunsfield. All trainings can be found on the [https://simpli.events/u/uottawaceed Simpli website] when they are posted each week. Each training is required in order to operate the associated machines on your own.

== [[Manufacturing Training Center/Shop Trainings/Basic Training|Basic Training]] ==
=== About ===
Basic Training is the first training that all users should take. It grants you access to all manufacturing spaces and reassures staff that you are comfortable handling basic hand tools.

Basic training takes place in MTC and a session is run roughly every other week during the fall and winter semesters. The training takes 2 to 3 hours, during which users will listen to a brief safety presentation, then take part in a workshop where they will make a sheet metal box.

'''Basic Training is required before any other training can be taken.'''
[[File:Basic_-_Basic_-_Box-1.png|thumb|398x398px|Technical Drawing for the sheet metal box that is made during the basic training.]]

=== Preparation ===
Brunsfield staff will provide necessary PPE for the training.

In order to take the training, you must sign-up via a link in the CEED Newsletter or via QR code. This will take you to the [https://simpli.events/manage/events ''Simpli'' page] where you can register for a particular session.

It is also the user's responsibility to create a Makerepo account before taking the training. This is done when taking GNG courses, or can be done manually at [https://makerepo.com/ Makerepo.com]. This will allow to sign-in/out of all the CEED spaces and is necessary to take all trainings.

There are no prerequisite trainings to take the basic training. There is an optional '''pre-lab''' that can be completed ahead of time virtually.

=== Tools Used ===
During the training users will use a variety of tools and machines:

* [[The Brunsfield Center/Manufacturing Technologies/Hand Tools|Hand Tools]]
** Files
** Cutters/Tin Snips
** Marking Tools
** Pliers
** Hammers
* [[The Brunsfield Center/Manufacturing Technologies/Drill Press|Drill Press]]
* [[Manufacturing Training Center/Manufacturing Technologies/Corner Notcher|Corner Notcher]]
* [[The Brunsfield Center/Manufacturing Technologies/Sheet Metal Brake|Sheet Metal Brake]]
* [[The Brunsfield Center/Manufacturing Technologies/Welding/Spot Welding|Spot Welder]]

Click on a tool or machine to go to its page and learn more.

== [[Manufacturing Training Center/Shop Trainings/Lathe Training|Lathe Training]] ==

=== About ===
Lathe training takes place in MTC and teaches safe operation of the lathe. The training will consist of a briefing of the machines, and the guided production of a simple plastic part.

Making the part required three operations: Facing, Turning, and Drilling, all of which are instructed before hand.

=== Preparation ===

* Brunsfield staff will provide necessary PPE for the training.
* Basic training must be taken prior to taking lathe training.
* In order to take the training, you must sign-up via a link in the CEED Newsletter or via QR code. This will take you to the ''Simpli'' page where you can register for a particular session.
* There is an optional prelab available.

== [[Manufacturing Training Center/Shop Trainings/Mill Training|Mill Training]] ==

== [[Manufacturing Training Center/Shop Trainings/Welding Safety & MIG Training|Welding Safety & MIG Training]] ==

=== About ===
Welding Safety & MIG is an entry-level welding course offered in Brunsfield. The training can host up to 6 people and take roughly 3 hours.
[[File:Maxresdefault_(1).jpg|thumb|334x334px|MIG weld on a T-joint]]
It is designed to teach users the basics of welding in the shop, from machine setup, shop use and safety, basic welding science, and MIG welding technique.

=== Requirements ===

* All users need to have a [https://makerepo.com/ Makerepo] account to sign in the space and be accredited with the training certification.
* All users need to arrive wearing the propper PPE
** Long hair tied back
** No hand jewelry such as watches, bracelets, or large rings.
** Closed-toed sturdy shoes
** Long pants made of a natural material like cotton or denim (synthetic materials like leggings will melt with sparks.
** All other PPE will be provided
* All users must have completed the [[Manufacturing Training Center/Shop Trainings/Basic Training|Basic Training]]

[[File:Step_2.webp|thumb|MIG torch internals]]

=== Material Covered ===

* Shop Safety
** E-stops, First Aid Kit, Fire extinguisher, Brun Kit, Safety Shower, etc.
** Operation of the fume extractor.
** Basic Shop PPE
* Welding Area
** Special Flame-Rated area to be used for any operation producing fire or sparks.
** PPE Cabinet
** Welding Tables
** Gas Cylinders
* Grinders
** Pedestal and Hand-held grinders
*** different wheels, techniques and safety
* Welding PPE (Red Cabinet)
** Helmets
** Jackets
** Gloves
** Beanies
** Helmets
* Different metals and their weldability
* Machine Setup
** Gas
*** Propper setup, operation, and safety.
** Machine Settings (Feed rate and Voltage)
** Grounding, & Powering the Machine
* MIG machine internals
* Torch Internals
* Welding accessories
** Clamps
** Cutters
** Magnets

[[File:018-mig-welder-set-up.jpg|thumb|390x390px|Internals of the MIG machine]]

=== How to Sign-Up ===
All of the training sessions are posted on the [https://simpli.events/u/uottawaceed Simpli] website. You can sign up for the CEED newsletter on [https://makerepo.com/ Makerepo] to stay up to date on the schedule. We try to change the times of trainings each week to accommodate everyone's schedules.

== [[Manufacturing Training Center/Shop Trainings/TIG Training|TIG Training]] ==

== [[Manufacturing Training Center/Shop Trainings/CNC Training|CNC Training]] ==

=== What is CNC? ===
CNC (Computer Numerical Control) is a manufacturing method where machines like mills, lathes, routers, 3D printers, laser cutters, and more are controlled using computer codes—primarily G-code, a language that tells machines what movements to make and actions to perform. These codes are interpreted by a controller, which converts them into signals that operate various machine components. While different machines may use different variations of G-code, the underlying principles remain the same. CNC machining offers high precision, speed, and the ability to produce complex parts with tight tolerances, making it ideal for large-scale production and detailed work. However, due to its time-consuming setup and need for specialized programming knowledge, it is less suitable for simple or low-volume projects.

For more information on CNC machining, including G-code, CAM, and speeds and feeds, visit the following YouTube channels:

Haas Automation

NYC CNC

=== About CNC Training ===
The CNC Training Course offered by CEED is a two-part course that covers the basics of G-Code and writing machine programs, a brief overview of feeds and speeds, basic functions in the Fusion 360 CAM workspace, and the operating procedures for the CNC routers in the Wood Room. After completing both parts of the training, students should be able to create a program for a simple part with one setup using common materials like MDF, plastic, or aluminum.

Manufacturing Training Center/Shop Trainings/Welding Safety & MIG Training

2025-07-18T16:18:17Z

Benrundle:

{{DISPLAYTITLE: Welding Safety & MIG Training}}
== About ==
Welding Safety & MIG is an entry-level welding course offered in Brunsfield. The training can host up to 6 people and take roughly 3 hours.
[[File:Maxresdefault (1).jpg|thumb|334x334px|MIG weld on a T-joint]]
It is designed to teach users the basics of welding in the shop, from machine setup, shop use and safety, basic welding science, and MIG welding technique.

== Requirements ==

* All users need to have a [https://makerepo.com/ Makerepo] account to sign in the space and be accredited with the training certification.
* All users need to arrive wearing the propper PPE
** Long hair tied back
** No hand jewelry such as watches, bracelets, or large rings.
** Closed-toed sturdy shoes
** Long pants made of a natural material like cotton or denim (synthetic materials like leggings will melt with sparks.
** All other PPE will be provided
* All users must have completed the [[Manufacturing Training Center/Shop Trainings/Basic Training|Basic Training]]
[[File:Step 2.webp|thumb|MIG torch internals]]

== Material Covered ==

* Shop Safety
** E-stops, First Aid Kit, Fire extinguisher, Brun Kit, Safety Shower, etc.
** Operation of the fume extractor.
** Basic Shop PPE
* Welding Area
** Special Flame-Rated area to be used for any operation producing fire or sparks.
** PPE Cabinet
** Welding Tables
** Gas Cylinders
* Grinders
** Pedestal and Hand-held grinders
*** different wheels, techniques and safety
* Welding PPE (Red Cabinet)
** Helmets
** Jackets
** Gloves
** Beanies
** Helmets
* Different metals and their weldability
* Machine Setup
** Gas
*** Propper setup, operation, and safety.
** Machine Settings (Feed rate and Voltage)
** Grounding, & Powering the Machine
* MIG machine internals
* Torch Internals
* Welding accessories
** Clamps
** Cutters
** Magnets
[[File:018-mig-welder-set-up.jpg|thumb|390x390px|Internals of the MIG machine]]

== How to Sign-Up ==
All of the training sessions are posted on the [https://simpli.events/u/uottawaceed Simpli] website. You can sign up for the CEED newsletter on [https://makerepo.com/ Makerepo] to stay up to date on the schedule. We try to change the times of trainings each week to accommodate everyone's schedules.

