Sherline
Sherline
PRODUCTS
INCORPORATED 1974
Seventh Edition
P/N 5326
2010, Sherline Products Inc.
Full One Year Warranty
On Sherlines 3.5 Metal Lathe, Vertical Milling Machine and Accessories
If within one year from the date of purchase a new* Sherline power tool fails due to a defect in material or workmanship,
Sherline will repair it free of charge. In addition, it has always been our policy to replace at no cost all parts, regardless of
age, which are determined to have been incorrectly manufactured or assembled and have failed due to this cause rather than
because of improper use or excessive wear caused by continuous use in a production environment. In cases such as this,
Sherline will inspect the machine or part and will be the sole judge of the merit of the claim. Freight charges for returning a
machine are not covered. Merchandise which has been abused or misused is not subject to warranty protection. Disassembly
of a machine or accessory beyond normal maintenance procedures described in this manual may void the warranty. Before
attempting major repairs, call the factory for advice and instructions.
Warranty service is available by simply returning the machine, defective assembly or part to:
Sherline Products, Inc., 3235 Executive Ridge, Vista, CA 92081-8527
Please write, fax, call or e-mail to let us know that you are retuning a part and to receive a return authorization number.
This will speed up the warranty process. (E-mail is sherline@sherline.com)
This warranty gives you specific legal rights, and you may also have other rights which vary from state to state.
*NOTE: Only new machines purchased directly from Sherline or from an authorized Sherline dealer are covered by this warranty. This includes machines
purchased via on-line auctions when offered by Sherline or its authorized dealers. Machines purchased second-hand or from a non-authorized dealer are
considered used and are not subject to warranty even if they appear to be new in the box. If you are in doubt about the status of a dealer or are suspicious
about an offer that doesnt seem quite right, you can always confirm a dealers status by checking our DEALERS page (www.sherline.com/dealers.htm)
for a listing or by calling (800) 541-0735 to confirm a dealers authority to represent Sherline.
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Safety Rules for Power Tools
1. Know Your Power ToolRead the owners manual kept near an operating grinder, it should be kept covered
carefully. Learn its application and limitations as well as when not in use.
the specific potential hazards peculiar to this tool. 21. Don't Let Long, Thin Stock Protrude from the Back of the
2. Ground All ToolsIf a tool is equipped with a three- SpindleLong, thin stock that is unsupported and turned
prong plug, it should be plugged into a three-hole at high RPM can suddenly bend and whip around.
receptacle. If an adapter is used to accommodate a two- 22. Wear Your Safety GlassesForesight is better than NO
prong receptacle, the adapter wire must be attached to SIGHT! The operation of any power tool can result in
a KNOWN GROUND. Never remove the third prong. foreign objects being thrown into the eyes, which can
(See Figure 1.) result in severe eye damage. Always wear safety glasses
3. Keep Guards in Placeand in working order. or eye shields before commencing power tool operation.
4. Remove Adjusting Keys and WrenchesForm a habit of We recommend a Wide Vision Safety Mask for use over
checking to see that keys and adjusting wrenches are spectacles or standard safety glasses.
removed from the tool before turning on any machine. GROUNDING TYPE 3-PRONG PLUG
5. Keep Work Area CleanCluttered areas and benches PROPERLY
GROUNDED
invite accidents. TYPE OUTLET USE PROPERLY
6. Avoid a Dangerous Work EnvironmentDo not use power GROUNDED
GROUND PRONG RECEPTACLE AS
tools in damp or wet locations. Keep your work area well SHOWN
illuminated. NOTE: Power cords are
available with UK and
7. Keep Children AwayAll visitors should be kept a safe European plugs. PLUG ADAPTER
distance from the work area. UKP/N 40630
EuropeP/N 40640
8. Make Your Workshop Childproofwith padlocks, master
switches or by removing starter keys. GROUND WIRE
9. Do Not Force a ToolDo not force a tool or attachment FIGURE 1Proper grounding for electrical
to do a job for which it was not designed. Use the proper connections.
tool or accessory for the job. Electrical Connections
10. Wear Proper ApparelAvoid loose clothing, neckties, The power cord supplied is equipped with a 3-prong
gloves or jewelry that could become caught in moving grounding plug that should be connected only to a
parts. Wear protective headgear to keep long hair styles properly grounded receptacle for your safety. Should an
away from moving parts. electrical failure occur in the motor, the grounded plug
11. Use Safety GlassesAlso use a face or dust mask if a and receptacle will protect the user from electrical shock.
cutting operation is dusty. If a properly grounded receptacle is not available, use a
12. Secure Your WorkUse clamps or a vise to hold work grounding adapter to adapt the 3-prong plug to a properly
when practicable. It is safer than using your hand and grounded receptacle by attaching the grounding lead from
frees both hands to operate the tool. the adapter to the receptacle cover screw.
13. Do Not OverreachKeep your proper footing and NOTE: The electrical circuit designed into the speed
balance at all times. control of your lathe or mill reads incoming current from
14. Maintain Tools in Top ConditionKeep tools sharp and 100 to 240 volts AC and 50 or 60 Hz and automatically
clean for best and safest performance. Follow instructions adapts to supply the correct 90 volts DC to the motor. As
for lubrication and changing accessories. long as you have a properly wired, grounded connector
15. Disconnect ToolsUnplug tools before servicing and when cord for your source, the machine will operate anywhere
changing accessories such as blades, bits or cutters. in the world without a transformer. This has been true
16. Avoid Accidental StartingMake sure the switch is for all Sherline machines built since 1994. Prior to that,
OFF before plugging in a power cord. an AC/DC motor was used. Use that motor ONLY with
17. Use Recommended AccessoriesConsult the owner's the power source for which it was intended. It will not
manual. Use of improper accessories may be hazardous. automatically adapt to any other current and using it with
18. Turn the Spindle by Hand Before Switching Motor OnThis an improper power source will burn out the motor or speed
ensures that the workpiece or chuck jaws will not hit the control. Also, the first few DC units built did not include
lathe bed, saddle, crosslide or cutting tool and that a key the circuits to adapt to other currents. If you think you
or spindle bar was not left in the chuck. may have an early DC model, remove the plastic speed
control housing and look for a label on the aluminum
19. Check that all Holding, Locking and Driving Devices Are
TightenedAt the same time, be careful not to overtighten speed control frame. If it has a small metallic label on top
these adjustments. They should be just tight enough to of the frame that lists input voltage as 120VAC, DO NOT
do the job. Overtightening may damage threads or warp ATTEMPT TO CONVERT THIS MODEL TO OTHER
parts, thereby reducing accuracy and effectiveness. CURRENTS. Models that can be used with any current
have a paper label on the end of the speed control frame
20. Don't Use Your Lathe for GrindingThe fine dust that
results from the grinding operation is extremely hard on which lists the model number as KBLC-240DS.
bearings and other moving parts of your tool. For the See page 1 for information on ordering an optional CE
same reason, if the lathe or any other precision tool is compliant electronic filter if required in your country.
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An Introduction to the World of Miniature Machining
Getting Answers to Your Questions About Machining There Are no Shortcuts
Over the years we have found that the majority of our Machining is a slow process because parts are made one at
customers are both highly intelligent and skilled craftsmen. a time. The interesting thing is, a skilled machinist may take
Often they are also new to machining. The instructions we almost as long to make the same part as a novice. Shortcuts
have included in this book, while far more extensive than usually end in failure. Unlike some other trades, mistakes
anything included with other machine toolseven ones cannot be covered up. There are no erasers, white-out or
costing thousands of dollarsstill only scratch the surface putting-on tools for machinists; you simply start over. To
when it comes to machining. We have tried to anticipate expand a little on an old rule: Think three times, measure
the most common problems and questions asked by a new twice and cut once!
machinist. What we have provided in this book and with each The Craftsmans StrengthAnticipating a Tools Limitations
accessory, when combined with a liberal amount of common The skill in machining isnt just moving the dials. It is a
sense, is more than enough to get you started. If you apply combination of engineering and craftsmanship. A file is just
what you learn here, you will be well on your way to making as useful a tool to a good machinist as a multi-thousand-
good parts. No doubt you will also have many questions dollar machine tool. Tools deflect or bend under load,
specific to your project that simply cant be addressed in a and anticipating this bend is what it is all about. Sharp tools
manual of this type. deflect less than dull tools, but with each pass the tool gets a
Answers to questions beyond the scope of this booklet will little duller and the deflection becomes greater. If you try to
have to come from your own research. Bookstores and machine a long shaft with a small diameter, the center will
libraries are full of excellent books on machining, and the always have a larger diameter than the ends, because the part
Internet offers some great user groups that can put you in direct deflects away from the tool where it has less support. You can
contact with others who share your specific interests. Our own go crazy trying to machine it straight, or you can simply pick
Worldwide Web site is a great source of information as well. up a good, flat mill file and file it straight in a few moments.
We have published there all the instructions for all our tools Machine tools will never replace the craftsmans touch,
and accessories for you to read and print out for free. There and machining is a combination of both good tools and good
are also links to many other fascinating sites. For the past forty technique.
years I have found Machinerys Handbook to be the source I You Dont Become a Machinist by Buying a Machine
turn to most for answers to my own questions. You should strive from the beginning to make better and
I recently wrote a book called Tabletop Machining that is more accurate parts than you think you need. Work to closer
specifically directed to the owners of Sherline tools and to tolerances than the job demands. Be on the lookout for ways to
anyone who wants to learn to make small, metal parts. The make a job easier or better. Having a selection of appropriate
instructions you are reading that come with your machine are materials on hand and a good cutoff saw to get them to rough
quite complete; however, if you want to get into more detail size is a good start. Take some time and read through this
or want to see color photos of setups and projects made by instruction book before you try machining anything. We
some of the best craftsmen around, I am sure you will find want you to enjoy the process of creating accurate parts from
more than your moneys worth in Tabletop Machining. May raw metal. Buying a machine didnt make you a machinist,
your journey toward becoming a skilled machinist be an but using it along with the skill and knowledge you acquire
enjoyable one. along the way eventually will. With the purchase of Sherline
equipment, you have taken your first step toward many years
What New Machinists Like Most and Least of machining satisfaction. We thank you for letting us be a
If you are new to machining, you may find it to be either one of part of that.
the most rewarding skills one can learn or the most frustrating
thing you have ever attempted. What makes machining fun Joe Martin, President and owner
for some is the complexity and challenge. The same thing Sherline Products Inc.
will drive others up the wall. One customer may be overjoyed
because he can now make parts that were not available for SHERLINE FACTORY TOURS
purchase. Another may wonder why he just spent all day Visit Sherlines factory in North San Diego County and
making a part that is similar to one he could have purchased see miniature machine tools being produced. If you cant
for two dollars. The difference is that it is not the same as the come by, see the photo factory tour on our web site at www.
two-dollar partit is exactly the part needed. sherline.com/factour.htm.
