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Chapter 17: Milling

Milling  . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .17-1
Holding Milling Cutters  . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .17-2

Arbors  . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .17-2

Collets and Holders  . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .17-2

Adaptors  . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .17-3

Milling Cutters  . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .17-4

End Mill Cutters  . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .17-4

Plain Milling Cutters  . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .17-6

Side Milling Cutters  . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .17-6

Slitting Saws . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .17-6

Angle Milling Cutters . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .17-7

Form Relieved Cutters . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .17-7

Flycutters . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .17-7

Using Cutting Fluid . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .17-8

Tool Grinding  . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .17-8

Speeds and Feeds for Milling  . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .17-8

Feeds  . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .17-9

Up Milling  . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .17-9

Down Milling . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .17-10

Common Milling Operations . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .17-12

Milling Flat Surfaces  . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .17-12

Squaring a Workpiece . . . . . . . . . . . . . . . . . . . . . . . . . . . . .17-12

Milling a Cavity  . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .17-13

Tapping . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .17-13

Chapter 18: Workholding

Mounting to the Table . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .18-1

Using a Vise  . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .18-1

Dividing Heads  . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .18-2

Rotary Tables  . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .18-2

Chapter 19: Troubleshooting

Powerfeed and Thread Cutting  . . . . . . . . . . . . . . . . . . . . . . . . . . . . .19-1

Carriage and Milling Table . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .19-2

Lathe Turning  . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .19-3

Milling  . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .19-4

Drilling  . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .19-4

Drive System . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .19-5

Chapter 20: Removing the Quill and Quill Feed Assembly

Steps  . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .20-1
Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .20-2

Summary of Contents for MIDAS MI-1220 LTD

Page 1: ...MIDAS 1220 1230 LTD Combination Lathe Mill Drill OPERATOR S MANUAL Updated Feb 2019 170 Aprill Dr Ann Arbor MI USA 48103 1 800 476 4849 www smithy com ...

Page 2: ...ithout prior written permission of Smithy Co For information on getting permission for reprints and excerpts comments or suggestions contact info smithy com While every precaution has been taken in the preparation of this manual Smithy Co shall not have any liability to any person or entity with respect to any loss or damage caused or alleged to be caused directly or indirectly by the instructions...

Page 3: ...TD Moving the machine 5 1 Uncrating and Positioning the machine 5 1 Millhead 5 2 Tailstock 5 2 Three Jaw Chuck 5 3 Selecting Location 5 3 Cleaning and Lubricating the MI 1220 LTD 5 4 Oiling the Ways 5 4 Oiling the Millhead 5 4 Oiling the Headstock 5 4 Oiling the Carriage 5 5 Oiling the Compound Angle Toolpost 5 5 Oiling the Apron 5 5 Oiling the Leadscrew 5 6 Oiling the Tailstock 5 6 Oiling the Mil...

Page 4: ...hining Brass 8 3 Special Chip Craters and Chipbreakers 8 4 Using a Center Gauge to Check V Thread Forms 8 4 Acme or Other Special Threads 8 5 Carbide Tipped Cutters and Cutter Forms 8 5 Chapter 9 Setting Up Lathe Tools Cutting Tool Height 9 1 Turning Tools 9 1 Threading Tools 9 2 Cutoff Thread Cutting and Facing Tools 9 3 Boring and Inside Threading Tools 9 3 Chapter 10 Setting Up with Centers Col...

Page 5: ...2 1 Knurling 12 2 Chapter 13 Cutting Off or Parting with a Lathe Cutting Off or Parting with a Lathe 13 1 Chapter 14 Lathe Drilling and Boring Lathe Drlling 14 1 Reaming 14 1 Boring 14 2 Cutting Internal Threads 14 3 Cutting Special Form Internal Threads 14 4 Chapter 15 Changing Gears on Your MI 1220 LTD Changing Gears 15 1 Chapter 16 Cutting Threads on Your MI 1220 LTD Threading Terms 16 1 Cuttin...

Page 6: ...eeds and Feeds for Milling 17 8 Feeds 17 9 Up Milling 17 9 Down Milling 17 10 Common Milling Operations 17 12 Milling Flat Surfaces 17 12 Squaring a Workpiece 17 12 Milling a Cavity 17 13 Tapping 17 13 Chapter 18 Workholding Mounting to the Table 18 1 Using a Vise 18 1 Dividing Heads 18 2 Rotary Tables 18 2 Chapter 19 Troubleshooting Powerfeed and Thread Cutting 19 1 Carriage and Milling Table 19 ...

Page 7: ...ull Specifications 21 1 Chapter 22 Parts Diagram and Parts List Tensioner AssemblyDiagram 22 1 Millhead Assembly 22 3 Tailstock Assembly 22 8 Bed and Table Assembly 22 11 Powerfeed Engagement 22 14 Apron Assembly 22 17 Lathe Head 22 21 PulleyBox 22 25 22 28 ...

