Smithy Midas 1220 XL Manual do Utilizador

MIDAS 1220 XLCOMBINATION LATHE/MILL/DRILLOPERATOR’S MANUALUpdated August, 2008170 Aprill Dr., Ann Arbor, MI, USA 48103 Toll Free 1-800-476-4849www.smi

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Bevels and chamfers are cut at an angle to the main work-piece surface. A bevel cut(Figure 23.3) goes from side to side, completely removing the perpe

Chapter 24Common AdjustmentsBevel Gear AdjustmentOccasionally you will have to adjust the bevel gears that drive the millhead. Theadjustment is on top

Figure 24.2 Remove the screw at the bottom of the bevel gear.Millhead T-KeyThe millhead has a T-key between the drive shaft and drive pulley. If you r

Bend back the tab on the lockwasher (Figure 24.4) and remove the spanner nut andlockwasher from the spindle. Remove the four screws from the bearing c

Chapter 25TroubleshootingPowerfeed and Thread CuttingPowerfeed does not move carriageCause Solution• Carriage locked • Unlock carriage• Speed selector

Tool is not cutting “on thread”Cause Solution• Half-nut fully engaged • Keep half-nut engagedCarriage and Milling TableTable won’t moveCause Solution•

Too much backlash in the cross-slideCause Solution• Loose screw • Tighten screw, review how to eliminate backlash• Loose brass nut • Put a shim bet

• Speed too high • Reduce speed• Too much pressure at tailstock • Reduce pressure and increase lubricationWorks stops turning but machine continues

• Tool not on center • Center tool• Improper tool shape, tool dull • Reshape, sharpen or replace toolDepth of cut is not consistentCause Solution• Qui

• Debris in chuck • Clean chuckChuck wobblesCause Solution• Chuck loose on arbour • Clean arbour and remount• Drawbar not tight • Clean spindle and re

Chapter 1IntroductionCongratulations on purchasing a Smithy Midas 1220 XL lathe-mill-drill. We are pleasedyou chose Smithy to fulfil your machining ne

Chapter 26MI-1220 XL SpecificationsGeneral DimensionsLength 42”Width 20”Height 37”Shipping Weight 530 lbsMachine Weight 419 lbsCrate Size 43-1/2” x 22

X-Axis Travel (w/tailstock installed) 15”Y-Axis Travel 7-3/8”Mill SpecificationsColumn Diameter 3-1/8”Dial Calibration Drill-Coarse Feed 0.042”Dial Ca

Chapter 27Removing the Apron from the MI-1220 XLPlease have the manual at hand when working on the machine and when calling SmithyCo. for assistance.

Chapter 28Changing the Lateral Drive Shaft in the MI-1220XL ApronPlease have the manual at hand while working on the machine and when calling SmithyCo

Chapter 29Machine Warranty30 Day Trial OfferTry a Smithy for 30 days. If, for any reason within that time, you decide to return yourSmithy, just call

In no event shall Smithy be liable for indirect, incidental or consequential damages for thesale or use of the product. This disclaimer applies to bot

Chapter 2SafetyYour workshop is only as safe as you make it. Take responsibility for the safety of all whouse or visit it. This list of rules is by no

13. Use the correct tool for the job. Don't try to make a tool into something it isn't.14. Keep your mind on your work.Pay attention to thes

Chapter 3Knowing Your MachineThe Midas 1220 XL has a 3/4 hp, 110 V motor. The motor powers the lathe and millheadthrough the main belt drive and the m

Chapter 4Caring For Your MachineThe Midas 1220 XL is a delicate, precision tool with ground ways and hand-scrapedbearing surfaces under the table and

Chapter 5Basic Parts of the MI-1220 XLTo learn the operations of your machine, you have to know the names and functions ofits basic parts. Figure 5.1

2. Carriage- The carriage consists of the saddle and apron. It moves by hand or poweralong the bed, carrying the cross slides, compound rest, and tool

6. Drill Press and Fine Feed Clutch- Pushing in the drill-press clutch engages the finefeed. To work the clutch, release the spring tension by rotatin