2-SPEED GIB
STEPPED PULLEY ADJUSTMENT
SCREWS
HEADSTOCK
LOCKING SCREW LEADSCREW
HANDWHEEL
GIB
GIB LOCK
SADDLE
FIGURE 6Aligning the slide screw with the brass slide
screw insert
the leadscrew where the set screw was previously tightened.
When reinstalling the handwheel, try to have the set screw
pick up this same position on the leadscrew.
4. Slide the handwheel onto the end of the leadscrew shaft and
SLIDE SCREW INSERT
push until the handwheel is fully seated and the thrust collar
is clamped tightly between the handwheel and the leadscrew
collar. A 3/32" hex wrench is included with your machine to
tighten the handwheel set screw.
FIGURE 4 Lathe bed, saddle and gib Digital Readout Handwheels
Next, see that the gib is in the proper position on the saddle. If you ordered your mill equipped with a digital readout,
(See Figure 4.) It is taped into position for shipping. Remove the X-axis handwheel will again be removed to prevent
the tape holding it in place. If the gib has come off, reposition damage during shipping. The proper thrust collar has been
it on the gib lock as shown. factory installed. If a 1/4" shim washer is required, it will be
included in this package. Place it on the leadscrew shaft before
From the front of the lathe, engage the crosslide dovetail with installing the handwheel. Follow the installation instructions
the gib and matching dovetail on the saddle. Slide it onto the included with the P/N 8100 digital readout to install the
saddle about 1/4" (6-7 mm) until it stops. (See Figure 5.) encoder housing and handwheel unit.
Look underneath and align the slide screw with the threads 5000-Series MillsMounting the Column
on the brass slide screw insert on the side of the saddle. (See The mill is shipped attached to a piece of
Figure 6.) Turn the crosslide handwheel clockwise to engage plywood to keep it from moving in the box.
the threads. Continue to crank the handwheel clockwise until Before you begin, remove the screws holding
the crosslide is in the desired position on the saddle. the mill base to the plywood. It was installed
All MILLSX-Axis Handwheel Installation strictly for packing purposes and will need
Mills with adjustable zero handwheels come with the X- to be removed so that the column can be
axis handwheel removed to prevent damage to the leadscrew installed.
during shipping. Reinstalling the handwheel is a simple The Z-axis column is mounted to the base with
process: two 1-3/4" long, 1/4-20 socket head screws.
These screws and the hex key tool you will
1. Loosen the X-axis table lock (the barrel-shaped lock on need to tighten them are packaged in the bag
the saddle that is tightened against the side of the mill table with the motor mounting bracket and
with a socket head cap screw). From the end of the mill table drive belt. It is much easier to
where the X-axis leadscrew protrudes, push on the end of the mount the column to the base
mill table to make sure it seats tightly against the leadscrew. before you mount the motor and
2. Examine the red collar on the handwheel to see that the speed control to the saddle.
small hole is aligned with the head of the set screw. If it is not, Set the column on the base
loosen the black locking nut on the handwheel and rotate the aligned with the mounting holes
collar until you can see the head of the set screw. FIGURE 7Mounting the and hold it in position while you
3. The handwheel was installed at the factory and then 5000-series mill Z-axis insert the first screw up from the
removed for shipping. You should be able to see a mark on column bottom of the base. Hand-turn
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the first screw part way in, and then start the second screw.
This can be done with the machine upright by letting the base
hang over the edge of your table or bench just far enough to
expose the first hole. Using the large 3/16" hex key provided,
snug up both screws lightly first, and then tighten evenly.
2000-SERIES MILLSAssembling and Mounting
the Multi-Direction Column
To assemble the multi-direction column, make reference to
the exploded view on pages 43 and 44 of these instructions
and complete the steps that follow:
1. Attach the round column base (P/N 56700) to the mill base
with the two 1/4-20 x 1-1/2" socket head cap screws.
2. Screw the arm hold-down bolt (P/N 56130) into the top of
the round column base and tighten with an adjustable wrench
using the two flat indentations on the shaft. FIGURE 8The assembled power unit.
3. Slip the round column top (P/N 56550) over the pin and
rotate it until the flat sides are parallel to the mill base and Mounting the Motor and Speed Control Unit
the engraved degree lines are on the same side as the X-axis to the Headstock
handwheel. (Refer to Figure 13 and the exploded views and number list
4. Using an 11/16" or a 17 mm wrench, loosen the flange on pages 40 through 45 for part number references.)
nut holding the bed and swing arm together. Rotate the bed In order to keep shipping costs and damage to a minimum,
away from the swing arm until they are at approximately a 90 all new Sherline machines are shipped with the motor and
angle to each other. Retighten the flange nut firmly to hold the speed control disassembled. The same power unit assembly
column in this position. Discard the protective wood spacer is used on all Sherline lathes or mills, so these instructions
that was installed between the bed and arm during shipping. apply to all machines.
5. Set the swing arm over the column and align it
approximately square with the mill base and in about the
center of its travel. Make sure the swing arm registers on
the flats of the column top and is properly seated. While still
holding the swing arm unit in place, set the hold-down washer
(P/N 56200) over the end of the bolt. Put a flange nut on the
end of the bolt and tighten it against the hold-down washer
firmly to lock the swing arm in place. NOTE: There should
be NO lubrication on the mating surfaces between the arm
and the column base. Friction between these surfaces keeps
the arm from moving during cuts.
6. Place the column adjustment block (P/N 56350) on top
of the swing arm and attach it with two 10-32 x 5/8" socket FIGURE 9Components ready for assembly.
head cap screws at both ends. Adjust the 1" long center bolt Assembly Procedure
so that it is just touching the flat in the bottom of the relieved
section in the top of the pivot knuckle when the column is in Gather all the needed components as shown in Figure 9 above.
the 90 position. Assemble them as follows:
NOTE: If you remove the column adjustment block to 1. Using the small hex key, remove the motor pulley from
accommodate a backward tilt movement of the column, the motor shaft by loosening its set screw. Place the inner
make sure you replace it when returning the column to an belt guard against the motor and secure it using the two hex
upright position. It not only serves as a reference point when aluminum standoffs (P/N 43100). There are four threaded
returning the column to the 90 position, it also keeps it from holes in the motor. Use the pair that aligns with the brush
accidentally swinging down and damaging the table if the housings so the cord to the speed control housing points
flange nut is loosened. downward as shown. (See Figure 10.) Reinstall the motor
pulley (P/N 43360) to the motor shaft and tighten the set screw,
7. Slip the alignment key into its keyway in the mill saddle. making sure it engages the flat on the motor shaft. The end of
Place the assembled headstock/motor/speed control unit the pulley should be even with the end of the motor shaft with
(See next section) over the pin on the mill saddle and over the smaller pulley toward the outer end of the shaft.
the alignment key. Tighten the set screw in the side of the
headstock to hold the entire unit in place. Recheck to be sure 2. Place the drive belt over motor pulley. (See Figure 10 on
you have tightened the flange nut on the shouldered bolt pivot next page.)
pin (56210) securely so that all the weight of the column is 3. Make sure the drive belt is routed properly. Then set the
not resting on the column adjustment block bolt. outer belt guard in place on the inner belt guard, locating the
holes in outer belt guard over the ends of the motor standoffs.
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Pin
Pin
Press the two nuts into the hex shaped depressions in the rear
of the inner belt guard and secure the outer cover with two
1-3/8" pan head screws through the covers and into the nuts. Ear
ALIGNMENT KEY
LATHE BED
LATHE BASE
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NOTE: Alignment keys are custom fitted to each machine. If speed up the process by working faster. Keep in mind this is a
you have more than one component that uses an alignment key, small machine, and work with patience and precisiondont
try to keep the key with the slot it was originally fitted to. be in a hurry. Your parts will come out better, and your
Removing the headstock alignment key permits the headstock machine will last much longer if it is not overstressed.
to be mounted in positions other than square. This allows you What to do if the Motor Suddenly Shuts Down
to mill parts at an angle or turn tapers on the lathe. When If your thermal protection circuit shuts down the motor while
using the lathe or mill without the alignment key, keep cutting work is in progress, immediately shut off the power switch
loads light. and then back the tool out of the work. It should only take 10
Operation of the Motor and Electronic Speed Control seconds or less for the circuit breaker to reset. Then you can
The motor is supplied with current from an electronic speed turn the motor on and start the cut again, this time putting a
control that produces a comprehensive range of speeds little less stress on the motor. If you leave the tool engaged
suitable for all operations. Special circuitry designed into in the part and the power on, when the circuit breaker kicks
the DC motor speed control automatically compensates for back on, the motor must start under load. This can be very
speed changes due to increased load. If the spindle RPM drops hard on your motor.
noticeably when cutting, you are taking too heavy a cut. The Remember that the circuit breaker turns the speed control off,
speed range of the spindle using the speed control is from 70 which turns off the motor. If power were to be applied to the
to 2800 RPM in the normal belt position. This is achieved speed control with the motor disconnected, it could damage
without the inconvenience of belt or gear ratio changes as is the speed control.
the case with other designs. A second belt position is offered Thermal protection is built into your motor to insure it is not
as an additional feature to provide extra torque at low RPM damaged by overloading. Use good common sense when
for larger diameter parts should your job require it. operating the motor for years of trouble-free operation.
To operate the motor, turn the speed control knob Replacing Brushes on a DC Motor
counterclockwise as far as it will go Then turn the toggle Since 2002, Sherline has used DC motors with externally
switch to ON and select the desired speed by turning the replaceable brushes. The brushes are removed by using a
speed control knob clockwise. large, flat-bladed screwdriver to unscrew the brush covers
The Advantages of Sherline's DC Motor which are located in round bosses on the sides of the motor
and Electronic Speed Control near the rear. New brushes and springs are inserted and the
Sherlines 90-volt DC motor is very smooth and powerful, covers replaced. Brushes should be replaced if they are
particularly at low RPM. The specially designed electronics chipped, worn unevenly or if they are less than 1/4" long.
package also provides some unique advantages in addition DC motors supplied before 2002 utilize a different brush
to smooth speed control and a broad speed range. A special replacement procedure. If you have the older style internal
circuit compensates for load, helping to keep RPM constant. brushes, instructions for changing them can be found at www.
