Training Objectives:

• Using a Bandsaw and setting the guard/guide height
• Proper set up of the part
• Proper end mill choices
• +/- .005" tolerance machining

Tool List:

• 3/8" End mill w/ short flutes
• 3/8" Collet
• 1-5/8" Parallels
• Caliper
• File
• Dead blow hammer
• Vise jaw extensions 3-3/4" x 6"
• Kant-twist clamps

Important Notes:

• Ask pro staff if you have questions
• Deburr and clean the part after all operations
• Clean the vise area and parallels before all set ups
• Keep the parallels within the jaws of the vise

Prepare The Aluminum Flat Stock Material

Ask pro staff for material.

Layout the flat stock to approximately 4-1/8" x 4-1/8". 

Set the guard/guide height on the aluminum bandsaw and cut the stock.

Use a file to deburr the sharp edges and clean the stock.

Mill The Part Square To 4.000" x 4.000"

Indicate the vise and check the hold down clamps for tightness.

See shop staff for the location of the kant-twist clamps and jaw extensions. Place the part in the vise vertically on one edge between the vise jaw extensions and tighten the vise. Use a set of Kant-twist clamps and clamp them across the top of the jaw extensions.

Raise the quill up and lock it. Insert a 3/8" collet and a 3/8" end mill. Lower the quill 1-2" and lock the quill. Raise and tighten the quill stop and zero the quill caliper.

Check the zero of the quill caliper by raising the quill up and then back down to the quill stop. If the caliper does not read zero when holding the quill handle down re-zero the caliper and repeat the process. Lock the quill.

Turn on the spindle and raise the Z-axis near one end of the part until contact is made with the bottom of the end mill. Zero the Z-axis D.R.O.

Lower the Z-axis slightly, move the X-axis to the other side of the part and raise the Z-axis to make contact with the end mill. Determine the higher side and re-zero the Z-axis D.R.O. if needed.

Start from the highest point on the part and machine roughing cuts until it is flat and then machine a finishing cut. Turn off the spindle.

Move the part in the X-axis from the end mill, about 8" to allow space for removal of the part.

Remove the part and deburr the sharp edges. Clean the part, vise and jaw extensions.

Place the part with the machined edge at the bottom of the vise between the vise jaw extensions and tighten the vise. Turn on the spindle and use roughing cuts to machine the top edge until flat. Turn off the spindle and move the part from the end mill about 8".

Remove, clean and measure between the machined edges and enter the length into the Z-axis D.R.O.

Place the part with the first machined edge at the bottom of the vise between the vise jaw extensions and tighten the vise. Turn on the spindle and continue machining to the final size. Turn off the spindle and move the part from the end mill about 8".

Remove the part and deburr the sharp edges. Clean the part, vise and jaw extensions.

Set the part on 1-5/8" parallels with the machined edge against the solid jaw. Keep one side outside of the vise about 1/2". Tighten the vise and use a dead blow hammer to seat it down. Do not be concerned if the parallels are slightly loose.

Raise the Z-axis up until the bottom of the end mill is slightly below the bottom of the part. Turn on the spindle and move the X-axis near one end of the part until contact is made with the side of the end mill.

Zero the X-axis D.R.O. Move the X-axis slightly away and move the Y-axis to the other end and contact it to determine the closer side. Re-zero the X-axis D.R.O. if needed.

Use climb milling (see reference chart on top of D.R.O) and machine roughing cuts until the edge is square and then machine a finishing cut. Turn off the spindle and move the part from the end mill about 8".

Remove the part and deburr the sharp edges. Clean the part, vise and parallels.

Place the part on the parallels with the final edge outside of the vise about 1/2". Tighten the vise and use a dead blow hammer to seat it down.

Turn on the spindle and contact near one end using the side of the end mill. Zero the X-axis D.R.O. Repeat on the other end to determine the closer side and re-zero if needed. 

Use climb milling and machine roughing cuts until the edge is square. Zero the D.R.O. and turn off the spindle. Move the part from the end mill about 8"

Measure and record the length. Move the X-axis back to zero and enter the measured length into the X-axis D.R.O. Turn on the spindle and machine to the finish size. Turn off the spindle, unlock and raise the quill.

Remove the part, deburr the sharp edges and clean it.

Lock the quill before removing the end mill and collet. Clean the machine and work area.

Measure the part, check the squareness and go over it with pro staff.

Save the part, it will be used for Intermediate Mill 4.