Sherline 5000 Mill Assembly Instructions

-2-
TABLE OF CONTENTS
Sherline warranty and service policy . . . . . . . . . . . . . . . 1
Ordering replacement parts . . . . . . . . . . . . . . . . . . . . . 1
Safety rules for power tools . . . . . . . . . . . . . . . . . . . . . 3
An introduction to the world of miniature machining . . . 4
General precautions . . . . . . . . . . . . . . . . . . . . . . . . . . 4
Customer’s responsibilities . . . . . . . . . . . . . . . . . . . . . . 5
Learning more about machining . . . . . . . . . . . . . . . . . . 5
Lubrication . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5
Initial assembly of a new machine . . . . . . . . . . . . . . . . 5
Mounting the lathe crosslide . . . . . . . . . . . . . . . . . . . . . 6
Installing the mill X-axis handwheel . . . . . . . . . . . . . . . . 6
Installing the mill X-axis digital readout handwheel . . . . . 6
5000/5400-series millls, installing the column . . . . . . . . . 7
2000-series mills, installing the multi-direction column . . . 7
Mounting the motor and speed control assembly . . . . . . . 7
What to do if the motor shuts down . . . . . . . . . . . . . . . .8
Operation of the motor and speed control . . . . . . . . . . . 9
Industrial applications for Sherline components . . . . . . . 9
Mounting the headstock to the lathe or mill . . . . . . . . . 9
Mounting lathe and mill to a base board . . . . . . . . . . . . . 10
Converting machines from inch to metric . . . . . . . . . . 10
ADJUSTMENTS
2-speed pulley . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10
Preload . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11
Gibs . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11
Leadscrew backlash . . . . . . . . . . . . . . . . . . . . . . . 11
Handwheels . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .11
Saddle nut . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .12
Tailstock gib adjustment . . . . . . . . . . . . . . . . . . . . .12
Aligning the lathe headstock and tailstock . . . . . . . . 12
Aligning your mill . . . . . . . . . . . . . . . . . . . . . . . . . 13
Use of cutting oils . . . . . . . . . . . . . . . . . . . . . . . . . . . . 17
General machining terms . . . . . . . . . . . . . . . . . . . . . . . 17
Rules for feed rates and cutting speeds . . . . . . . . . . . . . 17
LATHE OPERATION
Leveling the tool . . . . . . . . . . . . . . . . . . . . . . . . . . . 18
Initial test cutting . . . . . . . . . . . . . . . . . . . . . . . . . . 18
Lathe terminology . . . . . . . . . . . . . . . . . . . . . . . . . . 19
Controlling “chatter” . . . . . . . . . . . . . . . . . . . . . . . . 19
Holding the workpiece . . . . . . . . . . . . . . . . . . . . . . 19
Turning between centers . . . . . . . . . . . . . . . . . . . . . 19
Removing tools from Morse tapers . . . . . . . . . . . . . 20
Center drilling . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20
Tailstock drilling . . . . . . . . . . . . . . . . . . . . . . . . . . . 20
Headstock drilling . . . . . . . . . . . . . . . . . . . . . . . . . . 21
Reaming . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 21
Faceplate turning . . . . . . . . . . . . . . . . . . . . . . . . . . 21
Taper turning . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 21
Tool shapes and cutting angles, use of tools . . . . . . 21
Inserted tip carbide tools . . . . . . . . . . . . . . . . . . . . . 24
Turning speeds and feed rates, general rules . . . . . . 24
Accessories for the lathe
3-Jaw, 4-jaw and drill chucks . . . . . . . . . . . . . . . . . . 25
Thread-cutting attachment . . . . . . . . . . . . . . . . . . . . 25
Steady rest . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 26
Additional lathe accessories . . . . . . . . . . . . . . . . . 26
3-JAW CHUCK OPERATION. . . . . . . . . . . . . . . . . 28
VERTICAL MILLING MACHINE OPERATION
General description . . . . . . . . . . . . . . . . . . . . . . . . . 29
Helpful tips for machining . . . . . . . . . . . . . . . . . . . . 29
Mill terminology . . . . . . . . . . . . . . . . . . . . . . . . . . . 30
Securing the workpiece . . . . . . . . . . . . . . . . . . . . . . 30
Before you cut . . . . . . . . . . . . . . . . . . . . . . . . . . . . 31
Purchasing raw materials . . . . . . . . . . . . . . . . . . . . 31
Types of work . . . . . . . . . . . . . . . . . . . . . . . . . . . . 32
Types of milling cutters . . . . . . . . . . . . . . . . . . . . . 32
Standard milling vs. “climb” milling . . . . . . . . . . . . . 32
Working to a scribed layout line . . . . . . . . . . . . . . . 33
Use of a dial indicator . . . . . . . . . . . . . . . . . . . . . . . 33
Accurately locating the edge of a part . . . . . . . . . . . 34
Determining the depth of cut . . . . . . . . . . . . . . . . . . 35
Suggested cutting speeds, end mills and drills . . . . . 35
End mills . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 35
Locking the column saddle . . . . . . . . . . . . . . . . . . . 36
Accessories for the milling machine
Sensitive drilling attachment . . . . . . . . . . . . . . . . ..36
3/8" end mill holder . . . . . . . . . . . . . . . . . . . . . . . . . 36
Mill collet set . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 36
Boring head . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 37
Fly cutter . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 37
Drills and drill chuck, center drills . . . . . . . . . . . . . 37
Milling vise . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 38
Step block hold-down set . . . . . . . . . . . . . . . . . . . 38
Tilting angle table . . . . . . . . . . . . . . . . . . . . . . . . . . 38
4" rotary table. . . . . . . . . . . . . . . . . . . . . . . . . . . . . 38
CNC rotary indexer . . . . . . . . . . . . . . . . . . . . . . . . 39
Horizontal milling conversion . . . . . . . . . . . . . . . . . 39
Multi-direction column upgrade . . . . . . . . . . . . . . . . 39
Additional mill accessories . . . . . . . . . . . . . . . . . . . 40
Books and videos for machinists . . . . . . . . . . . . . . . . . 41
Speed control electrical wiring layout and color codes . . 41
Exploded view, typical CNC stepper motor mount . . . . . 41
Exploded view, 4000/4400-series lathes . . . . . . . . . . . . . 42
Exploded view, 5000/5400-series mills . . . . . . . . . . . . . . 43
Exploded view, 2000 series 8-direction mill . . . . . . . . . 44
Part numbers and descriptions . . . . . . . . . . . . . . . . . . . 45
Tips on using the handwheels . . . . . . . . . . . . . . . . . . . 46
Technical specifications, lathes and mills . . . . . . . . . . . 46
“A man who works with his hands is a laborer.
A man who works with his hands and his brain is a craftsman.
A man who works with his hands, his brain and his heart is an artist.”
—Louis Nizer