The machines can also be used on any electrical current sherline.com/DCbrush.htm or .pdf.
worldwide from 100 to 240 VAC, 50 or 60 Hz without further Mounting the Lathe or Mill to a Board for Stability
adjustment other than seeing that the proper wall plug is used. Mounting the lathe to a board is necessary because of the
The control reads the incoming AC current and automatically narrow base. This keeps the machine from tipping. We
adjusts to output the proper DC current to the motor.
7.19 5.0 The overall sizes are based on standard
Motors are Pre-tested at the Factory laminated shelf material. You may adjust
Your new motor should run smoothly the first time you use it, 4000/4100 them to fit the material available to you.
LATHE The mill mounting boards will have to
as it has been run in for about an hour before being shipped be cut to length as shelf material is not
to you. Despite our secure packaging, there have been cases 2.25 normally available in lengths that short.
where extremely rough handling by a shipper has damaged the 2.25
magnets in the motor. If the motor does not run when plugged 3.5
in, turn the motor by hand. If it does not turn smoothly, it may 17.0
have been damaged in shipment. Call Sherline for instructions
on making a damage claim with the shipper. Do not attempt
4400/4410
to repair the motor yourself. LATHE
CAUTIONMotor is Thermally Protected 2.25
Thermal protection means there is a built-in circuit breaker 2.25
that will shut off the motor if it gets too hot. This keeps the (12 Base) 1.5 (5000)
motor from burning out. The breaker will automatically reset 10.5 .75 (5400)
as soon as the motor cools, and you can go back to cutting, 2000-SERIES MILLS 8.5
(10 Base)
but you should be aware of how it works and what to do if the
FRONT 2.38
machine suddenly shuts itself off. If your motor is shutting 5000-SERIES 2.38
down from overheating on a regular basis, it means you are 2.38
MILLS 2.38
taking cuts that are too heavy or operating at too high an RPM 12.5 10 x 12
for long periods. Slow your speed down, reduce your cut or 1.75
feed rate, and you should have no further problems. FIGURE 18Plans for mounting board hole patterns.
Due to the nature of miniature machining, overloading the Confirm actual dimensions from your lathe or mill before
machine is a common problem. It is often tempting to try to drilling.
-11-
CAUTION! Check the Tightness of all BoltsVibration in shipping can cause some bolts or screws to loosen up. Before using
your new machine, check the tightness of all fasteners. It is also a good idea to check tightness periodically when using the
machine, as vibration from operation may cause some fasteners to loosen up.
A B
FIGURE 20The two pulley positions. Position A is the
conventional setting, position B offers more torque at low
RPM when turning large diameter parts.
RUBBER FEET larger motor pulley and smaller headstock pulley, will suffice
for most of your machining work. Moving the belt to the other
position (smaller motor pulley, larger headstock pulley) will
recommend mounting the lathe on a piece of pre-finished shelf provide additional torque at lower RPM. It is particularly
material, which is readily available at most hardware stores. useful when turning larger diameter parts with the optional
(See Figure 18 for sizes.) The machine can be secured to the riser block in place. To change the pulley position, remove the
board using four 10-32 screws with washers and nuts. Lengths speed control hold-down screw and pivot the speed control
should be 1-1/2" for short bed lathes and 1-7/8" for long bed housing up out of the way. Remove the mounting plate from
lathes. Rubber feet should be attached at each corner on the its position on the rails of the two halves of the belt guard
bottom of the mounting boards. They are also readily available housing. Loosen the two nuts that hold the motor to the motor
in hardware stores. This arrangement gives the machines a mounting bracket and take the tension off the belt. With your
stable platform for operation yet still allows for easy storage. finger, push the belt off the larger diameter groove of the
The rubber feet help minimize the noise and vibration from pulley and into the smaller one. (Depending on which way
the motor. Mounting the tool directly to the workbench can you are changing it, this could be either the motor or spindle
cause vibration of the bench itself, which acts as a speaker pulley.) Then move the belt to the larger diameter groove on
and actually amplifies the motor noise. Bench mounting also the other pulley, and rotate the headstock by hand to get it to
eliminates one of the best features of Sherline machines...the seat. Push the motor outward on the motor mounting bracket
ability to be easily put away for storage. to put the proper tension on the belt, and retighten the two
The mill may be mounted in a similar manner on a 10" x 12" motor mounting screws. Now you can replace the mounting
to 12" x 24" pre-finished shelf board with rubber feet using plate, pivot the speed control back down, and refasten it.
10-32 x 1" screws to attach the mill to the board. You may want Moving the belt back to the other position is simply a reverse
to drill clearance holes through the mill base board to access of the above procedure.
the column screws so the column can later be removed from Spindle Preload Adjustment
the mill without removing the mill base from the mounting If any end play develops in the main spindle, it can be easily
board. eliminated by re-adjusting the preload nut. (See part number
REMEMBER: Do not lift your machine by the motor! 40160 in the exploded view.) When the headstock is assembled
Carry the machine by lifting under the base or by the mounting at the factory, the preload nut is adjusted to .0002" (.005
board. The cast motor bracket was not designed for lifting. mm) of end play. This is controlled by the outer races of the
To keep your Sherline tools clean, soft plastic dust covers bearing being held apart by the headstock case and the inner
are available. The lathe cover is P/N 4150 for the Model races being pulled together by the preload nut. This setting
4000/4100 and 4500/4530 short bed lathes and P/N 4151 was determined through experience, and, like everything in
for the Model 4400/4410 long bed lathe. A mill dust cover is engineering, it is a compromise. If the machine is only to
available as P/N 5150 for 5000-series mills and P/N 5151 for be run at high-speed, this setting may be too tight. The
2000-series 8-direction mills. headstock will run fairly warm to the touch normally, but
extended periods of high speed operation may bring about
Converting Machines from Inch to Metric and Vice Versa excessive temperature. The headstock should not become
All Sherline tools and accessories are manufactured in your too hot to touch. If this is your case, the preload tension may
choice of inch or metric calibrations. Converting a lathe or need to be reduced slightly.
mill from one measurement system to the other is possible, but
it takes more than changing the handwheels. The leadscrews, To change the adjustment, remove the spindle pulley, loosen
nuts and inserts must also be changed. A look at the exploded the set screw in the preload nut and back the preload nut off
views of the machines on pages 40 through 45 will show which 4 of rotation (counter-clockwise). The bearings are lightly
parts need to be purchased. (Look for parts that have both a pressed into the case, so the inner race will not move without a
metric and inch version in the parts listing.) Conversion kits sharp tap with a plastic mallet to the end of the spindle where
with all the necessary parts are available. If you are a good the pulley is attached.
mechanic, you can do the conversion yourself, or you can If you find your bearings are set too loose, you may want to
return your machine to the factory for conversion. take up on the end play. You can check them with an indicator
or by spinning the spindle without the motor belt engaged. If
ADJUSTMENTS the spindle spins freely with a chuck or faceplate on it, it is
TWO-SPEED PULLEY too loose for normal work. Adjust the preload nut until it turns
The normal pulley position, which is placing the belt on the only about one and a half revolutions when spun by hand.
-12-
Want to see some projects built by other Sherline
SADDLE machinists? Visit www.sherline.com/workshop.htm.
BED
FIGURE 21 Handwheel Adjustment (Lathe and Mill)
Adjusting the gibs The handwheels are secured to their corresponding leadscrew
GIB
shafts by a small set screw in the side of the handwheel base.
Gib Adjustment Check them periodically to make sure they have not been
(Lathe and Mill) loosened by vibration. On the adjustable zero handwheels,
(See Figure 21.) you must first release the rotating collar by loosening the
Tapered gibs are locking wheel. Then rotate the collar until you can see the
GIB LOCK
fitted to the mill set screw through the small hole in the side of the collar and
headstock, saddle adjust the screw as necessary.
and table and to the
lathe saddle and If a handwheel has been removed, when reinstalling it, make
crosslide. Correct sure it is pushed up tightly against its thrust collar before
adjustment of the gibs will ensure smooth and steady tightening the set screw. Push the appropriate table or saddle
operation of the slides. The gib is effectively a taper with an toward the handwheel to remove any excess play before
angle corresponding to the one machined into the saddle. It tightening. For the mill Z-axis, lift up on the headstock to
is held in place by an L wire gib lock that is secured with remove play.
a locking screw. It is adjusted by loosening the gib locking If excessive backlash develops at the handwheel and thrust
screw and pushing the tapered gib inward until play is collar junctions, adjust by first loosening the handwheel set
removed. After adjusting, retighten the locking screw. Milling screw. Index (rotate) the handwheel so the set screw tightens
operations require a tighter adjustment of the gibs than lathe on a different part of the shaft. (If you dont, it may tend
operations. to keep picking up the previous tightening indentation and
returning to the same spot.) Push the handwheel in tightly
LEADSCREW SET SCREW ANTI-
BACKLASH
while holding the saddle and retighten the handwheel set
NUT screw.
Saddle Nut Adjustment (Lathe and Mill)
Both the lathe saddle and mill column saddle are connected
to their respective leadscrews using a similar brass saddle nut
(P/N 40170/41170 or 40177/41177). The saddle should first be
positioned at the end of its travel as close to the handwheel as
NUT possible. A socket head cap screw attaches the saddle nut to
SADDLE the saddle, while two set screws align the nut to the leadscrew.
FIGURE 22Mill Backlash Adjustment Loosen the cap screw, bring each set screw into light contact
(NOTE: Older mills use a pointer type lock instead of with the saddle nut and retighten the cap screw. If binding
the star gear.) occurs, readjust the set screws.
NOTE: The mill column saddle nut differs from the lathe
Backlash Adjustment (Lathe and Mill) leadscrew saddle nut in that it includes a spring-loaded ball
Backlash is the amount the handwheel can be turned before that engages a detent in the saddle locking lever. See pages 18,
the slide starts to move when changing directions. This is a 33 and 34 for details on use of the saddle locking lever.
fact of life on any machine tool, and on machines of this type
it should be about .003" to .005" (.08 mm to .12 mm). Adjustment and Use of the Tailstock Gib
The brass tailstock gib should be adjusted so that it is equally
Backlash must be allowed for by feeding in one direction only. tight at both ends and slides easily on the bed dovetail when
Example: You are turning a bar to .600" diameter. The bar the adjustment screw is loosened. As the brass gib wears,
now measures .622" which requires a cut of .011" to bring it any play that develops can be adjusted out by loosening the
to a finished diameter of .600". If the user inadvertently turns two set screws, readjusting the two button head screws and
the handwheel .012" instead of .011", he couldnt reverse then relocking the set screws. To lock the tailstock in place
the handwheel just .001" to correct the error. The handwheel on the bed, tighten the center socket head cap screw. Do not
would have to be reversed for an amount greater than the overtighten.
backlash in the feed screw before resetting the handwheel to (Note: Lathes made prior to 1999 do not have a tailstock gib
its proper position. adjustment. They are locked by means of a horizontal screw
Backlash on the X- and Y-axes of the mill may be reduced to through a split in the tailstock case.)
a minimum by adjustment on the anti-backlash nuts. These
nuts are located on the handwheel ends of the mill saddle. The TAILSTOCK CASE
nuts are secured by button head screws that hold a star gear LOCKING SCREW
that interlocks with teeth on the nut.