Page 8: ... you with any machining problems you may have Dial our toll free number 1 800 476 4849 Monday through Friday 8 00 am to 5 00pm Eastern Time You can also find Smithy on the Internet at www smithy com Check for service updated and service bulletins We are always interested in your suggestions to improve our products and services Feel free to contact us by phone or email us at info smithy com If you ...

Page 9: ...t everything in place 5 Keep children away from the machine while it is in use Childproof your shop with padlocks master switches and starter keys or store the machine where children do not have access to it 6 Wear appropriate clothing Avoid loose fitting clothes gloves neckties or jewelry that could get caught in moving parts If you have long hairs tie it up or otherwise keep it from getting into...

Page 10: ...ake a tool into something it isn t 14 Keep your mind on your work Pay attention to these simple rules and you will spend many safe enjoyable houses in your workshop Note Your safety depends largely on your practices 2 Safety 2 2 Or Visit www smithy com ...

Page 11: ...r its accuracy 3 Before inserting collars centers adapters or drawbar attachments in either the spindle or tailstock spindle wipe them a clean oily rag Also wipe all internal surfaces carefully with an oily rag on a ramrod Chips or dirt on the centers or in the spindle nose can scratch or mark surfaces and interfere with the assembled part s alignment 4 Lubricate the machine before each use as see...

Page 12: ... point and work piece from one end of the machine to the other the ways must be absolutely true and accurately aligned to the line of centers and to one other 2 Carriage The carriage consists of the saddle and apron It moves by hand or power along the bed carrying the cross slide compound rest and toolpost Its function is to support the cutting tool rigidity and move it along the bed for different...

Page 13: ...e lathe spindle 9 Lathe Spindle The end of the lathe spindle facing the tailstock is the spindle nose The spindle nose which has an MT4 taper rotates the work piece and drives the lathe chicks and other workholding devices All attachments like three jaw chucks four jaw chucks faceplates etc bolt to the spindle flange either directly or via an adapter plate 10 Leadscrew The leadscrew which runs the...

Page 14: ...ck which provides right end support for the work moves along the bed and can stop at any point on it It holds centers drills reamers taps and other tools To move the tailstock spindle which has an MT3 taper turn the tailstock hand wheel The scale of offset calibrations on the back of the tailstock is in millimeters Note To offset the tailstock loosed the four base locking bolts To offset to the le...

Page 15: ...fore signing for it Note any damage on the bill of lading shipping document Fill out the claims forms and notify both Smithy Co and the shipping terminal about the damage Failure to notify both parties can complicate and or invalidate a claims process Trucking company terminals usually have forklifts to assist customers It s most convenient to transport the machines in trucks without canopies and ...

Page 16: ...t Without a mechanical device to aid in your lifting you can lighten the machine by removing a few or all of the following Millhead 1 Remove the four hexagon socket head screws at the base of the millhead support column If a screw runs through the belt box into the flange of the support column remove it too 2 Lock the millhead locking handle 3 Lift the millhead and column off the lathe head You ma...

Page 17: ...n electrician about the proper size Provide ample working light over the operator s shoulder Figure 5 3 Check along and across the bed to make sure it is level Place the machine on a solid foundation concrete if possible If you must put it on a wood floor make sure it is adequate Brace it if necessary to prevent sagging or settling Make allowances at the back of the machine tool as at its end and ...

Page 18: ...nd complete follow this routine Oiling the Ways Run the carriage as far to the left as possible Put a few drops of oil on the ways Run the carriage to the extreme right and repeat You may want to use Way Lube special oil formulated for the ways Oiling the Millhead Quill Using your mill handles or your fine feed crank to lower the millhead down Apply a thin layer of oil to the quill and work it dow...

Page 19: ...ling the Carriage Lubricate the oil buttons in the cross feed table There are two buttons on the left of the saddle for the bedways and two on the front of the cross slide for the cross slide ways Oil the button in the center of the cross slide Put a few drops of oil on the compound slides Oiling the Compound Angle Toolpost Figure 5 8 Oil the buttons along the cross feed table Oil two buttons on t...

Page 20: ...uttons on top of the tailstock Oiling the Mill Drill Clutch Figure 5 10 Oil the clutch housing button Put oil in the button on top of the clutch housing Notice To keep your machine in peak condition lubricate it daily after removing any debris Do not fill the gearbox sight glass more than half way Too much oil will make the motor lug and sling oil out form behind the chuck and inside the belt box ...

Page 21: ...s toward the lathe head Turn the knurled knob clockwise to tighten the belt and counterclockwise to loosen it Adjusting the Gibs The MI 1220 LTD machines have straight gibs Before using the machine adjust the gibs evenly First tighten the screws all the way This will lock the movement Then loosen each screw one quarter turn and check it Tighten the gib the more accurate it will be Removing and pol...