File:Step 2.webp

2025-07-18T16:18:01Z

Benrundle:

MIG Torch

File:018-mig-welder-set-up.jpg

2025-07-18T16:17:11Z

Benrundle:

MIG machine

File:Maxresdefault (1).jpg

2025-07-18T16:16:28Z

Benrundle:

MIG

Manufacturing Training Center/Shop Trainings/Welding Safety & MIG Training

2025-07-18T16:14:50Z

Benrundle:

{{DISPLAYTITLE: Welding Safety & MIG Training}}
== About ==
Welding Safety & MIG is an entry-level welding course offered in Brunsfield. The training can host up to 6 people and take roughly 3 hours.

It is designed to teach users the basics of welding in the shop, from machine setup, shop use and safety, basic welding science, and MIG welding technique.

== Requirements ==

* All users need to have a [https://makerepo.com/ Makerepo] account to sign in the space and be accredited with the training certification.
* All users need to arrive wearing the propper PPE
** Long hair tied back
** No hand jewelry such as watches, bracelets, or large rings.
** Closed-toed sturdy shoes
** Long pants made of a natural material like cotton or denim (synthetic materials like leggings will melt with sparks.
** All other PPE will be provided
* All users must have completed the [[Manufacturing Training Center/Shop Trainings/Basic Training|Basic Training]]

== Material Covered ==

* Shop Safety
** E-stops, First Aid Kit, Fire extinguisher, Brun Kit, Safety Shower, etc.
** Operation of the fume extractor.
** Basic Shop PPE
* Welding Area
** Special Flame-Rated area to be used for any operation producing fire or sparks.
** PPE Cabinet
** Welding Tables
** Gas Cylinders
* Grinders
** Pedestal and Hand-held grinders
*** different wheels, techniques and safety
* Welding PPE (Red Cabinet)
** Helmets
** Jackets
** Gloves
** Beanies
** Helmets
* Different metals and their weldability
* Machine Setup
** Gas
*** Propper setup, operation, and safety.
** Machine Settings (Feed rate and Voltage)
** Grounding, & Powering the Machine
* MIG machine internals
* Torch Internals
* Welding accessories
** Clamps
** Cutters
** Magnets

== How to Sign-Up ==
All of the training sessions are posted on the [https://simpli.events/u/uottawaceed Simpli] website. You can sign up for the CEED newsletter on [https://makerepo.com/ Makerepo] to stay up to date on the schedule. We try to change the times of trainings each week to accommodate everyone's schedules.

Manufacturing Training Center/Shop Trainings/Welding Safety & MIG Training

2025-07-18T15:59:31Z

Benrundle:

{{DISPLAYTITLE: Welding Safety & MIG Training}}
== About ==
Welding Safety & MIG is an entry-level welding course offered in Brunsfield. The training can host up to 6 people and take roughly 3 hours.

It is designed to teach users the basics of welding in the shop, from machine setup, shop use and safety, basic welding science, and MIG welding technique.

== Requirements ==

* All users need to have a [https://makerepo.com/ Makerepo] account to sign in the space and be accredited with the training certification.
* All users need to arrive wearing the propper PPE
** Long hair tied back
** No hand jewelry such as watches, bracelets, or large rings.
** Closed-toed sturdy shoes
** Long pants made of a natural material like cotton or denim (synthetic materials like leggings will melt with sparks.
** All other PPE will be provided
* All users must have completed the [[Manufacturing Training Center/Shop Trainings/Basic Training|Basic Training]]

== Material Covered ==

== How to Sign-Up ==

Manufacturing Training Center/Shop Trainings/Welding Safety & MIG Training

2025-07-18T15:59:00Z

Benrundle:

== About ==
Welding Safety & MIG is an entry-level welding course offered in Brunsfield. The training can host up to 6 people and take roughly 3 hours.

It is designed to teach users the basics of welding in the shop, from machine setup, shop use and safety, basic welding science, and MIG welding technique.

== Requirements ==

* All users need to have a [https://makerepo.com/ Makerepo] account to sign in the space and be accredited with the training certification.
* All users need to arrive wearing the propper PPE
** Long hair tied back
** No hand jewelry such as watches, bracelets, or large rings.
** Closed-toed sturdy shoes
** Long pants made of a natural material like cotton or denim (synthetic materials like leggings will melt with sparks.
** All other PPE will be provided
* All users must have completed the [[Manufacturing Training Center/Shop Trainings/Basic Training|Basic Training]]

== Material Covered ==

== How to Sign-Up ==

The Brunsfield Center

2025-07-18T15:54:38Z

Benrundle:

Manufacturing Training Center/Shop Trainings/Welding Safety & MIG Training

2025-07-18T15:51:53Z

Benrundle: Created page with "== About == Welding Safety & MIG is an entry-level welding course offered in Brunsfield. The training can host up to 6 people and take roughly 3 hours. It is designed to teach users the basics of welding in the shop, from machine setup, shop use and safety, basic welding science, and MIG welding technique. == Requirements == * All users need to have a [https://makerepo.com/ Makerepo] account to sign in the space and be accredited with the training certification. * All..."

Manufacturing Training Center/Manufacturing Technologies/CNC Router

2025-07-18T15:43:18Z

Benrundle:

{{DISPLAYTITLE: CNC Routers}}
[[File:8abfea 26fd5c7576cb44ffad84962f086fad29.jpg|thumb|386x386px|CNC router (2 small and 1 large one in the Wood Room)]]

== About Routers ==
Routers and mills both operate in a very similar fashion and share many G-codes, but routers are lighter, faster, and used for cutting soft materials like wood or plastic. Mills are heavier, more rigid, and designed for precise machining of hard materials such as steel. The main difference lies in their construction, cutting power, and the types of materials they’re built to handle.

Routers typically use a gantry setup to move the cutting tool around the part, rather than the part moving around the tool. This allows for much faster travel speeds since the spindle and motor typically weigh less than the table. They also generally operate in the range of 10 000-15 000 RPM, and can get as high as 30 000 RPM, but with very low torque. For this reason, routers are ideal for soft materials like MDF, polycarbonate, or delrin since they require little effort to cut but have very high surface speeds.

Routers also come in many different sizes, from desktop routers as small as a printer to table routers big enough to lie down on. This, and the fact that most are gantry-style, make routers potentially much more affordable than mills as well as being able to be built by hand from a kit or from scratch.

=== What Changes? ===
While it is completely possible to make the same part out of the same material on a mill and a router, the path to do it will differ. The first thing to consider is machine limitations; some mills can't run the spindle beyond 5000 RPM and some routers can ONLY run above 5000 RPM. Routers are also limited in power output while mills are limited in feedrate. All of these factors will necessarily affect how the part is programmed for one machine versus another.

Something else to consider which often gets overlooked is work holding (see [[The Brunsfield Center/Manufacturing Technologies/Mill|Mill]] page for more info). Most mills have a sturdy, usually cast iron or similar, table with T-slots and typically a vise as well. Routers are much more diverse in their work holding options; some tables have T-slots like a mills, while others have grids of threaded holes, magnets, or vacuum systems. It is important to understand the tools at your disposal in order to create a rigid fixture. This is very commonly the longest step of any manufacturing process besides designing the part, so it's worth it to be careful and mindful and not to rush.

However, keep in mind that the machine itself is only so rigid as well. Since routers are not usually as rigid as mills, it is recommended to take cuts with a smaller depth and width to not stress the machine. With a smaller depth of cut, it is now also possible to run the machine faster, which works to the router's advantage.

File:8abfea 26fd5c7576cb44ffad84962f086fad29.jpg

2025-07-18T15:42:04Z

Benrundle:

CNC router

Manufacturing Training Center/Manufacturing Technologies/CNC Router

2025-07-18T15:40:57Z

Benrundle:

{{DISPLAYTITLE: CNC Routers}}
== About Routers ==
Routers and mills both operate in a very similar fashion and share many G-codes, but routers are lighter, faster, and used for cutting soft materials like wood or plastic. Mills are heavier, more rigid, and designed for precise machining of hard materials such as steel. The main difference lies in their construction, cutting power, and the types of materials they’re built to handle.

Routers typically use a gantry setup to move the cutting tool around the part, rather than the part moving around the tool. This allows for much faster travel speeds since the spindle and motor typically weigh less than the table. They also generally operate in the range of 10 000-15 000 RPM, and can get as high as 30 000 RPM, but with very low torque. For this reason, routers are ideal for soft materials like MDF, polycarbonate, or delrin since they require little effort to cut but have very high surface speeds.

Routers also come in many different sizes, from desktop routers as small as a printer to table routers big enough to lie down on. This, and the fact that most are gantry-style, make routers potentially much more affordable than mills as well as being able to be built by hand from a kit or from scratch.

=== What Changes? ===
While it is completely possible to make the same part out of the same material on a mill and a router, the path to do it will differ. The first thing to consider is machine limitations; some mills can't run the spindle beyond 5000 RPM and some routers can ONLY run above 5000 RPM. Routers are also limited in power output while mills are limited in feedrate. All of these factors will necessarily affect how the part is programmed for one machine versus another.

Something else to consider which often gets overlooked is work holding (see [[The Brunsfield Center/Manufacturing Technologies/Mill|Mill]] page for more info). Most mills have a sturdy, usually cast iron or similar, table with T-slots and typically a vise as well. Routers are much more diverse in their work holding options; some tables have T-slots like a mills, while others have grids of threaded holes, magnets, or vacuum systems. It is important to understand the tools at your disposal in order to create a rigid fixture. This is very commonly the longest step of any manufacturing process besides designing the part, so it's worth it to be careful and mindful and not to rush.

However, keep in mind that the machine itself is only so rigid as well. Since routers are not usually as rigid as mills, it is recommended to take cuts with a smaller depth and width to not stress the machine. With a smaller depth of cut, it is now also possible to run the machine faster, which works to the router's advantage.

The Brunsfield Center/Manufacturing Technologies/CNC

2025-07-18T15:37:37Z

Benrundle:

[[File:Bf427295-f16b-4ef8-b44c-2833565a8454.webp|thumb|421x421px]]

== What is CNC? ==
CNC stands for Computer Numerical Control. It is a manufacturing method that involves controlling a machine tool by feeding it computer codes for certain operations. There are many different machines that operate using CNC technology, most commonly mills, lathes, and routers. However, many people don't realize that other machines like 3D printers, laser, plasma, and water jet cutters, wire EDM (electric discharge machining), grinders, pick & place machines and more operate on the same principles, often even using some of the same codes.

All these machines and more use G-Code. G-code is the language we use to talk to the machine, it uses codes like words to tell the machine where to go and what to do. Once the code is uploaded to the machine, the controller turns code into electrical signals which control different parts of the machine like motors, coolant pumps, heaters, and so on. Think of the controller like a translator that translates the code we know to signals the machine understands. Keep in mind that mills will have different codes from routers, lathes and so on (they speak different dialects of the same coding language), and there are even different codes for machines that have 3, 4 or 5 axes or that are made by different brands (like regional accents).

CNC manufacturing can be incredibly useful, but only in the right situation. It is more precise and can produce more complex parts than manual machining, and the time spent actually machining is faster. This is ideal for production runs, complex parts, tight tolerances, or surface finish requirements. On the other hand, it takes much longer to setup (CAD, CAM program, tool setup, machine setup). It also requires in-depth knowledge of programming and CAM software. As such, it is not useful for simple parts, low-scale production, or prototyping.

For more information on CNC machining, including G-code, CAM, and speeds and feeds, visit the following YouTube channels:

[https://www.youtube.com/@haasautomation Haas Automation]

[https://www.youtube.com/@nyccnc NYC CNC]

== Our CNC Machines ==
[[File:Mini mill.png|thumb]]
[[The Brunsfield Center]] and [[Manufacturing Training Center|MTC]] are home to several different CNC machines with a variety of capabilities.

* Haas Mini Mill 2
* Haas TL1 lathe
* Tormach PCNC 1100 mill
* two Larken Automation Camtool 24/36 routers
* Larken Automation System 100 router
* FoxAlien Desktop router

The two Haas machines are our newest and most powerful machines. They are reserved for JMTS teams making custom parts and are operated by the manager of JMTS, Jason Demers. All other CNC machines are available for use by students upon completion of both parts of the [[Manufacturing Training Center/Shop Trainings/CNC Training|CNC training]] and with approval from the Brunsfield manager, Alex Vendette.

== G-Code ==
G-Code is the language used to communicate with CNC machines. Invented in the 1950's at MIT, it used to be punched onto rolls of tapes that were fed into the machine on a wheel. In learning G-Code, you will notice that some codes have become less useful in modern times as technology advances. For example, the code M30 calls the machine to rewind the code as if it were still on a physical tape, even though computers have been in use for three decades.

Nowadays, the power of computers and CAM (computer-aided manufacturing) software has made CNC machining significantly more accessible. Once you have a model of your part, you can simply load it into the CAM software, define the desired tool paths, and adjust a few parameters, and the software will output dozens or even hundreds of pages of code in an instant.
[[File:G code.png|thumb|An example of G-Code syntax]]
As a coding language, G-Code is relatively simple. A single code will always follow the format of a letter followed by several numbers; this is called a word. A string of words together on the same line is called a block, you can think of this like a sentence. Every code can be sorted into one of three categories: Preparatory codes, Miscellaneous codes, and Address codes. Preparatory codes, or G-codes for short, are the codes that control the machine's movement and geometry. Miscellaneous codes, or M-codes, control auxillary functions of the machine, such as coolant or tool changers. All other codes fall under Address codes.

There is a generally accepted format to organize any G-code program to make sure it runs smoothly, and more important safely.

# Safe start-up codes: this section will includes codes to do things like switching between imperial and metric units, initializing the part origin, selecting a motion mode, and more. The idea is to reset any odd settings that might still be active from the last program and make sure everything is operation as it should.
# Tool loading: this is usually a very small section. It takes care of loading the tool into the spindle of the machine, calling up all the offsets for that tool, and turning the spindle on. It will also turn on cool pumps or other auxillary functions of the machine.
# Rapid to part: this is when the machine will position the tool above the part to start machining. Up until this point, you should run the program in single-block mode, meaning one line of code at a time, to check that everything is working properly.
# Machining operation: from here on, turn off single-block mode and run the program normally. This section is where the fun happens.
# Shut-down sequence: once the machining is done, the tool will move away and the spindle, coolant, and auxillaries will turn off. If you have a multi-tool program, then the next section will restart at step 2 and continue in a loop for however many tools are needed.
# Program end: once all machining passes are done, there should be another line of codes similar to the safe start-up codes to make sure the machine doesn't do anything weird when it comes back online. Finally, you'll see the code to terminate the program and you can grab the part.

== Computer-Aided Manufacturing (CAM) ==
[[File:Fusion.png|thumb|225x225px]]
For all CAM work, CEED recommends Fusion 360 by Autodesk. Fusion 360 is free for students, easy to learn with hours of tutorials across the internet, and can even work in conjunction with Solidworks by uploading Solidworks file types to your Autodesk account.

The following video provides a brief but relatively detailed tutorial on making a part and CAM program in Fusion 360. If you're only interested in the CAM portion of the tutorial because you prefer Solidworks for modelling, you can skip to 5:30.

[https://youtu.be/xRVVUteI1PY?si=-48zC0pI0I_rPwn0&t=329 Fusion 360 tutorial]

You can also find more detailed tutorials and additional resources on the Autodesk website, [https://www.autodesk.com/learn/catalog/product%7Crole%7Ceducators/Fusion%7Ca8f296ee-ec03-4476-ad40-5b1eca5df91b%7Cuniversities here].

== Feeds & Speeds ==
The most important part of programming a part to be machined is feeds and speeds, meaning how fast is the tool spinning, moving across the part, and removing material. Although it may seem daunting at first and can take years of experience to truly master, there are a handful of simple equations that can provide a good starting point.