To adjust backlash, simply loosen the button head screw that ADJUSTMENT LOCKING
SET SCREWS
locks the star gear. Rotate the anti-backlash nut clockwise FIGURE 23
on the X-axis or counter-clockwise on the Y-axis until snug. Components of the
Retighten the button head screw while pushing the gear toward tailstock case and
the nut. With the anti-backlash nuts properly adjusted, the BRASS GIB
adjustable gib.
leadscrews should turn smoothly and have no more than the ADJUSTMENT SCREWS
proper .003" to .005" of backlash.
-13-
General questions about tools or accessories? See our Frequently asked questions section at www.sherline.com/faq.htm.
Aligning the Headstock and Tailstock on the Lathe an adjustable live center (P/N 1201) that can help you attain
The versatile feature of Sherline machines that allows the near perfect alignment at the tailstock should your job require
headstock to be removed or rotated for taper turning and it. Instructions for their use are included with each item.
angle milling keeps us from being able to lock the headstock Remember that unless you drill very small holes (less than
in perfect alignment. Precision ground alignment keys 1/64") or turn a lot of long shafts, you are giving up a very
and accurate adjustment at the factory, however, make the useful feature to solve a problem which can usually be
machines highly accurate. In standard form, alignment should handled with a few passes of a good mill file. The inaccuracy
be within .003" (.08 mm). This should be more than acceptable inherent in any drill chuck is such that perfect machine
for most jobs you will attempt. alignment is meaningless unless you use adjustable tailstock
Only someone new to machining would talk about perfect tool holders.
alignment. Machinists speak instead in terms of tolerances,
because no method of measurement is totally without error.
Squaring Up Your Mill
We believe the tolerances of your machine are close enough
The following tips are taken from the Model 2000 mill
for the work for which it was intended; however, for those
instructions. Though the 8-direction mill is shown in the
searching for maximum accuracy, here are some tips for
examples, the same procedures would be used for aligning
maximizing the accuracy of your machine.
the 5000-series mills, or any mill for that matter.
Loosen the headstock, push it back evenly against the
FIGURE 24The
alignment key and retighten. This will maximize the accuracy Z axes of movement of
of the factory setting. To achieve greater accuracy, you will
a Sherline 8-direction
have to be willing to sacrifice one of the better features of your
6 mill. Table left/right
lathe or mill; that is, its ability to turn tapers and mill angles
movement is referred
in such a simple manner.
to as the X axis. Table
HEADSTOCKIf you choose total accuracy over versatility or 5 in/out movement is
need it for a particular job, proceed as follows. Remove the the Y axis. Headstock
headstock and clean any oil from the alignment key and slot 4 up/down movement
and from the area of contact between bed and headstock. 8 is referred to as the Z
Replace the headstock, pushing squarely against the key axis. The headstock
and retighten. Take a light test cut on a piece of 1/2" to 3/4" 7 can also be rotated on
diameter by 3" long aluminum stock held in a 3-jaw chuck. its saddle on Sherline
Use a sharp-pointed tool to keep cutting loads low so as not
to cause any deflection of the part. Measure the diameter of
X Y m ills (Shown as
movement #4). Four
both machined ends. If there is a difference, the headstock additional column movements available on the model 2000
is not perfectly square. Now, without removing the key, tap mill are also illustrated here as numbers 5, 6, 7 and 8.
the headstock on the left front side (pulley end) if the part is Determining the Level of Accuracy You Really Need
larger at the outer end. Tap on the right front side (chuck end) Squaring up a multi-direction mill can be a chore if you want
if the part is larger at the inner end.) You are trying to rotate perfection. It is best to determine how accurate the setup
the headstock ever so slightly when viewed from the top until must be before you start. The larger a close tolerance part is
the machine cuts as straight as you can measure. There should the better the setup required. An error of .001" (.025 mm)
be enough movement available without removing the key, as per inch (25.4 mm) would be a very small error on a part .4"
its factory placement is quite accurate. (10 mm) long. However, a part that is 5" long would have
Take another test cut and remeasure. Repeat this procedure an error of .005". The type of machining that is going to be
until you have achieved the level of perfection you seek. Then performed also has a bearing on the quality of the setup. As
stand the lathe on end with the alignment key pointing upward an example, a drilled hole doesnt usually require the quality
and put a few drops of LocTite on the joint between key of setup that would be used for a bored hole, (assuming the
and headstock. Capillary action will draw the sealant in, and hole is being bored for accuracy rather than for lack of a drill
when it hardens, the key will be locked in place. We prefer this of the proper size). The amount of work that will be done with
method to pinning the head with 1/8" dowel pins, because the setup should be considered too. If your setup is just to do
it offers you the option to change your mind. The headstock one particular job you only have to set it up close enough to
can be removed by prying with a screwdriver blade in the do that job. If the setup will accommodate future operations as
slot between the bottom of the headstock and the lathe bed well, it should be adjusted to the tolerances of the most critical
to break the LocTite loose should you wish to be able to job. For example, squaring up a mill and vise to work on a
rotate the headstock again. number of precise parts is worth more of your attention than
setting up to drill one clearance hole in a non-critical part.
TAILSTOCKTo maximize the machines tailstock alignment,
first make sure that there are no chips caught in the dovetail Limitations of the Production Process
of the bed and no chips or dents in the taper of your tailstock Before starting you should realize that these mills are
center. Now put a 6" long piece between centers and take a relatively inexpensive machine tools. They have accurately
long, light test cut. Measurements at either end will tell you milled slides but the surfaces are not ground. To increase the
if you need to use an adjustable tailstock tool holder in the accuracy of a Sherline tool only a percentage point would
tailstock to achieve better tailstock alignment. We manufacture dramatically increase the price. We try to give a customer
adjustable tailstock tool holders (P/N 1202, -03, -04, -06) and what we consider the most bang for the buck.
-14-
Why Arent Alignment Pins Used to Square Up the Machine? FIGURE 25Checking
If you are a novice to machining, you probably believe a for built in error in the
machine should be designed so that a couple of pins could be table travel along the
dropped into holes, squaring up the machine and eliminating Y-axis
this whole alignment process. After all, that is the way they
do it with woodworking tools. The truth is the tolerances
that work well for wood cutting tools simply arent accurate
enough for most metalworking jobs. You just cant hold the
tolerances required with pins. When they fit tight enough to
lock the head square to the table you cant remove them to do
work that isnt square. They become more of a problem than
the problem they were installed to eliminate. For example, WHEN SQUARE,
an alignment or assembly error of .010" in a wooden kitchen SCRIBE ZERO
table will never be noticed. Usually the floor it sits on is not REFERENCE
even flat. It would be a waste of time and effort to make it MARK HERE
more accurate than it has to be. On the other hand, a cylinder
that has been bored out of square with the crankshaft in an
automobile engine could wear the entire engine at an alarming
rate. The piston can go up and down over a million times in a
normal days use. The additional cost in fuel and shortened life
demands accuracy. Your Sherline mill should be adjusted and
aligned to the degree of accuracy demanded by the particular
job you are attempting to do.
Start by Getting the Column Close to Square with the Table
All Sherline MillsThe first place to start is to get the column to the worktable and move the X-axis back and forth while
approximately square with the table using the pointers and reading the left and right surfaces of the column bed near the
laser engraved scales on the machine. The first time you bottom. This only has to be done if you will be rotating the
set it up you will have to use a machinists square on the column and want to be able to rely on the angle graduation
side-to-side column rotary adjustment as the pointer will not readings. Once set, lock the ram in place with the flange nut.
have been zeroed in yet. None of these adjustments must Now you can scribe a line on the column base opposite the
be extremely precise at this point because a finger type dial zero mark for future reference as shown in Figure 25. We
indicator will be used to make the final adjustments later. can't pre-engrave this mark at the factory. For perfect accuracy,
Remove the headstock/motor/speed control unit from the it must be done after each machine is aligned.
saddle. Place a machinists square on the table and line up the Model 5000-Series MillsThough the column ram does
front of the saddle to get the column approximately square not rotate on the 5000-series mills, its squareness can still be
front to back. Then line up on the right side of the saddle to checked in the same manner if desired. The factory alignment
get the column approximately square side to side. Reinstall of the holes is quite accurate, but a small amount of adjustment
the headstock assembly. is available by loosening the two screws that hold the column
Check for Any Built-in Error in Your Machine base to the bed and pressing the base to one side or the other
All Sherline Mills(See Figure 25.) To check the built-in error while retightening.
of the machine use a dial indicator mounted in the spindle. Squaring the Column with the X-Axis
Move the table under spindle with the Y-axis handwheel Model 2000-Series Mills OR 5000-Series Mills with Optional
and note the error. This error will usually be around .001" to Rotary Column Attachment(See Figure 27.) The column
.002" (.05 mm) in 3" (76 mm). (Remember, the components should next be squared with the X-axis. This is accomplished
are not precision ground, they are precision milled.) When with an indicator mounted in the spindle. Have the four socket
squaring the head later on this error should be accounted for. head cap screws used to clamp the column rotation tight
Remember you are squaring the head and spindle to the base enough to keep the column from rotating, but not so tight
of the machine where the saddle travels, not the surface of that you cant move it with a light tap from a plastic mallet
the table itself. The head doesnt have to be square for this to the column bed. Because the axis that allows you to tilt the
operation as long as you dont rotate the spindle since you column in and out hasnt been squared yet you should only
are only checking for square in one direction. read the indicator at the same Y-axis location on the worktable
Squaring Up the Column that you used before. Offset the indicator at an angle in the
Model 2000-Series Mills(See Figure 26.) The next decision spindle so that when the spindle is rotated it describes about
to make is where the spindle is to be located. With all the a 2" to 3" circle on the table. Take readings at the extreme left
adjustments that can be made with the 8-direction mill youll and right positions. Adjust the column with light taps until
probably start with the spindle located near the middle of there is little difference in the readings at either extreme. I
the X/Y table movements. Something that isnt too obvious wouldnt try to get it perfect yet, just close enough so there
should be considered now. If the ram (the two-bar slide that isnt a gross error.
allows you to move the head in or out and left or right) isnt Hint: To keep the tip of the indicator from falling into the T-
square with the X-axis, the rotating column calibrations will slots, some machinists keep a large ball bearing on hand. The
have an error. To square up the ram, mount a dial indicator two surfaces of a precision bearing are generally parallel. The
-15-
WHEN SQUARE,
SCRIBE ZERO
REFERENCE
MARK HERE
LOCK ADJUSTMENT
IN PLACE WITH
11/16 FLANGE NUT
HEADSTOCK PIVOTS ON
SADDLE PIN. EVEN WITH
ALIGNMENT KEY IN PLACE,
SLIGHT ADJUSTMENT
CAN BE MADE TO GET
HEADSTOCK PERFECTLY
SQUARE.
