Welcome to the world of manual machining, where creativity meets precision. Today, we dive deep into the process of using a converted American Tool Works metal planer as a milling machine.
This unique setup allows for milling long pieces of material, making it a valuable asset in any machine shop.
Let’s explore the journey of milling, the setup, and the techniques that make this process efficient and effective.
Overview of the Machine Setup
In the heart of the shop, the American Tool Works metal planer has undergone significant upgrades.
Originally designed as a planer, it has been transformed into a milling machine equipped with a Bridgeport head.
This modification enables it to handle lengths exceeding eight feet, which is perfect for milling long bars.
The first job involves milling a bar that will be welded into a beam for guiding a heavy door. These rails need replacement every couple of years due to wear from the ten-thousand-pound door they support.
The setup is crucial for achieving the desired angles and ensuring the material is cut accurately.
Clamping and Positioning the Workpiece
Setting up the workpiece is straightforward yet essential for precision. A clamp holds the material down securely to the table, utilizing precision holes for locating, which were originally designed for the planer.
The clamps used are homemade and have proven effective over the years, ensuring that the workpiece does not shift during the milling process.
After securing the material, a three-quarter inch solid carbide end mill is employed, along with a cold air gun to keep the cutting area cool.
A touch of anchor lube is added to enhance the milling performance, ensuring a smooth operation.
The Milling Process
With everything set, the milling begins. The machine is capable of climb milling, which is advantageous for this type of work.
The combination of the cold air gun and anchor lube allows for effective heat management, resulting in better tool life and finish quality.
However, not everything goes smoothly. The end mill, while functional, shows signs of wear.
Despite this, it is hoped that it can complete the milling of all four pieces needed. The process involves careful monitoring of the cut and making adjustments as necessary.
Adjusting for Quality
Quality control is paramount in machining. After a few passes, the operator notices excessive chatter, indicating that the milling parameters need adjusting.
The depth of cut is reduced to avoid vibration and ensure a smoother finish. This adjustment is crucial as it not only affects the quality of the cut but also the longevity of the tool.
By reducing the depth of each pass and increasing the number of passes, the operator can achieve the desired result without compromising the tool or the material. It’s a balance of speed and quality, a common challenge in machining.
Finalizing the Cuts
As the milling progresses, measuring becomes essential. The operator checks the progress frequently to ensure that the dimensions are accurate.
With about one hundred sixty thousandths left to mill, the decision is made to split this into three passes for better control.
The final cut is executed with care, focusing on achieving a smooth surface finish. By slowing down the feed rate, the operator ensures that the last pass will yield a quality surface that meets specifications.
Handling Material Tension
After completing the milling process, it’s time to remove the finished piece. The operator carefully loosens the clamps, starting from the ends to relieve tension gradually.
This step is crucial to prevent the material from warping, which could occur if released too quickly.
Once the tension is released, the piece is examined. Although it has some bowing, it is within acceptable limits for the customer’s requirements, as it will be clamped into their fixture for welding.
Reflections on the Process
This journey through milling with a converted metal planer highlights the versatility of manual machining. The ability to adapt and upgrade equipment is vital in maintaining efficiency and quality in production.
The operator’s experience and knowledge play a crucial role in troubleshooting and optimizing the milling process.
With the completion of the task, the operator reflects on the capabilities of the machine and the uniqueness of this setup. This American Tool Works metal planer, now a milling machine, stands as a testament to resourcefulness and engineering ingenuity.
Conclusion
The transformation of a metal planer into a milling machine showcases the potential of manual machining.
Through careful setup, monitoring of the milling process, and adjustments, high-quality results can be achieved.
As we conclude this overview, it is clear that with the right tools and techniques, even older machines can perform tasks that meet modern standards.
So, get out in your shop and remember: it’s all about doing it right the first time.
Watch the full video here:
