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VERTICAL MILLING IN THE HOME WORKSHOP Arnold Throp
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ARGUS BOOKS
Argus Books Books Argus Argus House House Argus Boundary Way Bounda ry W ay Hemel Hempstead Hempstead Hemel Hertfordshire HP HP2 7ST Hertfordshire 2 7ST England Eng la nd
CONTENTS Chapter Chap er One One
EVOLUTION OF 12 OF THE THE VERTICAL VERTICAL MILLER MILLER 12 Early history strial m achines:: milling e history off indu industrial machines mill ing in th the early sma ll lath es : mi lling attachmen ts for hes small lathes: milling attachments for lat lathes 20s: E.T, estbu ry's experimental ci rca 19 19205: E.T. W Westbury's experimenta l machine mach ine circa 1964: e-Westbury m achine 1968: cu rre ntly 1964 : the Dar Dore-Westburv machine curre avail able sma nes and ments, available smallll machi machines and attach attachments.
Chapt err Tw o Chapte Two
MILLING FLAT 27 27 FLAT SURFACES SU RFACES Surf aces paralle Surface parallell to to table: simple fixed-radius fixed -radius f1flycutters: ycutt ers: var iab le-radius bor utting: ng head flyc flycutting: variable-radius boriing multiple -tooth face m ills: work hol ding: m ult ip le multiple-tooth mills: holding: mUltiplepass mi it h table milllling: ng ' surfaces square square w with table:: using uSing side of mill. of end endm lll.
Chapter Th ree Three
SLITTING AND 35 D CUTTING CU TTIN G 35 S LITTI N G AN of slitting saw for cutting Use of slit ing saw cut ing through machinery component bosses bosses : eccentric sheaves and straps straps:: mar ine type big ends of connecting rods. marine
Chap te r Four Chapter
KEYWAY CUTTING 37 UTTI NG K EYWAY C Endm ill ing round ended 'feath keyways : keyways Endmilling feat er' kevways: taper shafts : use of disc type tvoe cutters for plain on taper \Noo druuff ff keyways keyways:' making sunken keyways : Wood workshop : table of Woodruff cutters in the home ome workshop: suggested \N oodruff keys and keyways kevv vavs for fo r sugges ed sizes of Woodruff engineers, model engineers.
Chapter Five Fiv e Chapter
FLUTING COMPONENTS OTHER THAN FL U T ING CO MP O NENTS OTH ER T HA N TOOLS 43 TOO LS Correct form form of of flute flutes ir ir loco loco connecting connecting and and Correct cou pling rods: rod s: moun mounting rods against against angleplate anglepla te for for coupling ing rods flu ti ng:: paralle parallell flutes: flutes: taper taper flutes flutes:' preferred preferred type type of of fluting cutting tool. too l. cUlting
First pub published 1977 First lished 1977 Second im impression 1979 Second pression 1979 Second edition 1984 Sec ond edi ti o n 1984 Reprinted 1986, 1988 1988,1989,1990,1991,1993 Rep rin ted 1986, , 1989, 1990, 1991 . 1993 Books Ltd 1977 1977 © AArgus rg u s Bo o ks Ltd
All rights may r ights re~erved reserved .. No part p art of this publication m ay be rep roduced repro d uced In in any any form f o rm by by print, print. photography, photography, microfilm microfilm or any other othe r means mean s without wi thout written permission from the th e pub pub lisher. lisher.
ISBN ISB N 085242 0 852 42 843 843
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Phototypesetting Ph o t ot y p esetti n g by by Performance Perf o rm an ce Typesetting, T y pesetting, Milton Milton Keynes Key n es P~ i nted Print ed and and bound bound in i n Great G reat Britain Br it ai n by by Biddies n Biddies Ltd Ltd ,. Guildford Guil d f o rd and and King's K in g 's Lyn Lynn
Chapterr Six Six Chapte
BOR ING 45 BORING 45 Dealing with with parts parts too too large large to to swing swing in lathe: lathe: Dealing trepanning large ho holes. les.
Seven Chapter Seven
'JIG-BORING' 46 'J I G- BORIN G' 46 the miller as a measuring measuring machine : drilling Using the holes one setting of of work and precise cent centres: ho les at one res: beam: lash pr precautions: trip gearr com engine p gea eng ine be am: bbackack-lash ecaution s: tri ponent mUlti-hole pon ent : mu lti-ho le boiler plates.
Chapter Eight Eight
PROFILING 49 too large for for lathe: loco frames frames:: Curves on parts too smokebox castings castings:: machine pad pad bolts: loco con con- necting rodss and coupling rod rods. nec ting rod s.
Chapter Nin Nine e
END-ROUNDING 52 hardened ffiling guides Use of hardened ilin g gu ides deprecated: mounting rotary standard mou nting work on rot ary table: sta nd ard size guide plugs: anti-slip precau precautions: of feed for for plugs: tio ns: direction of external surfaces. exte rnal and iinternal nte rnal surfaces.
Chapter Chap te r Ten
DIVIDING HEADS 54 Simple ungeared dividing div iding heads: heads : using change wheels a index plates: off dividing w hee ls as plat es: examples o d ividing work w or k : hexagons, squares, dog clutch teeth : avoiding odd h exagons. squares. numbers: numbers : the Myford worm--geared w orm -geared dividing head: head : avoiding back-lash errors erro rs : packing block for bringing to lathe centre height: universal universa l steady stand for Myfo rd head: three further dividing heads. fo r Myford
Chapter Eleven
DIVIDING HEADS 62 HEA DS AND GEAR-CUTTING GE AR- C UTT IN G Limitations to straight strai ght spur spu r gears : simple sim ple head : Myford n M yford worm-geared worm -geared head: tooth tooth cutting on integral pinion pi nion : use use of home home made f'vcutters: Ilvcut ters: Brown & Sharpe disc type cut ers:: selec ionn 0of cutters selectio cutter to to suit number numb er of teeth teet h : cutting a large large coarse coa rse tooth gear: gea r: anti-slip back-up devices. de vices ,
Chapt er Tw elve Twelve Chapter
DIVI DING HEADS L MAK ING 66 DIVIDING HEADS AND AND TOO TOOL MAKING 66 Fluting Fluting taps taps:: example example 5-flute 5-flute Acme Acme tap tap:: producing producing a small th milling ith ball small fine fine too tooth milling cutter w with ball end end : use use e of of table table stop blocks: blocks: combination combination of of rotary rotary tabl table with ma in table ree coun main table movement: large 60 deg degree coun te rsink fluting tersink fluting..
Chapter Thirt een Thirteen
DIVIDING UATED DIV I DING HEADS AND GRAD GRADUATED SCALES 7711 Cutti ng graduation marks : use of avi ng' Cutting of rotary 'engr 'engraving cutters n-r otating plani ng ttype ype tools : use cutters:: use of no non-rotating planing ooff table table stops to contro contrqll line line lengths lengths:: graduating cyli ndr ica l scales: gradua ting flat angular scales cylindrical graduating scales:: checking correct way of of figuring when stamping scales scales,
Chapter Fourt een Fourteen
CUTTER SPE EDS FOR VERTICAL MILLERS 74 SPEEDS Speeds affect titime me occupied on job: speeds too too high may cause cause excessive cutter wear and chatter chatter:: rigi di ty of work, cutter and mac hine inferior as a rigidity machine rule to iindustrial ndu st rial condi tions, dry cutting inst ead of conditions. instead lubricated e III gives speeds for cutters in lubricated:: Tabl Table different kinds of tas ks : m achi ne speeds may tasks machine may no nott alwa ys be suitable . always
Chapter Fifteen
WORK -HOLDING WITH D IFFICULT WORK-HOLDING DIFFICULT SHAPES 78 scale engineering engi neering : use of Comparison with full scaie of chucki ng pieces on components: components : thin components chucking ad hesives : advisability of making fixtures and use of adhesives: fo r difficult difficul t pieces: pieces : threethree -ssided ided angleplates. angleplates. for
Chapter Sixteen
81 CHUCKS FOR MILLING CUTTERS 81 tools or chucks without Never use taper shank tools drawbar: chucks for screwed screw ed shank selfself -tightening drawbar: tightening Clarkson Dsborn Titanic chuck: collets : Cl arkson chuck : Osborn tee -headed locking cutters: Clare Chucks for tee-headed withou t use of small end mills and D-bits without chucks : use locking features : phi ph ilosophy 't hrow - aw ay ' losophy of 'throw-away' cutters.
List of Illustrations Fig..
Fig 1 2 3 4 5 6 7 8 9 10 111 1 12 13 14 14 15 16 17 18 19 20 21 22 22 23 24 4 25 25 26 26 27 27 28
wood m illing attachment the 19 1920s Ab w oo d mi llin g attac hme nt of the 2 0 s
E. T. Westbury's millln E. W estb ury 's m ill ing m achine machine Dore-Westbury achine Dore-W estbu ry m achine Dare-W estbury M Mkk II 11 machine Dore-Westbury Rodney attachm ent Rodneyattachment Rod ney m ach ac hine Rodney in e Amo mentt Am o lco attach men Amolco machine A mol co m achine Mentor machine M ent or mach in e Maximat attachmen M aximat attach me n t Astraa m mCtchine Astr ach ine Twin machine Tw in machi ne Senior achin e Sen ior m mach i ne fl ycu tt ers Set of three flycutters Flycutting Flycu tt ing a bracket Flycutti ng connecting rod ends Flycutt ing Flycutting mater;a Flycutti ng ttapered apered bar mat eria l cylinde soleplatee Flycutting cy linde r soleplat Facem ililll Milling flyw heel joint face M illing flywheel Milling crosshead Mi ll ing crosshe ad slide Milling bearing bedplale M illing bear ing jaws jaw s in bedpl at e Slitting boss sting boss of ca casting Milli ng feath er kevw av Milling feather keyway M illing feath er keyw ay on tap ered shaft Milling feather keyway tapered Mil ling keyway wi th slitting Milling with sl'tting saw saw Se Sett of four Woodruff keyway cutters M ill ing W oodruff kkeyway evwav Milling Woodruff
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29 3 0 30 311 3 32 33 34 3 4 35 35 36 36 37 38 38 39 39 40 40 41 41 42 4 2 4 3 43 44 44 45 45 46 46 47 48 49 50 5 511 52 53 54 55 55 56 5 7 57 58
Fluting locom con nect ing rod Fluti ng loc omootive tive co nnect Drawing steam Draw ing of stea m hook (lever) Photograph stear.1 Phot ograph of st eam hook Profiling bolt Profilin g pad bo lt Profiling coupling rods with tablee End-rounding wi th rotary tabl Cutting dog partt Cutti ng tteeth eeth in do g clutch par Drawing of st steady Myford dividing Draw ing of eady stand for Myfo rd div id ing head Steady cutting St eady in use on a gear cutti ng operation opera tic Throp dividing Thro p divid ing head Thomas versatile dividing Th om as versat ile divid ing head Kibbey/M dividing Kib bey/M .E.S. dividl nq head Close-up flycutter pinion ter and pi nio n Clos e-up of flycut Gearcutting Brown Sha rpe cutter Gearcu tt ing w ith Brow n & Sharpe Flycutting d.p. Fly cutt ing 10 d .p, gearwheel. gearwh eel. front view F 10 d.p. d.p. gearw gea rwheel. view Flyycutting cu tt ing 10 hee l. rear view Flut'lng Acme Flut ing A cm e thread tap Culling ball-end cutter Cutt ing teeth of ba ll-end cu tt er Close- up of ball-end cu Close-uD c tte tterr Gashing countersinking Gashin g flutes in large count ersinking tool iew showing stead Rear vview steadyy stand in use Cylll'\drical machine component graduated Cyli nd rical m achine compone nt being grad uated Close-up previous operat Close -up of prev ious ope rat ion Graduating part-ci part -ci rcul ar arcua t e scal e on flflat at surface surfa ce rcular scale Tape -he ld w orkpiece being bein g flycut flyc ut Tape-held workpiece Hern inpwav three-side d anglep late Yerringway three-sided angleplate Tw o of the th ree sizes of Herninqwav leplates Two three Hemlngwa~' ang angleplates Clare mi ll ing chu ck chuck Clark son mi ll ing chu ck Clarkson chuck Osborn mill rrill iinng g chuc chUCKk
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Preface In th e eng ineering in dustry the ic al the engineering industry the vert vertical y used nly for miller is very very widel widely used . no nott oonly batch product lorrbu t also king production:bu also for tool ma making and the the 'one 'one--off' off' jobs whi ch are so common inee ring. In commo n in in general eng engineering. In the the home worksho p. w her e most job s are workshop. where jobs e machi ne 'one-o ff' th e ve rsatility of 'one-off the versatility of th the machine makes m port ant comp anion to the makes it an iimportant companion the lathe. Thi crib es many of Thiss book des describes of the the er ation s wh ich infinitely i nfinite ly wid e range o off op operations which can be done. and all those described are illustrated by photographs photographs so that under underst anding of th e methods is assured standing the assured.. These cove mot ives. coverr work on part partss of of model loco locomotives. stationary machi nery . cutting stationary engines engine machinery, too ls. gea rs, clutches, ion tools. gears. clutches. etc. Full informat information is given o n the machine accessories wh ich which are requi red,. suc h as var ious types of are required such various cu tters and tthe he chucks chuck s needed heir cutters needed for fo r ttheir mounting on the m achi ne spind le.. The machine spindle The use of cheap chea p hom e- m ad e cutters cutt ers iiss shown home-made and encouraged. encouraged. Guidance is also given give n th e work- holding devices dev ices such as on the clamps. packings. packings, vices. vices. angle plates, clamps. angl e plates. heads. rotary rot ary table s. s, and which w hich of dividing heads. thes e are needed for particular part icular kinds of these w ork . work.