The goal of these calculations is to find the values for the S code (spindle speed) and the F code (feed rate) in the NC program. However, these values will be different depending on the material of the workpiece, the material of the tool, the size of the tool, the power output of the machine and more. Therefore, we must derive the S and F values from these material and geometry properties.
[[File:RPM_formula.png|thumb|205x205px]]
The first and simplest equation helps us calculate the S value for spindle speed. In this equation, D is the diameter of the tool in inches and SFM is surface feet per minute which is a property of the material. SFM refers to the optimal linear speed of the cutting edge across the surface of the material. Consider cutting a piece of wood with a hacksaw, the SFM value would correspond the speed you push and pull the saw blade through the wood.
[[File:Feed_formula.png|thumb|479x479px]]
To calculate the feed rate, we must first have the spindle speed. The equation that follows also uses the number of flutes or cutting edges on the tool, and a value called Chip Load, also known as IPT, CPT, or FPT (Inch/Chip/Feed per tooth). Chip load refers to the thickness of the chip, or more specifically how much material each flute removes each revolution.

Find more information on calculating feeds and speeds in the Sandvik Coromant blog, [https://www.sandvik.coromant.com/en-gb/knowledge/machining-formulas-definitions/milling-formulas-definitions?utm_source=google&utm_medium=paid-search&utm_campaign=2025_ca_product-focused-sold-round-tools here].

=== Other Condiserations ===
[[File:Chip_thinning.png|thumb]]

==== Chip Thinning ====
Chip thinning<ref name=":0">NYC CNC. (n.d.). ''Getting started: Feeds & speeds''. Retrieved June 16, 2025, from <nowiki>https://nyccnc.com/getting-started-feeds-speeds/</nowiki></ref> is a phenomenon caused by the circular geometry of a milling tool. As radial engagement decreases, the actual thickness of the chips being cut will end up smaller than what the programmed S & F values should produce. At a radial depth of cut (RDOC) of 50% of the tool diameter, the actual and programmed chip load will be exactly equal, but as the RDOC decreases, the cutting edge of the tool will start to enter the material at an angle. Illustration from Harvey Performance<ref>'''Harvey Performance Company. (n.d.).''' ''How to combat chip thinning.'' ''In The Loupe.'' Retrieved June 16, 2025, from <nowiki>https://www.harveyperformance.com/in-the-loupe/combat-chip-thinning/</nowiki></ref>.

For most operations, chip thinning won't be an issue. Where it becomes a problem is in situations where a big tool has a small RDOC, for example a half inch tool taking a .001” finishing pass at a programmed FPT of .005” '''''results in an actual FPT of only 0.0004”'''''<ref name=":0" />. It's important to realize that no cutting edge is ever perfectly sharp. The flutes of most endmills have a radius on the edge of about 0.0001-0.0003", so the operation mentioned above would create chips barely wider than the sharp edge. This will cause the tool to rub more and drastically decrease its useable life.
[[File:Chip_thinning_calc.png|thumb]]
To avoid rubbing, there is a formula to convert the programmed chip load into the actual chip load, based on RDOC and tool diameter. NYC CNC understands that this equation is not very nice to deal with, so they've made a wonderful [https://nyccnc.com/speeds-feeds-excel-worksheet/ excel sheet] that can do almost any S&F calculation you may need. Once you've calculated the optimal chip load for your material, you can adjust the spindle speed, feed rate, and RDOC to achieve it. Keep it mind, however, that changing one of these to the ideal window may bring another outside of that window.
[[File:Mrr.png|thumb|239x239px]]

==== Machine Limitations ====
An important and often overlooked part of dialing in your speeds and feeds is the capability of the machine itself. Some machines have weaker spindles or slower axes than others, and settings that work on one machine may not on another. To find the power requirement of a certain operation, first we need to determine the Material Removal Rate (MRR) which typically has units of cu in/min. Once the MRR is known, divide it by the material's K factor, which represents the MRR that can be acheived by 1HP and is a function of the material hardness.

Another factor of the machine that's less understood is rigiditiy. This refers to how stiff all the joints and connections in the machine are, as well as how much backlash the motors have and the integrity of the work holding method. Any part of the machine or setup that's less rigid than it should be is a potential source of vibration, which can lead to tool chatter, higher wear on the tool and internal parts, poor surface finishes and low tolerances. Therefore, it's important to make your setup as rigid as possible and adjust your feeds and speeds as needed. Although it may seem counter-intuitive, generally it actually helps to go faster to mitigate vibration<ref>Sandvik Coromant. (n.d.). ''Milling vibration''. <nowiki>https://www.sandvik.coromant.com/en-us/knowledge/milling/vibration</nowiki></ref>.
[[File:Screenshot 2025-07-16 165907.png|thumb]]

==== Tool Geometry, Materials, and Coatings ====
While most of the above calculations have been based on solely the work material, it is also important to consider the tool itself. Choosing the right cutting tool material is essential for machining efficiency, requiring a balance of hardness, toughness, and resistance to wear and heat. Materials like High-Speed Steel (HSS), carbide, ceramics, and silicon nitride each offer advantages based on machining conditions. Tool geometry and coatings such as CVD and PVD also play key roles in performance by affecting chip flow, wear resistance, and toughness. While premium tooling may slightly increase costs, it enables higher feeds and speeds, significantly boosting material removal rates and reducing cycle times—often far outweighing the added expense.<ref>'''Hess, E.''' (2024, May). ''Easy guide to cutting tool material selection''. CNC Cookbook. <nowiki>https://www.cnccookbook.com/cutting-tool-materials/</nowiki></ref>

<references />

File:Bf427295-f16b-4ef8-b44c-2833565a8454.webp

2025-07-18T15:37:13Z

Benrundle:

CNC pic

The Brunsfield Center/Manufacturing Technologies/Vertical Bandsaw

2025-07-18T15:33:48Z

Benrundle:

{{DISPLAYTITLE: Vertical Bandsaw}}
== About ==
[[File:Ts325.jpg|thumb|KING 17" vertical bandsaw, located in Brunsfied.]]
The KC-1700WM-VS is a 17” vertical bandsaw capable of cutting wood, plastics, and various metals. It features a variable speed drive with a digital readout and supports both wood and metal cutting through easy belt configuration changes and blade swaps. In Brunsfield, there are separate machines set up with blades for cutting metal and wood/plastic.

== Usage ==

=== Wood/Plastic Bandsaw Unit ===

* Resawing and ripping of large wooden panels or blocks

* Cutting curves or intricate shapes in plywood, MDF, and plastics

* General-purpose woodworking

=== Metal Bandsaw Unit ===

* Cutting mild steel, aluminum, brass, and other non-ferrous metals

* Making straight or slightly curved cuts in metal stock

* Slow-speed cutting suitable for dense materials
[[File:Bandsaw27.png|thumb|477x477px|Propper operation of the bandsaw.]]

== Safe Operating Procedure ==
* Verify correct blade type is installed (Wood: coarse tooth, Metal: fine tooth)

* Confirm proper blade speed setting using the digital control

* Ensure guards are in place and the area is clean and dry

* Adjust upper blade guide to 1/8”–1/4” above the workpiece

* Changing Speed (Wood/Metal)
** Wood (540–3600 SFPM)
** Metal (100–650 SFPM)
** Changing the speed is done by ear. Slowly increase the speed using the hand wheel until the workpiece starts to whine loudly, then back it down until it quiets down.

=== Cutting Best Practices and Tips for Vertical Bandsaw Use ===
[[File:Teeth-per-inch-1024x341.webp|thumb|Blade tooth measurement.]]

==== 1. Tooth Engagement and Material Thickness ====
When cutting metal, it's critical that '''at least 3 teeth''' of the blade are in contact with the material at all times. This ensures:

* A smooth, controlled cut

* Prevention of tooth stripping or chipping

* Reduced blade wear
* '''Minimum Material Thickness Guide'''

If you're using a 24 TPI blade (typical for thin metals), the minimum material thickness should be:

'''3 contact teeth / 24 TPI = 0.125" or 1/8"'''

For a 14 TPI blade, that would be roughly '''0.21"''', or about '''3/16" thick'''.

Always match blade pitch (TPI) to the '''thinnest section''' of the material you're cutting.

