Milling with a drill press and cross vise is a versatile and cost-effective way to machine small parts. This technique can be used to create a variety of shapes and features, including slots, keyways, and profiles. Milling with a drill press is also a great way to learn the basics of milling without investing in a dedicated milling machine.
To mill with a drill press, you will need a cross vise, a milling cutter, and a drill press. The cross vise is used to hold the workpiece in place, while the milling cutter is used to cut the material. The drill press provides the power and speed to rotate the milling cutter.
Once you have gathered your materials, you can begin milling by securing the workpiece in the cross vise. Next, select the appropriate milling cutter for the job. The size and shape of the milling cutter will depend on the desired shape and size of the cut. Finally, set the drill press to the correct speed and feed rate. The speed and feed rate will depend on the material you are milling and the size of the milling cutter.
Choosing the Correct Milling Cutter
The type of milling cutter you select will depend on the material you’re working with and the desired results. Here’s a general overview of the different types of milling cutters:
End Mills: Designed for cutting flat surfaces, slots, and pockets. Available in various shapes, including cylindrical, square, and ball-shaped.
Factors to Consider When Choosing an End Mill:
- Material: Choose a cutter made of High-Speed Steel (HSS), Cobalt, or Carbide, depending on the hardness of the workpiece.
- Diameter: Select the cutter diameter based on the width of the cut and the amount of material removal required.
- Flutes: Choose the number of flutes (cutting edges) based on the material and desired finish. More flutes provide a smoother finish, while fewer flutes offer higher material removal rates.
- Shank Diameter: Ensure the cutter’s shank diameter matches the capacity of your drill press or milling machine.
- Coating: Coatings like Titanium Nitride (TiN) can enhance cutter life and improve cutting performance.
- Geometry: Consider the cutting edge geometry, such as the rake angle and helix angle, to optimize cutting performance for the specific application.
- Coolant: Determine if the cutter requires external coolant for effective cutting.
Slot Cutters: Specifically designed for cutting narrow slots and grooves. Available in various widths and thicknesses.
Face Mills: Used for surfacing and finishing flat surfaces. Available in a range of diameters and tooth configurations.
Determining the Feed Rate
Feed rate refers to the distance that the cutter travels per revolution of the workpiece. It is a crucial factor in milling, as it directly affects the surface finish, tool life, and power consumption. Choosing the appropriate feed rate depends on several factors, including:
Material properties: Harder materials, such as steel or cast iron, require a slower feed rate to prevent excessive tool wear and breakage.
Cutter geometry: The number of flutes on the cutter and the angle of attack influence the feed rate. A higher number of flutes and a higher angle of attack require a higher feed rate.
Workpiece thickness: Thinner workpieces require a lower feed rate to avoid deflection.
Hole diameter: Smaller holes require a lower feed rate to prevent chatter.
Table 1: Feed Rates for Different Materials
| Material | Feed Rate (mm/rev) |
|---|---|
| Aluminum | 0.1 – 0.2 |
| Steel | 0.05 – 0.1 |
| Cast iron | 0.02 – 0.05 |
Tip: Use a tachometer to measure the spindle speed and divide it by the feed rate to obtain the feed per minute (FPM). A higher FPM generally results in a higher material removal rate and reduced cutting time.
Milling with a Plunge Cut
Plunge cutting refers to the process of milling by moving the tool straight down into the workpiece, instead of feeding it in gradually from the side. This technique is ideal for creating deep, narrow slots or pockets.
Advantages
Plunge cutting offers several advantages over other milling techniques:
- Increased accuracy: The plunge cut allows for precise control over the depth and position of the cut, resulting in a more accurate finished product.
- Faster cutting speeds: By plunging the tool straight into the workpiece, plunge cutting can significantly reduce the overall cutting time compared to side feeding.
- Reduced tool wear: Since the tool is not in contact with the workpiece during the feed-in phase, plunge cutting helps to minimize tool wear and extend its lifespan.
Limitations
However, plunge cutting also has some limitations:
- Increased stress on the spindle: Plunge cutting puts a significant amount of stress on the drill press spindle, which can lead to premature wear or failure if not properly supported.
- Burr formation: Plunge cutting can create burrs on the edges of the cut, which may require additional finishing operations.
- Limited depth of cut: The depth of a plunge cut is limited by the length of the end mill and the travel range of the drill press.
Procedure
To perform a plunge cut, follow these steps:
| Step | Description |
|---|---|
| 1 | Secure the workpiece firmly in the cross vise. |
| 2 | Choose an end mill with the appropriate diameter and number of flutes for the desired cut. |
| 3 | Position the end mill over the center of the cut and slowly plunge it straight down into the workpiece at a moderate feed rate. |
| 4 | Manually or automatically adjust the feed rate to maintain a smooth cutting action. |
| 5 | Continue cutting until the desired depth is reached. |
| 6 | Slowly retract the tool back to its starting position. It is important to retract the tool at a slow speed to minimize burr formation and prevent damage to the tool or workpiece. |
Milling with a Traversing Cut
Key points:
- This method involves moving the workpiece under a stationary cutter.
- The drill press provides the vertical motion, while the cross vise traverses the workpiece laterally.