Page 22: ...5 13 To reduce backlash tighten the setscrew so the bush bearing will be secured To install shims turn the hand wheel clockwise to move the cross table away from the screw seat Loosen the setscrew Then pull out on the hand wheel until the bush bearing is free of the seat Remove the cap nut hand wheel dial keys and bush bearing Install one or more shim washers and reassemble Running in the MI 1220 ...

Page 23: ...rt of normal operation procedures run each axis through the entire length of the proposed machining operation before engaging any of the power feeds to assure there is sufficient travel to accomplish the desired task Failure to do so could result in running one of the power feeds to the end of its mechanical limits This is what is known as a CRASH A crash can cause damage to the work piece and sev...

Page 24: ... belt from the motor pulley to the spindle pulley For 630 RPM position F run the belt from the out side sheave closest to the door on the motor pulley Move it one sheave for 1000 RPM position G For 1600 RPM position H run it from the largest motor pulley sheave to the smallest spindle pulley sheave Figure 5 15 Setting Mill Drill Speeds RPM Set mill speeds using various combinations of the mill bel...

Page 25: ...on a 3 diameter shaft will pass the cutting tool three times as fast as a point on a 1 diameter shaft rotating at the same speed This is because the point travels a tripled circumference For work in any given material the larger the diameter the slower the speed in spindle revolutions needed to get the desired feet per minute fpm cutting speed Lathes cut threads in various numbers per inch of mate...

Page 26: ...1467 1589 1711 1833 2446 3669 3 8 509 611 713 815 917 1019 1120 1222 1324 1426 1528 2038 3057 7 16 437 524 611 698 786 873 960 1048 1135 1222 1310 1747 2621 1 2 382 458 535 611 688 764 840 917 993 1070 1146 1529 2293 5 8 306 367 428 489 550 611 672 733 794 856 917 1223 1834 3 4 255 306 357 407 458 509 560 611 662 713 764 1019 1529 7 8 218 262 306 349 393 426 480 524 568 611 655 874 1310 1 191 229 ...

Page 27: ...icated gear combinations to cut the desired number of threads per inch TPI or the metric equivalent or to advance the tool a specified amount each revolution feed rate expressed as inches per revolution ipr The MI 1220 LTD has pick gear gearboxes gears are picked and placed to change the gear ratios The gearbox mechanism determines the leadscrews rotation rate in relation to the spindles for threa...

Page 28: ...ot only provide clearance from the cutting edge there must also be end and side clearance To help the chip pass with minimum resistance across the top of the tool it should often have top rake as well You determine the shapes and rakes to which you ll grind your tools by the tool holder you use TheCB 1220 XL LTD have a four sided turret toolpost that accommodates four high speed steel HSS carbide ...

Page 29: ...p safe rpm rates The formula is as follows rpm CSx4 D where CS cutting speed in surface feet per minute sfm D diameter of the workpiece in inches To use this formula find the cutting speed you need on the chart and plug that number into the CS portion of the formula After calculating the rpm use the nearest or next lower speed on the lathe and set the speed If you were to make a finish cut on a pi...

Page 30: ...unt up to four different tools at the same time You can install all standard shaped turning and facing tools with 1 or smaller shanks The centerline is approximately 5 8 above the bottom of the turret Smithy also offers quick change tool sets that greatly speed up lathe operations Contact a Smithy technician for details 7 Metal Theory 7 3 Or Visit www smithy com ...

Page 31: ...ted They are fine tools in the rough and generally superior to HSS shapes sold by the pound In grinding HSS cutter bits you have five major goals A strong keen cutting edge or point The proper cutting form the correct or most convenient shape for a specific operation Front clearance away from the toolpoint Clearance away from the side of the tool side rake Free chip movement over the tool and away...

Page 32: ...l preferably an 8 46 60A grit or 68A grit Carborundum wheel at 6000 or 6500 rpm When starting with an ungrounded cutter bit the procedure Figure 8 3 is usually to 1 grind the left side clearance 2 grind the right side clearance 3 grind the end form or radius 4 grind the end clearance 5 grind the top rake touching in a chipbreaker If you are honing the cutting edge for fine finishing or machining s...

Page 33: ...re possible The same general rule applies to cast iron Chilled or very hard cast iron requires tools with cutting edge angles as great as 85 For ordinary cast iron you obtain greatest efficiency with a more acute cutting edge approximately 71 Figure 8 6 With cast iron a 71 degree angle is most efficient Bits for Turning and Machining Brass Brass tends to pull or drag when machined It s best to mac...

Page 34: ...e convenient to grind a standard cutter bit for thread cutting especially for cutting standard 60 V threads When grinding an ordinary square cutter into a thread cutting tool take care to ensure a true thread form The easiest way is to use an ordinary center gauge for a standard V thread tool or a special thread gauge for special thread forms To grind a cutter for an ordinary V thread grind first ...