General Rules for Feed Rates and Cutting Speeds When a tool chatters, it gets dull faster, because it must keep
Before attempting to machine any metal, please try to cutting through the previously machined surface that has
remember this simple rule about machining: been work hardened by machining. As you can imagine,
there are limits to how much you can increase feed rate, so
If the tool chatters,
the answer lies in adjusting both speed and feed to achieve
decrease speed and increase feed. the proper cut.
Understanding this simple rule can save you many hours of Proper cutting speed is the rate a particular material can be
grief. When the tool chatters, it is not cutting in a continuous machined without damaging the cutting edge of the tool that
fashion. Metal likes to be machined in a way that allows the is machining it. It is based on the surface speed of the material
material to come off in a continuous strip while the tool is in relation to the cutter. This speed is a function of both the
in contact with the metal. If the tool is not fed at a rate that RPM of the spindle as well as the diameter of the part or
is fast enough, the tool skips along the surface, occasionally size of the cutter, because, as the part diameter or cutter size
digging in. The surface of the tool that is doing the most increases, the surface moves a greater distance in a single
cutting will find a frequency of vibration that is a product of rotation. If you exceed this ideal speed, you can damage the
all the variables involved. This can cause anything from a high cutting tool. In the lathe and mill instructions, we give some
pitched whine on light, high speed cuts to a resonating racket examples of suggested cutting speeds, but what I wanted to
that can rip the work out of the chuck on heavy cuts. If you get across here is that the damage isnt a slow process. A tool
maintain the same feed rate and reduce the RPM, the feed will can be destroyed in just a few seconds. It isnt a case of getting
increase because chip will be thicker. (If that sounds wrong only one hour of use instead of two. The cutting edge actually
at first, think of it this way: At the same feed rate, if you cut melts. If you machine tough materials like stainless steel, you
the RPM in half, twice as much metal must be removed with will ruin more tools than you care to buy if you dont pay a
each rotation to get to the end of the cut in the same amount lot of attention to cutting speeds. Charts showing suggested
of time. The chip is twice as thick, so the feed is GREATER cutting speeds for various materials are included in both the
at lower RPM if the feed RATE stays constant.) lathe and mill sections that follow.
LEFT-HAND RIGHT-HAND
INSIDE
THREADING TOOL PARTING TOOL***
THREADING TOOL** (P/N 1200)
*These shapes are available in high speed steel tool set, P/N 3007.
**The 60 threading tool is included as part of the carbide tool set, P/N 3006
and also comes with the thread cutting attachment (P/N 3100.)
***The parting tool comes with the cutoff tool holder, P/N 3002. Other
FIGURE 38Turning a taper with the headstock slightly shapes are custom ground to accomplish special purposes as needed.
rotated.
FIGURE 40Cutting tool shapes
Do not grind the top face of the tools, but confine sharpening
to the end and/or sides except form tools which are ground
on the top surface. Remember that heavy cuts and rapid feed
will cause greater strain on the chuck and lathe. This may
induce spring or binding of work and tools that can produce
a poor finish.
NOTE: Because of the importance of a sharp and properly
ground tool to the cutting process, Sherline has prepared a
special instruction sheet on Grinding Your Own Lathe Tools.
There are a few tips that can make the process a simple one.
The instructions are included with each lathe and with cutting
tool sets when you order them from us, or you may call us and
request a copy. (Cost is $5.00 postage paid.) They are also
available from our web site at no cost. (See www.sherline.
FIGURE 39Long, shallow tapers can be cut in a continuous com/grinding.htm.) Unfortunately, space does not permit us
pass by pivoting the headstock to the proper offset while to reprint them as part of this booklet.
supporting the other end with the tailstock. The work is driven Cutting tools are ground to various shapes according to their
by using a drive dog in the faceplate. The dog acts like a usage. Tools are usually ground to shape as needed by the
universal joint as the drive pin slides in the faceplate slot. operator. Some standard tools are described below:
A dead center is used here in the tailstock but an optional live Normal Turning Toolor RIGHT-hand tool feeds from right
center could also be used. to left, is used to reduce work to the desired diameter and is
the most frequently used of all tools.
of the headstock, and replace the headstock unit on the pin.
Side ToolsThese are used to face off the ends of shoulders
While pressing down on the headstock, rotate it to the angle
and may also be used as normal turning tools. Note that a tool
you desire by referring to the angle scale on the bed. The base
that is fed from left to right and has its cutting edge on the right
is calibrated in 5 increments up to 45 on either side of center.
is called a LEFT-hand side tool because the chip comes off to
When set to the proper angle, retighten the set screw against
the left. Cutting tools are named based on which direction the
the pin to lock the headstock into position. Tapers can also
chip comes off, not which side has the cutting face.
be cut without turning the headstock by using a compound
slide (P/N 1270). Parting ToolThe conventional parting tool or cutoff tool
is shaped like a dovetail when viewed from above and is
Short work can be inserted in a 3- or 4-jaw chuck and turned
used to cut off work pieces by feeding the end of the tool
as shown in Figure 38. If the headstock is angled towards the
across the lathe bed and through the work piece. The Sherline
lathe front, the taper will be cut smaller at the right. Tapered
parting tool instead uses a thin .040" (1 mm) blade that has a
holes can also be bored in work held in the 3- or 4- jaw chuck.
slightly thicker ridge at the top to accomplish the same job of
To machine a taper on longer stock, center drill both ends of
providing clearance for the tool while cutting. Parting tools
the bar, set the headstock angle and mount the part between
thicker than .040" (1 mm) will be too thick for use on your
centers using a faceplate and drive dog. (See Figure 39.)
Sherline lathe.
Tool Shapes and Grinding Your Own Cutting Tools
Boring ToolA boring tool is used in the tool post on a lathe
The shaping of cutting tools to suitable angles for the type
or in an offsettable boring head on a mill to enlarge holes in
of material and nature of work being performed can be very
a work piece. (See Figures 41 [lathe] and 58 [mill].)
important to satisfactory work. When tools become dull,
gently re-grind and preserve the original angles and shapes.
-22-
NORMAL TOOL SLIGHTLY SIDE TOOLS
ROUNDED
CORNER
CLEARANCE
LEFT-HAND RIGHT-HAND
TOOL TOOL
CLEARANCE
FIGURE 43Arrows show direction of tool feed in all
diagrams.
handy feature normally found only on larger, more expensive
machine tools. New tools may be ordered with them already
FIGURE 41A boring tool in use on the lathe installed, and existing tools can be retrofitted with them on
any axis.
The second feed is now commenced, stopping at the same
FIGURE 42Form tool and part
PART reading on the leadscrew handwheel as before. This procedure
enables turning to accurate length.
Form ToolA custom contour can be Repeat the procedure until the work has been reduced to within
ground into a tool to produce a special about .010" (0.25 mm) of desired diameter, noting that each
shape like a radius in a part. The width .015" (0.4 mm) increase in depth of cut will reduce the work
TOOL of the cutting edge must be less than 2- diameter by twice this amount; that is, .030" (0.8 mm). For
1/2 times the smallest diameter. Cutting the finishing pass, advance the tool by the required amount
speed must be slow to prevent chatter. and feed along the work just far enough to gage the finished
The clearances ground behind the cutting diameter. Adjust depth of cut if necessary and complete the
edges indicate the type of material for which the tool may final pass using a SLOW feed to obtain a smooth finish and
be used and the direction in which it is fed along the work. exact size.
When grinding tool bits, correct clearances are essential or Using the Cutoff or Parting Tool
rubbing can occur. (See Figure 44.) After completing a part in the lathe,
The shape shown here would be difficult to grind on a home it is frequently necessary to separate the part from the
bench grinder; however, the same form could be achieved by excess material used for chucking. This operation is best
grinding two separate tools with half the needed arc on the accomplished with the use of a cutoff tool or parting tool
outside corner of each toola left and a right. By using as it is sometimes called. The Sherline cutoff tool and holder
a number of simple shaped tools in sequence, complicated utilizes a very slender, high-speed tool steel cutting blade
forms can be generated. mounted in a special tool holder. The thinness of the blade
Turning Tools (Left- and Right-Hand)Reference to Figure (.040") enables it to feed into the part quite easily and at the
43 will illustrate the lateral positioning of this tool. Note the same time minimizes the amount of waste material. A word
clearance behind the point between the end of the tool and of caution: Never use a parting tool on a part mounted
the work. Insufficient clearance will cause the tool to rub, between centers. The part may bind on the cutter, resulting
and excessive clearance will produce a ridged or wavy finish in a scrapped part or a broken cutting tool.
due to the small length of tool edge in contact with the work. Always try to lay work out so the cutoff tool is used as close
This ridging becomes more pronounced with rapid feed. to the spindle as possible. Set blade height by sliding the blade
To provide a smooth finish, the sharp cutting point may be back and forth in the slightly angled slot in the tool holder. It
slightly rounded with an oilstone, taking care to preserve the should be set so the tip is aligned with the centerline of the
side clearance underneath this corner. part being cut. An unusual diameter may require a shim under
This type of tool should not be advanced directly endwise the front or rear of the holder to accomplish this. The tool can
into the work. The depth of cut is set while the tool is clear also be mounted on the back side of the table by using the
of the end of the work. The starting procedure is to advance rear mounting block, P/N 3016.
the tool until the point just touches the work. Note the reading
on the crosslide handwheel, withdraw the tool slightly and IMPORTANT!
move along until clear of the end of the work. Now advance Always use cutting oil when using the cutoff tool. The
the crosslide to the above reading, add desired depth of cut and cut will be made much smoother, easier and cooler.
then feed the tool along the work piece the desired distance. The turning speed for parting should be about one-half the
Withdraw the tool clear of the work, having noted the reading normal turning speed, and feed rate should be a little heavy
on the crosslide handwheel. Mentally note the reading on the so the chip will not break up in the slot. If speed and feed are
leadscrew handwheel, return the tool to starting position and correct, there will not be any chatter, and the chip will come
advance to the previous reading plus the desired cut. out as if it were being unrolled. Cutting oil plays a major roll
NOTE: Sherline offers optional adjustable zero handwheels in this occurring properly.
that allow you to reset the handwheel to zero at any time...a
-23-
Where a hole must be bored right through the work, it should
be shimmed out from the faceplate to provide clearance for the
tool to feed through. The leadscrew handwheel graduations
can be used to indicate the correct depth at which to stop the
feed. Notice that, with boring, the depth of cut is increased
by moving the tool and crosslide towards the operator and
not away as with normal turning.