==== 2. Blade Selection Tips ====

* '''Wood/Plastic''': Use coarse blades (e.g., 6–10 TPI) with wide gullets to clear sawdust

* '''Aluminum''': Use 10–14 TPI bi-metal blades

* '''Steel/Brass''': Use 14–24 TPI; lower speeds and cutting fluid help prolong blade life

[[File:FH14NOV_BANDSW_05.webp|thumb|Depiction of relief cuts in order to cut sharper angles.]]

==== 3. Feed Rate and Pressure ====

* Let the saw do the cutting — apply '''steady, light pressure'''

* Forcing the cut can cause overheating or blade deflection

* Observe chip formation: fine dust means too slow, heavy blue chips mean too fast

==== 4. Avoiding Blade Drift ====

* Use a '''sharp, properly tensioned blade'''

* Make sure the '''blade is tracking''' on the center of the wheels

* Use the '''rip fence''' for straight cuts and always align the workpiece squarely

==== Safety Notes ====

* Only trained individuals may change blades or speed settings (Class 3)

* Always wear safety glasses and avoid loose clothing

* Turn machine off and remove key when not in use
* The band saw cannot cut tight corners, use relief cuts as pictured.

== Maintenance (staff only) ==
{| class="wikitable"
|'''Task'''
|'''Frequency'''
|'''Notes'''
|-
|Clean blade guides and table
|After every use
|Prevents buildup and wear
|-
|Lubricate bearings and moving parts
|Monthly
|Follow manual specs
|-
|Inspect belt condition and tension
|Monthly
|Check both A28 & A44 belts
|-
|Blade tracking and tension check
|Before each use
|Use tracking knob and tension handwheel
|-
|Replace blades
|As needed
|Replace if dull, missing teeth, or cracked
|-
|Clean and inspect motor/pulleys
|Quarterly
|Look for signs of wear or misalignment
|}

Manufacturing Training Center

2025-07-18T15:30:34Z

Benrundle:

== About the space ==
[[File:Maxresdefault 0.jpg|thumb|345x345px]]
The MTC work as a part of [[The Brunsfield Center|Brunsfield]] and serves as a location to conduct trainings such as Basic Training, Mill Training, and Lathe Training.

MTC also is home to the Wood Room, a small room containing various wood tools, as well as some CNC routers.

Finally, MTC houses CEED's HAAS Mini Mill and Mini Lathe CNC machines. These are our most advanced pieces of equipment and are mainly used for the JMTS competitive team to custom manufacture components with the help of our teams manager, Jason Demers.

== [[Manufacturing Training Center/Shop Trainings|Trainings]] ==
[[File:2019-HAAS-SUPER-MINI-MILL-2-1600806853730.jpg|thumb|327x327px|HAAS Mini Mill as seen in MTC]]
Trainings offered using the MTC are as follows:

[[Manufacturing Training Center/Shop Trainings/Basic Training|Basic Training]] - The first training all users should take. It is mandatory for entry to all Brunsfield spaces.

[[Manufacturing Training Center/Shop Trainings/Mill Training|Mill Training]] - Basic operation and understanding of the milling machines. Training takes place in MTC but certifications apply to Brunsfield mills.

[[Manufacturing Training Center/Shop Trainings/Lathe Training|Lathe Training]] - Basic operation and understanding of the lathes. Training takes place in MTC but certifications apply to Brunsfield lathes.

[[Manufacturing Training Center/Shop Trainings/CNC Training|CNC Training]] - Introduction to CNC. Basic understanding of computer numerical control and operation of the cnc routers in the wood room.

== [[Manufacturing Training Center/Manufacturing Technologies|Technologies]] ==

* [[The Brunsfield Center/Manufacturing Technologies/Mill|Mills]]
* [[The Brunsfield Center/Manufacturing Technologies/Lathe|Lathes]]
* [[Manufacturing Training Center/Manufacturing Technologies/Corner Notcher|Corner Notcher]]
* [[The Brunsfield Center/Manufacturing Technologies/Drill Press|Drill Press]]
* [[The Brunsfield Center/Manufacturing Technologies/Sheet Metal Brake|Sheet Metal Brake]]
* [[The Brunsfield Center/Manufacturing Technologies/Hand Tools|Hand Tools]]

=== [[Manufacturing Training Center/The Wood Room|Wood Room]] ===

* [[Manufacturing Training Center/Manufacturing Technologies/CNC Router|CNC Routers]]
* [[Manufacturing Training Center/The Wood Room/Miter Saw|Miter Saw]]
* [[Manufacturing Training Center/The Wood Room/Router Table|Router Table]]
* [[Manufacturing Training Center/The Wood Room/Panel Saw|Panel Saw]]

Manufacturing Training Center/Manufacturing Technologies/Corner Notcher

2025-07-18T15:19:57Z

Benrundle:

{{DISPLAYTITLE: Corner Notcher}}
== Corner Notchers ==
[[File:HCK-SPNOTCHER-e1530894931681.jpg|thumb|MTC Corner Notcher]]
A '''sheet metal corner notcher''' is a mechanical cutting tool used in metal fabrication to remove square or angular sections from the edges of sheet metal. This tool is essential for creating clean corners in boxes, trays, panels, and other sheet metal forms. It provides high precision and repeatability, making it a common feature in metalworking shops, HVAC fabrication, and manufacturing facilities.

=== Overview ===
A corner notcher typically consists of:

* '''Two angled blades''' (commonly set at 90°)

* A '''notching table''' or work surface with guides or rulers

* A '''lever''' to drive the blades downward

* '''Back gauges and stops''' for repeatable cuts

When engaged, the upper blade descends in a shearing action against the fixed lower blade, removing a triangular or rectangular piece from the sheet’s corner.

=== Common Applications ===
* Cutting '''90° notches''' in metal boxes or frames

* Preparing '''bends or folds''' in sheet metal

* Making custom '''panels, brackets, trays''', or '''ductwork'''

* Removing '''excess corners''' before folding or welding

=== Safety First ===

# Do not exceed the capacity of the machine.
# Do not leave the handle on the down position.
# Ensure that the guides are clear of the blades when using.
# Be mindful of your hand placement as the lever comes down to cut through the material so you don’t cut yourself during the swing

=== Clean Up Procedures ===

# Remove scrap pieces and place in scrap bins if usable, garbage if not
# Leave the handle in a vertical position so that no one walks into it.

=== Material and Capacity ===
'''Maximum Depthː''' 6.0in

'''Notching Capacityː''' 16 gauge (~1.6mm/ 0.039in)

'''Compatible Materialsː'''

* Mild steel

* Aluminum

* Copper

* Brass

* Stainless steel (thin gauge only)
[[File:2200-cpa.jpg|thumb|350x350px|Using a corner notcher to punch out 90deg corner in sheet metal used for the Basic Training Box.]]

=== Operating Instructions ===
'''''Step-by-Step: How to use a corner Notcher'''''

'''1. Prepare the Notcher:'''

* Ensure the notcher is clean, mounted securely, and blades are sharp.

'''2. Adjust Guides or Stops:'''

* Use built-in rulers or back gauges to set the desired notch position.

* Lock the guides in place for consistent cuts.

'''3. Position the Sheet:'''

* Slide the metal into the notching area until it contacts both guides.

* Ensure the corner you want to remove is aligned with the blade intersection.

'''4. Make the Cut:'''

* Put both hands on the lever and apply steady pressure until the material is sheared.

* Bend with your knees, not your back.

* Lift the lever all the way back before letting go.

'''5. Remove the Material:'''

* Retrieve the notched piece and inspect for accuracy.

* Repeat as necessary with adjusted guides for multiple cuts.

=== Maintenance (STAFF ONLY) ===

* '''Degrease and oil''' notching table and blades

* Clean metal shavings and debris from the notching area.

* Inspect and '''tighten hardware''' to maintain accuracy and safety.
* '''Sharpen or replace blades''' regularly.

Manufacturing Training Center/Shop Trainings/Lathe Training

2025-07-18T15:19:29Z

Benrundle:

{{DISPLAYTITLE: Lathe Training}}
=== About ===
Lathe training takes place in MTC and teaches safe operation of the lathe. The training will consist of a briefing of the machines, and the guided production of a simple plastic part.

Making the part required three operations: Facing, Turning, and Drilling, all of which are instructed before hand.