Page 35: ...t easy machining of chilled cast iron hard and tough steels hard rubber Bakelite glass and other difficult or unmachinable materials its primary use in industry is for long production runs on ordinary steels On such work carbide tipped tools permit higher running speeds and much longer runs between resharpenings The cutting edge of carbide tools stands up 10 to 200 times as long as the edge of HSS...

Page 36: ...l and center together The cutting edge on the tool should meet the point on the center It may be necessary to use shims which can be of various thicknesses and materials Figure 9 1 Many seasoned cutting tool height machinists use pieces of old hacksaw blades as shims If the toolbit is too high shim the back of the toolbit If it s too low shim the entire tool Figure 9 1 Placing shims under the tool...

Page 37: ... straight shanked tool held perpendicular to the line of lathe centers in the right side of the toolpost The tool will tend to swing out of the cut rather than hog into the work if you reach a stalling point Figure 9 3 The tool will swing out of the cut left rather than hog into the work right if you reach a stalling point Note the tool is in the right hand side of the toolpost Threading Tools Thr...

Page 38: ... 6 For greater cutting efficiency position the bar while parallel to the line of lathe centers sufficiently below center to give the cutter a 14 1 2 degree approach angle For internal threading grind the top face of the cutter to compensate for this angle giving a flat true form top face Some machinists prefer to position the tool slightly above center when boring With the bit above center if a to...

Page 39: ...u can improve centering greatly by first squaring or facing the ends of the workpiece Section 12 1 This gives you a true cross section in which to locate the centering holes First chuck the stock in the appropriate chuck Let the stock protrude about an inch Place a right hand side tool or a straight turning tool with a facing cutter in the toolpost Carefully adjust the cutting edge so it is exactl...

Page 40: ... tailstock centers Revolve the headstock slowly against the tip of a tool or a piece of rigidly held chalk The chalk should touch just the high spots Figure 10 5 If the center is off 0 002 or more correct the position of the center by repunching at an angle Figure 10 5 When you revolve the headstock against a piece of chalk the chalk should just touch the high spots Next drill and countersink the ...

Page 41: ... faceplate to the spindle if l angle Figure 10 8 and put in both headstock and tailstock centers Fasten a lathe dog Figure 10 9 to one end of the work For ease of operation use a live or rotating center in the tailstock end so you won t need lubrication Before centers starting the lathe make sure the centers don t hold the workpiece too tightly Heat may cause the workpiece to expand so watch for b...

Page 42: ...ceplates For work setup faceplates serve two purposes First they drive workpieces held between centers Second they hold workpieces shaped so you can t chuck them or mount them on centers Faceplates for driving workpieces on centers are generally small They re notched and slotted to receive the tail of the lathe or clamp dog bolt drive or other driving tool Figure10 9 Faceplates for holding workpie...

Page 43: ...the faceplate slot so it won t lift off the true line of centers Figure 10 11 Counterweights can help with unbalanced setups Setting Up Work on a Mandrel You can machine cylindrical or bored pipe work or cored castings too long to fit in a chuck by mounting them first on a mandrel Figure 10 12 Then mount them between centers The solid mandrels which are driven into the hole of the work piece must ...

Page 44: ...t from the thrust of the tool The purpose of a rest is to support the workpiece and maintain it in accurate alignment for machining Rests are classed as steady rests or follow rests Steady Rests Steady rests mount on the lathe bed Figure10 14 Clamped over the ways they provide three bearing surfaces These surfaces bear down lightly but rigidly against the surface of the shaft and keep it from movi...

Page 45: ...Work in a Chuck Chucks usually hold work that is too short to hold conveniently between centers or work requiring machining at into boring or inside threading or across its end While it is possible to set up such work on a faceplate the convenience of chucks has made them part of every complete lathe Lathe chucks come in many types and sizes and hold workpieces of diameters approaching the swing o...

Page 46: ...me way 3 Revolve the spindle slowly with your left hand while holding a piece of chalk until the chalk touches the high point the nearest surface of the work Figure 10 6 4 Guided by the chalk marks readjust the jaws until a chalk line lathe chucks hold round will carry completely around the work Then tighten all the jaws securely square eccentric or odd shaped workpieces For greater accuracy after...

Page 47: ... or storing it Never remove a chuck or heavy faceplate without first laying a board across the ways to protect them in case the chuck falls when it comes off the spindle nose Or use a chuck cradle to ease chuck removal and installation Mounting Work in a Three jaw Universal Chuck Work is set up in a three jaw universal chuck as in a four jaw independent chuck with these exceptions On three jaw chu...

Page 48: ...he 3 jaw Figure 10 20 A serial number is stamped in the 1 slot of the three jaw chuck Figure 10 21 With the slot for the 1 jaw in the 12 00 position the slot for the 2 jaw is at 8 00 and the slot for the 3 jaw is at 4 00 Collets and Collet Attachments To hold small diameter work whether bar stock fed through the hole in the spindle or small pieces of semi finished parts collet attachments are pref...