The boring of holes often necessitates greater than normal
overhang of the tool from the tool post, so the depth of cut
and rate of feed should be reduced from normal.
Inserted Tip Carbide Tools
Sherline brings the home shop machinist into the space age
with cutting tools that add a new dimension to small lathes.
When working with tough metals, high-speed steel tools need
FIGURE 44A parting tool used to separate a part from constant sharpening and have a relatively short life. Brazed
carbide tools cut great but chip easily. Inserted carbide cutting
its bar stock. tools are the answer and have replaced those other tools in
If the tool chatters, first check to see if the work is being held the modern machine shop. Carbide inserts have the ability to
properly. Then decrease speed (RPM) or increase feed rate or consistently give good finishes and long tool life at a much
both. Once the blade has chattered, it leaves a serrated finish higher cutting speed. This is especially important with small
that causes more chatter. Sometimes a serrated finish can be lathes, because they do not have excessive power at low
eliminated by stopping the spindle, adding a liberal amount of RPM. With inserted carbide tools you can cut stainless steel
cutting oil, bringing the blade up so there is a slight pressure at the same RPM you were formerly using to cut aluminum
on it without the spindle turning, and then turning the spindle with high-speed steel tools without any sacrifice in quality
by hand or as slowly as possible with the speed control. in surface finish.
Very small work may be completely cut off when held in a
chuck and allowed to fall onto the crosslide. It is too small A SPECIAL TORX DRIVER
FOR TIGHTENING THE
and light to cause any damage. Hollow articles, such as P/N 7600 TOOL POST INSERT HOLD-DOWN
rings, may be caught on a piece of wire whose end is held in FOR 3/8 INSERT SCREW IS INCLUDED
HOLDERS AND 3/8 WHEN CARBIDE TIPS
a suitable position. ROUND BORING ARE PURCHASED
TOOLS
Side Tools
While these may be, and often are, used as general purpose
turning tools, their specific use is for facing the sides of collars
and shoulders; that is, finishing these to correct dimension and CARBIDE INSERT
with a smooth, flat surface. They are also for facing work held
P/N 2256 TOOL HOLDER
on a faceplate or in a chuck. The facing of work in this manner
is very useful for the production of truly flat surfaces and for FIGURE 46Carbide insert tool and tool post. The tool post
producing articles to an exact thickness. The uses of side tools holds both 3/8" square and round tools.
are illustrated in Figures 40 and 43. The sharp corner at the
cutting point should not be slightly rounded, as may be done These tools are more expensive than high-speed steel;
with the normal turning tool, as knife tools may be required however, they are worth every penny if you have problems
to produce sharp corners. grinding your own steel tools or are cutting exotic materials
Boring Tools like stainless steel. Sherline offers a tool post (P/N 7600) that
The use of this tool requires the existence of a drilled or cored holds the larger 3/8" square tool shanks used to hold carbide,
hole, or it may be used to enlarge the bore of a tube. The work ceramic or diamond inserted tips. It also has a 3/8" round
must be mounted in a chuck or on a faceplate and the boring hole for boring tools.
tool set as shown in Figure 41. Note the clearance behind the A good starting point for an inserted tip tool is the P/N
cutting point as shown in Figure 45 below. 2256 right-hand holder with a 35 offset. This holder uses
A slow rate of feed should the P/N 7605 carbide insert,
be used, as the turnings are which is a 55 insert good for
CLEARANCE not able to escape freely turning, facing and profiling. A
from the hole and can left-hand tool is also available
jam the tool. Frequent as P/N 2257, or a set of both
withdrawal of the tool to left- and right-hand tools is P/N
allow turnings to escape 2258. Tools are also available
may be necessary. Care to hold 80 inserts, which are
FIGURE 45Boring tool should be taken not to slightly less versatile but offer
clearance feed the tool beyond the FIGURE 47Negative longer tool life because of their
depth required or to feed so deeply as to damage the chuck rake insert tool holder stronger, more square shape.
or faceplate. (P/N 7610) These tools should not be used to
-24-
FIGURE 48The P/N 2265 Keep in mind that, apart from possible production of excessive
negative rake ceramic insert heat and the fact that excessive speed may damage the cutting
and 3/8" holder make it possible edge or cause it to rub instead of cutting, turning speeds are
to cut hardened tool steels. not too critical. Slower than normal speeds cause no harm,
except by increasing the time involved. Aluminum, however,
cut hardened steels or piano wire. Materials such as those are usually gives a better finish turned at high speed and with the
normally ground to shape, not cut, although ceramic inserts use of lubrication (coolant).
can sometimes be employed to cut these materials. Abrasive
materials such as glass-reinforced plastics can be easily cut Accessories for Your Lathe
with these tools. Your lathe can be made more versatile with the addition of
Another tool available to Sherline machinists that holds suitable attachments and accessories. These include various
carbide inserts is the 3/8" IC 55 negative rake insert tool chucks and collets, a thread-cutting attachment, vertical
holder (P/N 7610). The indexable carbide insert sits on the milling column, knurling tool, a live center and many others.
tool holder at a 5 negative angle. This gives the sides of the Remember that accessories and attachments must be cared for
cutter clearance even though the insert has square sides. By in the same way as the lathe. Always make sure that threads
having square sides, both top and bottom of the insert can be are free from metal chips and dirt. Chucks should be lightly
used as cutting edges, giving a total of four cutting edges on oiled frequently so that they continue to function smoothly
each insert. Because of its design, it cuts like a positive rake and accurately. Gears in the thread-cutting attachment should
cutter, which requires less rigidity than a negative rake cutter. be lightly greased when in operation. Some attachments have
It gives you the best of both worldsthe four cutting edges moving slides, and these should be lubricated in the same
of a negative rake tool along with the lower stress loading way as the slides in your lathe. Each accessory comes with
of a positive rake cutter, which is appropriate for a lathe of complete instructions for its use when it is purchased.
this type. 3-Jaw, 4-Jaw and Drill Chucks
Sherline also offers a ceramic insert and holder, P/N 2265. Chucks are used to hold work in the lathe. They can also be
(See Figure 48.) The 3/8" IC negative rake ceramic indexable used to function like a vise to hold a part for milling. Drill
holder will bring a lot of enjoyment to your machining, chucks can be used in the lathe headstock or tailstock or in
particularly if you choose to turn hard materials such as tool the mill for drilling. Here are some of the chucks available
steel or abrasive materials like fiberglass or composites. for your Sherline tools:
When searching for a mirrorlike finish on copper or aluminum, Three-Jaw Self-Centering ChucksThree jaws
diamond inserts are also available. Though expensive, certain scroll in unison to grip round or hex stock
jobs can make their use desirable. The 2.5" chuck (P/N 1041) holds from
3/32" (2 mm) up to 1-3/16" (30 mm) in
While inserted tip carbide, ceramic and diamond cutting tools diameter. Jaws are reversible for holding
will improve the performance of the Sherline lathe, they will larger stock up to 2-1/4" (56 mm) in
not correct poor machining technique. Rigid setups are a must diameter. The chuck has a .687" (17 mm) through hole and
for tools such as these. 3/4-16 spindle thread. The larger 3.1" (70 mm) diameter P/N
Turning Speeds 1040 chuck is similar but holds parts up to 2-3/4" in diameter
The following chart in Figure 49 provides a guide to speeds with the jaws reversed.
at which work of differing materials should be rotated. Note Four-Jaw Self-Centering ChucksThese scrolling
that the turning speed is inversely proportional to the diameter chucks hold round or square stock. The
of the work; that is, the larger the diameter, the slower the 2.5" diameter P/N 1075 version holds
turning speed. Material often differs in hardness, so these from 3/32" (2 mm) up to 1-3/16" (30 mm).
figures may have to be adjusted. The harder the material, the With the jaws reversed, it will grip stock
slower the turning speed should be. up to 2-1/4" (56 mm). The jaws scroll in
unison as on the 3-jaw chuck. (NOTE:
Guide to Approximate Turning Speeds stock held in this chuck must be perfectly round or square to
Material Cut Speed 1/4 (6mm) 1/2 (13mm) 1 (25mm) be gripped by all four jaws.) The larger 3.1" diameter version
S.F.M. Diameter Diameter Diameter of this chuck is P/N 1076, which can hold parts up to 2-3/4"
in diameter with the jaws reversed.
Stainless, 303 67 1000 RPM 500 RPM 250 RPM
Stainless, 304 50 800 400 200 Four-Jaw (Independent) ChucksEach jaw is
Stainless, 316 47 700 350 175 adjusted independently, allowing precise
Steel, 12L14 174 2600 1300 650 adjustment for perfect centering or for
Steel, 1018 87 1300 650 300 holding odd-shaped parts. Four-jaw
Steel, 4130 82 1250 650 300 chucks take a little more time to use, but
Gray Cast Iron 57 900 450 220 offer much greater accuracy and versatility
Aluminum, 7075 400 2800 2800 1400 than a 3-jaw chuck. Holding range is the
Aluminum, 6061 375 2800 2800 1400 same as for the 2.5" and 3.1" 3-jaw chucks above. The 2.5"
Aluminum, 2024 268 2800 2000 1000 4-Jaw is P/N 1044 and the 3.1" 4-Jaw is P/N 1030.
Brass 400 2800 2800 1400 Jacobs Drill ChucksVarious size conventional Jacobs drill chucks
are fitted with a #0 Morse arbor for use in the tailstock for
FIGURE 49High-speed steel cutting tool turning speeds center drilling parts. They also come with a #1 Morse arbor
-25-
and drawbolt for use in the headstock With this attachment and your lathe, you will never be stuck
on the lathe or mill. Adjustment keys without a way to come up with the right thread. Even if a tap
are included. Chucks available include a or die is available, you can set up and cut a thread faster than
5/32", 1/4" and 3/8" size. you could get to the store and back to buy it and save yourself
5/32 Drill ChucksThese small chucks hold tiny drills from some money as well!
size #80 up to 5/32". Because they have a #0 Jacobs taper Steady Rest, P/N 1074
in the back, the adapter arbor must be pressed in, so it is not A steady rest supports longer work with
interchangeable. P/N 1010 comes with a #1 Morse arbor and three adjustable brass pads that rub on
P/N 1015 has a #0 Morse arbor. A sensitive drilling attachment the outside surface of the part. It keeps
(P/N 1012) using this same chuck is available for the mill. long parts from deflecting away from
1/4 Drill ChucksThe 1/4" drill chuck has a threaded hole in the tool or from wobbling while turning
the back so it can accept either a #1 Morse or #0 Morse arbor. and centers the end of a part for center
Drills from 1/4" down to 3/32" can be held in the chuck. P/N drilling. Along with a live center, this
1072 comes with both arbors, a drawbolt and key for use on is one of the first accessories most lathe
either the lathe or the mill. P/N 3072 comes with just the #1 owners acquire.
