Description
A Sharp milling machine is a rigid, manually operated precision machine equipped with X, Y, and Z axis digital readouts (DRO). While our shop is primarily focused on woodworking, this machine provides a level of accuracy, control, and repeatability that exceeds what is practical with handheld routers or router tables.
Unlike CNC machines, the milling machine is operated entirely by the user using hand-wheels and feed controls, allowing for direct, hands-on machining without programming. The Digital Read Out system enables precise positioning and depth control, making the mill especially useful for woodworking tasks that demand tight tolerances.
In our shop, the Sharp milling machine is commonly used for:
- Cutting juice grooves in cutting boards
- Machining precise tongue-and-groove joints
- Cutting accurate slots, dados, and rebates (rabbet joints)
- Repeatable precision work where CNC is unnecessary or impractical
Because the milling machine is extremely rigid and powerful, correct setup, secure workholding, and disciplined operation are essential for safe and successful use.
⚠️ Warnings
Extreme cutting force hazard. The milling machine does not slow or deflect like woodworking tools. Contact with the cutter can cause severe injury instantly.
Secure work-holding is mandatory. Work pieces must be firmly clamped or held in a fixture. Loose material can shift, break cutters, or be violently ejected.
Training is required to use this machine. Once you complete training you will be allowed to checkout the key that secures the accessories required to use the Mill. You can sign up here.
Usage Instructions
- Verify your authorization and training at the Tool Crib and check out the key.
- Inspect the machine before use. Ensure guards are in place, controls function properly, and the work area is clear.
- Wear required PPE. Safety glasses are required; hearing protection is recommended.
- Select the correct cutter for wood or approved materials and install it securely.
- Be sure to remove the wrench after tightening the cutter.
- Secure the workpiece firmly using clamps, vises, or fixtures—never hold material by hand.
- Set X, Y, and Z zero points using the digital readout, if you intend to use the DRO.
- Confirm cutter clearance by manually moving the table before starting the spindle.
- Start the spindle and allow it to reach full speed before feeding material.
- Feed the cutter slowly and deliberately. Do not force the cut.
- Make multiple light passes rather than removing excessive material at once.
- Keep hands clear of the cutter and moving table at all times.
- Stop the spindle before adjustments, measurements, or clearing chips.
- Turn off the machine and wait for complete stop before cleaning up the area.
Cleaning
- Remove chips and debris from the table, ways, and surrounding area using a brush or vacuum.
- Clean chips from vises, clamps, and fixtures.
- Wipe down exposed surfaces to remove dust and residue.
- Inspect the DRO scales and cables and ensure they are clear of debris.
- Sweep the floor around the machine to remove chips and reduce slip hazards.
- Return cutters, clamps, and tools to their designated storage locations.
- Report unusual wear, damage, or issues to a Floor Monitor.
- Lock the cabinet once you have finished.
Safety Issues
- Severe injury potential The rigid cutter and table movement can cause catastrophic injury instantly.
- Spinning cutter exposure End mills and cutters remain dangerous even at low feed rates.
- Work piece ejection Improper clamping or fixturing can cause material to shift or be thrown.
- Unexpected table movement X, Y, and Z axis motion can pinch fingers or pull hands into the cutter.
- Entanglement hazard Loose clothing, gloves, jewelry, or long hair can be caught by rotating tooling.
- Flying chips Cutters can eject chips or broken tooling at high speed.
- Improper cutter selection Using the wrong cutter for wood can result in tool failure or poor control.
- False sense of familiarity Woodworkers may underestimate the power and rigidity of a metalworking machine.