Alignment and Setup

Machine Alignment
1) Clean the table and column face, making sure there are no nicks that rise above the surface
2) Attach the dial indicator
3) Bring the dial indicator in contact with one edge of the column face
4) Move in one-fourth of the indicators operating range, and zero the dial by turning the bezel
5) Move the table manually and note any changes in the dial indicator reading. The gibs on the knee, saddle and the table must be in good condition and properly adjusted to eliminate lost motion. The table cannot be adjusted accurately if there are any loose mating surfaces.
6) If any error is noted, loosen the saddle clamps and move the table one-half of the error in the proper direction and retighten. If the dial reads 0 at the right-hand side of the column and 0.008 inches at the left-hand side, shift the table so that the reading becomes 0.004 inches.
7) Repeat the process until the dial indicator reading does not change as it traverses the column face.

Head Alignment
1) Clean the table thoroughly and place a flat and parallel plate on it if one is available.
2) Attach the dial indicator to the spindle.
3) Feed the spindle down with the dial plunger at the operator’s right or left-hand side until it registers about one-fourth of its operating range and zero it.
4) Carefully rotate the spindle one revolution. If the head is of the swivelling or semi-universal type, the fore and aft reading in line with the cross feed will be identical; the right and left readings may vary if the head is not vertical. If the head is of the universal type, the reading may vary on both the axes.
5) Adjust a semi-universal head by loosening the head and swivelling it so that the dial indicator reading is cut in half. For example, if the highest dial indicator reading is 0.010 inches, stop rotation of the spindle at the point. The head should be moved so that the reading is reduced to 0.005 inches. Recheck by rotating the spindle and readjusting the head if necessary.
6) Universal heads should be adjusted in one plane at a time. For example, adjust the head to correct fore and aft tilt until both the fore and aft readings are zero. Then adjust the head so that the right and left readings are zero.
7) Securely tighten all head locking bolts and recheck.

Vise and Fixture Alignment
Vise Alignment
1) Clean all parts thoroughly. Make sure that there are no burrs or nicks on mating surfaces.
2) Lightly clamp the vise and fixtures in approximately the correct position.
3) Bring the dial indicator in contact with one end of the part to be aligned. Move in about one-fourth of the indicator’s operating range and zero indicators.
4) Move the table or cross slide the full length of the jaw or fixtures.
5) Note the variation in indicator reading and move appropriate direction using a soft hammer.
6) When the indicator shows no deviation, retighten all bolts and recheck.


Basic Setup Procedures
Mounting the Work
1) When the work is held in a vise, it should be placed and supported so that the loads imposed by the cutter are directed at the solid jaw of the vise.
2) Parallel bars should be used under any work that is too thin to protrude above the jaws of the vise.
3) When castings are held in a vise, the part that contacts the fixed jaws should be ground as smooth as possible. If this is not possible, place a sheet of soft aluminium or copper between the vise and the casting.
4) Place a mild steel or aluminium between the movable jaw and the casting. This protects the rear jaw and applies pressure more evenly to the work piece. The round bar should be place in line with the screw of the vise is possible.
5) A combination of straps, clamps, T bolts, step blocks and many other work-holding devices can be use to hold a work piece on the milling machine.