Morse arbor, drawbolt and key for use on the mill. Live Center, P/N 1197
3/8 Drill ChucksLike the 1/4" chucks, the 3/8" chuck has a The lathe comes with a "dead" (non
threaded hole to accept either a #1 or #0 Morse arbor. Drills rotating) center for the tailstock. This is
from 3/8" down to 3/32" can be held. P/N 1069 includes both the traditional way of supporting the free
arbors, drawbolt and key, while P/N 3073 includes just the #1 end of long work, but a live center is more
Morse arbor, drawbolt and key. popular for this task. On a "live" center,
the center point rotates in a ball bearing, turning with the work.
Thread Cutting Attachment, P/N 3100
This eliminates the need for lubrication at the tailstock center
Common threads are most easily cut using taps and dies, but
and prevents the buildup of heat from friction.
it would be impossibly expensive to own a tap and die for
every conceivable thread size. Cutting threads on a lathe is Digital Readouts, P/N 8200
the traditional alternative and one of the real advantages of Add the convenience of electronic digital readout to your
owning a lathe. A lathe cuts threads by gearing the leadscrew lathe. They can be ordered that way from the factory or you
directly to the spindle. This is called single pointing a thread. can install them as an accessory later. Reads out to .0005" or
When the spindle turns, the saddle moves. .01 mm plus a readout of spindle speed is also included. Return
the count on any axis to zero with the push of a button. No
HANDWHEEL DRIVES more counting handwheel revolutions on long moves.
SPINDLE SHAFT
(HANDWHEEL REMOVED
FOR CLARITY.)
HANDWHEEL
LEADSCREW SHAFT
1 (X-axis) 2 (Y-axis)
Used with the right angle attachment (P/N 3701) and right A linear version of this same keypad and motor unit is
angle tailstock (P/N 3702), it can also be used to cut gear available that functions like a power feed on any axis of the
teeth. A rotary table used with a mill allows a machinist to lathe or mill. Various kits are available with motor mount,
produce virtually any part he can design. On a Sherline mill, keypad and stepper motor to convert any mill axis from
the only limits are size, not complexity. The compact size of manual to stepper motor driven. The motor and keypad unit
this high quality rotary table also makes it a good choice for is P/N 8800. If you need to install a motor mount in place
use on larger machines as well, where its size would offer an of a handwheel, the P/N 8850 kit includes the mount, motor,
advantage in working with small parts. (See Figure 56 for a keypad, power supply and everything you need to convert
photo of the rotary table in use.) either the X or Y axis of the mill. Other kits are available for
CNC Rotary Tables the Z axis or for the lathe leadscrew or crosslide.
The rotary table can Additional Mill Accessories
also be purchased in For a complete list with links to the instructions for use of
CNC-ready form with each, see our web site at www.sherline.com/accessor.htm.
a stepper motor mount
attached ready to accept
a NEMA 23 size stepper CNC and CNC-Ready Sherline Lathes and Milling Machines
motor of your choice. Computer Numeric Control (CNC) is the way most machine
The CNC-ready table tools are run in the modern machine shop. As more people
is P/N 3700-CNC. If have learned the advantages of using CNC and costs have
you prefer to purchase come down, it has become more popular in the home shop
a rotary table with a as well. Therefore, Sherline now offers you several options.
FIGURE 73The CNC-ready Sherline stepper motor Any existing Sherline lathe or mill can be purchased in any
rotary table can be purchased already attached it is one of three configurations:
with or without a stepper motor. P/N 8730. The motor
1. MANUALAny standard machine can be converted to
is prewired with a 5-pin plug that is ready to plug in to the CNC later with the purchase of a CNC upgrade kit.
Sherline driver box (P/N 8760) and go to work as the 4th axis
2. CNC-READYThese machines come with stepper
of your CNC mill system.
motor mounts on all axes ready for the application of stepper
CNC Rotary Indexer (P/N 8700) motors. You can use our P/N 8760 4-axis driver box, our
This completely self-contained, programmable unit is perfect stepper motors and your own computer running either our
for repetitive radial operations like gear cutting, drilling Linux/EMC2 G-code software (included with driver box) or
multiple hole patterns, cutting splines on a shaft or spokes in Windows based software you purchase elsewhere. (Note:
a wheel. Using the keypad, you enter the parameters such as These machines cannot be operated manually until stepper
the number of divisions or degrees of rotation required, speed motors with dual shafts are installed.)
and direction of rotation. When the command is given, the
indexer will move precisely to the next programmed position. 3. FULL CNCThese CNC packages include a mill with
The computer keeps track of the divisions to many decimal three stepper motor mounts or a lathe with two stepper
places, so error is virtually eliminated. Backlash can also be motor mounts, the appropriate number of stepper motors,
accounted for electronically if a direction change is required. a new computer with built in 4-axis driver box (includes
The unit includes a programmable keypad unit, rotary table, keyboard and mouse but not a monitor), a Linux operating
motor mount, stepper motor, power supply and all connecting system and EMC2 (Enhanced Machine Controller) G-code
cables. It can also be daisy chained with other rotary or control program preinstalled in the computer and all necessary
linear units to produce sequenced operations. cables to connect it. With handwheels mounted to the rear
motor shafts, the operator has the choice of manual or CNC
operation.
Of course, no matter how you order your machine in relation
to CNC, all machines are still available in your choice of
metric or inch leadscrews and any of the accessory packages
can also be ordered with the machine itself.
Learning About CNC
CNC means instead of you turning the handwheels directly,
you are giving a computer instructions to turn the handwheels
for you. The language the computer uses to communicate
with the machine is called G-code. G-code is a simple
text-based language where each line of code tells each axis
of the machine where to go next. A driver box converts these
instructions into signals the stepper motors understand, and
they move the various axes for you. A stepper motor accurately
divides a single rotation into several hundred steps, providing
a predictable and repeatable method of precisely moving the
FIGURE 74This simple programmable indexer brings table when the appropriate number of pulses are sent to it
computer control to operations like cutting gears. from the driver box.
-37-
FIGURE 75P/N 8020 CNC
system includes 2000 mill,
motors, computer and software.
Books and Videos about Machining
very small drills or turning small shafts. Although torque is BLACK (MO-
somewhat reduced, this is not normally a problem because TOR)
you will be removing only small amounts of metal in those L1 A+ A- L2
types of operations. We recommend reducing the preload USA colors listed first, European
adjustment on the spindle bearings from .0002" end play to P1 P2 P3 colors in parenthesis when different.
.0003" to keep from overheating the bearings when using this
accessory. Instructions to do this are provided. FIGURE 79Electrical wiring color codes for motor and
speed control
Sherline is on the InternetGet Prices, Tips, Projects, Instructions and More at www.Sherline.com
To take a look at the newest offerings from Sherline list as well as a Resources page with links to many
Products, visit our Internet site. You will find a other items of interest to miniature machinists. There
complete list of all our accessories as well as the fully is even a factory tour in photos. You have a wealth
illustrated instructions for each one. Learn how a part is of free information at your fingertips. Our address is:
used before deciding to buy, or print out the directions www.sherline.com. You may now place your order
for your later use. There is also a U.S. and worldwide by e-mail at sherline@sherline.com or order on-line
dealer listing, replacement parts listing, current price 24 hours a day at www.sherlinedirect.com.
-39-
Replacement parts can be ordered through your dealer or We will be glad to help you make sure you are selecting the
directly from Sherline. If in doubt about whether you are proper parts for your needs. For a complete list of parts and
ordering the correct part number, please contact Sherline. prices see www.sherline.com/prices3.htm.
40400
40561 40510
40570 34220
34410
40550 34260/34270
34250
40580 40340
44120 NOTE: Some factory assembled machines
40660 may have a 0.005 thick shim washer (P/N
40690 40030, not shown) placed between the
44200/44230 11980 handwheel and thrust to adjust backlash.
11990 If removed when servicing the machine they
11950 should be replaced in the same position.
44010
40250
FIGURE 80
-40-
Sherline CNC-Ready Lathe Exploded View and Part Numbers
NOTE: Where different, Inch part first, followed by Metric part number.
41130 30220
SADDLE (40910)
40510
LEADSCREW BACKLASH
90080 40177/41177
40660 LOCK DETAIL
90060 40660 44172/44173
30230
40740
43110 43200 (Label)
43170 Crosslide: 40050/41050
44171 40173 Leadscrew: 40080/41080
43460
43150 43160 40510 40520 STANDARD HANDWHEELS
43140 40520
ADJUSTABLE ZERO HANDWHEELS
43170
34250
40620 (USA) Crosslide: 34230/34240
40630 (UK) 43120 Leadscrew: 34260/34270 34210
40640 (Europe) 43190 40520
34220
43100
32100
43360
40440 34260/34270
40090
43130 40520
34210
32100 40340
41080 43180 34220
40320
45450 (Leeson) 40440 34250 40080/41040
45460 (Hill House) 40070
40660 40380 40860
40670 40690 40870 40520
40420 40230
40111 40590
40100 40440 40330
40390 40520 40340
40980 40660 40220/41220
40910
40820 40330
40020 40600
40270/41270
40820 40112 40180
40600 40501
40040 40890/41890 40250
40540 67035
40420
40160 40900 32140
40520 40330
40590
40990 67035 (6)/67036 (8)
43230 67022 40670 44211/44221 (6)
31080 40177/41177* 67210/67221 (8)
40900 *See Lock Detail at Top
67040/67041 67106/67108
67025
40260 24/
670 67120
12050 (4)
40660
40510 67111
40370/41370 67102
40240 67115
67120
67111 67105 40520
40010
40570 40400
40510
40550
67111
67115
40560 12050 (4)
67105
40580 40520
67020 40340 67111
67120
40660 67102
67026/67027 40690 67120
11980 67104
44010 11990
11950 40250
FIGURE 81
-41-
Sherline Manual 5000- and 5400-Series Vertical Milling Machines
NOTE: Where different, Inch part number is given first, followed by Metric part number.