CHAPT ER 1 CHAPTER
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Evolution of the Vertical Miller ng machine evolved evo lved Th e horizontal mi lllliing natura fr om tthe t he first fi rst or he lathe in the na tura lly from seco nd decade of t he nine tee nt h century. second nineteenth Elii Whitney W hitney (U (U.S.A.) said t o have have had El .SA) is sa id to 18 . and in Tools for one in use about 18 18, the unt ed how the Job the lat latee LTC L.T.C . Rolt reco recounted how the yo ung eng engineer yth (later {later ineer J ames Nasm Nasmyth to become famous as the inventor inven tor of the th e stea m ham mer and ot her app steam hammer other applliances iances)l fixed one illed the fla ts on one up and m milled flats hundreds of tiny hexagon nuts for a model of a Mauds lay marine eng ine. hile Maudslay ine . w wh ile working uds lay . Draw ings of working fo forr Henry Ma Maudslay. Drawings of the ly hori zont al mill the ear early horizontal mi ll ers show show suc suchh a resemb th es of resemb lance to t he la lathes of that period period that almost nly they al most certai certainly th ey were in fact fact lat hes w hich ed to mil wh ich had been adapt adapted millling. ing . The re really files. Th e cutters we were fil es. made by by the th e fifille akers of the tim es, using he 'hand e m makers times, usi ng tthe 'handcu tt ing ' methods er and a cutting' meth ods (really (real ly a hamm hammer spec ia hic h we iall chisel) ch isel) w which werre the only only practice available e. at that tim time. ava ilable at The evolution rti ca l m iller evolu tion ooff the ve vertical miller came nat ural ly afte he ho rizo nt all naturally afterr tthe horizonta m achi ne. I have not machine. not found any any reliable rel iable refe rence hic h the ical refere nce to a date date by w which th e vert vertical m iller ad appeared in industry, thoug though ille r hhad in industry this ust have 0. this m must have been we wellll before 190 1900. W he n model ineering sta rted to When mode l eng engineering started to beco m e an esta bl ished hobby at urn become established at the the tturn of ll of th th e century ce ntury quite quite a variety va ri ety ooff sma small 12 12
lath es were we re provided by different di fferent makers. makers. lathes ver satili ty of the th e lathe il ity and the great versat it self a tendency te ndency to make the created in itself lathe do every operation opera tion that arose . This wa enhan ced by the th e fact that th at many ma ny wass enhanced with very modellers were working men en wilh litt le cash to spend o little onn their hobby. Many M any we re the inge nious attachment ingenious at achmentss devised to enable the he to carry out work itit had the lat lathe never never been intended to do do.. Such makers as Drum m ond Brothe rs modified their Drummond Brothers lathes wit h tee-slott ed boring tables to with tee -slotted help in this work . and even bro ughtt out brough out tthe he famous ro h r und - bed lat he. wh ic ich -price market. although int ended for a cut intended cut-price market . also had bu ilt into itit the lity to do built the abi ability do a lot lot more than just simple turning . But But as the than just years wen wentt by it it became ever more appa rent somet hing better was apparent something was needed ffor or mi lling operations ne of milling operations.. No None of the the small mille rs produced by the mac hine tool millers machine industry we re oriented towards the home were w orkshop, workshop. T hen in Then in the the 1920s the the Abwcod Abwood Tool Tool l and neeri ng Co. produced an a'n exce exceland Engi Engineering lent tachmen t fo lent vertical mi mi lling l ling at attachment forr mounting on lly the on smal smalll lathes. especia especiall~' he in. m ond . though popula in . flat bed Drum Drummond popularr adjustable adjustable features features made made itit applicable to0 othe hes too otherr lat lathes lOO.. ItIt had had a No. 11 Morse Morse tape to the taperr arbor arbo r which which fitted fi ted in into the lathe lathe
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Fig.. tr Abv/ood Abll'lood milling milling attachment attachment of of the the j:ig 19205 1920s
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spindle, and bevel bevel gear gears with keywa keywayed spindl e. and s with yed took the the drive drive up up to to the the vert vertical shafts took shafts ica l spindle. le, w which had aa No. No. 11 M Morse cu tter cutt er spind hic h had orse were equall internal taper, AAll the gears gears w inte rna l taper. ll the ere equa rotated at ratio mititre bevels. so the the cutter cutter ro rat io m re beve ls. so t at ed at as th the lathe spindle, and same speed as tthe he sam e speed e lat he spi ndle . and all tthe six speeds speeds of of the the lathe lathe were were usable. usable. all he six work was mounted on the the lathe lathe The w The or k wa s mounte d on boring table, and and po power feeding in in one one bo ring table. wer feeding direction ca came from the the lathe la th e screwcut screwcutdirection me from ng gear. gear. A A phot pho tograph of this this uni unitt set set up up ograph of ttling Myfor Super Super 77 is is show shown in Fig. Fig. 1. ItIt on a Myford n in was unfortunately low-volume, labourr wa s unfort una tely aa low -vol um e. labou intensive unitt w with vee slides slides needing needing int ensive uni it h vee hand scrapi sc raping was sell in g in 19 1930 ng ., but w as selling 30 for gu ineas, about aa quar quarter of the the cost cost of of 77 guin eas. about ter of
the Dru Drummond lathe. he. AAlthough of the mmo nd lat lt ho ugh oout ut of production for ma many years n w., itit was was in in producti on for ny year s now time aa co courageous effort but be belonged its time its urage ous effo rt ., but lo nge d to the the age age w when most home home lathes lathes were were to hen most driven by by fla flatt belt belt fro from treadle or cou coundriven m aa tread le or n tershaft, and the the cost cost of of electric electric mot motors tars haft. and ors made th the ind ependent motor drive made e in d ep enden t m o to r drive uneconomic ic in in ho home hobby applications. uneconom m e hobb y appli cati ons. Butt th the need for for aa handy handy vertica verticall Bu e need miilli lling ng ma mach ine had had been been recogn recognised, and m chine ised. and in the the ear early 1 9660s that very very good good friend friend of of in ly 19 0s that model engineers. engineers, Edgar Edgar T. T, W Westbury, model est bury . completed an ex experimenta ma com plete d an pe r im en ta l m acchine, hi ne. which described with drawings and wh ich he desc ribed w it h drawings photog raphs Model Eng Engineer pho t og rap h s in tthe he Model ineer dunng 19 1964. That too wa was very labou labourr during 64 . T hat too s a very
ig, 3 D ore- W est bury machine Fig. Dore-Westbury
Fig. T. Westbury's Fig. 22 E, E.T. Westbury 's milling milling machine machine
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inte nsive machine ith vee slides, intensive mac hi ne w with slides, and the main castings were w ere much m uch ttoo oo big to be be th e average ave rage ho mee workshop. workshop. machi ned in the hom A t that time ti m e he was w as unable una ble to find any At engi neering fir m willing wi lli ng to take take it over and en gine ering firm manu facture ev en to do do the th e machinmachin manuf cture it. or even such a price price as as it ing on a contract basis at such m odel enginee engi neers be was thought model rs would be wl llinq to pay. p ay. willing T hree years years later I found myself with Three the opportunity opportunity to to take tak e a fresh fresh look loo k at this th is the desig n, which whi ch he had had discussed di scussed with w ith me me design. evolved during the the experimental experim ent al period. pe riod . I evolved during new set set of of drawings d rawi ngs for for aa similar sim ilar aa new machi ne, but but using using flat flat slideways slideways more more machine, economically constructed. constructed. aa reduction reducti on economically speeds , hollow hollow gearr for f or lower low er bottom bottom speeds. gea spindl e for for aa drawbar, draw bar. and and other othe r changes changes spindle
ies or prove int ended to intended to make make econom economies or im improve the rformance . This new design design was was the pe performance. This new discussed ith Edgar. ho agreed discussed w with Edgar. w who agreed to to the the use tburv ' , the of the the name name 'Dore-Wes 'Dore-Westbury, the use of machi ne to i machine to be be sold sold as as aa kit kit of of sem semififinished nished compone nts by m components by my my existing existing fir firm Dore nee ring, II was e to ce th e Dare Engi Engineering. was abl able to pla place the m achi ning ooff the nen ts w ith aa machining the compo components with number read y kno w n to number of of firms firms al already known to me me.. and and the rst sets erials began the fifirst sets of of mat materials began to to go go ou outt mers early nce that to to custo customers early in in 1968. 1968. Si Since that n ttime im e m any hundreds many hundreds ooff sets sets have have bee been distributed rld .. and distributed., all al i over a er the the wo world and are are still still be ing made iti es by being made in in ever ever grea greate t err quant quantities by M o d e l En g i ne e r in g S er v i c e s ., ooff Mode Engineering Services Chest erfield . w ho too k itit over from Chesterfield, who took from me me in nted ,. on unt 19 7 1, w he n II wa 1971, when wanted on acco accou nt ooff age age,, to red uce m y comm it men ts , reduce my commitments. Castin gs to na ll design Castings to the t he origi origina design are, are. howeve r, st ill available m Waking however, still available fro from Wokin Pre Preccision is io n M od els ooff 16 Models 16 Dovecot Dovecot Park Park ., A berdour. Fife. Aberdour. Fife , Scotland KY3 OTA OTA.. and a machine m these w n in machine fro from these is is sho shown in Fig. Fig. 2. The re-W estbu ry hi ne is The Da Dore-Westbu ry mac machine is depicted depi ct e in Fig. ila rity be twee n the m he sim similarity between them Fig . 3 and the wi ren t. Du ring ititss willll be be at at onc oncee appa apparen t. During entire the Dar en tire life life the 0 ree-Westbury -Westbury has has been been un dergoi ng sma provement s. and th thee undergoing smallll im improvements, present supplie rs have ided that that present suppliers have now now dec decided he o d i f i c a t io i o ns ns a re ss uffi u ff ic n t ly tt h e m m odificat are c ie i e nt ly st abilised for for the the present presen t version ve rsion to t o be stabilised be titled the the Mark M ark 11 II model. model. Fro From now on on all all titled m now ma chines supplied supplied will w ill be be of of this this form form .. machines though still st ill subject subject to to certain certain optional op tional though vari ations which which customers custome rs w w ill ill be be able able to to variations select as they t hey wish wi sh.. importan t changes chang es include incl ude an an T he more more important The in crease in in the t he qu quill travel from from 2f 2i in. in. to to increase ill travel 4-1- in. in . Extra Ext ra pulley pull ey steps ste ps with with aa new new type ty pe 4-} of belt be lt extend extend the the speed speed range rang e slightly sligh tly of fro m 32 32 to to 1880 1880 r.p.m. r.p.m. with w ith more more interint er from m ediat es. providing provid ing for for boring boring head head flyfl y mediates, cutting on on large large radii radii right right through th ro ugh to to cutting keyw ay cutting cu tt ing with with 1/16 1/ 16 in in.. cutters. cutters. The The keyway reduction gear gear system system now now fitted fi tt ed has has reduction helical gears gears which w hich run run In in an an oil-bath, oil-bath. helical
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Opposite, Fig. 4 The Oore- Westbury Mkll
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Fig. 5 Rodney Attachment
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Rodne ymachine ma chine Fig. 66 Rodney Fig.
sealed hen incli sealed against against leakage lea kage even even w when inclined ned away an away from from the the vertical, vertical, and and is is Quieter Quie ter th than former ly. AA large r table formerly. larger table,, 20 20 in. in. by by 66 in., in., can can be terna tive to as an an optiona optionall al alternative to the the be had had as in. n and norm al 16 16 in. in. by by in. The The co colum lumn and normal cros s tube cross tube are are steel. steel. as as always, always, but but now now tt in. rmously st iff. in. in. thick thick and and eno enormously stiff. in. diamete r m icro m et er d ials are now diameter m icrometer dials are now
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standa rd. Th e down-feed orm has standard. The down-feed w worm has for for conveni convenience ence been been transferred transferred to to the the right right hand rser pitch of the the head, head, aa coa coarser pitch rack rack han side side of is . and e are is now now used used, and ther there are aa numbe numberr of of oth er m ino r im provements. other minor improvemen ts.
2t 2t
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Opposite, chm ent Opposite, Fig. Fig. 77Amolco Amolcoatta 8tt8chment
19 19
Although co colleg ll eges and commercial commercial Although es and workshops wil willl probably probably wish wish to to use use the the workshops all-over belt guard, itit may may be be ddebatable -over be lt guard, eba ta ble ifif all the cos of this this is is justified justified fo forr the the so sollititary th e co stt of ary mature ure m mode alone his home mat ode lllleerr alo ne iin n hi s home workshop. An An alternative alternative belt belt gua guard which ich workshop. rd wh pulley only only and and do does covers tthe spindle es covers he spi nd le pulley not im impede belt chang changing so mu much is not pede belt ing so ch is shown on on the the M Mark available il able and and is is shown ark IIII ava machine in in Fig. Fig . 44.. machine
No do doubt the most most importan importantt iimproveNo ubt the m pro ve ment is is the the (optional) (optionall provision provision of of po power ment w er feed fo for the lo long movement of of the the table. table. AA feed r the ng movement motor with 4- step pul pulley and small m ot o r wit h aa 4-step ley and small worm reduction gear gear provides provides enclosed enc lose d w o rm reduction feed rates rates of of .5 .5., .62 .62., .85 .85 and and 1.1 1. 1 inches inches feed perr mi minute. pe nute. number of attachm attachments similar in in A num ber of ents similar A concept,, though though much much different different in in general concept general detail. to tthe old Abwood Abwood.. have ha\'e com come on e on de ta il. to he old
<, Fig .Fig.. 9 Menror machine, now superseded by by th thee FB2 and Maximal F82 Maximat attachment
rn a rk e t in recent years year s . Tew tthe he marke: M achlnerv produce the t he '.Rod ney' to suit su it Machinery Rodney' th e Myford Mvfo rd V1 M L7 and Super 7 lathes. lat hes. and the Myfords . It is shown in :hi s is :his s marketed by Myfords. t he complete vertical vertica l miller m ill er Fig. 5 and the atta chme nt is that th at shown i n ba sed on this t his attachment based Fig. 6. 6. Fig A not her attachment, attachment, t he 'Amolco' 'A m o lco is Another N. Mole M ole & Co Co. Ltd . and supp lied by N. supplied it s own ow n motor motor appears in Fig. Fig. 7 This appears his has its and attaches to t he top of the t he lathe lath e bed bed and 0 the made as as aa complete compl ete machine, ma chi ne. also. IIIt is made also. snown In in Fig. Fig. 8. 8. snown Fig. Fig. 88 A A molco mateo machine machine
20 20
Fig. 1, rt Ascra A stra machine machin e Fig.
22 11
Fig. 12 12 Twin Twin machine machine Fig.
Elliot machine m achine Equipm Equipment supp a Elliot ent su ppllied ied a continental mac hi ne,, the th e ''Mentor' M entor' wh ich continental machine which was available bo th in ench and was available both in b bench and floor floor m ounted forms Th e bench achine is mounted forms.. The bench m machine is shown shown in in Fig. Fig. 9. 9. They They also also have have the the 'M axim al' attach he of 'Maximal' attach ment ment to to suit suit the the lat lathe of the e,, whi ch fit the same same nam name which fitss on on the the back back of of the e bed otor the lath lathe bed and and has has independen independentt m motor drive ). This lable as drive (Fig, (Fig. 10 10). This is is also also avai available as aa floo achi ne,, the floorr m machine the FB2 FB2 .. Ot m plete achin es inclu de the Other her co compl ete m machines include the 'Astra' ed by uhart, w hic h which 'Astra ' suppli supplied by Scot Scat Urq Urquhart, is all m iller ra Is really really a horizont horizonta mill er w w itithh an an ext extra ver tical spindle s own tor . Made vertical spindle with with itits own mo motor. Made in w n in in several several sizes, sizes. the the smal smalll one one is is sho shown in Fig. Fig . 11. 11 . Twi n Engin Twin Engineering eering Co. Co. introduced introduced aa bench chine illus trated in bench ma machine ill ustrated in Fig. Fig . 12 12 and and also ounted machi ne of ilar mounted machine of sim similar also aa floo floorr m size htly di ff erent desi gn. size but but slig lightly different design. Fina lly the Tom Finally the old old established established firm firm ooff Tom produce their Senior Ltd . now Senior Ltd. now produce their type type EE
mach ine which w hich isis floor floor mounted mounted and and machine in Fig. Fig, 13. 13. shown in shown So itit will will be be seen seen that that there there are are now now So many machines machines and and attachment attachme nt s which which many are of of suitable suit ab le dimensions dimensions for for inclusion inclusion in in are ed space sp a c e of o f most m o s t home home t h e lim l i miitted the w ork shop s. ItIt wou would be useless useless to to give give workshops. ld be any details deta ils of of prices prices in in aa book book of of this this kind kin d., any as such such information info rmation would would probably probably be be as was incorrect by by the t he time ti me the the book boo k was incorrect printed, and and readers readers are are th therefor recom- printed. erefo ree recom mended to t o enquire enquire of of the th e various various adveradve r mended tisers. tisers. summ ary of the the leading leading particular particulars of of A summary these mach m achines etc. is is given given in Table Tab le 11 all these ines etc. again specifications specificat ions are ame nded by by but again re amended m akers as as time t im e goes by, by, and it can be nno makers m ore than tha n a general general gu guide more ide.. fore ign w o rd m ust be sai said about foreign A brief word mac hin es. particularly part icularly those coming from machines, countries. It I t would wo uld ap appear Far Eastern countries. pear th ere are several factories facto ries producing there mac hine tools tool s and acce ssories. Some machine accessories. app ear to be quite good appear good., bu butt others are definitely not good, e personal good. and I do hav have exp erie nce o ese. I have not experience off some of of th these. not had the ing the chance to see one one of the mill milling ma chines ing,. but chi nes work working but those I have have inspect ed iin n exh ibi tions have some inspected exhibitions some che che ap and ur es, although the mai and nasty feat features. mai nn item s suc h as spind les, bear ings , and items such spindles, bearings. and slideways ay be t. Some he slideways m may be excellen excell ent. Some of of tthe machines machines are ar more more suitable su itable for for com com- merci all fact orie s th an home mercia factories than home workshops workshops but ere ar e oothers thers of dest dimen but th there are of mo modest dimening buying sions. sions. To To anyone anyone contemplat contemplating buying on ese on e ca ly suggest onee of of th these one cann on only suggest that that aa close ld be close inspect inspection ion shou should be made made by by aa kno w ledg eab le engineer knowledgeable engineer., and and that that aa wo str at ion should working rking demon demonstration should be be requested e actua requested,. of of th the actuall machine machine which which isis to t. to be be bough bought. Fig. 10 10Maximar Maximat ettscbrnent attachment Fig.
22 22
23 23
.,.
t>..l
TABLE TABLE 11
Makeor orsupplier supplier Make
Machineoor Machine r attachment attachment
Tab le sisize ze Table
Sp indle speeds Spindle speeds
Spindle Spindlenose nose
Commen ts Comments
Woking Preci Prncision Woking sio n Models Co.Ltd Ltd. M on els Co. . 16 Doveco Dovecot Park 16 t Park Ahernollr, Fife. srdou r. Fifp.. Ab Scotl!fI1d land Scot
Westbury' W estbury' benchmach machine bench ine parts. kitofofparts. kit
14 14 xx 66
6650, 50 . 11 2 0. , 18 50. 1120 1850, 50 31 3150
22MT M Tp1 1l~ plus
M Myforn yford ththread read
Unmachined castings Un-machined castings only onlysupplied supplied Head ivels. Head sw swivels.
Model Fngineering M ode l !'ngin eering SStlrvicel;, ervices . 6 . Ken Kennel Vale, 6. net Vale, Brockwcll, Broc kwel l. ChestertiFlld. Ches lJou1ie lrt.
'Dare W estbury' ' Do ra Wp. ~tb llry· bench m machine bench ach ine kit uf of parts parts kit Westbury Dore Do re W est bury Mk.11l Mk.l bench machi machine bench ne kit of of parts. parts. kit
16 16 xx 55~~
334~,90, 4~ .90 . 188 188 304 . 7790. 9 0 . 16 50 304, 1650
22M l pl uss MTplu M y fo rd thread Myford thread
Now Now superseded superseded by 11 Mk.11 by Mk.
16 t 16 xx 55t (20 (20 xx 66 option) op tio n ]
3322- 18 80 1880
22MTn M T plus lus M y ford thread Myford thread
Comp lete kikitt o01 f parts. pans. Complete AAll ll machining ne machining do done that ul d be ifficu lt that wo would be ddifficult in me w o rk shop. in ho home workshop. Head ive ls. Head sw swivels.
22MTplus M T plus M yford thread Myford th read
Rigid Rigid head. head.
2 T p lu~ 2M MTplus
Rigid Rigid head head..
Tew M Machinery I td. Tew aChin ery ltd Manor Works M an o r W o rks Church SI. SI. Church Coggcmhoc, Cogg cnh o c, Nonh;Jmrton. Northampton. N. Mule Mole & & Cu. Co. Ltd. Ltd . N. 5 . Tulp Tolpits alltl. 5. il s II line. WilI!md HHrlS. WH l t",d . HHrtS.
'Rodney' 'Rodney' ent. aattachm tta chm ent. plus' ''Rodney Rodney plus' floor rnachinc. machine. floor 'Amolco' 'Amolco
Myford For My/o rd Dri ven from For Driven from M L7 anrt Ml7 and lathe in dl e lathe sp spindle 57 7 lat hes. S77 lathes. 32 0, 450, 0, 15 xx 4± 4-!15 320, 450, 61 61O, 8850, 50.1040,1 490, 1040, 1490, 750 22190, 19 0 . 22750
Oench m miller. Oench iller.
Fo Forr Myfurd Myloru & Ao xfor dd Hoxlor tat hes. lilthes. 15 xx 66 15
Mutur riv e. Motor ddrive. 44 speeds, speeds, 325 325 to 16 00 1600 325 -11600 600
Mllchine M ll c h in e or attachment atta ch m en t
sizt! T able size Table
c
M yf o rd th read Myford lhread 22MT MT pl us plus Myfurd Myloru thread thread
Rigid Rigid head head..