Page 49: ... lathe spindles MT5 taper to the collets MT3 taper A drawbar holds the collet in place Toolpost Grinders A fully equipped lathe has a toolpost grinder a small independently operated grinding head with an integral electric motor that mounts as a unit in the toolpost T slot of the compound rest For lighter work some are held in the toolpost You can maneuver it as you would any other cutting tool Too...

Page 50: ...ms under the cutter and raising or lowering it Figure 9 1 With the tool properly positioned tighten the Allen capscrews Next run the carriage to the right end of the workpiece with the hand crank Make sure the lathe is set to feed toward the headstock Now determine the depth of the cut Move the tool to the desired depth till it just touches the stock and zero the cross feed dial Start the lathe Ru...

Page 51: ...ly with a caliper or micrometer to be sure you are working to proper dimensions Note The diameter will reduce twice the thickness of the cut For rough turning most machinists prefer a deep cut and a comparatively fine feed but the reverse is true for finishing cuts They usually use a very light crossfeed and a coarse transverse feed with a cutting edge wider than the feed per revolution In Figure ...

Page 52: ...cing cut across the shoulder away from the center Finishing and Polishing After machining you ll want a smooth polished surface free of machine marks You ll obtain the best results with a toolpost grinder If you don t have one use a file With a file take full biting strokes across the revolving workpiece at a slightly oblique angle Do not drag the file back across the work piece instead lift it cl...

Page 53: ...r Turning There are two ways to turn a taper with the compound rest and by setting over the tailstock In both methods the cutter must engage the work on dead center if the taper is to be accurate Compound rest Tapers cut with the compound rest are usually short abrupt angles such as centers bevel gear blanks and die parts Figure 11 5 In general these are not considered taper turning which applies ...

Page 54: ...rror will spoil your work The distance of tailstock set over needed to machine any given taper depends on three factors The differential between the parallel positions with the tool s traverse travel The length of the taper in relation to its extreme diameters if the entire shaft is to be tapered The ratio between the length of the tapered portion to the entire length of the shaft or work between ...

Page 55: ...e difference between the finished diameters of the ends or 0 T x L 2 where T taper per inch and L length of work in inches Note A Because most drawings give the taper in inches per foot of length it may be easier to convert all dimensions to inches B Be sure to zero the tailstock before resuming straight turning Midas 1220 LTD Operator s Manual 11 6 For Assistance Call Toll Free 1 800 476 4849 ...

Page 56: ...hand side tool or a straight turning tool with a facing cutter in the toolpost Carefully adjust the cutting edge so it is exactly on center then tighten it into the toolpost If you don t do this a small tit or projection will remain in the center of the stock and perhaps cause the center drill to run off center Start your lathe on the slowest speed Bring the tool into cutting position against the ...

Page 57: ...l into a pattern As with all other forming operations your work can be no better than the pattern your knurling no better than the knurls Be sure the knurls are sharp clean cut preferably hob cut and properly hardened To make a true uniform knurl maintain uniform pressure on both knurls Select a self centering knurling tool that equalizes pressure on the knurls automatically and is strong enough t...

Page 58: ...ne force the tool into the work another 1 64 reverse the lathe without removing the tool and feed it back to the starting point Feed both ways using the automatic longitudinal feed Once across each way usually makes a good knurl Figure 12 3 Feed the knurling tool at a slight angle off from perpendicular to the line of the work piece 12 Lathe Facing and Knurling 12 3 Or Visit www smithy com ...

Page 59: ...he workpiece as possible with the top of the blade on dead center and exactly perpendicular to the line of centers Extend the blade only far enough to pass through the work piece just beyond its center The tool should feed to the workpiece on exact center slowly and evenly with the cross feed If the tool hogs in and the spindle stops rotating turn off the motor and reverse the spindle by hand befo...

Page 60: ...er the drill the greater the number of peripheral feet cut per revolution That is why you should use a slower drilling speed If no drilling speed data are available it s generally safe to run drills under 1 4 diameter at up to 750 rpm and drills up to 1 2 diameter at 500 rpm with larger drills at proportionately slower speeds With the workpiece in the headstock and the drill in the tailstock chuck...

Page 61: ...14 2 A tool with a smooth ended bar won t mark the workpiece Except with cored castings pipes or tubing begin by drilling a hole large enough to admit the end of the boring bar Because the holes in cored castings often deflect boring bars from their true axis you may want to chamfer or turn out a starting cut in the open ing of the hole to be bored with a turning tool before introducing the boring...

Page 62: ...ng This is especially true when enlarging out of round holes when you take several small cuts rather than one heavy cut Figure 14 5 To machine ends of a bar use a boring bar that angles the cutter so it extends beyond the bar After the last finish cut it is common to reverse the feed and take one last fine cut with the tool coming out of the work This last cut taken without movement of the cross f...