Figure 5.5 To adjust the tension on the lathe belt, move the tensioner handle forward or back.13. Lathe / Mill / Drill Clutch- The lathe/mill/drill cl

© 2008 Smithy Co. All rights reserved (Revision 1).170 Aprill Dr., Ann Arbor, Michigan, USA 48103 Toll Free Hotline: 1-800-476-4849 Fax: 1-800-431-889

17. Micrometer Dial Collars- Just inside the handles of the tailstock (Figure5.1),crossfeed (Figure 5.1), drill press (Figure 5.1), compound feed (Fig

Figure 5.8 To offset the tailstock, adjust the base-locking bolts.5-6Or Visit www.smithy.comBasic Parts of the MI-1220 XLRight TresleSetscrewTailstock

Chapter 6 Uncrating and Setting Up The MI-1220 XLMoving the MachineMoving a machine tool can be dangerous. Improper techniques and methods may injurey

Now open the accessories box. Check the items in it against the accessory checklist. Afteraccounting for all parts, you're ready to move your Mid

Figure 6.3 The chuck attaches to the spindle flange with three bolts. The one bolt located on the other side of the spindle does not show. Put the mac

Figure 6.5 To check bench and bed level accuracies, successively place level at A, B, C, D(longitudinal positions) and E and F (transverse position).

Once it's cleaned, your Smithy is ready for lubricating. Do this carefully and thoroughlybefore starting the machine. Use pressure oil can and go

Figure 6.7 Oil the buttons (circled) along the cross-feed table and cross slide.2. Put a few drops of oil on the compound and cross-slide feedscrews.3

Oiling the Leadscrew1. Put oil in the oil buttons in the left trestle.2. Put oil in the support for the right end of the leadscrew (figure 6.9).Figure

Setting up Your MI-1220 XLThe Midas 1220 XL comes with all major components assembled, but it is not ready touse right out of the crate. Do not start

Table of ContentsInventory Check List . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .i-ivChapter 1: Introduct

Table 6.2 Setting Mill/Drill Speeds (RPM)Adjusting Belt TensionTo get maximum performance from your machine, keep the drive belts snug.To adjust the t

To tighten the lathe belts, move the tensioner handle above the motor (Figure 5.5) so itpoints toward the lathe head. Turn the knurled knob clockwise

Tailstock gib.The tailstock gib also has two adjusting screws (Figure 6.14). This gib canbe free than the others so it is easier to position the tails

Push and pull on the cross slide. If there is movement, remove the two bolts that attachthe rear screwseat to the cross slide, remove the screwseat an

3. Start the motor by pushing in on the green button. To reverse the motor, push the redbutton to stop it, lift the cover over the rocker switch, and

Chapter 7TurningThe lathe rotates a workpiece against a cutting edge. With its versatility and numerousattachments, accessories, and cutting tools, it

The modern lathe offers the following:• The strength to cut hard, tough materials• The means to apply power• The means to hold the cutting point tight

Gear RatiosThe lathe lets you use various indicated gear combinations to cut the desired number ofthreads per inch (tpi), or the metric equivalent, o

Chapter 8Metalcutting TheoryA machine tool is no more efficient than its cutting edge. Because lathe operations requirecontinuous regrinding and resha

Figure 8.2 Wedging-off action in cutting hard steel. Note the false edge or crust that builds up on the cutting edge.On harder substances, the wedging

Chapter 8: Metalcutting TheoryTool Sharpness . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .8-2Heat . . . . .

HeatThe energy expanded at the lathe's cutting point converts largely into heat, and becausethe energy is great, the heat is intense. Before toda

To use this formula, find the cutting speed you need on the chart and plug that numberinto the CS portion of the formula. After calculating the rpm, u

Chapter 9Grinding Cutter Bits for Lathe ToolsHigh-Speed-Steel Cutters The advantage of HSS cutter bits is you can shape them to exact specifications t

Figure 9.2 The edge weakens if front clearance is too great.Grind cutters on a true-surfaced, good-quality, medium-grit grinding wheel (preferably an8

Figure 9.4 When honing, draw the cutter away from the cutting edge across the oilstone.Materials Other Than Steel As pointed out earlier, when grindin