=== Preparation ===

* Brunsfield staff will provide necessary PPE for the training.
* Basic training must be taken prior to taking lathe training.
* In order to take the training, you must sign-up via a link in the CEED Newsletter or via QR code. This will take you to the ''Simpli'' page where you can register for a particular session.
* There is an optional prelab available.

Manufacturing Training Center/Shop Trainings/CNC Training

2025-07-18T15:18:50Z

Benrundle:

{{DISPLAYTITLE: CNC Training}}
== What is CNC? ==
CNC (Computer Numerical Control) is a manufacturing method where machines like mills, lathes, routers, 3D printers, laser cutters, and more are controlled using computer codes—primarily G-code, a language that tells machines what movements to make and actions to perform. These codes are interpreted by a controller, which converts them into signals that operate various machine components. While different machines may use different variations of G-code, the underlying principles remain the same.

CNC machining offers high precision, speed, and the ability to produce complex parts with tight tolerances, making it ideal for large-scale production and detailed work. However, due to its time-consuming setup and need for specialized programming knowledge, it is less suitable for simple or low-volume projects.

For more information on CNC machining, including G-code, CAM, and speeds and feeds, visit the following YouTube channels:

[https://www.youtube.com/@haasautomation Haas Automation]

[https://www.youtube.com/@nyccnc NYC CNC]

== About CNC Training ==
The CNC Training Course offered by CEED is a two-part course that covers the basics of G-Code and writing machine programs, a brief overview of feeds and speeds, basic functions in the Fusion 360 CAM workspace, and the operating procedures for the CNC routers in the Wood Room. After completing both parts of the training, students should be able to create a program for a simple part with one setup using common materials like MDF, plastic, or aluminum.
[[File:Router.png|thumb]]
The first portion of the training covers the basic functions of a CNC machine, the history and meaning of G-Code, how to structure a program, and the basics of feeds and speeds. The second portion goes into more detail on feeds and speeds, and then moves on to a Fusion 360 demo and finally machining a part on the Larken Camtool routers.

The material of the training is very dense, so it is strongly recommended to review the following resources before attending in order to develop a basis of knowledge and help the lecture portion go faster.

[https://www.youtube.com/watch?v=iMx_UYrvuos&ab_channel=HaasAutomation%2CInc. What is G-Code? – Haas Automation Tip of the Day]

[https://nyccnc.com/getting-started-feeds-speeds/ Getting Started with Feeds & Speeds]

[https://www.youtube.com/watch?v=gbcMm-rSXZY&ab_channel=HaasAutomation%2CInc. Make a Part From Start to Finish; Mark's Greatest Setup Tips - Haas Automation Tip of the Day]

== After the Training ==
Once the training is complete, certified students may use any of the routers, as well as the Tormach PCNC 1100 mill at the discretion of the Brunsfield manager or qualified staff.

Manufacturing Training Center/The Wood Room/Jigsaw

2025-07-18T15:18:10Z

Benrundle:

{{DISPLAYTITLE: Jigsaw}}
A '''jigsaw''' is a '''handheld power tool''' used to cut a wide range of materials—including '''wood, plastic, metal, and laminate'''—with a '''narrow, straight blade that moves reciprocates.'''

Common uses are c'''utting curves and shapes''' in plywood or thin boards and making '''interior cutouts''' (like sink openings in countertops). It can also be used for '''Bevel cuts''' (usually up to 45°) with an adjustable base or cutting '''thin sheet metal''' with the right blade.
----

=== Advantages: ===

* Highly versatile for '''freehand or template-guided''' cuts.
* Small and portable.
* Safer and easier for curved cuts than circular saws or table saws.

=== Safety Precautions: ===

* '''PPE Required:''' Safety glasses, hearing protection, dust mask (for wood), and gloves (when handling sharp material).
* '''Clothing:''' No loose sleeves, jewelry, or dangling items. Tie back long hair.
* '''Workspace:''' Ensure work area is clean, well-lit, and free from obstructions.

[[File:11975491_L.jpg|thumb]]

=== Pre-Operation Checklist: ===

* '''Inspect the Jigsaw:'''
* Check for frayed cords or damaged plugs.
* Ensure shoe plate is tight and square.
* Confirm the blade is sharp, straight, and appropriate for the material.
* '''Select and Install Blade:'''
* Choose correct TPI (teeth per inch) for material.
* Unplug tool before changing blades.
* Ensure blade is locked securely in place.
* '''Secure the Workpiece:'''
* Clamp material firmly to a bench.
* Keep cut lines clear of clamps or vises.

=== Operating Instructions: ===

* '''Power On:'''
* Plug in the jigsaw or insert the battery.
* Hold with both hands for control.
* '''Start the Cut:'''
* Position baseplate flat on the material.
* Align blade just off the cut line, with the saw ''not'' running.
* Start motor before making contact with the workpiece.
* '''Cutting:'''
* Let the blade reach full speed before advancing.
* Move slowly and steadily—don’t force the tool.
* Let the blade come to a stop before removing it from the cut
* '''Corners and Curves:'''
* Use relief cuts for tight curves.
* Don’t twist the tool—let the blade do the work.

=== Post-Operation: ===

# '''Turn Off and Unplug:'''
# Wait for blade to stop completely before setting down.
# Unplug or remove battery.
# '''Clean Up:'''
# Brush off tool and work area.
# Store jigsaw and blades properly.
# '''Inspect Blade and Tool:'''
# Check for any damage or wear before putting away.

=== 🚫Limitations and Warnings:🚫 ===

* Do '''not''' use jigsaw on unsupported materials—can cause binding or kickback.

* Do '''not''' cut materials thicker than the blade’s rated depth.

* Avoid cutting metal unless using appropriate blade and speed.

* Never remove guards or operate one-handed.

Manufacturing Training Center/The Wood Room/Router Table

2025-07-18T15:17:35Z

Benrundle:

{{DISPLAYTITLE: Router Table}}
=== Description: ===
The router table is used to shape, cut, and profile the edges of wood or plastic stock using a rotating router bit mounted under the table surface.
[[File:Miter-Gauge-Rabbet-768x511.png|thumb]]

=== PPE Required: ===

* Safety glasses
* Hearing protection
* Dust mask or respirator (when cutting MDF or plastics)
* No gloves, loose clothing, or jewelry

=== Hazards: ===

* Rotating bit can cause serious injury
* Risk of kickback from improper feeding
* Eye and respiratory hazards from dust and chips
* Noise exposure

[[File:Router-edge-profiling-bits-chart.jpg|thumb|563x563px]]

=== Pre-Use Checklist: ===

# '''Inspect router bit''' – ensure sharp, undamaged, and securely tightened.
# '''Check table fence''' – square and locked in position.
# '''Set bit height and depth''' using the router lift or adjustment mechanism.
# '''Verify workpiece''' – free of nails, screws, or knots.

=== Operating Procedure: ===

==== Setup: ====

# Unplug the router before making adjustments.
# Install desired router bit and set cutting depth.
# Align and lock the fence; use featherboards for consistent pressure.
# Use push blocks/sticks for small or narrow stock.

==== During Use: ====

# '''Power on the router''', wait for full speed.
# '''Feed workpiece from right to left''' (against the bit rotation).
# Maintain steady, controlled feed rate—do not force the cut.
# Keep hands clear of the bit at all times.

==== 🚫Do Not:🚫 ====

* Use without fence unless using bearing-guided bit and a jig.
* Change bits with the router plugged in.
* Route pieces shorter than 6" or narrower than 2" without a jig.

=== Post-Use Procedure: ===

# Turn off and unplug the router.
# Remove dust/chips from the table and undercarriage.
# Store bits and tools safely.
# Report any damage or issues to staff.

=== Maintenance Tips: ===

* Clean router collet and bit shanks regularly.
* Lubricate lift mechanism as needed.
* Inspect power cord and switch monthly.