Page 63: ... workpiece Figure 14 7 There must be enough end clearance for the cutter to lift clear of the thread Because the feed of successive cuts is toward not away from the operator the thread cutting set is reversed Also you must take lighter cuts because of the cutter s extension from the toolpost Take an extra finishing cut without changing the setting of the compound rest Cutting Special Form Internal...

Page 64: ...Figure 14 8 Use different clearances between nut and screw for different thread types 14 Lathe Drilling and Boring 14 5 Or Visit www smithy com ...

Page 65: ...lacement Figure 15 1 Remove all C clips nuts and gears 2 Select the proper A D gear combination from the list outside the pulley box door 3 Use the Allen wrench to loosen the bolt at the bottom of the bracket assembly for full swing and easy gear replacement Figure 13 1 4 Place the selected D gear on the D shaft flange side in Replace the spacer washer and nut 5 Place the selected C gear flange si...

Page 66: ...l the A and B gears mesh Hold the bracket assembly in place and tighten the bolt Make sure the gears turn smoothly before engaging the powerfeed You may need to make some adjustments 10 Engage the E gear between the C and D gears to reverse the leadscrew Figure 15 3 Engage the E gear between the C and D gears to reverse the leadscrew 15 Changing Gears on your MI 1220 LTD 15 2 Or Visit www smithy c...

Page 67: ...l threads as well as special threads You may cut coarse or fine threads in a great range of threads per inch in V or square shapes in established profiles like Unified National acme and metric You can cut single threads or multiple threads that run concurrently along the shaft You determine the type of thread by how you ll use the screw Each thread form requires a different shaped tool to cut or c...

Page 68: ...ure 16 1 Check dead center with a credit card Set the compound perpendicular to the line of centers and rotate it 29 1 2 to the right Figure 16 2 With the compound perpendicular to the line of centers rotate it 29 5 degrees to the right Place the thread gauge on the point of the threading tool and feed the tool toward the work piece Figure 16 3 Adjust the tool so the edge of the gauge is exactly p...

Page 69: ...esired length turn off the lathe and back the tool out of the work Then reverse the motor to return the tool to the starting position Using a screw pitch gauge check the thread pitch The benefit of taking the light cut is that you can correct any mistakes you might have made Figure 16 4 Chamfer the end of the thread to protect it from damage It s time to take the real cut now so apply the appropri...

Page 70: ...engaged and the carriage can be moved back to the start of the thread without stopping the spindle or reversing the motor Disengage the half nut back the cutter away from the workpiece and move the cutter back to the beginning of the thread with the hand wheel Turn the cutter the desired amount and you are ready for the next threading pass The threading dial is marked with lines numbered 1 2 3 4 5...

Page 71: ...s off the centers When you think the thread is finished and ready for testing and only if absolutely necessary remove the workpiece from the center leaving the lathe dog attached then test the thread If it does not fit properly and you have to remove another chip or two place the woprkpiece back in the centers exactly as it had been then remove the chips and test again Repeat until finished Finish...

Page 72: ... 50 63 X 42 32 48 20 10 70 X 40 32 30 60 30 70 X 30 48 54 0 80 49 X 60 50 32 18 9 70 X 45 27 36 64 32 70 X 30 48 60 1 75 49 X 63 48 32 16 8 70 X 45 27 32 80 40 70 X 30 48 60 1 00 2 00 63 X 49 32 42 14 7 60 X 60 27 32 96 48 39 X 45 60 48 1 25 2 50 60 X 49 32 32 12 6 70 X 60 27 32 120 60 42 X 30 54 48 1 50 3 00 63 X 56 32 32 333 167 30 X 27 60 63 2 00 4 00 70 X 63 30 32 MM A A B C D E B C D I 0 II I...

Page 73: ...36 0 0157 0 0314 0 0018 0 0037 70 X 40 32 33 0 0171 0 0343 0 0020 0 0041 70 X 40 32 30 0 0189 0 0377 0 0022 0 0044 70 X 45 27 36 0 0210 0 0149 0 0025 0 0049 70 X 45 27 32 0 0236 0 0471 0 0028 0 0055 60 X 60 27 32 0 0269 0 0529 0 0032 0 0063 70 X 60 27 32 0 0314 0 0628 0 0037 0 0074 A X C B D I 0 II I 0 II I 0 II I 0 II A B C D E A B C D Midas 1220 LTD Operator s Manual 16 7 For Assistance Call Tol...

Page 74: ...erations and high metal removal rates rank the mill in importance with the lathe The millhead rotates 180 degrees and adjusts up and down A quill that moves in and out of the head carries the spindle You can move the table horizontally in two directions by turning the cross slide and long feed handwheels The cross slide handwheel turns the table longitudinally at right angles to the spindle axis t...

Page 75: ...d to fit the bore in the end of the machine spindle The arbor of theCB1220 XL LTD which has an MT3 taper is driven by the friction between the arbor and spindle The arbor stays in place by means of a drawbar screwed into the end of the arbor from the top of the spindle Take good care of your arbors Store them in a rack or bin If you won t be using them for several days or longer oil them to preven...