2 M Tpi ll s 2MT plus M yf or d tthread hread Myford
Rigid d. Rigid hea head.
spe eds Sp indle speed8 Spindle
no se Spindle n08e
Comments Comments
1I ABI ABI F. F1 1 (continued) (continued) Milk!! or lIupplier Ma klllH supp lter Cllio Cllio lllt M M Achine nc:hlne Equipment. F.'1,Jipm ent. U.l.C U.LC. HOtlHH, HnllHH, Vic\orlfl ViClu ,iH Rd Hrl,, LOI1lJoll 0 6NY London ,. NW NW 110 6NY
'Mentor' ' M ento r mtlchinp. rtlHch il1p. Bench B.1nch and an d floor. f loo r. F02 FS2 Maxim M axim at at attachrntlrH attach me nt ~1r nr floor floor machine machine
x{ 20t xi
3 50 ,,640 7 80 . 350 640,. 780, 14 50 1450
2MT 2MT
Swive ll ing head. head. Swivelling
2 4 t xx 66 24t
120-2000 120-2000 (six) (six)
2 MT 2MT
Swivelli ng head haad Swivelling
Scnl Scot Urquhilrt Urquhart Ltd Ltd.,.. 317. 3iJ , Earlsfitlltl 3 17. 33 //:~,1 Earl sfield Rd., Rn .. Earlsfitlld. Earl sfie ld . DO Lonnon l ondo n SW18 SW18 3300
'Astra 'A str a'' bench bench ann anrt floor floor machines Il1sch in()l'; Hor. Hor. with with ven. v ert .
13 xx 44~ 13 ~
62 0 .90 0 . 620.900. 12 0 0 . 1850 18 50 1200,
2MTT 2M
M o torised sed head. head . Motori
ht!8d. head.
N (J1
Twill T wi ll 1:r19. en!'!.Co. Co. Ci!)(lOnWay, eelxton Way. Holywclllnd Est . Ho ly we ll i nd . Est. Watford, Harts. W atf or u. Herts.
Twin' 'Twin ' bench bench machine machine and and floor floor machine. machine.
20 xx 66 20
52 0 . seo. 520,960. 165 0 .2 8 80 1650. 2880
2 M T plus plus 2MT M yf or d threa thread Myford d
head . Rigid head. Rigid
20 xx 66 20
3 80, 640. 380,640, 10 0 . 19 1900. 00. 11100, 31 0 0 3100
2MT plus 2MTplus thread M yford rd thread Myfo
Swive l head. head . Swivel
Tom , Ltd Ltd ,., To m S(lnior Senior. Atlas A tl asWorks W or ks. Hightown Heights. Hig hto wn Heights, Liversedge, Liversedg e. West W estYorks Yor ks.
'Senior 'Seni o rtype type E'E' floor lIoor machine. m achine.
25 xx 4t 4t 25
480. 950, 50 . 480,9 16 4 0, 2 7 6 0 1640,2760
2MT 2MT
Swivel head head Swivel
CHA PT ER 22 CHAPTER
Milling Flat Surfaces
Surfaces Of al-w o rking operations Of all all m met etal-working operations the the production aces is production of of true true flat flat surf urfaces is perhaps perhaps one of st di fficult ifIf rel iance has of the mo most difficult reliance has to to oo ls be placed on on han dd ttoo ls and and ha ha nd nd methods. for jus t abo ut com for it depends depend Just about com pl et ely ete ly on on the persona l sk skii ll ooff the workm an. But a poi nt offse workman. offsett from the the spi le c en t re of rt ica l mill ing spi nd ndle entre of a ve vertica milling machine m achine must when rotated ro tated describe a fla t plane in i space if there is no axia l movement. Therefore Therefore.. provided the the le. an spind le is truly square to t the tab table. t ool must generate a flat offset cuttin g tool w ork- piece attached att ached to the surface o n a worktabl e. Model engineering , iust just th e same as table. th e producproduc fullll size eng ineering. demands the fu tion of a great many flat surfaces. so th the of the machine to perform this th is task ability of in a simple simple way, way, without without expensive in tooling,, is is extremely extremely im important to the the tooling portan t to home worker. work er. home
Fig. Fig. 13 13 Senior Seniorm8chine machine
26 26
FlYC UTTERS FlYCUTTEAS The ccheapest tool for for the the purpose purpose is is the th e The eapest tool flycutter. usual'" usua ltv consisting consisting of of aa small small flycutter. toolbit set in in some some kind kind of of holder. holder. There There oolbit set are commercially co mmercially made made holders ho lders available. avai lable. are but 'itt is is quite quite easy easy to to make make satisfactory satisfactory but holders at at home. home. and and they they serve serve just jus t aas holders well Three Three home-made ho me- made flycutters flycutters are are well
shown shown in in Fig. Fig. 14. 14. Each Each is is jus Justt aa Morse Morse tape ith an taperr arbo arborr w with an enlarged enlarged head hea having having aa sla nti ng hole ille d in er slanting hole dr drilled in itit to to take take aa cutt cutter bit h aa screw bit (t (t inin.. inin these these samples) samples) wit with screw to to iameters are t lock ace. The lock itit in in pl place. The head head ddiameters are 11-k in.. e face in .. q 1}. in. in. and and 2t 2t in. in. so so th the face ss that that can can bbe e mac hin ed at machined at one one pass pass are are roughly ro ughly tin. tin . to e. They ere to 1t inin.. wider wider in in each each cas case. They w were m ade by ring through made by bo boring through short short pieces pieces of of st eel of steel of these these sizes sizes to to suit suit th thee parallel parallel parts of Morse M or se taper taper arbor s. It parts of arbors. It is is not not pe rhap s wid ely enough enough known that perhaps widely known th at tool tool merch ants can, can. if if th th ey ey will will ., su supply M orse merchants pply Morse taper arbors arbors of of this this kind, ki nd. which w hich are are a a stock st ock taper pr oduct of of the the large large drill dri ll makers. m akers. Thi This product s m et hod of of fabricating fabricating flycutters flycutt ers by by usin using a a method ready made made arbor arbor with wi th aa head head Loctited Loct ited on on ready saves aa good good deal deal of of time time and and some heavy saves om e heavy st eel. The The effectiveness effectiveness of of tools to ols made made in in steel. this way way is is beyond beyond question. question . Fig. Fig. 115 this 5 shows aa brack bracket et cllamped amp ed against aga inst aa larg large shows e anglepl ate and and being being m milled with one. on e. angleplate illed with Fig. 16 16 shows shows one one working workin g on on aa steel steel Fig. connecti ng rod rod which which has has to to be be red reduced uced connecting from aa circular circular section section at at each each end. end. The The from rod is is about about 99 in. in. long. lon g. so so itit is is held held in in two tw o rod vices at the same time. and each end is vices at the same time, and each end is down to t o fin finished ished size size before b efore itit isis taken down taken tumed over. over. Packings Packings are are used, used . different diffe rent turned at each each end end to to ensure ensure the the finished finished·-surface surface at jaws, to avoid cutting is above the vice is above the vice jaws. to avoid cutting
27 27
of three flycutters flycullers Fig. ' 4 Set of
into these packings ensure the int o them , and the se pa ck ings en sure the rod right attitude ing ro d is at tthe he ri gh t att itu de fo r keep in g t he mill led surf surfaces para to the ax axis aces pa ra lllel le l to is ,. mi
Owning Ow ning tthought ho ugh t soon as so on
Flycu((ing bracket Fig. 15 '5 Fly cu tt ing a brack et
28
two vices alike may tw o vi ces ali ke m ay at fifirst rst see m somet something luxury, see hi ng of a luxu ry , bu t long articles have to to be deal dealtt as lon g art icles have
Fig Fig.. 16 16 Flycutting connecting rod rod ends
with the e at once apparen t. the benefit benefitss ar are apparent. Ano t her flycutting flyc u ttin g operation is shown Another in Fig . 17 wh ere a steel ba ing where barr is be being
reduced t o a ttapered apered sec tio n tto o cu section cutt up into into wedge cks for nnec t in g ro ds or wedge blo blocks for co connecting rods of the e pr evio us picture. Thes e wedge type in th the previous These
Fig. Fig. 17 Flycutting tapered bar bar material
29
Fig. 19 Facemill Facem ill
Fig. 18 Fl ycu tt ing cylinder soleplate Flycucting
off to th thee same projection. ground off pro jec tio n. and sharpened to a diameter of of approx. 2* in. shown mill milling the off In Fig. 2 0 it is shown ing th e face o half-flywheel model a half -flyw hee l iro n cast ing for a mo del
2t
bloc ks are needed for adjusting blocks adjus ing the beari ngs in the rod ends ngular ends.. The Th e rec recttaangular sect io n bar is held in ng section In a vice on a tilti tiltin ang le-p late whi ch has b een set att 6 which been le-plate de grees to thee mil ler le r with a degrees t o th e table t able of th St ar rett com bin ro trac to r. Th Starrett bi n atio ati o n p protractor. Th e ta pe red form w wilil l be seen on th thee end of of tapered tthe he co m p l e t ed piec e llyi y inn g on ompleted piece on th th e anglep lat e.. This is an easy w ay of getti ng way getting angl eplate a speci al section which cannot be bo ug ht, special bough t, and wh whiich ch would, woul , to to say say the th least. leas t. be tediou to make by filing. filing. tediouss to er hol ders do w Th ese ese flycutt flycutter holders do not allo allow m uch adjust meent nt of the radius off the much adjustm cutte it h some kes ooff bo ring cutte r bit, bit. but w with some ma makes boring head there meent. nt . For lott of of adjust adjustm Fo r there is quite quite a lo exam ple the rmits of example the Dare boring head head pe permits of n, dia m . ba r at any usi tt er in a f usi ng a cu cutt i iin. diam in., ingg th e rad ius up to radius to In .. and and by by sett settin the saddle in or out out on the the slide slide body body the the in or radius unts to radius can be be adjusted adjusted by by fine fin e amo amounts to suit any b w ithin the range. Fig. 18 any jo job within 18 shows ring head shows an an old old type, type . pre-wa pre-warr bo boring head
2t 2t
30 30
be ing used to face a cy linde r sole-p late fo being cylinde sole- plate forr a slide valve va lve engine mode modell of 2~ in. in. stroke. stroke.
2t
ing is suppor su ppor- stationary st ationary engi ne. The cast casting of fifixture, xture. plate typ typee of ted by a spec ial angle plate th e patte pa tt ern wh ich w was made rn for w hich as m ade in an hour. opera ti on th e ope ration ho ur. W ithout this fixture the
Fig. 20 Milling flywhee l joint face
FACE MILLS Of cou rse, mu lt i-cuttting-edge ing-edge face mi lls multi-cul mills perm hinin g a surface na perm it mac machi ning su rface quicke quickerr tha than singl e point t ool single ool can ca n do, do. and with less less snat ch and m mercia lly snatch and jerki ng, ng. but bu t co commercially m ade they are very expens ive ,. and in the made expensive the hom e workshop e greate home workshop th the greaterr productivity is no uch conseq uence. nott usuall y of of m much uence. Never Neverthel ess, for anybod y w ill ing theless, anybody ing to spend spend the the tim e needed th ey can be made in the ti me they the ho me w orkshop , w ts home workshop. wiith th several cutte cutterr bi bits mounted in oone ne m ild ild steel steel body body.. Fig. 19 19 show s a face m ill of his kind shows mill of tthi kind ,. which which was m ade y to screw on the spind le ad e originall originally le of of a M yf ord lat Myford lathe to to do do some repetitive mi llin g of mill ing of a fa irly irl y heavy heavy nature nature., now now no no ll a good longe longerr required, required . but but itit is is sti still general rpose too general pu purpose to l.I. It It has has 12 12 tool bits bits :l in. di am .. set diam set into into flat fla t bottomed bottomed holes, holes, all all
t
31
Fig . 21 2 ' Millmg Milling crosshea crosshead slide Fig. d slide
wo u ld be so me w ha t diffic u lt. If th wou.ld be so m ewhat diffic ult. If th par alle l passes w itith h an uc h paralle an end end mi mi llll m much cas ting was w as held the t able the ca~tlng held in in a a vice vice on on the table the th an the face requ ired . Apar narrower narrowe r tha n t he requ ired. Apartt point a long way fro m pOint of of cutting cutti ng would would be be a lon g way from fro m taki ng mor e time th an aa too ith aa fr~m taking more ime than too ll w with th e holding ho ld ing point. vem en t o f th e the point, and and mo movem ent of th e wid e sweep. e ridges te nd to be Wide sweep , m inut inute tend to be left left casting o f cu tti ng casting under under the the pressu pressu re re o f utting w here the passes overlap. and these m ay where overlap , and these may wou ld be prevent. Vibra tio n would be no nott easy easy to to preve nt. Vibratio n have removed lat er by filin g have. to to be be remove d later by fil ing or or and ter w ou ld be likely. It very and chat chatter would be more more likely. It very scrapin g.. So w hile this meth od is scraping So while this method is feasible feasible ofte n happens only wa y to ge t a oftr:m happens that that the the only way to ge t a the flyc the utter ring head tte r flycu tter or or bo boring head is is be better satis fac cto~ to ry jo b is som e equip satlsfa job is to to make make some equipw he re the re is wher t~ere is room room to to use use it, it, and and the the ment specia lly for it. This is no t usuall y ment specia lly fo r it. This is not usu lIy cutter ill ss and cut~er bits bits are are cheape cheaperr than than endm endmill and wasteful. especia ll y jf a d uplic ate co m po wast~f ul , especia lly if a duplica t e compo easily he too l. easily sharpened sh arpened like like any any lat lathe tool. nent red., bu t t he equipme nt is nen t is ISever ever requi require but the equ ipment is However. example of work wh ere aa Howeve r. an an example of work where usually some o ther usually found found adaptable adaptab le for for some other sma smallll Cutte rr and successive pas ses mus cutte and success ive passes mustt job al cutti ng by 'knife job later. later: Doing DOing met metal cutting by 'knife - be used is shown in Fig. 221 1 wwhere here aa flat be used is shown in Fig. flat and-fork' Soon lead to a~d-fork method methodss can can soon lea to bedplat de for e crosshead bedplatee sli slide for th the cross head on on aa disaste r.. The other half of the w heel disaster The other half of t he . h ee I mo . model de l sta t ion ary ne isis be ing m illed. station ary engi engine being milled. cast ing. " wit h th e cast- in teeth forw the cast~ng Wlt~ the cas t-i n teeth for th e The ce being The surfa surface being cut cut isis inin aa recess recess tin. i- in. barring 'rack', can be seen in the bo tt om barnng rack , can be seen in the bottom deep t be lt wwith it h deep and and the the Corners corners canno cannot be dea dealt half of th e picture. The w heel is 9f in. h~lf of the picture . The whee l is 9 1 in by ol l cutting full Width. as the by a.a totoo cutting the the full width, diamete r and has 96 teet h. as the diamete r and has 96 teeth. 4' ld be e ththe e radius radiUS left left wou would be too too great. great. Not Note some flat surfaces can be. and . Broad Broad flat surfaces can be , and some- stop r bo ththe e table. Accura tely stop ba bar ~olted l ted to to table. Accurat titme s have to be, produ ced by Success ive ely Imes have to be ,pro d uced by success ive squared ithththe bl e ititprovides squaredwwi the tatable providesnot notonly only
32 32
corre ct tlocation correc locationfor for the the casting casti ng(which (wh ichwas was fol lowed e others) but but also also insuranc insurance follo w ed by by others) agai nst slipping against slipp ing, . InIn the the full fu ll sized sized engines engi nes these these slides slides we werere always always planed planed,, and and every every engineeng ine building build ing shop shop had had planers planers for for this thi s kind ki nd of of wo work. rk. In In the the one one where wh ere II worked w ork ed there there were we re several seve ral of of differen diHere ntt sizes. sizes. and and the the largest. built by by Joshua Joshua Bucklon Buckt on of of Leeds, Leeds. arqest, built could auld plane plane any any casting cast ing up up to to 20 20 ft. ft. long long., 12 wide and and 12 12 ft. ft. high. high . ItIt was w as said said at at 12 ft. ft. wide tha re ,. thatt time time to to be be the the largest largest in in Yorkshi Yorksh ire and y itit often and certainl ce rtainly often did did castings castings for for other o ther irm s. Cutting bot h direcdirec firms. Cutti ng could could be be done done in in both tio tions ns of of the the table tab le travel travel at at equal equal speeds speeds,. or or in in one one directio directionn with with aa quick qui ck return return the the oth er way. heads ha o ther wa y. Each Each of of the the four four tool too lheads had power ndent of table pow er operatio operat ionn indepe independent tab le movem ent , so mo ve ment, so that that cross-p lanin g cou ld bE' be done done through through bearing bearing recesse recessess,. etc. etc. One hawss th is operatio n One of of the the pictures pictures show this operation on on a a model model being be ing done do ne by m illing ill ing. Each
head could also be swivelle d so that head co uld also be swive lled so t hat angular faces could be planed also. ang ula r faces could be planed also . Afte r the planing of crosshe ad slides After the planing of crosshead slides they were tackled by th e fitter and they we re tackled by the fillers and scraped to a portable surface plate . This scraped to a portable surf ace plate. Thi s was coated sparingl y with a mixture of was coa ted sparing ly with a mixture of lamp black and oil . slid to and fro on the lam p black and oil. slid to and fro on the slide, lifted off, and then all the black slide . li ft ed off. and then all the black marks scraped away . The surface plate marks scraped away. The surfa ce plate was then put on again and a fresh lot of w as then put on aga in and a fresh lot of marks made , which in turn were scraped marks mad e. w hich in turn w ere scraped away. This work went on for many hours, away. This work went on for many hours, indeed on a big slide two men could indeed on a big slide tw o m en cou ld spend two or three ays. For such work spend two or th ree days. For such work the surface plate would be so large th at the surface plate wo uld be so large th at twO men could not lift it without the use two men cou ld not lift it wit hou t the use of the shop crane . Eventua lly after a long of the shop crane. Even tuall y afte r a lon g time the fini sh obta i ned would be t ime t he fi nish obta ined wou ld b e regarde d as accepta ble. It then consiste d rega rded as acce ptab le. It then consisted of a very large n Im er of extreme ly o f a very large num ber of extre me ly shallow depress ions betwee n the marks, shal low depressions bet w een the marks . and each of th ese proved to e an oil and each of these proved to be an oi l
Fig. 22 Milling bearing jaws in bedplate Fig . 22 Milling bearing j aw s in bedp la te
33 33
pocket. When the engine was was eventually putt to work, with the the cross-head having pu hav ing treatment, the resu result was that lt was had similar treatment. the crossthe cross - head ran to and fro on a film of lubricant wearr to a very lubr ican t which reduced wea amount. mills small amou nt. Engines in textile m ills would run 60 years and at the end you would find find the scraper marks still there there.. was continuously renewed by The T he oil was brass brass combs attached to the crosshead which picked up oil from a well at each engine ru nning night end of the slide . An eng ine running day, as many of of them did did.. with a and day.
of about 80 r.p.m. would make make speed of approx. 3600 million cross-head strokes Nott a bad performance? in that time! No When flat surfaces have to be produced right angles at rig ht ang les to the table table it is necessary of an endm ill ill.. Th This the side of to use the is may be quite unavoidable on some components, components. such engine suc h as the model eng ine bedplate shown in Fig. 22 . There is not much choice about for the crankshaft milling out the jaws for which bearings. This This is an operation wh bearings. ich the the power drive big planer used to do with the heads of the cross cross-rail. on the heads -rail.