Bits for Turning and Machining BrassBrass tends to pull or drag when machined. It's best to machine it on dead center withthe top rake in the hor

Figure 9.8 Insert the point into the nearest seized V in the center gauge.Acme or Other Special Threads Thread gauges are available for all standard t

Table 9.1 Carbide Types and Cutting Tool ApplicationsApplication Use GradeCast Iron Roughing cuts C-1Non-ferrous, non-metallic, high-temperature

Chapter 10Setting Up Lathe ToolsAfter selecting a cutter, insert it in the toolholder. Allow the cutter bit to project justenough to provide the neces

Figure 10.2 The harder the steel (left),the less above center you set the cutter point. For soft brass and aluminum (right), set the cutter on dead ce

Chapter 13: Lathe Facing and KnurlingFacing Across the Clutch . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .13-1Knurling . . .

Cutoff, Thread Cutting and Facing ToolsFor cutoff, thread cutting, and facing, feed the cutter to the work on dead center (Figure910.5). For the begin

Chapter 11Setting Up with Centers, Collets, and ChucksBefore setting work up on centers, make sure the spindle and tailstock centers alignaccurately.

5. Feed the tool from the center of the stock outward, toward yourself, using the handcrossfeed. One or two light cuts is usually enough to true up an

Figure 11.5 When you revolve the headstock against a piece of chalk, The chalk should just touch the high spots.6. Next, drill and countersink the cen

Mounting Work Between Centers Remove the chuck from the lathe, bolt the faceplate to the spindle if l angle (Figure 11.8),and put in both headstock an

Figure 11.9 Fasten a lathe dog to one end of the work piece.Note:Before starting to machine work set up on centers, check to see the lathe dog tailis

Setting Up Work on a Mandrel You can machine cylindrical or bored pipe work or cored castings too long to fit in a chuckby mounting them first on a ma

Steady Rests - Steady rests mount on the lathe bed (Figure 11.14). Clamped over theways, they provide three bearing surfaces. These surfaces bear down

Setting Up Work in a Chuck Chucks usually hold work that is too short to hold conveniently between centers or workrequiring machining at, into (boring

To place work in a chuck, follow these steps:1. Adjust the chuck jaws to the approximate opening to receive the work. Roughlycenter them by matching t

Slitting Saws . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .21-4Angle Milling Cutters . . . . . . . . . . .

CautionNever leave the chuck key (wrench) in the chuck while the chuck is on the spindle. Anymovement of the spindle can crash the key into the ways,

Figure11.21 With the slot for the #1 jaw in the 12:00 position, the slot for the #2 jaw is at 8:00and the slot for the #3 jaw is at 4:00. Collets and

Toolpost Grinders A fully equipped lathe has a toolpost grinder, a small, independently operated grindinghead with an integral electric motor that mou

Chapter 12Lathe TurningRough Turning1. In turning a shaft to size and shape where you have to cut away a lot of stock, takeheavy, rough cuts to get th

To reduce the diameter, advance the tool only half as many thousandths on the dial. Thisis because the tool takes off an equal amount from both sides

Figure 12.3 You can do other turning cuts with different cutter bits and cutting tools.Machining Square CornersTo machine an accurate corner, follow t

Figure 12.4 With a file, take full strokes at an oblique angle and never hold the file still.For an even finer file finish, rub railroad chalk into it

Figure 12.6 Tapers cut with the compound rest areusually short, abrupt angles.Figure 12.7 In setting over the tailstock, the lathe centers move from t

Figure 12.8 Tailstock set over should be half the difference between the finished diameters ofthe ends. That is 0=T” x L”/2 where T= taper per inch an

Chapter 13Lathe Facing and KnurlingBefore removing your work from the centers, face or square up the ends. On accuratework, especially where shoulders

Inventory Check ListIt is a good idea to take inventory of the parts of your machine soon after it is unpacked.By doing so, you can quickly determine

the lathe is turned on. Once the cutter has been positioned as per the above paragraph,move the crossfeed lever down. Pull the lever up at the end of

Use plenty of oil, lubricating both knurl and workpiece. Then start the lathe and engagethe automatic feed, moving the knurls across the portion to be