Page 76: ...d with a drawbar follow these steps 1 Loosen the locknut on the drawbar about two turns 2 Hit the end of the drawbar with a dead blow hammer releasing the arbor or adapter from the spindle hole 3 Hold the arbor or adapter so it won t fall out of the spindle when the drawbar is removed 4 Unscrew the drawbar and remove the arbor or adapter Figure 17 4 End mill holders also receive straight shanked e...

Page 77: ...at a time in the cut End Mill Cutters End mill cutters cut on their ends and sides They are either solid cut from a single piece of material or shell separate cutter body and shank They have two three four or more teeth and may do right or left handed cutting Their flute twist or helix may also be right or left handed Solid end mills have straight or tapered shanks shell end mill adapters have tap...

Page 78: ...t cutters cut T slots After machining a groove for the narrow part of the T slot with an end or side mill finish up with the T slot cutter Keyseat cutters cut keyseats for Woodruff keys shaped like a half circle Shell end mills which mill wide flat surfaces have a hole for mounting on a short arbor The center of the shell is recessed to provide space fro screw or nut that fastens the cutter to the...

Page 79: ...lain milling cutters side milling cutters also have teeth on one or both sides The teeth on the periphery do most of the cutting those on the sides finish the side of the cut to size They cut grooves or slots and often work with other cutters to mill special shapes in one operation Figure 17 8 Side milling cutters are similar to plain milling cutter but they have teeth on one or both sides Plain s...

Page 80: ...he straight side and they usually have 45 or 60 angles Double angle cutters machine V grooves Those with equal angles on both faces usually have an included angle of 45 60 or 90 Form Relieved Cutters Formed tooth cutters machine surfaces with curved outlines You can sharpen them without changing the tooth outline Concave cutters mill convex half circles convex cutters cut concave surfaces Corner r...

Page 81: ...nt and regrinding very dull cutters shortens their life considerably The form of the cutting edge and the clearance back of the cutting edge land affect cutter operation significantly The angle formed by the land and a line tangent to the cutter at the tooth tip is the primary clearance The angle between the back of the land and the heel of the tooth is the secondary clearance Check both clearance...

Page 82: ...ula rpm CS mpm x 1000 D mm x it where CS cutting speed mpm meters per minute D mm diameter of the cutter in millimeters it 3 14 You can use an rpm chart for selected diameters of cutting tools at different cutting speeds To change speeds set the belts according to Figure 5 3 Feeds Set the direction of feed before you begin milling Up milling or conventional milling is when the direction of feed is...

Page 83: ...d per tooth and there is no easy formula to follow Here are several principles to guide you Use the highest feed rate conditions allow Avoid using a feed rate below 0 001 per tooth Harder materials require lower feed rates than softer materials Feed wider deeper cuts more slowly than narrow shallow cuts Slower feed rates gives a better surface finish Never stop the feed before finishing the cut If...

Page 84: ...095 125 175 175 225 80 140 60 110 250 500 225 400 Plain high carbon steels 1060 1095 125 175 175 225 70 120 60 110 250 450 225 400 Tool Steels W1 W7 H20 H43 D1 D7 150 200 200 250 200 250 80 120 40 85 30 60 300 350 175 300 100 200 Stainless Steel 302 430F 135 185 135 185 70 100 100 140 225 350 350 450 Gray Cast Iron ASTM Class 20 Through Scale Under Scale 110 160 140 200 130 225 350 700 400 800 Alu...

Page 85: ...r way to mill flat surfaces is by face milling In this method the cutter teeth operate at right angles to the cutter axis Inserted tooth face milling cutters face mill large surfaces Figure 17 12 Inserted tooth face milling cutters face mill large surfaces Bevels and chamfers are cut at an angle to the main work piece surface A bevel cut Figure 17 13 goes from side to side completely removing the ...

Page 86: ...ng is efficient for removing material quickly on low horsepower Plunge the end mill a predetermined width and depth retract it then advance and plunge it again repeatedly The maximum cutting force is in the machine s strongest axial direction Milling a Cavity After laying out the outline of the cavity to cut rough it out to within 0 030 of the finished size before making finish cuts Use a center c...

Page 87: ...meters Plain and swivel vises range from 3 to 10 76 to 254 mm Tilting and universal vises range from 3 4 to 5 76 102 mm to 127 mm The bases of many vises are fitted with keys small steel blocks that fit into the milling table T slot for quick alignment of the vise Before mounting a vise make sure the bottom is clean and smooth If there are any nicks or burrs remove them with a honing stone Set up ...

Page 88: ...o the handle An indexing plate is set in from the handle By counting how many turns of the handle it takes to turn the workpiece a certain number of degrees you can make cuts at different angles This is how to cut gears Rotary Tables A rotary table is a precision worm and wheel unit that lets you cut gears precision holes and curved slots Rotary tables mount vertically or horizontally to the table...