CHAPTER CH A PT ER 3
Sitting and Cutting Slitting It is common practice to des design machinery ign mac hinery sp litt bosses w v-:hich components with spli hich can be contracted with a screw for tightening purposes. The slitting can be do ne with ?one wit~ a hacksaw. bu butt if done in unskilful fashion completed . will not look good when completed Slitting saws and many other disc disc type t~pe cutters readily cu tters can be readi ly used on the vertical millerr by mounting tthem Morse mille hem on a Mo rse taper for the arbor having a pa rallel portio parallel portionn for
cutter. and a nut to secure itit.. Its Its a good good cutter, pair of of flats on on the arbo arborr to thing to put a pair hold it by when turning the the nut. Fig. Fig. 23 23 saw in use cutti cutting shows a slitting saw ng of the boss of one of of the through one side of parts of the Quorn grinder. On that t hat several components machine there are several with w ith this feature, so time will be saved if cut th through they are all collected col lected and cut rough while the saw saw and vice vice are in position.
of casting Fig. 23 Slitting boss of
34 34
35
M any other o th er jobs jo bs of of similar simila r nature nature will w il l Many co me to to mind, m ind, such suc h as as engine engi ne eccentric eccent ri c come sheaves,, and and especially especia ll y eccentric ecc ent ric straps straps ,. sh~aves wh ich can can be be cast cast in in one one piece pi ece and and then the n which two surfaces surfaces that that cut through thr oug h,, leaving leavi ng two cut with aa file fi le to to remove rem ov e need only only aa touch to uch with need
burrs to to enable enable them th em at at once on ce to to be be bolted bolted burrs together. Not Not only on ly are are castings castings involved inv olved together. but also also parts parts made ma de from from bar bar materia material. but l. Ma rin e type type connecting connecting rod rod ends ends are are an an Manne method can can also also be be example. and and this this method example, used for for producing producing bearings bearings in in halves, halves. used
CHA PTER CHAPT ER 4
Keyway Cutting Cutting
Keys Keys and keyways are are a very v ery common co m mo n fea ture of machinery feature machi nery and naturally of models mod els too too.. The Th e common comm on round-ended ro und-e nded kflyway keyw ay.. for a 'feather' 'feather' key, key . is easily produced on a parallel shaft sha ft by holding hol di ng the sha ft in the vice and using a small ill , shaft sma ll endm end mill -flute 'slot-drill' showss the or two two -f lute 'slot -drill'.. Fig. Fig . 24 24 show for this ope operation setup set up for ratio n.. Various parts of of car and motor cycl cyclee
engines, machiinery nery engi nes. gearboxes gearboxes,, and other mach components compone nts in the past have had wheels whee ls mounted mount ed on on tapered tapered shafts shafts with wi th the the keyways following owin g the th e slope of o f the th e taper. taper. keyw ays foll Modelling M odellin g one one of of these these would w ou ld involve involve following fo llo wi ng the same procedure. proce du re. One One way in which this can is shown shown in in Fig. Fig . wh ich this can be be done done is 25. vice holdi holding the sha shaft is set set on on a a 2 5. The The vice ng the ft is tilting angleplate so so th that top o off the the tilting angleplate at the the top
Fig. 24 24 M Milling feather keywayy Fig. illing Ieet her keywa
36 36
37 37
Fig. Fig. 26 2 6 Milling M illing ic.eyway keyway with w ith slitting sli tt ing saw saw
Fig. 25 25 Milling Millin g feather fe at her keyway ke yway on on tapered tap er ed shaft sha l t Fig.
es pa ralle l w it h the tapered part pa rt com tapered comes parallel w ith the m achinne e ttable. ab le. The he machi The shaft shaft show shownn in in tthe pictu re is a sim ple on e and q uit e short picture is a simple one and quite short .. ust ttililted he vice and and could could have have been been jjust ted in in tthe vice like t hat of Fig. 24 . But in a set-up in a set-up like th at of Fi g. 24 . But aa long long shaft ig ht well ull th e tt able s low er well fo fou the able at at itits lower shaft m might which t he ang lepl at e end so t he elevation end so the elevation which t he angleplate gi ve s co uld in ase prove ial.l. gives could in such such aa ccase prove essent essentia o ls at Sma ll endm ill ss are Small endmill are rather rather frail frai l to tool at sc best able to best and and liliable to easy easy breakage breakage.. The The di disc er is ust and ll ecti ion on ty pe cutt type cutter is more more rob robust and aa co collec of of these these acquired acquired either either as as the the need need fo forr crops up , o r bo ug ht cheaply seco nd one one crops up, or bought cheaply secondurse th e ddisc isc hand, o rt h while hand, isis wworth while.. Of Of co course the cu tte r canno t always go clos e to a cutter cannot always go close to a shou lder o n t he shaft , and copying a shou lder on t he shaft, and copying a pro totype may ut . prototype may in in some some cases cases rule rule itit oout. For e wwork o rk do ne inin tthe he hom e workshop done home workshop For th the t he re is no need to insist on the rel ativel y there is no need to insist on the relatively expe nsive side - and -face cutt ers, (t hose expensive side- and-face cutters, (those with te et h on t he f aces as w ell as th e pe ri with teeth on the f aces a we ll as the periphery ) because the sli tting saw , w ith te eth phery) because the slitting saw, with teeth ite wel o nly on t he periphery, wwill do qu quite well.l. only on the periphery, il l do TThese hese are e inin aa very reat va riety of are mmad ade very ggreat variety of
38 38
hicknesses , an are always ng on tthicknesses, an d d are always co co mi m ing on t he surp lus m arket at low prices. One surplus On of tt hese 6 m illi ng an hese is is shown shown in in Fig. Fig . 2 26 milling an ord inary sunk en keyw ay, th e shaf ng ordinary sunken keyway, the shaftt bei being held in a vice th eno ugh rha ng t o vice wi with ugh ove overhang he cutt er ttou ou chi ng tt he avoid avoid tthe cutter ching he vice. vice .
For a sta start he key itself rt tthe of ro round off from fro m a piece of und sil ver st steel. diiam ameter silver eel. So itits sd eter
can be part ed milld d st stee mi eell orr is sett se ttled led w itith h
accu ac c u racy racy thi kness thi ckness comes off com es off
e b ba r. he ff ro ro m m th t he b right ri ght ba r. T T he needs ca refu l control, but if it need s careful co nt ro l, but if it ab bit oo tthick it can can be be rubbed rubbed a it tt oo hick it
Fig. 27 27 Set Set 01 of four four W Woodruff keyway cutters Fig. oodruff ke yw ay cutters
WOODRUFF WOODRUFF KEYS KEYS The d ruff key ew ly used The Woo Woodruff key is is on one w ide idely used in in e off ind ust ry . This industry. This is is in in effec effectt aa slic slice off aa roun roundd ba r, cut lf and to tthe bar, cut in in ha half and set se t in into he shaft sh aft in in aa ng recess ad e by ia m eter slitti recess m made by aa sma smallll ddia meter slitting plified saw er an saw.. Th This is isis rath rather an oversim oversimp lified ll serve h des cr iptio n ,, but description but itit wi will serve we wellll enoug enough as rod uct io n to ood ru ff key r to the th e W Wood ruff key fo for as an an int introduction thos e inin ho me wworkshops o rks h op s wwi it t hou t those home hout perien c e. Se riou sly . , th e ind ust ria l l ex i ndustria experience. Ser iously the h I I tth hink W ood ruff key. Woodruff key, wwhic hich ink was was of of AAmmerican ig in, e ve ry real erica n or origi n, has has som some very rea l e mmass ass pr o d u cti on ad v an t tag es for advan ages for ththe production ind ust ry , and me of hes e are industry, and so some of t these are of of just just as as rkshop gr eat im po rt ance inin t the he home great importance home wo workshop and he fifield eld ofoflig ht en gineerin g. andt the light engineering.
39
39
on a flat file file.. ItIt needs needs tto cutt in down on o be cu two on a lin line which diameter. tw o on e w hich is nearly a dia me te r, the cut edge edge can can readily be filed filed to to but the bring to fina l shape shape.. Th The keyway br ing itit to e keyw ay is made like a slitting saw, saw, of of the by a simple cutter like diameter as the the ba barr from wh which same diameter ich the same
key is ma made, an int integral of pre prekey de, with an egral shank of some sta standard diameter which can ferably some nda rd di ame t er w hich can in a collet on the mi miller. So the the be run true in ller. So of the the keyw keyway profile and its its shape shap e of ay pro fi le - and width settled by by tthe cutter form.. The w idt h - is settled he cu tter form cutting partt of of the the cutter is set set in line line w with cutti ng par ith
TABLE II11 TABLE
G~
2
the tra l liline ne of n th e the diame diametral of the shaft. shaft, the then the cutt er is fed cutter fed in by by a predetermined predetermined amount. ng keyw ay is deep h to The resulti keyway deep enoug enough resulting give ld , so that it cannot give the the key a good ho hold, roll over, and yet yet the shaft shah is no nott unduly wea kened. Norm all y th e ttop op ooff the key weakened. Normally the key is just clear of of the the keyway in the the wheel or or lever wh ich is being secu red , itits s purpose which secured bei ng to provi de eit her tor qu e or being provide either torque or angular locat io n, and some mea ns such location, means such as a grub screw may have to be used nt used to to preve prevent endwise end wise movement. W ood ruff cutters are not eap , Woodruff not very ch cheap, but they they can easily be made made in the home workshop, workshop , from silver steel. steel. The The process is really ite sim ple. A blank quite simple. blank can be turned , rea lly qu mak ing a shank to sui nda rd making suitt some some sta standard shank collet , then with the sha collet. nk held in the colle e working part collett th the part of the cutte cutterr can be turned to ititss diam eter, and th ickness. The diameter, thickness. sides uld be very tly undercut sides sho should very sligh slightly undercut by by setting a kni fetool knife tool a little off square. Using a sim ple un-gea red dividi ng head th simple un-geared dividing thee
teet h can be cu rations using teeth cutt in in two two ope operations an ordinary ll ; the re is no mill there no need for for ordinary end end mi angu lar cu tters. as tthe he ddiagram iagra m on angular cutters, on the the opposit e page ber of number of opposite page indicates. The num nt, but six is a co nteeth is Is no nott importa important. con ven ient numb er for number for small cutters cutters.. ItIt is venient possible to have to file file the teeth ifif you you do do not have access iding head. to a div dividing head , as the spacing access to is not not at at all critical critical., but it's a little more difficult. Fig. Fig, 27 27 shows a batch of of cutters made made to the the sizes in Table Table II11 and and Fig. 28 shows a keyway being cu t . There seems cut. seems to be no place place where sizes of of Woodruff keys rs are disp layed for m odel keys and cutte cutters displayed model 's H andbook giv es engi neers . Machinery engineers. Machinery's Handbook gives sizes wh ich are used in ind ustry. but the which industry, shee sheerr range of sizes is itself itself confusing, confusing. and and of cou rse tthe he tables are libe rally sprin kled course liberally sprinkled wit h to lerances that model lers cou ld with tolerances modellers could neither follow no nt . I have therefore norr wa want. picked ich I think wi outt a few sizes wh which willll picked ou serve rpo se. and as we 't have serve ou ourr pu purpose, we don don't to provide interchange ability in our interchangeability products, if anybod yw ant s tto o depa rt a bit anybody wants depart
Fig. 28 ay 28 Milling Woodruff keyw keyway
33", F ~ "ZO x20 B,S.F. B.S.F. FOR OSeORN CHUCKS. CLARKSON &, Be. OSBORN
WOODRUFF KEYS & KE.YWAYS K E.YWAYS KEY S &
A ~ ~ 44
~6 3-'8 ~
~
2
40
B I
C
0 D
E
CUTTERS
F
-109 '10 9 '073 '037 '1 '100 00 0 4 '037 .6 140 '/'104 '03 7 '104 '/04 '172 '/23 '123 '053 '129 -/ 29 %2 "112 -203 "155 '155 '053 -187 ~ 2 '203 -1 87 -(, -(6 .% 16
%a
%2
G -030 '030
'037 -045 '04 5 -060 '0 60 41
from tthese dimensions certainly hese di mensions he can certai nly do writing ritin g I have not seen so. Up to date of w specification Woodruff any spec ifica tion of W oodruff keys in metric met ric sizes. The cutters shown shown in Table II hav havee Clarksonn and screwed sha nks to suit Clarkso Osborn which collets ich have colle ts that th at Osbo rn chucks, wh shankk through close on the cutter shan throug h end nst the th rust exerted by the thrust th e cutter agai against making inside of the chuck. If you are maki ng for use in a Clare chuck or just to cutters for 3-jaw threads use in a 3 -j aw ., these thr eads are not It may be noticed that needed. It that the cutters cu tters
shown wiith th thei theirr sho wn in Fig. 27 are stamped w detai It is a goo good set size de tai ls. It d plan to have a set of small stam stamps, in.. character characters, of ps. say 1;16 1/1 6 in s. ropriate identity can ca n be mar marked so that app appropriate ked homee m made tools, jigs. jigs, etc as we wellll as on all hom ade tools. components. holes drilled model co m po nents. The hol es dr il led in cutters conthese cu tte rs were provided fo r the co n hardener. venience venien ce of the har dener . They were hardened uid- harde ned for me by a firm where liq uid bathss are used fo forr heat ing and salt bath que nching tools. A sma ll hole enables enables the q uenching too l to be hung hu ng on a w ire in the bat baths tool hs without edges. w ith out da mage to cutting edg es.
CHAPTER CH APTER 5
Fluting Components other than Tools Fluti ng of locomotive con necti ng rods and simila coupli ng rods is an operation very sim ilarr cutting farr as tthhe remova keyw ay cu tto o keyway tting so fa e rem ova l of meta concerned , bu butt the le ngth of the me ta l is concerned. leng th of usually greater, and th e lengt le ngth of flutes is usually h of the pieces de demands somee we arran ge the pieces man ds som w ellll arrange holdi ng m ethods. ethods . One occasiona occasionally ho lding ll y sees rods which w hich hav havee been fluted w ith an endm illll by tthe he same sa me metho method endmi d as show n in 24, giving rou nd nded Fig. 24. ed end flutes flute s like a fea th er keyw ay. Thi s is ent entirely feath irely wrong ., no thi s w ay. They full size rods w ere ffluted luted this rou nded int inteernal rnal corne corne rs have flutes w ith rounded bottom, w ith rin the bot tom . and wi th swept out tteer minations w hich ch is done to m ina tio ns at the ends, whi avoid th e notch fatigue fatig ue cracks w hic hi ch ca n avo id the h can propagate from sha rp co corne rs. Fortunately Fort unately propaga te fr om sharp rners. quite produce whichh are itit is qui te easy to produ ce flutes whic accorda wi th full size practice. pract ice, and in acc ordannce ce with not miillll ing not even necessary to have a fancy m cutteer. r. A simp sim ple bit. gro ground likee cutl le tool bit, und rather lik p rting tool,l. wi with a partin g too th the corners rounded rou nded off, is put pu t into a ttransverse ransverse ho hole tt er le in a cu tler off. mounted miller. bar,, and m bar ounted in a chuck on tthhe e mil ler. Thee rod to be dealt dea lt with w ith is fixed edgewa ys Th up es in the loco rably up,, as it go goes loco,. prefe preferably aga inst a long against long ang leplate leplat e,. and th e rotat rotatiing ng cutle ood ruff cutler cutterr is fed in like a W Woodruff cutter wou ld be. en in to proper depth. be. Wh When depth, usually Quite quite shallow, the ta ble move ment table movement is started started and th thee flute is then then made
42 42
along t he leaving rogressively p rogress ive ly alo ng th e rod , leav ing behin the t he swe swept Where ere the cut behind pt end . Wh finisshhes t here is als also swe p t en end fini es there o a swep d,, au tomatica Coup liling usually atica lllly. y. Coup ng rods usua lly have autom flutes that are parall parallel ed,, and so do el sid sided of Canadian Canadia n and Am eric ericaan n some ttype ypess of connecting rods. ese case casess a single con nec ting rod s. In th these pass with a cutle cutterr th thee right w width wiillll idt h w l ete t h e jo job. Mosstt Br B r iitis om p lete b. Mo t i sh ccomp otives,. on th e ot other hand,, had locom otives her hand tapered connecting wi th parallel para ll el tape red con nec ting rods wi flanges.. l.e. i.e. tapered flutes, flanges flutes. For these two tw o passes are needed this passes need ed., and th is can be ach ieved in a very simpl simplee way. achieved w ay. In Fig Fig.. 2 29 9 the rod of a Canadi an engi ne angleplate. eachh is seen fixed on the th e ang leplate. In eac end is a screw screw with a head tu turned rne d to the th e hole size of the ho le in the rod end end.. This Thi s is a 12 long with slots, as hol holes in. lon g angleplate angl eplate wi th no slots. es tapped wherever are drilled and ta ppe d just w herever they are needed for each job. ill be many job, It It w will years before it is so perforated as to be no further fur ther use. The two ho les for the locating screws are tthhe same dista nce from the the screws e same location table. and they only provide the locati on ., the rod being secured he cu tting cutting sec ured agains againstt tthe forc es by two sma forces smallll clamps as shown. shown. For rod s the set -up is set-up this rod and for coupling rods exac tly as shown. But exactly But for British type rods rods,. the screw in the big end is made smaller smalier than the hole in th thee rod by the the 4 433
CH APTER APT ER 6
Boring
ec ting rod Fig. 29 Fluting locomotive conn connecting amou nt of the taper (at th e hol amount holee centres) cen tr s) and for for the first operation operation th thee rod ro can ca n be allowed to dro p down o le d rop onn the th screw screw whi while the fifirst rst cut is t aken. Th en for th thee second cut ed up as fa farr as th cut the rod is lift lifted thee screw w ed.. and a wililll let it go go.. and re-c tarnp lamped seco nd cut taken, second taken . The rod w ill il l now now finish fi nish w ith a taper flu te and flute an two parallel para ll I flanges. Th Thiiss fluti flutinng g is a very very simple ope ration rat ion.. The angleplate ly rigid. extremely rigid. The angleplate is extreme mach ine in the pi cture is happily provided machine picture wi th a t in. w ide keyw ay alo ng the with wide keyway along th e centre of the table. only onl y t in. in. deep deep.. but a it in. in .
t
square opp ed int o it. That square ba r can be dr dropped into enables fixtures to be instantly lin ed up lined w it ab le ithh th thee ttab ie movemen t . in incc lud ing in g dividing heads hea s as we wellll as ang lep lates. The thrust of the cutte cutterr in this example tends to move the ate awa y from the bar th e ang an lepl leplate away bar,. but it is secured w ith tw o good bo lts in two bolts th e t ab l e slot s. no isi b le i n tthe he he able slots. ott vvisible tt en pho tograph. It sho photograph. shouuld ld not be forgo forgotten that locomotive rods w hich ted at hich are flu fluted all m ust th sides. but wi th th a mu st be done on bo both setup li ke this the le it set-up th job is so simp si mple w ou ld be a pity wou pi ty not to have it righ t.
It is not uncom mon to s in uncommon t o have bore bor e hole holes com ponents which much o w hic h are m uch too large tto swing arou nd in tthe he lath lathees tthat hat are fou nd sw ing around fo und e workshops. But th ere is no in most mo st ho m me there need in m any cases ca ses t o resort to hand ha nd many holes where cy toolls. s. even for ho too les w here great accura accuracy IS not needed The verti ca l mil ler can be is needed.. Th e vertical bo rin g (w (with used for boring it h a trepanning tool in a boring head) such th thin gs as firefi re-hol e bo ring head) ings hole doors boiler pla tes. bosses o on ca st ings do or s in bo iler plates. n castings such levers, and many o other suc h as lon g levers. ther ob jec ts. In der tto o rnot ori se a shaper I order motorise objects. I n or to bore ore a hole throu th rough had to gh t in . o f cast mount redu ction gearbox ., iron tto o mo unt a worm reduction to be a true round hol hole. and tthis his had to e. It was do done fixiing ng t he cast casting i n. long was ne by fix ing (15 in. direction f rom th e centre o off the in one direc tion fro m the
t
ng a cu tter ho le) le) on the mi milller ler table tabl e and usi using cutt er head . W ith the w worm-act uated in a boring head. orm- actuat ed dow n feed. e bo m spe ed of th e feed. and th the bottto tom Dore-Wes tbu ry machine rpm Dare-Westbury m achine., 3 4 t rp m . an exce ll en t hole wa s obtained four inch es s excellen diameter. ith ou th these fa ci lities th e work diame ter. W ithout ese facilities t he w wouuld ld have been sent ou outt to some som e engineeri ng firm firm.. The ampler e engineering Th e am pler space on tthhe lin g machines. machi nes . com compared with tables of m il ling pared w ith wha get on a lathe lath e saddl sa ddl e w wiith th w hatt one can get anglep late.. makes m akes the th e miller mi ller invaluable an angle plate work thiss ki nd and of cour course for w ork of thi se by doing turnin wit h a boring bo rin g head do ing externa l tu rnin g w ith ca n dea l w with registeers rs as we ll one can ith male regist holes. simple operation too;; as hol es. This is a simp le op eration too one turn s the cutt cutting tool inw inward on e just turns ing tool ard outwa rd . instead of outw ard.
44 44
45 45
CHAPTER 7 .
t\
46
6+
=::--...,."
J ig-Boring Jig-Boring term like ly tto The ter m 'j'jig-boring' ig-boring' is lik ely o be unfamiliar many book, unfa m iliar to m any readers of this boo k, they may thi nk tha and they thatt w hateve r it meanss it m must long mean ust be a lon g way removed from model engineering. engineeri ng. This is no nott so, for making plenty ari se in model m aking pl enty of operations arise that ca n be don done 'jig-boring'' to adva advanth at can e by 'jig-boring n tage. Basically on ly means fixi ng a com com- t age. Basicall y it only ponentt to t he m machine tab le and th en ponen ach ine tab screwss as measuring using the table tab le screw spindle over any devices dev ices to position positio n the spindl e over thee com componen part of th ponen t tha thatt is desired In m many drilli before dr illi ng or boring a ho le. In any method ways tthis his m eth od is better than m arking measuring witt h a rule, rule , then centre centreout, measu ring wi ing on a drilli ng pu nch ing fo llowed by drill punching drilling one thing the workpiece machine. For one th e wo rkp iece is firml held,, tthe are fi r m lyy held he ttab ab l e screws are reasonably d measuri ng devices, reasonab ly goo good measuring devices. and ca n be m made, of any diameter manyy ho holes man les can ade, of needed, without losing losing the att attiitude tude of of the needed. table, or or on onee hole to another. piece to the table, another. Let's take a fairly com common mon componen t, Let's eng ine . ing of a mode the beam cast casting modell bea m engine. severall holes to to be dri lled , This will have severa usual ly along one straight line. usually line, and rather rathe; impo rtan t. all these shou ld be parallel th import ant, paral lel wi with ne is to run one another ifif the finished engi engine smoothly. There le at each There will be one one ho hole end end,, and a main trunnion ho le at the middle, for the links of middle, plus one or more for
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paralle pum p rods, rods, etc. The the pa rall ell motion, pump casting ca n be cl clamped e table casti ng can am ped tto o th the ta bl e qu ite firm ly, resting resting on packag pack aging reason able fir mly, ing of reasonable does thickness thic kness so that a penetrati ng drill do es not dip in into to the the ttable. able. A t this th is stage all ca n be faced w ith an end m ill ill,, bosses can Thee even ifif they are at differen t levels. Th line he cast casting centre lin e of tthe ing should have t h the line of of the tab le been parall ell wi bee n set paralle w ith t able movement. Put tthe he drill chuck in the movem ent . Put spind ith a fine point ed du m my dri ll s~ i~d le. le , w with poin ted dummy Simiilar lar to a ce centre punch, brin sim ntre punc h. and br ing this he first fi rst boss cen tre tre.. The Then over tthe n wind on thee table the amou amount th nt tto o tthe he next hole and comes rightt place check if the point com es in the righ ove that overr th at boss. W ind on again to th e next and so on check checking If all ing at each boss. If co me central welll.. If If one or mo more com e cen tra l., all is wel re don 't, then an allo allowance don't. w ance w ill have to be compromise. Make note off made m ade as a co m prom ise. Ma ke a not e o is, re-start re-sta rt at the begin ning, ni ng , and do wha t it is. another run ru n till you are satisfied you have another got tthe right starting got he rig ht starti ng point for the best re sults. If yo youu happen to tu turn le results. rn the tab ta ble bitt ttoo screw a bi oo far at one of the stopping points, n't worry, but do n' t turn it back a poin ts, do don't don't bit as a correc tion , because that th at way correction way you cou ld introd uce an error thro ug h back lash could introduce through backlash (lost mo tion due motion due to slackness) in the screw and nut. Go back back to the very start and com comee at it again. again. It's a good thing
,..38 ,..,38
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-+-......-'005 -+--II--005
I
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/6 16
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steam (lever) Fig. 3 0 Drawing of of stea m hook hoo k (l ever)
doiing ng an exercise o off tthis his kind kin d to w hen do pencil rite have a paper and pen cil handy and w rit e icrometer dow n the m icrom et er dial readings w hich stopping points. This redu reduces he are th e st opp ing points. ces tthe ch ances of acciden t al erro r. It is a method accidental error. whho o are engaged ngaged used by men in industry w delicate momentary on delica t e w ork w here a mom entary interrupti in t erru pti on ca n be disastrous. disast rou s. I have myself for m any year years. Att th is my self used it for s. A stage dri ll ing now stag e drillin g can no w start sta rt . Each hol e should be centred w with grou nd it h a D-bi lt groun d to about 1 18 degrees, foll ow ed by the followed appropri atee dri ll. ll , thoug though thee larger holes hol es app ro priat h th drill putting throug h first first.. may need a pilot dr ill put ting through eachh hole is finished ith reami reaming As eac fi ni shed., w ith ng ifif needed , move on to the next hole by the needed, table wi nd, and go th through procedure table wi nd. ro ugh the procedu re with th at. too. od all the holes that. too. By this th is meth method oles w ht distance apar t , and w ill all wiillll be the rig right apart, be pa ralle l to o plane s. It to one another in tw two planes. parallel w ill be clear that th at if any holes are wanted will which are no ain centre line, nott on the m main line , it is a simp le m at t er to t o drill these in an off-set sim ple matter
position usi ng tthe he table cross-screw to positio n by using providee the amount amo unt off th e m main provid ain line. When holes finished bea m W hen all the ho les are fin ished t he beam illed can be turned tu rned over and the bosses m ill ed oth er side. on the other side . The just Th e beam eng ine casting is ju st one example of of ho how ort of ttask ca n be w tthis his sort ask can drawing com pohandled. Fig. 30 is a draw ing of a co mpo gearr of a model steam nent of th e ttrip rip gea engine, hich to be engin e. and the holes w hic h have to onss w which would drilled are in posi ti tion hich w ou ld not be attained com mon marking markingeasily att ained by the co m mon centree punching proces process. out and centr s. Fig Fig.. 31 shows one of the th e finished finishe d pieces w itithh one part-made show th thee me thod only part-ma de , to show On e inch diame diamete wass used used,. adopted. One t err bar wa that gives th e outside profile needed. as that Set true fo ur- jjaw ck itit was aw chu chuck true in th e fourbore d 9/ 16 in., n set out of bored in ., the then of true true by le re-bored to the same same .047 in in.. and the ho hole setting setting.. Next it was set well off centre to dril drilll the No. 38 drill dri ll hole. hole. Th e correc correctt setting was established by measurements 47 47
taken off off the the outside outside surface surface of of the the 11 in. in . taken bright bar. With the th pi piece sti ll held. held , the the bri ght ba r. With ece still was removed from from tthe lathe nd chuck w chuck as removed he lath e and bolted on the th e m milling illing mach machine table. bolt ed on ine tabl e. AA number 338 drill running truee chuc chuck. number 8 dr ill ., ru nning iin n aa tru k. 'picked up' up ' th the existing hol hole and the the tthen hen 'picked e existing e and both screws screws of of the the ta table dia readings on both di all readin gs on ble noted (and w written down!. Th e drill drill were w ere no ted {and ri tten do wn !' The was chan changed for aa very very sho shorrtt stiff stiff 1/ 1/ 16 16 in. in . was ged for drill , the the tta bl e screw screws were ro rotated to drill. able s were t ated ., to in.. hol hole position under bring th e first firs t 1/16 1/ 16 in bri ng the e pos it io n un der thatt hole ho le then th en dr drill ed . Further Further and tha itit and illed. of th the screws broug ht in in turn turn rotation rota tio n of e scre ws brought each of of the the oother holes into into pos position and each ther holes ition and drilling wa was qu ickly com comp leted. The The the drilling the s quickly pleted. huck was was then the n re returned to the the lathe. lathe. Th Thee chuck turned to rst boss boss around aro und the the No. No. 338 hole was was fifi rst 8 hole turned and and tthe he piec piece parted off. off, care care bei bei ng ng turned e parted t ken to to leave leave the the shallow sha llow boss boss on on the th e taken parting side. Then Then the the second seco nd bos boss was part ing side. s w as turn ed ., anot another parti ng off off,. and and the the two two turned her parting co m po pone nt ss w were through part of of the th e com nent ere th rough tthat hat part process. It It rem rem ained ined only only to to cut cut the the process. out of of the the ring ring and and file fi le up up desired piece piece out desired the two two ends ends tto round d profile. profil e. By By the o tthe he rounded a compone nt of of a a rather ra th er th ese met methods these hods a com po nent complicated was produced und under com pli cated shape shape w as produced er
complete con tro l and and exactly exactly as as specifi specifie co mplet e co ntrol edd drawing. on the the drawi on ng. There are are m ma ny oother articles in model mode l There any ther artic les in engineering which lend them themselves selves very ery engi neering wh ich lend well11 to to th the jig-boring techn technique. Locomow e jig-boring ique. Locom o tive boiler boiler tube tu be plates plates w with ith aa large large num n mbe tive berr of holes holes can ca n be be do done this w way. and of ne this ay. and of the the hol holes may be J in. in. or or because some becau se som e of es m ay be even mo more in di diameter is vita vitall to to have hav even re in am eter itit is the met eta lamped ped do dow avoid th e m all cclam w nn ttoo avoi d personal injury,. as as copper copper is is not not one one of of the the pe rsonal injury kindestt of of m materials for machi machining. But ifif kindes at erials for ni ng. But clampe on packi packings the m miller. iller, any any cl ampe dd on ngs oon n the wh ich dr drills are not not avail avai llarge holes holes for fo r w large hich ills are able can ca n still sti ll be be dealt dea lt w w ith ith by by using using aa able head . IfIf aa large large drill d rill is available. ava il able , and and boring head. machin low enough eno ugh spee speed the th e m achinee has a low d ttoo w ill be be no no 'three 'th reeavo id chatte r. r, there th re w avoid cornered ' holes holes ma made cause em emb rrasscornered' de to cause barrass ment hen fittin fittin g flue fl ue tubes tu bes and silver si lverm ent w hen so ldering th the m at a later st stage. soldering em age. It w ill be found fa m iliarity w itith vert ical fo und that as fam h th e vertical mi ller dev deve lops, examples wi ll aris arise mi elop s. other exam pl es wi e r ally high-sou in w hich this highsounnding di ng but really quitte e simple technique te chnique can be bo rrowed qui from in ust ustri pract ice , w with grea ith g re a t fr o m ind rialI p ract ice. benefits. benefit s.
t
Fig. hook Fig. 31 3 1 Photograph Photograp h of of steam st eam hook
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48 48
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CHA PT ER 8
CHAPTER 8
Profiling
Profiling ItIt is nentts to is not not unusual unusua l for for large compo componen to have rti ons w hich rcular portions hich are ci circu lar arcs ,. have po Loco m oott i ve m e s a r e co m mo ve ffrr aam com m on exam ples. w it h cut -aw ays t o cl ear bogie with cu t-a ways clear examples, whe eces are m uch too large to wheeels. ls. Such pi pieces much to sw ing in th e lat he. and wh swing lathe, wh ile il e the th e bandsaw ba ndsa w ifif available o relieve availa ble can do a lot lo t tto reli eve the tedium ng. hack saw ing and filing. drilling, hacksawing fili ng . ted ium of drilli the the miller m ill er can do a lot lot mor mo ree.. Using a trep anniin ng trepann g cutt er in a boring head it can take aw ay the unwa nt ed metal in a single away unwanted si n le operation opera tion to finished size on any arc. A lte rnatively w it h a boring bor ing type typ e tool it can Al ternatively with follow th e bandsaw and ju just ll ow the st avoid th e fo filing. filing. Smokebo x ca castings locom otives Smokebox sting s for locomotive tractio n engines, eng ines. how ever, eve r, often oft en have have and traction circ ular arcs to t o fit fit the boile boilerr she llll., and the circular nohelp with wit h these. these. But if bandsaw can be no'help they are are set up up on the th e miller, mi ller. the th e radiu radi us they s can de ter mine sett ing of a ca n be e determ inedd by the setting bo rin head cu cutt er. and trave rse rse across across ngg head tter. bori wo rk provided provided by by the th e downfeed downfeed of of the the the work spindle ndl e., eve eve nn tho t houg th is is 's is usually us u all y spi ughh th m anual. Th at feed feed length lengt h may m ay not no t be be ma nual. That eno ug h to to cover cover the t he face face width, wid t h, but but aher aft er enough going as as far far as as th thee spindle spindle wi w illll move move.. aa going second cut cu t ca can be taken taken by by rese resetting th e n be tting the second head of of the th e machine. mach ine . head In m maac n erryy de de ta t aiils l s th t hee same s a me In c hhiine probl ems an arise. Fig. 32 32 shows shows aa pad pad bol bo lt problems se. Fig.
for ng tw o ma chine parts r. for locki locking two machine parts togethe together. s of e pad hich are Th e two The two part parts of th the pad bolt bolt w which are being fil ed tto o suit umn su it aa rou rou nd nd col colu mn we were re bei ng pro profiled made m one ece of from one pi piece of steel. steel, and and cut cut made fro apart e profilin g.. A ove can apar afte ahe rr th the profiling A gro groove can be be seen her e tth hee separating where sepa ra ti ng cut cu t wa wass to to be be see n w taken. err in ing bar as set in the the bor boring bar w was set taken. The The cutt cutte to shed radius. to tt he he fini finished ra di us. Only Only the the cross-feed cross-feed of of the the tt able abl e was was used used (to (to put put the the cut cu t on on bi ked. The bi tt by by bit) bit) th thee other other slide sl ide being being loc locked. The tool down feed. feed. It It is is too l w w as as tt raversed raversed by by the th e down no sible to the full ountt of nott pos possible to tak takee the full am amoun of metal remov al in in a job like like in a singl si nglee pass pass in a job metal removal t his, but but with w ith successive succe ssive cuts cuts a a pe perf job this, rfeecctt job is assu assured. Sim hol es for for such such pad pad is red. Si m ililarly arly tthe he holes bol t s are are 'part 'part holes' ho les' and and could could not not be be bolts drillled led in in the the second second stage st age to to full full si size dri ze w ith ou t guide gui de bushes bus hes for for the the drill. dril l. But But without drill ing undersize under size and and th th en en open open ing ing out out drilling with aa boring bo ring head head gets get s th there t he with ere jjust ust the same bit less less qu qu ickly. ickly. sam e,, aa bit Prof iling loco motiive ve connecting connec ting rods rods Profi ling locomo and coupling coup ling rods rods can can be be aa somewhat somew hat and t iring operation operation ifif one one has has to t o do do itit by by tiring sawi ng and and fil filing. Trying to to do do this this work w or k sawing ing . Trying on the the borin bo ring table of of the th e lathe lathe with wi th on g table vertica l slide slide or or angleplate angleplate is is not not very very vertical happy either. eith er. Usually Usually the the cross-slide cross- slide travel travel happy is much mu ch too too short short to to complete co mp lete the the length length is i n one one pa p ass. so tthhat a t re re-setting - se tt i n g is is in ss , so necessary . and and the th e la lath doe s not not have have necessary, thee does
49 49
th lities needed. rally thee in-feed in-feed faci facilities needed . Gene General ly with nt at hich with aa vertical vertical slide slide the the poi point at w which cutt ing is ing done s of cutting is be being done at at the the end ends of aa long long ay fro m th rod rod is aa very very long long w way from thee place place where de is where the the sli slide is secured, secured , so so that that apart apart from e pi ece there 'spring'' of of th the piece there is dange dangerr from 'spring of ing ttaking aking pla ce with astr ous of slipp sli pping place with dis disastrous result s. Com pare such ith the results. Compare such attempts attempts w with the
setw n in e aa pair set-up up sho shown in Fig Fig.. 33. 33, w w her here pair of of co up ling rods ith 'chucking coupling rods,. w with 'chucking pieces' pieces' ooff extra ta l at ed on metal at each each end end,, are are clamp cl amped on extra me packings packings in in aa safe safe and and rigid rigid set-up set-up.. Generally e di am et er of ill used Generally th the diameter of end end m mill used can uss can be be arrange arrang dd to t o give give the the right righ t radi radiu where hee rod jo in s the where the the body body of of tth joins boss es. bosses.
bolt Fig. 32 Profiling pad bolt
Fig. 33 Profiling coupling rods rods Fig.
50
51 51
CHAPTER 9
9
End-Rounding EndRounding fulll sized machinery machinery,, In model work, as in ful su ch as crank cra nk webs, com ponents many comp on ents such connectin g and cou pling pl ing rods rods., m machine connecting achi ne rou nded ends. links, etc. have to have rounde d end s. produ ced by fili ng, and nd th the These can be produced e of hardenerd ha rde nerd steel steel collars coll ars and roller ro llers use of s guides often recommended for gu ides has oft en been reco m m ended thee not-sa-good not- sa-good in Model Engineer t o help th to achieve achi eve a good g od appe appearance. fil r to file arance. Even with these, li ng dema demands wi th th ese, this kind of fifiling nds a wh ich many ma ny modellers modell rs jus justt do not skill wh wi ll never neve r acqu acquire, have (and wi ire, for wa nt of practice , if nothing noth ing else) else ) so for fo r th that reaso n practice, at reason al one met alon e it is not a good m et hod. But it is now also rathe ratherr seve severe on hi ch are now re o n fi les, w hich quite expensive tools, unli ke ly ever ttoo qui t e expe nsive too ls, and unlikely cheaper. get che ape r. where ilSo w avail here there t here is a vertica vert ica l miller ava right able , why able, w hy not not do the job the th e rig ht way, w ay. as it wou ld be be done in comme com me rcia l engineereng ineer tablee.. ing? ing ? It means me ans investing in a rotary ro tary tabl but these th ese can can be bought bo ug ht in kit form as well we ll as d if us e. an and as complete co mp le t e ready read y for u machined mach ined and assembled by the the hom e worker himself. are not terribly expe nsive. expensive. Presumi ng tha Presum ing th att the component com ponent has a round ho le at one end . a plug is is needed in the the table ta ble so as as to locate loc at e by that th at hole. hol e. I have ll rotary have a sma sm all ro tary table table with w ith a it W hit. hit. hole ho le in the the centre cent re and and have a number of plugs plug s of standard sta ndard sizes sizes to fit fi t that. tha t. But Bu t 52 52
anott her t able wh which possesses ano ich I have poss esses a rborss taperr centra centrall hole and arbor No. 2 M orse tape for loca locattion. ion . It is. is, in fact fact., can be put in this for Eng ineerin g Services Type RT3 a Model Engineering whiich ch does oes not have a ttee-slotted tab le , wh ee-slo tt ed table, sp indle screwed lik like yford but has a spindle e the M yf ord lathes and will accept any chucks or facepla te s from the lathes. This ma kes it faceplates to turn turn., say, say. a cy cylilinder nder cover cover and an d feasible to transferr it to a rotary tab table li ng the th e transfe le for fo r dririllling bolt wi thou thoutt losing the accur accuracy bo lt hol es wi acy of Butt th thaatt is not not a featu feature impor setti ng ng., Bu setti re of impor endin g operat operations. io ns. I have tance for round ending fo r a numb number engine used it for er of engi ne cranks in shown the nn er show th e ma manner n in Fig. 34. 34 . Each crank was located on the arbor but also cla clam m ped was w ith a slot plate resting resti ng on Picador Picado r of these being stepped step ped packing packings,, a pair pa ir of be ing also under cutterr is a unde r the crank itself. The cutte t inin.. end m ill cutting itss side. cutt ing on it side . In all rotary ro tary mill m illiing ng of this kind kin d where w here the cutter is working work ing on on the the outside outs ide of o f the th e component com ponent it is is vitally vit ally necessary necessa ry to feed the table n from above ta ble clockwise cl ockwis e see seen abov e.. All normal e same no rma l milling m illing cutters cu tt ers rotate rot at e th the way ide of w ay as a twist twist dri dfl llll,. so wh ichever ich ever side the the work the the cutter cutte r is touching. touching, the work w ork must the cutte cut te r. and that t hat means mu st meet the l. Otherwise clockwise rotation ro tation is is essentia essenti al. Oth erwi se if the cutt er is going goi ng the the same way w ay at at th the the cutter surface as as the work it is certain certa in to grab
Fig. 334 4 End-roun dinq with rotary table En d- roun~ing hold and tha thatt mean meanss at least spo iled il ed work. work. probab ly a brok en cu tt er. and a lot rief. cutter. I t of g grief. probably broken But orki ng on an int ern al pro file, But if one is w working profil e. such as trimmin g the ins ide of th e rim of trimming inside the of a flywh eel.. th en flywheel n th e forces are reversed reverse and th ork needs rotat ing ant i-clockwise. thee w work rotating anti-c lockwise. No w the threads of th nd le are Now thee RT3 spi spind like th yf ord lathes. righ thee M Myford rightt hand han , so wh en one is do ing insid ck or when doing insidee work a chu chuck facepl ate is tight ened e faceplate tighten d by the tthrust hrust o off thhe w hen do ing the. perhaps. perh ap s, more dOing cutter. But when no rm al m ilillling ing on tthe ou ts ide of a piece. piece, normal he outside cutt er thrust th rust te tends un do the th e the cutter nds to undo faceplate. work facep late. and unless un less the wo rk is very light cuttit ing ng.. thi this w hat w ill cer cert ainly happen. happen. cu s is what T he only satisfactory answer to thi s drill and tap a hole hol e throug thro ug h problem is to drill th e boss bo ss of the faceplate. faceplat e. m ake ake a coned the di mp le in the th e t able able spindle at the same sam e dimple spot, and insert a screw with a cone co ne po int spot. dimple. No t a diffi cul cultt matter mat ter that fit s the dimp le. Not all. But if you are going to use a chuck chu ck at all. sam e table table for the th e same sam e kin kind of of on the same work, then the n make m ake a pencil penci l mark m ark to show work. wh ere the the dimple dim ple is is for for th the faceplate faceplat e,. and where
drill the chuck boss w ell aw ay fr om th is, well away f rom this. so th at you have tw o positive ly sepa rated two positively separate that dimp les, each for accessory.. dimples. for its own accessory I have used a 5/ 16 et grub 16 in. in. BSF sock ocket screw se. with a po int screw for this purpo purpose. point modified (in tthe he lathe) ger co ne.. lathe) tto o a lon longer con Bu und th dinary as Butt I fo found thee or ordi nary hexagon hexago n key w was no t really ent rea lly long enough to be conveni conve nient with a standard s. Myford faceplate. st andard 7 in ins. faceplate . So I cu cutt o off end of th ff th thee shor shortt bent en thee key ed tthe he Ion long part to an extension exte nsio n and fitt fitted made in.. bright brigh t mi ld steel. This was was } in mild steel. Thi m ade of 1 drilled 3/ 16 in. deep with w it h a dri ll ed in the the lathe 3/16 No . 16 d ririllll which wh ich is about the acrossacro ss No. corne rs size of the th e hexagon. hexagon , then 7/ 116 in . 6 in. corners further with w it h a No. No. 22 drill wh ich ic h is about about the across-fl across-f lats size. The The two tw o pieces were w ere th ats size. th en pressed together togethe r in a big vice ., the then squared-ooff ff en end of the the hexagon cutting cutt ing its its squaredway down down the t he hole hole in in the t he m ild steel. steel. A in.. cross pin pin was w as fitted. Loc Loctit ed in. in, 5/32 in ti ted and now II have have a Tee Tee wrench w renc h long enough enou gh reach the screw in the boss without any to reach difficulty. It took only on ly five fiv e minutes to make m ake is a conve convenience there for ever. and is nience there 53
CHAPTER 10
Heads Dividing Heads
dividiing ng For m any products the use of a divid absolute Ma ny ho home head is an absolut e necessity. M any me without workers, especia lly those w it hout any them engineering experience, experienc e, rega regard rd th em as mostt myst mysterious devices, bordermos eriou s devic es. almost border 0 cult, with out reall really ing on the occ ing ult, and say wi thout y thinking, 'O h. I cou could thinki ng, 'Oh. ld never use one of Wellll,, a dividing head is really no those !'. I'. We with spindle more than a headstock w ith a spind le on whi ch the wo work mounted, ith some som e w hich rk is mou nt ed, w ith off turn turn ing it through po positive ans o m eans sitive angularr amou amounts, angula nts , and holding itit there wheen n each movement move m ent has been made. made . wh Naturally there dividi Nat urally th ere are m any types of div idi ng t he years years many de designs head and over the signs have appeared appear d in M Model od el Engineer for which made heads w hich can be m ade in the home workshop. eaa t dea deall o off qu quite w o rksho p. A g r e ite satisfactory with it h a sat isfactory work can be done w simple typee shown in Fig. Fig . 3 35 sim ple head of th e typ 5.. On the spindl spi nd le,, provision is made for mounting wheel. pringmou nting a lathe cha nge w heel. A spring er wit withh a conica loaded plun ger conic all poin poi ntt drops into th thee gap between two tw o teeth of tthe he wheel. w heel, and then the spindle is locked by a screw bearing main bearin g on a pad inside the ma in bearing. IItt is advisable not to rely on tthe he plunger holding spindle against d i ng the spi ndl e agai nst plu nger hol rotation rot ation when screwing scre w ing on chucks of when w hen fixi ng a component co mponen t on an arbor by mea ns of a nut. If the spindle me ans spind le turns, the t he 54
teeth wheel may ba Iy teet h of tthe he change w heel m ay be badly da maged. I n fac factt w hen do ing th is sort o f dama ged. In fixing I alw always di sengage the plu nger. ays diseng age th e plunger, the n ifif the t he screw screwpad does nott hol d. d, no pad doe s no done.. damage is done selecting suitable change By selec ti ng a suit able ch ange w hee l it quite division s possi is pos sibble le to get quit e a lot o f divisions easily. For example a 60 toot tooth wh el very easily. hw heel wiillll gi give 4,. 5. 5, 6. 6 , 10 10,. 12 12,. 15 15,. 20 or 330 w ve 2 ., 3 , 4 0 divisions. It w will 8,. but a 40 40 tooth ill no t give 8 he I w ill do so. W When dividin g w heel hen doing dividing with thiss kind of device it is a go good thing w ith thi od thin g tto o have a bit of chalk handy and mark the e plunge plu nge r appropriate t ooth appropriat e toot h gaps w here tthhe 0 have to drop in, before be fore starting is go ing to cutt to avoi avoid se ttings w wh ich cu ttiing ng,, to d iincorrect nco rrect settings hic h woulld spoi l the w work. examples wou or k. Ma ny examp les of which simple h ad of m achinery parts to w hic h a sim ple head th is kind ki nd can be usefull usefully coulld d be this y applied cou given.. Suc Suchh ititems crankcase drain given em s as cr ankc ase dr ain or which hexagons, square filler plugs wh ich need hexagons. taps, ends on shafts, tools like ta ps, reamers, reamers. para ll ell flflats spaanne nne rs on ro round pa ralle at s ffo o r sp und articles, these formed art icles, all th ese can be fo rmed so very with physical easily with an end mill, mil l, w ith less phy sical effort than fil in g,, and w it h an accu racy with accuracy filing w hic h enhances enha nces th th e which thee appearance o off the article arti cl e even if dimensiona dim ension all accuracy as suchh is not suc no t important. im port ant. But there are examples where examp les w here accuracy is fairly important, im po rta nt, and one on e which w hich could cou ld
hardly e at it h hand tools is hardly be be don done at all all w with shown 5. This ber Fig . 335. This is one half half mem member shown in Fig. h are bei ng cut of a dog clutch clutch.. The 12 teet teeth being cut with a slitting saw hich saw w wh ich passes passes across across er the the work right on the centre line. Aft After each cut cut., the th e locking screw scr w was was eased eased,. the plung er lifted e w heel turned plunger lifted out, out. th the wheel teeth ., and t he plunger dropped in five teeth aga in. The spindle again. spi ndle was was then locked and the th gap cu t. Really a very the next next too tooth cu. simple the r ha lf si mple procedure. Now Now on the oother member of he clutc h the teeth have to of tthe cl utch to have pa rallel sides, and the gaps parallel gaps them themselves are t aper sided. This just involves involves sett ing the cu tt er with its se tting tter its bott bott om edge above the re lin e by ckn ess line by half half the the thi thickness t he cent centre of he teet h left e first of tthe teeth left upstanding upsta nding in th the first half. ng right ha lf. T he same procedu re of of cutti cutting righ t acr oss is fo llow ed ., and afte afterr six passes th e across followed job is co m plete. It is feasible. u are complete. fea si ble. if yo you wi willling ling to to t ake the trouble. trouble, to to make a clutch cl utc h w ith all tooth side s ttaapered. pered, so that the two ical. If maxim um two halves are ident identical. maximu m
stre ng th w as needed to was to transmi transmitt a lot of of strength pow er this mig ht have to ower might to be done. done , but but it is lt and a good dea re difficu deall mo more difficult and would rarely be w orth the u are worth the trouble. Unless yo you using a we ll-es tablished desi gn for wh ich well -established design which draw ings are available. drawings available . itit is advisable to to layout ing lay ou the tooth design on on the draw drawing boa rd , prefera bly at an en larged board preferably enla rged scale. to to verify hic h w ill verify the thickness ooff cutte cutterrs w which produce th e desired result. They may be the be the same th halves. bu forr bo both butt same thickness fo maybe not nd s on the not,. it depe depend the thickness th ickness of of too th selected. d thing tooth selected. It It is also a goo good th ing to avoid an odd be r of tee th.. bec ause od num number teeth because the curve of th e cutt er w hen going the cutter when through o the chewiing ng int into th roug h one side may be chew met al whi ch has to act on the which to be left left int intact metal opposite e the t h. If oppo ite side to to mak make th too to oth. If your yo ur des ign can arrange for n number of design fo r an eve even teeth this risk w ill be eli m inate d.. A notthe herr will elim ina ted An poi ntt is to k tthat hat th thee desired desi red number poin to chec check of tteeth eeth can y be s ecured t h the ca n reall really ecu red wi with dividing head you int end to intend to use. use .
Fig. 335 5 Cutt ing teet h in dog clutch part Cutting teeth
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STE.ADY STE A DY STAND STAND fOR fO R MYFOR MYFOR00 DIV'O'G Dlv'O'G HEAD HEAD
I
M YFOORD RD DIVIDING MYF DIVIDING HEAD HEAD The The Myford Myford dividing dividing head head isis an an exce excell lent ipment, wwith ith aa very ide lent piece piece of of equ equipment, very wwide ndle has range range of of divisions. divisions. The The main main spi spindle has aa 60 60 tooth tooth worm worm wheel wheel on on it. it, and and aa single singlestart ric start worm worm meshes meshes with with that. that. Concent Concentric with ion for with the the worm worm there there is is provis provision for mounting ult i- holed division mounting aa m multi-holed division plate plate which which remains remains stationary stationary and and does does not not rotate it h the rm . On rotate w with the wo worm. On the the worm worm spindle spind le is is fitted fi tted an an arm arm carrying carrying aa spring springloaded unger wh int of loaded pl plunger which ich has has aa po point of paral rs holes parallel lel shape shape that that ente enters ho les in in the the divi sion plat e .. This division plate This arm arm is is slotted slotted and and can can be ing the be set set to to such such aa radius radius as as w w ill ill br bring the plunge e right plungerr in th t he rig ht place place for any of of the the row s that rowss of of ho hole les that are already drilled drill ed in the the plate aving set plate.. H Having set the arm. arm, if one one tu rns rn s the the w orm one w hole turn and drops the worm whole plunger o the same hole plu nger bac bac k int into hol e fro m w hich ted , the m ain spi ndle wh ich it star started main nd le w wililll have rot at ed one sixt ieth o rotated sixtieth off a turn. tu rn. But if on es tthe he w o rm and onee m ov oves worm and arm arm fiv e comp let e tu rns befo re droppin g in, complete before dropping in. the ma in spindle will have turned elft h turn ed one tw twelfth rn. Basically. Basically. tthat of a tu turn. hat is all al l there is to getting any desired number of divisions. divisions. gettin Hav ing got got the rig right on the Having ht division plate on m any turns. turns, head one moves tthe he arm sso many necessary, a certain certa in number num ber of plus if necessary. holes extra to the comp lete turns. A chart holes wit h the head gives giv es all all the the availavail supplied with co mbinat ions. In In order order to accomplish accomplish able combinations. all divisions divisions up up to to 100 100 itit is is necessary necessary to to all have 44 plates. plates . but but two two of of th these ese are are needed needed have some rather rather outlandish out landish numbers numbers on ly for for some only with which whi ch few few model mode l engineers engineers will w ill ever ever with have to to deal deal., so so the the two two normal normal plates plates will w ill have serve. almost everything every thing. There There is is one on e se. ve . almost of practical practi cal importance imp ortance in in using using aa point of point
Opposite, Fig. Fig. 36 36 Drawing Drawing of of steady st eady stand stan d for for Opposite, M yforddividing dividing head head Myford
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wworm orm gea red dividi ng head n moving geared dividing head.. Whe When moving from n to fro m one one positio position to the the next. next .always always turn turn the y, never k. IfIf the worm worm the the same same wa way, never go go bac back. he rig ht hole . of by by chance chance you you overshoot overshoot tthe right hole. of but go we ll course you have to t urn back. course you have to turn back. but go well bac k. way nd the back. way beyo beyond the hole hole you you want want by by aa good n come esh. IfIf good margin margin,. the then come up up to to itit afr afresh. you ll have r in you fail fail to to do do this this you you wi will have an an erro error in your ng and -piece. your dividi dividing and aa scrapped scrapped work work-piece. ll see Our y 'backlash' wi Our old old enem enemy 'back-Iash' will see to to that. that. But it' s easy enoug h to avoid th is kind But it' s easy enough to avoid th is kind of of disaste r. Th ere is disaster. There is provided provided on on the the head head aa most po rtant rrect co unti ng of most im impo rtant aid aid to to co correct counting of the henn turning the number number of of holes holes needed needed w whe turn ing the o brass the worm worm.. Tw Two brass blades blades are are fitted fitted around ion aroun the the worm worm shaft shaft.. above above the the divis division plate, ive to pi te, and an these t hese can can be be moved moved relat relative to one her, by one anot another, by loosening looseni ng aa screw, screw, and and set brace e num ber of set to to em emb race th the number of holes holes needed. an afte g w it h the needed. Th Than afterr lockin locking with the screwdrive r, they w screwdriver. they make ma ke aa mask mask to to sho show nger sho uld be just just where where the the plu plunger should be dropped dropped in fter each en t you in.. A After each movem movement you rotate rotate them them titillll one r, one blade blade comes comes aga aga inst in st the the plunge plunger, and and yo youu are are the thenn ready ready (afte (afterr doi doi ng ng the the cutting rse) fo the next next move. move. In cutting of of cou course) fo rr the In this part pa rt of of the procedure the this the procedure the two two blades blades move together together as as if if they t hey were were one one piece piece of of move met al. metal.
STEADY STAND STAND STEADY have found found in in using using the the Myford Myford head head II have that itit is is aa convenience convenience to to be be able able to to set set itit that at lathe lath e centre centre height heigh t when when fixed fixed on on the the at wants to to drill drill cylinder cylinde r boring table. table. If If one one wants boring covers and and similar simila r work work the the radius radius of of the th e covers row of of holes holes can can be be readily readily obtained obtain ed by by row and the th e measure measure the cross cross slide slide screw screw and the men t is is direct. direct. So So II have have aa packing packing block block ment of the the right right thickness thi ckness which whi ch II can can place place of under itit for for this th is purpose. purpose. under There isis one one minor minor criticism cr it icism of of the th e There Myford head head which which is is nevertheless never theless impor impor Myford tant from from aa practical pra ctical point po int of of view. view. The Th e tant holds itit to to aa machine machin e single bolt bolt which wh ich holds single
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tab le or ica l slide table or vert vertica slide, etc etc.. does does on on ng way from the poi ntt occa sion come a lo long poin occasion whe re cu tt ing is being cutting bei ng done done,. and and accor accordi ly there nger of t here is da danger of the work being being di ng ngly spo ilt by the ng. To ove rco me spoilt t he head slippi slipping. overcome this I have made up a st eady stand from steady mi ateria l wh ic h bol h milldd stee steell bar m materia which bol ts ts on tthe tab le ooff the m ill er, and clamps on the table miller, the 1 in in.. overarm ba and has a barr of the head. The st stand vertic all t in. ba r set at base ve rtica set into a flflat ba se with wit h slot o-w ay cla mp two -way mp slo t for a table bo lt. A tw slides oon n thi ther thi s vertical vertica l bar, and ano anoth er t in. bba arr passes ally. A passes through through it horizont horiz ntally. Att the plate p the end end of of this is a twotwo-p late clam clamp ripping h provision also ripp ing the th e t in. in . ba r, r. w itith
for for gripp ing ing the the 1 in. in . bar bar ooff the the head. The various clamp s can ved separately clamps can be be mo moved and rsall fifitt tt ing. universa ing. The The and make make a pretty unive wh ng is 7. wh ole ole thi t hing Is shown shown in use in Fig. 337 sign is Th is fitting of of my my de design is no nott on the the ma rket , but but itit has proved so useful usefu l to to me market. that I am giv ng of itit in giviing ng a working drawi drawing Fig. 36 and anybody who likes li ke s can make a unit fo r hi msel f. himself.
OTHER DIVIDI NG H EADS DIVIDING HEADS Since the last edition of this this boo k was printed ee new din g heads have prin ted thr three new divi ivid ing appeared on th e market. The first. of my my the first, of
Fig. as Versatile ividing H ead Fig. 39 39 The George H. Thom Thomas Versat ile D Dividing Head
Fig. 37 Steady in use on a gea gearr cu cutting operation tt ing operation
Fig. 338 for simple dividing hea head 8 Author 'ss design for d
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58
59
own desi gn, rep laces that shown in design, replaces in Fig Fig.. 35 g out 35,, lon long out of of production after the the maker die d sever al years died several years ago. ago. It is is essentially similar wi t h detail im provem ents. ItIt has improvements. ha a w ith ta ilstoc k for rt ing long sle nde r ilstock for suppo supporting slender piece s, and pieces, and a pai pai r of of raising blocks which bring the cent re height centre height up to to just just ove overr 3 t ow fo r rotat ing work up in. and tthereby hereby all allow rotating up to to the size of of the 77"" diamete r Myford face pl ate. It is shown in 8. faceplate. in Fig. 338 The second typ o re typ e is a m uch uch m more elabo ra d vversa e r s a tit i le r at e a n nd l e appliance de sig ned by Mr Geo m as,, and designed Geo.. T ho homas suppl ied, like tthe he first one, by N.S. & su pplied, & A. Hem ingway , 30 Links cre, Hemingway, Li nks View View ,. Half A Acre. Rochdal e.. In this head a 24-ho le divisio n Rochdale 24-hole pplate late p rov ide s for simple provides sim ple dividing w ith thos e factor ed w ith 24. 0 those factorss associat associated 24. A 4 40tooth worm w heel and w or m ca n also orm Iso be engaged, h a si x- row dri engaged. w it ith sixdrilllled ed-- ha ho l division plat e, giving ch fin er di visions. plate. giv ing mu much finer divisions. This This plate can be rotated by a subsidiary worm, hereb y permi tting very high worm. tthereby permitting
nu m bers of numbers of divisions to to be obtained obtained.. Most peop le will need ake tthe he people need some help to to m make full est use s device and of thi th is and the the book by by fullest use of n Geo as himse lf on its Geo.. Thom Thomas himself its constructio construction and duating , Ar gus and use, (Dividing and Gra Graduating. Argus nd tthe he best source Books Ltd.) will be fou found of m ation. is head is also e of infor informatio n. Th This also ava ilabl ilable with tai lstock and raising raising blocks, blocks. but in normal for m is shown in Fig. 339 9. form The The third head is i supplied also in kit kit form by M odel Enginee rin g Serv ices . and Model Engi neering Services. was desig ned by designed by Mr Ron Kibbey. It It uses uses sta ndard Myfo rd cha ng e whee ls as standard Myford change wheels division plates, but ed lock ing but has a fork forked locking plu ch can er a to oth as plu nge ngerr whi which ca n span spa n ov over tooth we tw een o ttee eeth. wellll as drop dro p be betwe en tw two th . Th us the the num creases to ice the num ber of of divi sions in increases to tw twice number of teet h in any w heel. In teeth wheel. I n addition it has a mount ing for a w hee l- pa irr to m esh mou nting wheel-pai mesh w ith tthe he spindle ar ratio with spind le w heel. giving a ge gear to add to th e basic divisions. It is not at at present ided with a tailstock or present prov provided or raising rais ing bl ocks. Th ith ext ra gea blocks. Thee head head., w with extra gearr pair pair in pos itio n,, is show n in Fig. 4 0. position shown 40.
Opposite, Fig. 40 The Kibbey Kibbey dividing head head
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11 CHAPTER 11
Dividing Heads and, Gearcutting h ea~
The availability av ailabi lity of of a a dividing di vid ing head is is again again The essentia l for for doing doing gearc gearcutti ng on on the the essential utting mill ing m ach in ine. Of course cou rse the re are types milli ng mach e. Of of gears gears one on e jjust ust ca cann ot do, do, but bu t ordi ordinary of nnot nary spur gears gears can be done don e perfectly we wellll for spur m od el el engi engi neering neeri ng purposes ere mod purposes ,. wh w here nei the r high speeds neithe speeds,. extre m mee silence, sile nce , nor high ansm ission are high rate ratess of of pow po w er er tr transmission are dem anded.. The s is emanded The design design of of gear gears is a a subj ect outside tthe he scope of subject of this thi s book, which is intended to to deal with workshop ope rat ions. but operations, but there there are are plenty plenty of of sources source s of orma t ion on of inf information on gear design design.. The simp si mp le ty pe idi ng head already illu st rate d typ e of of div ividi illustrated w ill serve will serve very very w w ell ell ifif the the gears gears to to be be cu cu tt hav e such a num ber ooff teeth have number tee th as the th e indexing nge w hee ls th. indexing cha change whee ls can can deal deal wi with. Bu e num ber requ ired cannot Butt ifif th the number required cannot be b go gott ing wh eels, from from exist existing whe els, tt hen hen aa more more com plex head yfo rd. w ill be complex head such such as the M Myford, will is in ng needed. needed. Fig. Fig. 37 37 shows shows th this in use use cutti cutting the h are gr al the teeth teeth of of aa pin pinion ion w w hic hich are inte integral with e shaft. with th the shaft. The blank blank was was turne turned to to tt in. met err on o be in. dia diamete on the th e part part tto be held held and and this this was rd Myford was gripped gripped in in the the sta standa ndard Myford tt in. in. e com po coll et. w hi le the collet, while the othe otherr end end of of th the component ng centred ed by nent bei being centred wa wass support supported by aa 60 rarm fitt ing. 60 degree degree centre centre in in the the ove overarm fitting. w s the eady bracke This This picture pict ure sho shows the st steady brackett descr ibed in described in the the last last chapter chapter in in use. use. The The cutt er is err in cutter is aa simple simple flycutt flycutte in aa boring boring bar bar
co nven ienc e in a boring bo ring head. IItt is held for convenience closeup in Fig Fig.. 41 . Th The prof ile shown in clo se-up e profi le establi shed by grinding grindi ng to su suit w as established it a whee l of th thee same sam e pitch w ith sl slightly wheel ightly mo re teeth. The variation is so small sm all as to be of no importance, im port ance. especial the especi alllyy as th e pi nion nio n ro es at only a lo w speed. rott at ates low But if several ade ., and severa l gears gea rs are to be m made ed especia lly if du plicat es may be w ant especially plicates anted lat er, it can be w orth later, orth whil e to invest in one or more prope ers of properr disc disc typ typee gear gear cu tt tters of wha th e whatt is now universally universa lly known as the arpe' type, ey 'Brow n & 'Bro wn & Sh Sharpe' type, because th they we re deve lop ed by e famous fir were developed by th the fir m of Brown & Sharpe in U.S.A. m any years ago. ey are of e now ade by ago. Th They of cours co urse now m made Britis h firm s as w ell. th ers all an by oothers all ove overr British firms ell, and th e w orld . to racy of tern ational world to an accu accuracy of in interna iona l st and ards . far be tter th an anything standards. better than anythin g th that at is i needed fo eering , and are forr model engin engineering. prope rly back ed off ellll as being properly backe off as as w we being made ffrom rom high speed ste el. No er steel. No single cu tttter will properl y deal ber of properly deal with with all num number of tee teeth, th. so hey are s. ea c ~ cutter so tthey are m made ade in in set sets. eac~ cutter dea ling wi th aa lilim it ed range dealing with mited range.. and and each each bea rs an ify ing num ber. The number. The range range bears an ident identifying runs runs as as fo follows: llows: No.1 No. 1 135 135 to to aa rack ra ck No.5 No. 5 21 21 to to 25 25 No. 2 555 5 to No. 6 17 No.2 to 134 134 NO.6 17 to to 20 20 No.33 5 t05 No.7 No. 3 35 to 54 No. 7 14 14 to to 16 16 N o. 44 26 No No. No..88 12 26 to to 34 34 12 and and 13 13
I
III
411 Close-up of flflycutter pinion Fig. 4 ycu t ter and pin ion
Fig. 42 Gearcutting Gearcutting with Brown & Sharpe cu tter Fig.
63 63 62 62
Fig. u tting 10 d.p . gearw heel, fron Fig. 43 Flyc Flycutting gear wheel. frontt view
These cutt ers can be bought gly at cutters bo ug ht sin singl any tim e fro m regular ol merch an ts and time reg ular to tool merchants I doubt if any disco unt w ould en for wou ld be giv given fo r buying a com plete set o ere is no complete off 8. 8 . So th there need to go to 0 the expense expense of acquiring acqui ri ng a com plete set m ly kno wn complete s t unless unl ss it is fir firmly known th ere w il l be a use for 2 there will fo r every every one one!! Fig. 4 42 shows one of th ese doing a sim ilarr job to simila that depicted in Fig. 37 37.. The smoother acti on of the mul ed cu tter made it action multti-tooth i- toothed cutter po ssib le to dispe possible di pe nse with th thee use of of the th e ste ady stand. steady stand , though thoug h care was was taken take n not to be too roug th the cially roughh wi with th e feed. feed , espe especially at th e st art of each cut. the start Going now m w ha t m ight be called now fro from wha the sub li me tto o the ridiculous. sublime rid iculous. or at at leas leastt from th iniature to the thee m miniature th e outsize . the next next photograp h shows the uch the cutting of a m much larger gea r. act ua lly 9 .600 in. gear. actually in. p.c.d. p.c.d. This Th is is a gu nmeta gun metall gear gear needed need ed as par partt of a metal meta l patte rn from hic h the heel pattern from w which the flyw ffywh el of of Fig. 20 was 6 in. thick was made. ItIt is only o nly 3/1 3/ 16 thick but but the
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tteeth eet h are 10 10 d.p.. res. .p. , approx. 5/ 16 in. cent ce ntres, so qu ite a lot of met al had to be rem oved quite metal ne wi th at each too th. The cutting cu tt ing w waass do done with a flycu flvcuttter, ter. grou nd up by hand to match a si l ho u e tte of a 1 0 d .p oth in ouette .p.. t o oo M achinery's H andbook. using a m agnifier, Machinery's Handbook, agni fier , g set in a boring this thi s cutter bein being bo ri ng ba barr of rather excessive length in a bo ring head. boring head . Tw o cuts ere ta ken,, bu hen there Two cu ts w were taken butt even tthen th ere w as a good deal was dea l of spring and noise. Th e shape of the nk casting wa th e bla blank wass arranged to provide for mo untin g by 8 bo lt s on the mounting bolts large Myfo rd faceplat e. (9 in. diamete r! Myford faceplate, diameter) and th is wa xed on the m iller ttabl able this wass fifixed miller e so as to ov erhang the side. Tha ittgd fixi ng overhang Thatt pe rm r mit~d a sta ndard ang e on the table too. standard anglleplat eplate too, just to uchi ng the back ooff the facepl at e, touching facep late, which redu ced tthe he spring iness of reduced springiness of that. that, and provided a back -s top against the da nger back-stop nger of ould have been asking of slipping. It It w would asking a lot lot of di ng head to of the single bolt bolt of the divi dividi prevent movem ent, und er the co nd it ions movement under conditions
Fig. Flycutting d. p.. gearwheel, rear rear view Fig . 44 44 Fl ycu tt ing 10 d.p
prevailin g, but using this safeguard all prev ailing. w ent w ell. went well. keeping mind thee It is well worth keepi ng in m ind in th home workshop that method of hom e w or kshop th at th is m ethod of back-u p is wi widely ne ering back-up dely used in the engi neeri ng industry ally he heavie in d u stry . espe c i al ly iin n th e h eav ie r sections, machines ot her sect ion s, on planing m achines and others either or hig high w here tthere here is eit her high thrust or h impact.' sometimes both , because beca use it can im pact,' som etim es both,
avoid da mage to m achines and w o ork, avo id damage rk. as well possible in jury. Fig. Fig . 4 3 show shows w ell as po ssible injury. s the fro nt of th thee gear disc. and in this th is view the th e front dividing e. But in Fig. 44 divid ing head is not visibl e. both th e ang leplat e and the th e dividing head bo th th see n. The gear ge ar blank bl ank w ould o uld only just are seen. of the th e M Myford lathe swing in the gap of yf ord lath e so without ra ising block blockss it repres represents w ithout raising ents about th e largest job that can be tturned. the urned .