NOTE: Some factory assembled machines may have a 0.005 shim washer P/N
Exploded View and Part Numbers 40030 (not shown) placed between the handwheel and thrust to adjust backlash. If
removed when servicing the machine they should be replaced in the same position.
1297
45013
34220 41080
40620 (US)
34410 43180 40630 (UK)
43230
40520 40640 (Europe)
43190
34260/34270 34250 40040 45450 (Leeson)
31080 43120
45014 45460 (Protech)
40175/41175 41080
40670
45012 40160
(Nylon 43140
34000/34100 Button)
40177/41177 50240 40520 32100 43150
40600 40420 90060
45040
40670 43200 (Label)
40520 34060
90080
40590 43130
40020
40260
40540 40440
40600 41130
45200
40990 43360
40520
40820 40100 43100 40660
45010/45160
40670
40660 43460 43110 30220
40900 40420 43170
40690 30230
40320 43160
45030 40440 40080/41040
43170
40530 40520
40740 40230 45020
50050 54180/54190 (Engraved)
50180 (Plain) 40280 34220
34210
40510 50010
50211
50150 34250
LEADSCREW END DETAIL
50920 34260/34270
50280 Leadscrew Body*
40520 50170/51170 R/H See Leadscrew Detail
50930 40290
50200/51200 40510
40530 40520 50130/51130 40310
50910
40600 50190 50140/51140
50220 40690
50160/51160
*Leadscrew Body Part Numbers:
40520 See Leadscrew Detail
40980 X-Axis (All)50171/51171
40760
Y-Axis, 5000-Series50161/51161
40820 50150
45070 50211 Y-Axis, 5400-Series54161/54170
40890/41890 40520 40520 Y-Axis, 2000-Series56161/56151
40600 40980
40510 40820 See Leadscrew Detail
54160/54170 L/H
34250
34230/34240
40560 34210
40550 40520
54020/54120 40570 34220
40580
FIGURE 82
-42-
Sherline CNC-Ready 5000- and 5400 Series Vertical Milling Machines
NOTE: Where different, Inch part number is given first, followed by Metric part number.
1297
41080
43180 40620 (US)
40630 (UK)
40150 43230
43190 40640 (Europe)
40172 40040
31080 45450 (Leeson) 43120
40660
45460 (Protech)
40175/41175
40690 41080
40173 67115 (Nylon 40160
40520 67105 Button) 43140
40170/41170 50240 40520 32100 43150
40600 40420 90060
67111 45040
12050 (4) 40670 43200 (Label)
67111
90080
40600 43130
67120 40020
67102 40260 40440
67120 40540 41130
67104
40990 43360
40175 (Inch)
SADDLE NUT ASSEMBLY 41175 (Metric)
40177 (Inch), 41177 (Metric)
1/8 BALL, P/N 40178
Exploded View and Part Numbers SPRING, P/N 22630
56200 40330
40670
40340
56400 56350
45011 (Inch)
45161 (Metric)
56230
56220 56330 (Inch)
56331 (Metric)
35160
56450
56550
50211
40690
56440
56110 40670
35170
56770
56210
56130
56700
56470
NOTE
For part numbers of table, column bed
and headstock/motor/speed control
portions of mill, see exploded view in
the color Instruction Guide book that
came with your mill.
56160 (Inch)
56150 (Metric)
56010 (Inch)
56020 (Metric)
56240
-45-
56220 40520
56450 67111
40230 67120
56550 67102
40670 67021 67120
67051/67052
56470
56110 67106/67108 (RH) X and Z-Axes: 40080/41080
Y-Axis: 40050/41050
50211
35160 40520
40690 50150
56770 56210 56440
50920 STANDARD HANDWHEELS
35170 50171/51171
56130 40520
50200/51200 50930 40510 34250
40520 X-, Z-Axes: 34260/34270
56700 50910 50130/51130 Y-Axis: 34230/34240 34210
40600 50190 40520
40690 34220
40510 50140/51140 ADJUSTABLE ZERO HANDWHEELS
67115
67120
56240
67111 40520
FIGURE 85
67105
Machining BasicsUsing the Handwheels
P recision leadscrews and the handwheels that drive
them make it possible to produce highly accurate parts on
a mill or lathe. Here are some tips that should help first-time
keep a smooth, continuous feed going. On small machines, the
handwheel is turned by its outer knurled surface using the thumb
and a finger of one hand. Then, as that hand is released, the thumb
machinists get off to a good start. and finger of the other hand pick up the rotation. Using the handle
Handwheel Increments on the handwheel can introduce pushing and pulling motions that
The handwheels on Sherline machines are marked in increments can adversely affect the finish. (See Figure 86.)
of one one-thousandth of an inch (.001") for inch models or FIGURE 86A
one one-hundredth of a millimeter (.01 mm) for metric models. two-handed tech-
One turn of the handwheel causes the leadscrew to advance the nique for turning
tool or part .050" (inch models) and 1 mm (metric models). The the handwheels
leadscrews are precision rolled and are quite accurate. Therefore, yields a better
moving the handwheel three rotations, for example, moves that final finish on
axis exactly .150" (or .03 mm on metric machines). This precise your part. Shown
method of moving the tool or part is what makes it possible to in use here is an
make accurate parts on a metalworking lathe or mill. adjustable zero
When advancing the crosslide handwheel to take a cut on the handwheel.
lathe, keep in mind that the amount of metal removed is actually
twice the amount you dial in. You are removing a given amount
of material from the radius of the part, which means you are Adjustable Zero Handwheels
actually removing twice that amount from the diameter of the Adjustable handwheels are optional on all Sherline machines and
part. (Some lathes are set up with the crosslide feed reading the are standard on the deluxe models. The increments are marked on
amount the diameter is reduced; however, since it is possible a collar which can be disengaged from the handwheel and reset to
for Sherline lathes to also be used in a milling configuration zero or any other desired setting. To release the collar, turn the
where the crosslide feed becomes the X-axis feed for milling, black, knurled release knob on the outer face of the handwheel
this system was not used.) counter-clockwise. The collar can then be adjusted without
Turning the Handwheels moving the handwheel itself. When reset to zero, carefully
Each handwheel has a small handle. This is mainly used to retighten the black locking knob to reengage the collar and then
advance the leadscrew quickly over long distances. When advance the handwheel. The advantage of this system is that it
actually making a cut, or at least when making the final cut on can eliminate errors when dialing in a dimension, as you are
a part, most machinists will turn the handwheel itself, using the starting from zero each time, rather than adding one number to
outer surface and alternating back and forth between hands to another to come up with the next stopping point.
Technical Specifications
LATHES 4000 (4100) 4400 (4410) VERTICAL MILLS 5000 (5100) 5400 (5410) 2000 (2010)
Swing over bed 3.50 (90 mm) 3.50 (90 mm) Max. clearance,
Swing over carriage 1.75 (45 mm) 1.75 (45 mm) table to spindle 8.00 (203 mm) 8.00 (203 mm) 9.00 (229 mm)
Distance between centers 8.00 (200 mm) 17.00 (430 mm) Throat (no spacer) 2.25 (50 mm) 2.25 (50 mm) (Adjustable)
Hole through spindle .405 (10 mm) .405 (10 mm) (w/ headstock spacer) (optional) 3.50 (90mm) (Adjustable)
Spindle nose ext. thread 3/4-16 T.P.I. 3/4-16 T.P.I. Travel, X-axis* 8.65 (220 mm) 8.65 (220 mm) 8.65 (220 mm)
Spindle nose int. taper #1 Morse #1 Morse Travel, Y-axis 3.00 (76 mm) 5.00 (127 mm) 7.00 (178 mm)
Travel of crosslide 3.25 (83 mm) 3.25 (83 mm) Travel, Z-axis* 6.25 (159 mm) 6.25 (159 mm) 5.38 (137 mm)
Tailstock spindle taper #0 Morse #0 Morse Hole through spindle .405 (10 mm) .405 (10 mm) .405 (10 mm)
Protractor graduations 0 to 45 by 5 0 to 45 by 5 Spindle nose ext. thread 3/4-16 T.P.I. 3/4-16 T.P.I. 3/4-16 T.P.I.
Handwheel graduations .001 (.01 mm) .001 (.01 mm) Spindle nose int. taper #1 Morse #1 Morse #1 Morse
Leadscrew Pitch .050/rev (1 mm/rev) .050/rev (1 mm/rev) Handwheel graduations .001 (.01 mm) .001 (.01 mm) .001 (.01 mm)
Electronically controlled Leadscrew Pitch .050/rev (1 mm/rev) .050/rev (1 mm/rev) .050/rev (1 mm/rev)
spindle speed range 70 to 2800 RPM 70 to 2800 RPM Electronically controlled
Length overall** 23 (584 mm) 32.5 (826 mm) Spindle speed range 70 to 2800 RPM 70 to 2800 RPM 70 to 2800 RPM
Width overall** 10.25 (260 mm) 10.55 (267 mm) Width overall** 14.75 (375 mm) 15.00 (381 mm) 15.00 (381 mm)
Height overall** 8 (203 mm) 8.5 (216 mm) Depth overall** 11.75 (298 mm) 14.00 (356 mm) 22.25 (565 mm)
Shipping weight 24 lb. (10.9 kg) 30 lb. (13.6 kg) Height overall (Max.)** 20.75 (527 mm) 20.75 (527 mm) 23.38 (568 mm)
Table size 2.75 x 13.00 2.75 x 13.00 2.75 x 13.00
(70 mm x 330 mm) (70 mm x 330 mm) (70 mm x 330 mm)
Spindle Motor Specifications
Hold-down provision 2 T-slots 2 T-slots 2 T-slots
Input voltage100 to 240 VAC, 50 to 60 Hz
Shipping weight 33 lb (15.0 kg) 36 lb (16.3 kg) 38 lb (17.2 kg)
Output to motor90 VDC
Movements in addition Headstock rotation Headstock rotation Headstock rotation
Current draw.5 to 15 amps depending on load
to X-, Y- and Z-axes (90 L/R) (90 L/R) (90 L/R),
No-load output shaft speed6000 RPM (no pulley)
Column rotation (90 L/R),
NOTE: Motor and speed control can be purchased Column pivot (90 Fwd/Bk),
separately. Part numbers are as follows: *Standard
dimensions listed. Optional longer tables and taller Column swing (90L/R),
P/N 33050DC Motor and Speed Control columns
with extra travel are available. Col. travel (In/Out) 5.5 (140 mm)
P/N 33060 Headstock, DC Motor, Speed Control **All overall dimensions include motor and speed control.
-46-
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