Chapter 14Changing GearsTo change the gears on the MI-1220 XL, follow these steps. You will need a 10mmwrench, 6mm Allen wrench, screwdriver (to remov

Figure 14.2 Slide the B and C gearshaft until the C geal meshes with the D gear.8. Place the selected A gear, flange side in on the A gearshaft and re

Chapter 15Cutting Screw ThreadsThreading TermsBefore beginning to cut threads, it’s useful to learn the major terms used in threadcutting:Pitch. Metri

For right-hand threads, start the threading tool at the right end of the workpiece and feedit toward the headstock. For lef-hand threads, reverse the

15.3 Using a center gauge, set the threading tool at exactly dead center on the workpiece.Cutting Right Hand ThreadsNow you are ready to cut right-han

15.4 Chamfer the end of the thread toprotect it from damage.Cutting Left Hand ThreadsCut left-hand threads exactly as you cut right-hand threads, exce

What Not To Do When Cutting ThreadsDo not disengage the half-nut lever. Do not shift the powerfeed speed lever. If you arecutting between centers don’

Chapter 16Lathe Drilling and BoringYou can lathe drill on the MI-1220 XL in two ways, holding the drill stationary andrevolving the workpiece, or hold

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Boring Boring is internal turning, or turning from within. The diameter of the opening to be boredis often much smaller than its depth. Boring tools m

tool clearance. Except when using the adjustable boring tool (usually for very largediameter work), feed the bar into the hole, parallel to the holes

After the last finish cut, it is common to reverse the feed and take one last, fine cut withthe tool coming out of the work. This last cut, taken with

Because the feed of successive cuts is toward, not away from, the operator, thethread-cutting set is reversed. Also, you must take lighter cuts becaus

Chapter 17Cutting Off or Parting with a LatheYou can cut off in a lathe only when holding one end of the work rigidly, as in a chuck.It is not practic

Chapter 18MillingIn milling, one or more rotating cutters shape a workpiece held by a vise or other fixture.The cutters mount on arbors or at the end

Chapter 19WorkholdingThe most common ways to hold a workpiece during milling are to secure it directly to thetable via clamps or hold it in a vise (Fi

Using special fixtures. Clamp both workpiece and fixture securely in place. Be sure theyare clean. Watch them carefully during machining; a loose fixt

Chapter 20Holding Milling CuttersThere are several ways to hold milling cutters: in arbors, with collets and special holders,and in adapters.ArborsArb

Figure 20.3 End mill holders also receive straight-shank end mills.AdaptersAdapters mount various types and sizes of cutters on the spindle. Arbor ada

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Chapter 21Milling Cutters Choose milling cutters for the type of cut, the number of parts, and the material. Rakeangles depend on both cutter and work

•Ball end mills(Figure 21.2) cut slots or fillets with a radius bottom, round outpockets and bottoms of holes, and do die sinking and die making. Four

Plain Milling CuttersPlain milling cutters have teeth only on their periphery. Used to mill plain, flat surfaces,they may combine with other cutters t

Slitting Saws Slitting saws do narrow slotting and cut-off operations. •Plain slitting sawsare thin, plain milling cutters with only peripheral teeth.

toolbits for flycutters as you grind lathe tools (Section Seven). You can also use flycutters for boring. Note:When the tool revolves, the cutting too

Tool Grinding Sharpen cutting tools when they become dull, or extreme forces may build up at thecutting edge of the teeth, causing chipping or fractur

Chapter 22Speeds and Feeds for MillingSpeeds Milling cutting rates vary according to the machinability of the material being cut; whethercutting fluid

the backlash problems associated with it.Feed rates.Your feed rate should be as high as your machine, cutting tool,workholding method, and workpiece c

Table 22.1 Recommended Cutting Speeds for Milling (fpm)MaterialBrinellHardnessHigh-Speed-SteelCuttersCarbideCuttersFree-machining low carbon 1111steel

Chapter 23Common Milling OperationsMilling Flat Surfaces One way to mill a flat surface is by plane milling (Figure 23.1). Adjust the milling cutterve