- Traversing cuts can be used to create slots, grooves, and pockets, among other features.
- Ensuring a precise and consistent traverse is crucial for achieving accurate results.
Steps:
- Secure the workpiece in the cross vise and align it perpendicular to the drill press spindle.
- Select a suitable milling cutter and insert it into the drill press chuck.
- Adjust the table height so that the cutter just touches the surface of the workpiece.
- Set the drill press speed and feed rate according to the recommended specifications for the cutter and material.
- Engage the drill press and carefully lower the spindle to engage the cutter with the workpiece.
- Manually traverse the cross vise under the cutter to create the desired feature.
- Monitor the cutting process closely and make adjustments as needed to maintain a smooth, consistent traverse.
Tips:
| Tip | Benefit |
|---|---|
| Use a traversing table instead of a cross vise for larger workpieces. | Provides greater versatility and precision for longer cuts. |
| Clamp the workpiece securely to prevent movement during traversing. | Ensures accuracy and minimizes vibration. |
| Apply a coolant to the cutting zone to reduce friction and extend cutter life. | Improves cutting efficiency and durability. |
| Start the cut slowly and gradually increase the feed rate as confidence and experience grow. | Prevents excessive tool wear and sudden movements. |
| Use a stop block or gauge to control the traverse distance for precise cuts. | Guarantees consistent feature dimensions. |
Milling Holes and Slots
To mill holes, mount a milling bit in the drill press chuck and secure your workpiece in the cross vise. Lower the quill to bring the milling bit into contact with the workpiece, and then carefully start the drill press. Advance the quill manually or with the feed mechanism until the desired depth of cut is reached. For milling slots, use a slitting saw or end mill, and follow the same procedure as for milling holes.
Slot Milling
To mill slots, start by marking the location of the slot on the workpiece. Then, clamp the workpiece in the cross vise and insert a slitting saw or end mill into the drill press chuck. Lower the quill to bring the cutting tool into contact with the workpiece. Engage the drill press and advance the quill manually or with the feed mechanism until the desired depth of cut is reached. To finish the slot, move the cross vise back and forth while advancing the quill to cut the length of the slot.
| Tool | Purpose |
|---|---|
| Slitting saw | To mill narrow slots |
| End mill | To mill wider slots and pockets |
Additional Tips for Milling with a Drill Press
- Use sharp cutting tools to ensure clean cuts and prevent the workpiece from grabbing the tool.
- Securely clamp the workpiece in the cross vise to prevent movement during milling.
- Use a coolant or lubricant to reduce friction and extend the life of the cutting tool.
- Wear appropriate safety gear, including eye protection, hearing protection, and gloves.
- Practice on scrap material before milling on your actual workpiece.
- Take frequent breaks to avoid fatigue and maintain focus.
How to Mill with a Drill Press and Cross Vise
Milling with a drill press and cross vise is a versatile and efficient way to shape and machine metal. By using a drill press as a milling machine, you can perform a variety of operations, including surface milling, end milling, and slot milling. With a cross vise, you can accurately position and secure your workpiece, ensuring precise results.
To mill with a drill press and cross vise, you will need the following tools and materials:
- Drill press
- Cross vise
- Milling bit
- Workpiece
- Safety glasses
- Gloves
Once you have gathered your tools and materials, you can begin the milling process. First, secure your workpiece in the cross vise. Make sure that the workpiece is securely clamped and that it will not move during the milling process. Next, select the appropriate milling bit for the operation you want to perform. There are many different types of milling bits available, so be sure to choose one that is designed for the specific task you are undertaking.
Once you have selected the milling bit, insert it into the drill press chuck. Be sure to tighten the chuck securely. Next, set the drill press speed to the appropriate setting for the milling bit you are using. The speed will vary depending on the material you are milling and the size of the milling bit.
Once the drill press is set up, you can begin milling. Slowly lower the milling bit into the workpiece, using the cross vise to control the depth of cut. Be sure to hold the workpiece securely with your gloves to prevent it from moving. As you mill, move the workpiece back and forth under the milling bit, using the cross vise to control the feed rate. Continue milling until you have reached the desired shape and size.
Once you have finished milling, turn off the drill press and remove the workpiece from the cross vise. Be sure to wear safety glasses and gloves throughout the milling process to protect yourself from flying chips and debris.
People Also Ask
How do I choose the right milling bit?
The type of milling bit you choose will depend on the operation you want to perform and the material you are milling. There are many different types of milling bits available, so it is important to consult with a qualified machinist or refer to the manufacturer’s specifications to determine the best bit for your specific needs.
What is the correct speed for milling?
The correct speed for milling will vary depending on the material you are milling and the size of the milling bit. As a general rule, harder materials require slower speeds, and larger milling bits require faster speeds. Consult with a qualified machinist or refer to the manufacturer’s specifications to determine the correct speed for your specific milling application.
How do I secure my workpiece in a cross vise?
To secure your workpiece in a cross vise, first clean the jaws of the vise and the surface of the workpiece. Next, place the workpiece in the vise and tighten the jaws evenly. Be sure to use enough force to hold the workpiece securely, but avoid overtightening the jaws, which could damage the workpiece.