Manufacturing Training Center/The Wood Room/Panel Saw

2025-07-18T15:17:14Z

Benrundle:

{{DISPLAYTITLE: Panel Saw}}
'''Primary Use:''' Cutting large sheet goods like MDF, plywood, and other wood-based panels

'''Common Materials:''' MDF, plywood, particleboard, melamine, solid wood panels

'''Typical Cuts:''' Crosscuts (vertical), rip cuts (horizontal).
[[File:E499d39af09d4e99b6ee46e6e215e46a.webp|thumb]]

=== Safety Guidelines ===

* '''PPE:''' Always wear safety glasses and hearing protection.
* '''Blade Guard:''' Ensure the blade guard is in place and functioning properly.
* '''Material Support:''' Confirm that the workpiece is adequately supported and secured against the saw's frame.
* '''Hands Positioning:''' Keep hands away from the blade path and avoid reaching over the saw during operation.
* '''Blade Stoppage:''' Wait for the blade to come to a complete stop before removing offcuts or making adjustments.
* '''Training:''' Only trained and authorized personnel should operate the panel saw.

[[File:Panel_Saw_img.jpg|thumb]]

=== Operating Instructions ===

# Preparing for the Cut
## Material Inspection: Check the panel for defects, nails, or foreign objects.
## Measurement and Marking: Measure and mark the cut line clearly on the panel.
## Saw Configuration: Adjust the saw to the appropriate cutting position (vertical for crosscuts, horizontal for rip cuts).
# Loading the Material
## Assistance: For large panels, seek assistance to safely load the material onto the saw.
## Alignment: Align the panel with the saw's guides and ensure it rests evenly on the support rollers.
## Securing: Use clamps or the saw's holding mechanism to secure the panel if necessary.
# Making the Cut
## Blade Activation: Turn on the saw and allow the blade to reach full speed.
## Cutting Motion: For vertical cuts, smoothly guide the saw downward through the panel. For horizontal cuts, feed the panel steadily through the blade.
## Completion: After the cut, turn off the saw and wait for the blade to stop before handling the material.

=== Maintenance Tips ===

* '''Weekly:''' Inspect the blade for sharpness and damage; replace if necessary.
* '''Monthly:''' Check the alignment of the saw guides and adjust as needed.
* '''Quarterly:''' Lubricate moving parts according to the manufacturer's recommendations.

Manufacturing Training Center/The Wood Room/Miter Saw

2025-07-18T15:16:33Z

Benrundle:

{{DISPLAYTITLE: Miter Saw}}
[[File:19835411_L.jpg|thumb]]
[[File:Sawblades_5f00_anatomy1.jpg|thumb|643x643px]]

=== PERSONAL PROTECTIVE EQUIPMENT (PPE) ===

* Safety glasses (mandatory)
* Hearing protection
* Dust mask or respirator if cutting MDF or dusty material
* No gloves, loose clothing, or jewelry
* Tie back long hair

=== GENERAL SAFETY RULES ===

* Only trained users may operate this tool
* Inspect blade for damage before use
* Keep hands at least '''6 inches''' away from the blade
* Use clamps or a stop block for small pieces
* Never cut freehand – material must rest firmly against the fence
* Wait for the blade to stop fully before lifting it

=== MACHINE SETUP ===

* Ensure the saw is secured to the bench or stand
* Check that the work area is clear of debris
* Confirm the saw is unplugged before adjusting
* Adjust miter and bevel angles as required
* Ensure blade guard is functioning properly

=== OPERATING STEPS ===

* Plug in the saw and confirm blade is correct for material
* Mark your cut line on the workpiece
* Place workpiece flat against the fence and table
* Use clamps for narrow or short pieces
* Lower the saw head to align the blade with the cut line
* Power on and allow the blade to reach full speed
* Slowly lower the blade through the material
* Hold until the blade has completely stopped
* Raise the saw and remove the cut piece

=== CLEANUP & SHUTDOWN ===

* Unplug the saw when finished
* Brush away dust and debris from the saw and table
* Return clamps and stop blocks to storage
* Report any damage or dull blades to staff

=== 🚫LIMITATIONS🚫 ===

* Do not rip cut (with the grain)
* Avoid cutting very small pieces (<6” long without a jig)
* Use only appropriate blades for wood or composite materials
* Do not cut metal or masonry

Manufacturing Training Center/The Wood Room/Circular Saw

2025-07-18T15:15:53Z

Benrundle:

{{DISPLAYTITLE: Circular Saw}}
=== About ===
A Circular Saw or Skillsaw is a handheld power tool used for making straight cuts in sheet goods, dimensional lumber, and other wood products. It can perform crosscuts, rip cuts, and bevel cuts. Although a wood tool, the circular saws are located in Bunsfield.

It is a very versatile tool but must but used carefully.

==== Required PPE ====

* Safety glasses
* Hearing protection
* Dust mask (for MDF or long cuts)
* Fitted clothing; no jewelry or dangling sleeves

[[File:U6g7R.png|thumb]]

==== Pre-Use Safety Checklist ====

* Blade is sharp, clean, and appropriate for material
* Blade guard moves freely and springs back fully
* Base plate is square and bevel lock is tight
* Cord is undamaged and clear of the cutting area
* Saw unplugged while adjusting blade or angle

[[File:Download.jpg|thumb]]

=== Operating Instructions ===
[[File:Proper-Wood-Support-Photo.001-1024x768.jpg|thumb]]

==== Set Up ====

# '''Measure and mark''' cut line with pencil.
# [[File:Improper-saw-position-photo.001-1024x768.jpg|thumb]]Adjust '''cut depth''' to no more than 1/4” below material.
# Set '''bevel angle''' if needed; lock securely.

==== Positioning ====

# Secure workpiece using clamps or sawhorses.
# '''Stand to the side''' of the saw’s cutting path, not behind.
# Support offcuts to prevent blade pinching or binding.

==== Cutting ====

# Hold saw '''firmly with both hands'''.
# Start motor '''before contacting material'''.
# Allow blade to reach full speed, then move steadily along the line.
# Do '''not force the cut'''—let the blade do the work.

==== Post-Use Procedure ====

* Release trigger and wait for blade to stop.
* Unplug saw before setting it down or changing blade.
* Clean saw base and blade with brush or vacuum.
* Coil cord neatly and return to storage.

=== 🚫Common Hazards🚫 ===
{| class="wikitable"
|'''Hazard'''
|'''Mitigation'''
|-
|Kickback
|Support material correctly; never cut warped or pinched panels
|-
|Binding
|Use sharp blade, avoid twisting saw mid-cut
|-
|Eye injury
|Always wear safety glasses
|-
|Electric
shock
|Check cord; keep dry and away from blade path
|}

The Brunsfield Center/Manufacturing Technologies/Sheet Metal Shear

2025-07-18T15:15:11Z

Benrundle:

{{DISPLAYTITLE: Sheet Metal Sheer}}
This page contains information about the different shearing tools in Brunsfield Center & MTC.
== What is shearing? ==
Shearing is a metal cutting process that involves applying a high force to a material so that it fails and separates along a straight line. It is primarily used for cutting '''sheet metal''', '''plate''', or '''bar stock''' without producing chips or melting the material. In shearing, two blades—one fixed (lower) and one moving (upper)—work together like a pair of scissors to cut through the material. The material is placed between the blades, and as the upper blade descends, it exerts enough pressure to fracture the material cleanly along the intended line.[[File:Metal-shearing-example.jpg|thumb|500x500px|Metal Shearing process.]]

=== Required PPE ===
* Safety glasses
* Work gloves
* Long pants, non-ripped
* Steel-toed boots

=== Safety Precautions ===
Before using a sheet metal foot shear, it is essential to follow standard safety procedures:

* Wear safety glasses, toe caps and gloves.

* Keep fingers and hands clear of the blade path.

* Ensure all adjustments are made with the machine disengaged and not in motion.

* Do not exceed the material thickness capacity.

=== Potential Hazards ===
* Pinch points

* Sharp blade

[[File:6-125-055.jpg|thumb|Treadle shear as seen in Brunsfield.]]

== Treadle Shear ==
A Treddle Shear, also known as a foot-operated squaring shear, is a mechanical cutting device used in metalworking to cut straight lines through material with precision. This tool is commonly found in fabrication shops, HVAC operations, and metalworking classes due to its durability, ease of use, and ability to make clean cuts in a variety of metal types and thicknesses.

=== Overview ===
The foot shear consists of a sturdy frame, a fixed lower blade, and a moving upper blade attached to a pedal or treadle. By pressing down on the foot pedal, the operator lowers the upper blade in a shearing motion, slicing through the material placed on the cutting bed. Most foot shears are designed for cutting mild steel sheets up to 16 gauge (approximately 1.6 mm), though capacities vary by model.

Key components of a sheet metal foot shear include:

* '''Upper and lower blades:''' Hardened steel blades responsible for the shearing action.

* '''Foot pedal:''' Lever mechanism activated by foot pressure to operate the blade.

* '''Squaring arm:''' A guide used to align the material at precise right angles.

* '''Extension arms:''' Provides support for bigger pieces of material

Foot shears offer the advantage of manual control without the need for electricity or hydraulics, making them reliable and safe for classroom or light industrial use.

=== Safety First ===

# Stay within the capacity of the shear when cutting metal
# Sheet metal edges can be sharp after cutting; avoid running fingers along them.
# Ensure that the blade is not dull.
# Ensure that the metal is clamped when cutting.
# Keep fingers away from the blades when cutting.

=== Clean Up Procedures ===

* Remove scrap pieces and place in scrap bins if usable, garbage if not.
* Put away all tools.

=== Compatible Materials and Thickness Limits ===
Sheet metal foot shears are designed to cut a variety of thin, flat metal materials. The maximum thickness the shear can handle depends on the material's hardness and the shear’s specific design and blade capacity. Exceeding these limits can damage the shear, dull the blades, or result in poor-quality cuts.

'''''Brunsfield Center thickness limit:''''' 16 gauge (~1.6mm/ 0.039in)

'''Compatible Materials:'''

* Mild Steel (Sheet metal)

* Aluminum

* Stainless Steel

* Some plastics (NOT ACRYLIC)

Maximum cutting width: 50’’

'''Factors Affecting Cutting Capacity''':

* Material hardness: Harder metals like stainless steel have lower thickness limits.

* Blade condition: Dull blades reduce cutting efficiency and can affect performance.

* Machine build: Heavier-duty foot shears may handle thicker materials than light-duty models.

* Blade clearance: Properly adjusted blade gaps ensure clean cuts and reduce stress on the machine.

If consistently cutting thicker or harder materials is required, consider upgrading to a hydraulic or powered shear for better performance and safety.

==== Operating Instructions ====

==== Step by Step: How to Use the Treadle Shear ====

==== 1. Prepare the Material: ====
* Scribe marks where the material needs to be cut

* Ensure your cutting marks are accurate and visible

==== 2. Position the Material: ====
* Slide the material onto the bed of the shear.

* Align the cutting mark with the blades using the squaring arm or measurement markings.

* Press the material firmly against the squaring arm or guide.

==== 3. Secure the Material: ====
* Clamp or press down material to prevent shifting during the cut

==== 4. Make the Cut: ====
* With both hands clear, press down firmly and steadily on the foot pedals.

* It’s more easily done with one person on each pedal.

* The upper blade will descend, shearing the metal along a straight line.

* Release the pedal to raise the blade back to its resting position.

==== 5. Remove the Cut Material: ====
* Carefully retrieve both the cut piece and the remaining sheet.

* Inspect for accuracy and re-cut if necessary.

* Put away any scrap into the Scrap Bins (if reusable) or garbage

'''''Adding the Extension Arms:'''''

'''1. Identify the Mounting Location:'''

* Locate the threaded holes or slots on the front or side of the shear bed or table where the extension arms are designed to attach.

* These will usually be aligned with the shear’s edge and have visible bolt holes.

'''2. Clean the Mounting Area:'''

* Wipe down the surface and bolt holes to remove dust, metal shavings, or oil.

* Ensure the threads are clean for proper bolt engagement.

'''3. Align the Extension Arm:'''

* Position the extension arm so that its mounting holes line up with the shear's threaded holes.

* Arms may have adjustable brackets or slots for fine alignment.

'''4. Insert and Tighten the Bolts:'''

* Insert the bolts through the arm bracket into the shear’s mounting holes.

* Hand-tighten each bolt to hold the arm in place.

* Then, use a wrench or socket to firmly tighten the bolts evenly.

* Avoid overtightening to prevent stripping threads or distorting the arm.

'''5. Check for Level and Stability:'''

* Use a level or straightedge to ensure the extension arm is flush with the shear bed.

* Make adjustments if necessary and retighten.

'''''Removing the Extension Arms:'''''

# '''Support the Arm:'''

* Hold the arm securely to prevent it from dropping when bolts are removed.

# '''Loosen and Remove the Bolts:'''

* Using the same wrench or socket, loosen and remove each bolt.

* Place bolts and washers in a container so they’re not lost if the arms need to be reinstalled later.

# '''Lift Off the Arm:'''

* Gently slide or lift the arm away from the shear.

* Be cautious of any sharp edges or weight, especially on larger support arms.

# '''Clean the Mounting Area (Optional):'''

* Wipe the area clean and apply light machine oil to the threads to prevent rust if the arms will be off for a while.

=== Maintenance (STAFF ONLY) ===
Regular maintenance ensures consistent performance and longevity of the foot shear:

* Lubricate moving parts as specified by the manufacturer.

* Degrease and oil the bed and blades of the machine.

* Check and adjust blade alignment periodically.

* Replace or sharpen blades when cutting performance diminishes.

* Inspect for loose hardware and worn components.
[[File:1-397-1461.jpg|thumb|Lever shear available in Brunsfield]]

== Lever Shear ==
A lever shear, also known as a lever-operated bench shear, is a manually operated cutting tool used for slicing sheet metal and flat bar stock. It operates using mechanical leverage to multiply the user’s force, enabling clean, straight cuts without the need for electrical power.

Lever shears are commonly used in small fabrication shops, maintenance departments, and educational settings due to their affordability, portability, and simplicity.

'''Overview'''

A lever shear consists of:

* A cutting blade assembly fixed to a solid base or mounting platform.

* A long manual lever arm attached to a movable upper blade.

* A stationary lower blade affixed to the base.

By pulling the lever downward, the upper blade moves past the lower blade in a scissor-like shearing action. The length of the lever provides the mechanical advantage that allows the user to cut through metal with minimal effort.

=== Safety First ===

# Stay within the capacity of the shear when cutting metal
# Do not cut wire.
# If repeated cuts are done on the same edge, it can result in sharp slivers being created. Carefully remove these with a file to prevent cuts and other injuries.
# Keep fingers away from the blade when cutting.
# Leave the handle in a vertical position so that no one walks into it.
# When not in use, ensure the shear is locked with a bolt.

=== Clean Up Procedures ===

# Remove scrap pieces and place in scrap bins if usable, garbage if not
# Put lever shear back in its place
# Ensure the shear's movement is locked by a bolt

=== Material and Capacity ===
'''They are commonly used with metals like:'''

* Mild steel

* Aluminum

* Copper

* Brass

* Stainless steel (thin gauge only)

But they can also cut softer materials like rubber and some plastics.

'''Cutting Capacity'''

The cutting capacity depends on the material's hardness and the shear’s specific design and blade capacity. Exceeding these limits can damage the shear, dull the blades, or result in poor-quality cuts.

'''''Brunsfield center thickness limit:''''' 16 gauge (~1.6mm/ 0.039in)

'''Maximum Cutting Lengthː''' 12 in

A typical benchtop lever shear can handle:

* Mild steel up to 16–12 gauge (1.6–2.5 mm)

* Aluminum and softer metals up to 10 gauge (~3 mm)

* Flat bar up to 1/4" thick by 2" wide

Always check the manufacturer's specifications or ask staff to avoid overloading the tool.

=== Operating Instructions] ===
'''''Step-by-Step: How to Use a Lever Shear'''''

1. Mount the Shear (if necessary):

* Secure the shear to a sturdy workbench using bolts or clamps.

2. Mark and Position Material:

* Measure and mark the cut line on the sheet metal.

* Align the mark with the edge of the lower blade or guide.

3. Check Blade Clearance:

* Ensure the upper and lower blades are properly aligned and not damaged.

4. Engage the Lever:

* With a firm grip, pull the lever downward in a controlled motion.

* The upper blade will shear through the material as it passes the lower blade.

5. Return the Lever:

* Allow the lever to return to its upright position

6. Remove the Cut Material:

* Carefully retrieve the cut piece and check accuracy.

=== Maintenance (STAFF ONLY) ===
Regular maintenance is necessary for the upkeep of the tools

* Degrease and oil the blades regularly to prevent rust.

* Sharpen or replace dull blades to maintain cut quality.

* Tighten any loose bolts or linkages.

* Check for proper blade clearance to ensure safe operation.