Page 89: ...ter tool shim if needed Tools not mounted tightly in post Remount tools Cross slide gibs to bed and base loose Adjust gibs Gibs in toolpost loose Adjust gibs in toolpost Tool turret not tight Tighten toolpost Feed rate too fast Install correct gears Gears loose Tighten gears and posts Thread is not smooth Cause Solution Tool dull Sharpen tool Tool not centered Center tool Tools not mounted tight i...

Page 90: ...ly adjusted Adjust carriage gib Table gib improperly adjusted Adjust table gib Carriage moves smoothly in only one direction Cause Solution Debris on way or gib Remove debris Burr on gib Remove burr with fine file Gib improperly tensioned Loosen gib and re tension Cross slide handwheel turns during cutting operations Cause Solution Cross slide nut worn Replace brass nut Carriage locks not tight Ti...

Page 91: ...ect position of tailstock Spindle out of alignment Tighten taper bearings to return to alignment replace spindle bearings Machine vibrates Cause Solution Work mounted wrong Remount work Speed too high Reduce speed Too much pressure at tailstock Reduce pressure and increase lubrication Work stops turning but machine continues to run Cause Solution Work not mounted securely Remount work Tools forced...

Page 92: ...not locked Lock millhead Quill too loose Tighten guill lock Tool not on center Center Tool Improper tool shape too dull Reshape sharpen or replace tool Deph of cut is not consistent Cause Solution Quill moving Lock Quill Setup wrong Make sure setup is parallel to table Drilling Hole is off center or bit wandres Cause Solution Bit Dull Use Sharp Bit Bit not mounted correctly in check Remount Tool B...

Page 93: ...lly or stops Cause Solution Bit fed into work too fast Reduce feed rate Belts slipping Reduce feed rate re tension belts Chuck is difficult to tighten or loosen Cause Solution Chuck sticking Apply lubricant Debris in chuck Clean chuck Chuck wobbles Cause Solution Chuck loose on arbor Clean arbor and remount Drawbar not tight Clean spindle and replace drawbar Drive System Turn on machine and nothin...

Page 94: ...us if pulled out of the housing Now you will need to unhook the inner part of the spring from the screw 108 on the shaft 107 Use needle nose pliers and a flathead screwdriver while rotating the shaft to unhook the spring 4 Remove the screw 108 with needle nose pliers from the side and slide the spring housing out of the casting while making sure the spring stays inside the housing Please see note ...

Page 95: ...installed Put the mandrill in the lathe chuck and slip the spring over the screw head Drill and tap a hole in the side of a lathe tool and install a screw similar in size to the screw in the spring housing Put the tool in the tool post in a manner that the screw head can be hooked to the end of the spring Slowly turn the lathe spindle by hand as you also feed the tool post inward to keep pace with...

Page 96: ...d 002 Dial Calibration on Toolpost 002 Dial Calibration on Leadscrew 002 Dial Calibration on Longfeed Rack 02 Dial Calibration on Tailstock 002 Feed Rates 0011 020 Y axis 0022 040 X axis Headstock Taper MT4 Lathe Chuck Bore 1 17 Lathe Chuck Diameter 5 Lathe Chuck Max diameter work piece 5 Lathe Chuck Min diameter work piece 1 8 Lathe Chuck Mount Bolt On Lathe Chuck Type 3 Jaw Self Centering Spindl...

Page 97: ...022 040 X Axis Head Rotation 180 Degrees Head Travel 2 3 4 Quill Diameter 2 3 4 Quill Travel 3 1 8 Spindle Center to Front of Chuck 8 3 4 Spindle Center to Lathe Spindle Flange 11 Spindle Center to Support Column 12 1 8 Spindle to Table Distance min max 6 1 4 13 Spindle Speeds 9 315 2000 RPM Spindle Taper MT3 Tool Size Limits 1 X Axis Travel 12 1 16 Y Axis Travel 8 1 2 Electrical Amperage 11 Amps ...

Page 98: ...s and control systems for a period of one 1 year to the original purchaser from the date of purchase If within one 1 year form the date of purchase a SmithyCNC machine and or control system fails due to defect in material or workmanship SmithyCNC will at their choice repair and or replace components with new or remanufactured parts free of charge Some have asked why SmithyCNC machines have a short...

Page 99: ...o the duration of this written warranty This warranty gives you specific legal rights and you may also have other rights which vary from state to state Some states do not allow the exclusion or limitation of incidental or consequential damages so the above limitation or exclusions may not apply to you Telephone Support Service engineers are available 8 am to 5 pm EST Service and Parts Tel No 1 800...

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Page 101: ...mSnithy MI 1220 I rD Manual Tensioner Assembly 9 8 7 __ I 1 2 _ 13 6 j 14 1 _ _ 16 21 10 0 t 22 5 _ l 1 r I J _ _ 23 2 3 20 25 24 For Assistance Please call toll free number 1 800 476 4849 22 1 ...

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