65
CHAPTER 12
Dividing Heads and Tool Making Tool T here are many occa occasions in too tooll making sion s in w hen dividing divi di ng is necessa nec essary Multiple when ry.. M ultiple edged cu cuttting ing tools too ls like taps, taps. re reamers, amers, cou nte rsinks. et c. all reall really ng cutters, cutters, countersi m illi ill ing nks, etc. y need dividing divi di ng devices de vi ces to produce the th e best results, n th th ough me of th th e e simple sim ple results, eve eve n ough so som e of cutters made filing cutte rs can we w ellll be m ade by fil ing or free inding. r, th th e orm free hand hand gr grindi ng. Howeve However. e ffo rm of of the teet h or etim the teeth or flut fluteess som so meti m es es settles settl es that that
ready j ust w ill not do, do. rough and re ady methods just exam ple th the and as in the next exa m pl e physical di ffic ulty of o f getti getting th e metal that has difficulty ng at the taken mo re or less set settt les to be ta ken aw ay more le s that tha t m echannical ica l dividing divi di ng m ust be em ployed . mecha show s tthe utiing ng of a long-thread Fig. 4 5 shows he fl ut lo ng-thread Acm e ttap ap which whi ch is held in a collet coll et in the spindle of of a simple simpl e dividing dividi ng head, head , using us ing change heels for the divid in g. In order ch ange w wh eels for dividin ord er to
Fig. 45 Flu ting Acm Fluting Acmee thread tap
66 66
obtain e maxim um swa obtain th the maximum swa rfrf clea clea rance rance this this tap tes. The tap has has five five flu flutes. The head head has has no no tailstock tailstock so so the the outboard outboard end end of of the t he tap tap is is rested rested on on aa pa pairir of of Picador Picador blocks bloc ks and and the the clamp rests on on another anoth er pai pai r. r. These These are are clamp rests very very usefu usefu ll accessories acce ssories for for milling mi lli ng operaopera tio ns. Of course hat aa flute tions. course each each tim tim ee tthat flute is is com pl eted the i ased co mpleted the clam clam pp has has to be be re released before d to wo rk can bbe rotate rot at ed to the the bef o re the th e work posit po sitiion on for the next flute flut e.. A suitable suitable tailstock, il able, would tailstcck. w w ere ere it ava available, woul d obviate obv iate the need for thi s. The th is. Th e 5 flu tes are obtained obt ained by moving mo vi ng 12 te eth et h at a ti me m e on a 60 tooth wh ee l. T he cutter eel. The cutte r being used use d is a com merci al tap-fl uti ng cutter m ercial t ap-f luting cu tte r pi piccked ked up che aply at a sale. ade cheaply sale. These These cutter cutters are m made w ith ew h at lop-sided lo p- sided ro unded un d ed it h a som ewh profil prof ile specifically speci ficall y for this duty, duty, but if iit had not been ava il abl e, a flflycutt ycutter available, er woul w oul d n ground the profile have bee been gro un d up to the profil e of a si m il ar tap. The Th e prof profilile e is not de despe ra tel simil sperat elyy important small erro r wou ld not im por t ant and a sm all error matteer. r. matt
A Another nother example example of o f the the use use of of the the dividing dividing head, head, th this is time tim e coupled cou pled w with ith the the use in use of of aa small small rotary rotary tab table, le, is is shown shown in Figs. 46 and and 47 47 .. The The workpiece wo rkpiece to to be be Figs. 46 produced ne tooth produced was was aa fifine too th mill milling ing cutter cutter with with aa round roun d end end for for routing routing or or hand hand m m illing illing on on the the light light alloy alloy cy cylinde linderr head head of of aa ca e. The carr engin eng ine. The commercially co mmerc ial ly avai avai lable lab le cutters lls had uch cutters fo forr use use in in electric ele ct ric dri drills had such coarse eethh that coarse teet that once once they they touched touched the th e su rfac e of surf ace of t he alloy t hey hey we re uncontrolluncontroll able able and and pulled pulled sideways sideways so so violently vio lent ly that that damage nder head most aa dama ge to to the the cyli cylinder head was was al almost ce nty. utte rs fine pitch pitch cut t ers ce rt rt ai ain ty. So So as as fine appea appea red red to to be be not not purchasable purchasable it it was was decided de cided to to m m ake ake one one.. The The bla bla nk, nk, of of a a arbon ar to si lver steel carbo n steel st eel simil sim ilar silver st eel but so mewhat ade to som ew hat lowe low err in carbon carbon,, was wa s m made hold in a coll et and wa s give n a sm all collet w as rec ess in ng cutte to recess in tthe he end end for for the the flu fluttiing cu tte rr to run into. The The dividi ng head head ,, with with a a 50 run into. div idi ng 50 tooth ange w w heel heel an on its its spi spi ndle ndle,. was to ot h ch change was m ount ou nted on a a stee steell plat platee so so that that the end m ed on the end
Fig. 4 6 Cu Cutting teeth of o f ball ball-end cutter Fig. t ting teeth -end cu tter
67 67
Fig. 4 477 Close-up Close- up of ball-end cutter Fig.
of th thee wo work-piece eyond th thee centre of rk- piece w as beyond ha lf its diam diameetter. of the t he rotary table t able by half er. In words. th e centre of the ba ballll end other w ords , the was er tthe he centre o ary table tab le.. off th thee rot rotary was ov over The of the work w was rotation T he axis of as on the rot atio n centre nott app apparent from thee cent re.. This is no arent fro m th photograph, waass an essent essential pho tog raph, but w ial feature set-up. stop block wass clamped of the setup. A sto p blo ck wa unde rsid e of the m illing ill ing m ach achine to th e underside ine tool maker's clamp, visible table table with a to olmaker 's clam p, visi ble in hottoo g raph raph,, to to llimit tth h e p ho i m i t tthe h e ttaab blle e moveme nt po positively to thi position. move ment sitive ly to thiss posit io n. In direction movemen the other direct ion the mo vemen t of the table brought brou gh t the cutt er to a pa rt of th cutter part thee tooll shank sm smaller thann the diam diameter too alle r tha eter at the bottom of the flu te s so th at ind exing flute that indexing with thee cutte cutterr in th thee clear. clear. could be done w ith th The cutter used w as a carbon steel was steel one locom ot ive made origi nall y for producing locomot originally lubricator ratchet whee ls, w it h a 60 wheels, with degree single angle. ith the axis of tthe he angle . W With work parallel to the tabl tablee a cut was started at the requ ired full depth required depth., and the the
68
table traversed tra ve rsed alon along bringi ng the cutte cutterr table g br inging into operation thee cy cylilindrica ndrica l int o op eration cutting along th port io n. Wh en the tabl portion. When tablee was was arrested arreste by temporary the te mporary stop sto p block, the rotary table worm wa s turned by means of itits sw or m , so tthe he cutter continued cutting dovetail dovet ail cutt er co ntin ued cuttin g round ro und th e ball end of th e work. he n the cutter the w o rk. W hen th e culler recess, the feed fe ed w was ran into the recess, as reversed with rotary table, then withh the th the ro t ary table, then wit fi rst wi thee st starting point, main ttable, abl e, back to th arting poi nt , where thee cu cutter was clear of th thee w work w her e th tt er w as cl ear of ork shank The dividing head sha nk ,. T he d ivid ing h ead was then wheel, indexed one tooth on the w heel. and a Eventually new cut started st arte d,. Eventua ll y all 50 cuts were 47 7.. we re completed co mp leted as shown in Fig. 4 working'' diamete diameterr of this tool is f The working tillere are 50 perfect teeth. te et h. The tool too l in. and tlgere w as hardened and tem pered, and w hen was tempered, when put to use in an electric dri nd to drillll was fou found to com b ire ly satisfactory. sat isfac tory, It worked combee ent entirely pletel y chatter-free, cha tt er-free, wi th no tendency ten dency to pletely with to run away, fin e and away, and in spite of of its fine sha llo w tteeth eeth , removed metal at a very ll ow
Fig. 48 Gashing flflutes ut es in large countersinking tool
gratifying rate. The thee ports po rts in gr ati fyin g rat e. Th e w ork on th th e alloy head wa wass co com eted mppllet ed tto o the great sa tisfaction of the user, leaving a beau tiful satisfaction beautiful surface smooth surfa ce for the gas flow. flo w . Another example An other exam ple of cutting tool to ol making shown Figs. 48 and 49. is sho w n in Figs. 4 9. A large 60 degree count countersink needed ersi nk w as need ed for a commerci al operati operation th e com mercial on on steel tubes, the tool in. diam diameter. wass to ol being about 2 -!- in. ete r. It wa made with an interna l fo form identical with rm ide nt ical w it h the M Myford fro m a carb on onthe yford lathe spindles spi ndles from manganese chrome alloy of known ma nga nese ch rom e all o y of uent hardening identity, so th at subseq subs equent could without ri sk of failure in a coul d be done w ith out risk co mmerc ia l e s t ab li s hm en t wit h commercial establishment with this steel. I n tthe knowledge of th is st eel. In he pictu re it is shown mounted Myford sho w n moun ted on the M yford dividing divid ing head hav ing tthhe e flut es cu th a specia head having ffutes cutt wi with specia l ang le form fo rm di sc type cutt er. Beca use of angle disc cutter. Because of th e pec uliar es w hich are invol ved it the pecu liar angl angles which involved was necessary to be able ab le to set the head head with ititss axi nat ion to the table, axiss at an incli inclination table. and it proved that the simp lest way to do
2t
this w was ve rtical sli slide. was this as to use a vertical de. There was quit metal qu itee a lot of me ta l to be ttaken aken out of the thi s de decidedly tough steel , and an 25 flutes in this ci ded ly toug h steel usuall th e cutt cutting long wayy fro m ing was wa s a lo ng wa as usua anch orage point, po int. so the st steady the anchorage eady stand bro ught int into was brought o use at the back of t he head , as it proved too difficult se t it at head, too diff ic ult tto o set the sam samee side as tthe cutter. However, he cutt er. Howe ver, it te w well served qui quite ell in th at position and he re was never suggestio of t her e w as n ev er any su ggest ionn of insecurity. Thee m maain in gashes fo forr the flut flutes were Th es w ere cutss dow down taken out first, with w ith two cut n each wass til tilted new flu tte. e. Then the head wa ted to a new angle takenn to angl e and another series of cuts take accomplish reliief. ef. Because of the accomplis h the rel coni rtical coniccal al shap shapee of the work the ve vert ica l slid slidee had to have ititss base set at an ang le to the angle miller table. A th ese appa ren tly co m Allll these apparently complicated setti ngs had to be established experi mentally (t houg h possibly pos sib ly w ith a lot experimentally (though with ht have been calcul at ed) of effort they mig might calculated) sired for m of the cutt ing to give the de desired form cutting
69
CH A PT ER 13 CHAPTER 13
Dividing Heads and Graduated Scales
49 Rear vie view showing teady stand in use Fig. 49 w showin g s tea d y stand
edges of of the the count counteersink rsink and the rake small all angles desired in two directions. The sm which division plate pla te in use is one wh ich had previously been made some titime m e pr eviously for doing 125 division icrom eter dial dial s. for w hic hich 12 5 div isio n m icrometer h unfortunately th e st standard Myford platess unfo rt unatel y the andard M yford plate do not provide provide., or did no nott at tthat ha ttime. ime. However, th thi set-up too How ever, wi w ith th iss set -up and not too work i proved possible possib le with many hours w or k it home quipm nt to produce a ho me workshop equipme very w hich very suitable suitable specia specia l countersink which would inevitably inev itably have cost cost a small fortune
70
mercial if itit had had to be made in a com m ercial factory. It is ho hoped these examples of ese exampl es of ped that th tooll m maki willll enco encourage alll who need too aki ng wi urage al who know of of no standard ools, non- stan dard t oo ls, and wh o know that o uld take them on, or are firm th at w ould rred by the the high cost labourdet erred co st of labou r ve spe specials. intensi int ensive cials. Who kn ows. ow s, somebody workshop in a home home works hop might m ight ttake ake on th e job of hel ping out ou t some tool too l fact factory o ry that would w ould no nott wa nt to be diverted from its norma norm all w ork or k by jobs job s of this kind?
In the nstructio n of achine the co construction of sma smallll m mach in tools and access ories fte n de sira ble to accesso ri es it is ooften desirable to have grad ua d sca uatteed sca les les fo forr the th e co n ve nience of en ts, and of precise measurem measurements. venience the ical m icrometer dia ub the cy cyllindr in drical diall is undo undoubtedly the com moonest nest type ng on comm type.. Depe ndi ndin the number of graduation uired the graduat ion s req required eng rav ing of of the li nes can be raviing ng or cutt cutting done her a simp le head or done w ith eit either sim ple or the worm gea red type . There is a choice geared be tween usin g a non-rotati ng cutte between using non-rotating cutte r of of the th e ing type, g a pla ning or slott planing slotting type. and usin using rot at ing cutt er like tthose hose employed on rotating cutter pantograph achiines. nes. In each engraving m mach pa ntograph engraving case ividing ca se the work is mounted on th thee d dividing head and tthe he table screw is used to t o move the work against too l. It is advisable to gainst the tool. clamp table . if the mac hine cla mp stops to the table. machi ne op devices built stop bu il t in . so as does not have st the table t abl e movement an mit the to positively lilimit li nes th the co rrect length. Where W he re keep the lines e correct are li nes of more mor e than one one length on there are sam e dial di al,. one or more slips slip s of sheet she et the same ca n be be inserted in in front of the stop metal can obtai n the short sho rt lines. lines . The The cutting cu tting tool to obtain can be ground gro un d to an included angle of can degrees, Few modellers mode lle rs have about 50 degrees. gr inder. nder. access to an engraving cutter gri ideal machine m achine for for grinding grindi ng the which is the ideal conica l end which w hich D-bit type cutters with conical are needed neede d.. but they t hey can in in fact be be ground are
on the Quorn g rinde r. w hic h is becom ing rinder. which becoming more and more popular wi th model with engi nee rs. Those w ho do no ssess one engineers. who nott po possess one of hines of these these versatile mac machi nes may have some friend w ho can hel p ou ng who help outt by grindi grinding an occa siona l cutter. efer occasional cutter. For my par partt I pr prefer the rotating cutte cutterr bu butt then I do have the the ithout this a machine to grind them. W Without slo tting tt ing tool tool can easily be ground and an if rigid ly held w ill also rigidly Iso do do a good job, job. Fig. 50 shows a cy lindrica l scale ing cylindrica sca le be being eng raved on the ill er w ith a rot ating miller rotating th e m too llar, the scale is tool.l. This is no n t a loose co collar. on the co mpone ually par t of a m ponenntt itself. act actua ll y part Quo rn grinde r, llar wou ld Quorn r. but bu t a separate co collar ed on an arbor and treat ed mounted treated just be mount in tthe he same way. way. Fig. 51 51 is a close- up of th is operation ., this Some articles art icles need the sca le on on a flat surface but sstiillll in a curve curve,. One of these is needed on the the Quorn Ouorn gri nder. nder, and Fig Fig,. 52 tab le on shows this set on a rotary table n the miller and being dealt with by a rotating rot at ing cu tte r as as the last example. examp le. The The M M..E.S. E.S. cutter table in the the picture pict ure has a 90 tooth too th worm w heel. so one revolution revolut ion of the the worm wheel. gives 4 degrees movement and each division 16- line micrometer collar ivision on its 16-line gives one quarter quarte r of o f one degree. degree , The scale eng raved is is one specified sp ec ified iin being engraved n degrees, as as it is an an angleang le-setting degrees. setting scale.
71 71
Fig. 50 50 Cylindric Cylindrical machine component graduated al ma ch ine com p onent being graduate d
Fig. 5 51T Close-up Close -up of of previous Fig. previous operation operatio n
72 72
Fig. circular arcuat e scale on fla Fig. 52 52 Graduating Graduating partpart-circular arcuate scaleon flatt surface surface
Conic al mi cro me teerr collars etim es Conical micromet co ll ars are som sometim requ ired , bu butt they are more d diff ult to required, iffiiccult prod uc e and should be avoided in th the produce e desig ning all possib possible. graduat ing le. For gradu
th the right ay up as th at at th th e e figures fig ure s are are the right w way up as seen scale . The ay seen in in using using the the scale. The figures figures m may need to have risin g va value . . . 10, 10 , 20 20 ,, 3 0 have rising lue ... 30 need to the riright hand from tt he he zero zero m ark, .. .. .. to to the ght ha nd from mark, butt quite quite possibly, possib ly, depe depe nd nd ing ing on on circu circ um mbu sta nces tthey may need to to be be the the opposite opposite st ances hey m ay need way. It It is is as as we w ell t o get get this this th thoroughly way. ll to roughly sorted out out before before starting starting to to use use marking ma rking sorted punches to to put pu t the the figures figures in, in. because because itit punches can be very very difficult di fficu lt to t o rretrieve th e situa situaca n be trieve the tion if if the th e start start was was made made the the wrong wrong way. wa y. tion
73 73
CHAPTER 14
Cutter Speeds for Vertical Milling a~ am
In general gene ral I af raid mode l engineers eng ineers do afraid no t have very clear ideas about how ho w fast not they should run t heir lathes, lath es, drills or mi lling machines. m achines. To run too t oo slowly milling extends the working w or king time unnecessarily, but to t oo fa st will soo to ru n too fast soonn blunt a cutter and may ork finish may also cause poor w work tter. The wear on m ililling lin g through cha chatter. cutters (apart from uttersl is quite from flyc flycutters) impo rta nt because of tthe he trouble of important of sharpening t hem n cut ters can hem,, and broke broken cutters be qu ite an expe nse.. The pri nciples w quite expense principles whhich ich govern the speeds speeds of of cutting metal in othe hines such as the otherr mac machines the lathe and dri ll can ul guide, e ca n be taken as a usef useful guide , in in tthhe sense tthat hat any speed which an a particular pa rticular materia materiall w wiillll blunt a lathe tool too l or or drill wil wi lll likewise blunt a m ill ing cutter. But on tthe he milling vertical m iller there are other problems miller problems too. Generally tthe he point of uch of cutting is m much furth err from the ort than that furthe the supp support t hat of of the the y co mlathe ttool. ool. ItIt wi willll also also be aa long long wa way com pa ratively fro m the spind le bearings. paratively from spindle bearings. The work may uch furthe may be m much furtherr from the the slideways than than itit wou ld ld be be from the the bed bed of of th e lathe. Th e cutt ing the The ing tool is normally unsupport ed at s cuttin g end, s unsupported at itits cutting end, and and itits own elasticity is is added added to to that of of the chuck, chuck, spindle ,, work, etc etc.. So So speeds speeds which he may which might be be feasible feasible on on the the lat lathe may h on ller. well nd much well be be fou found much too too hig high on the the mi miller.
74 74
exampl e, tturni 2 0 wi ll As an example, urni ng back to Fig. 20 show how elevated eleva ted the surface surfac e of o f the w or k is fro f rom t able slides, and in th is work m the table exam ple lo w speeds speed s were essential esse ntial to to example low obtai n a reas onably goo d fi nis h. obtain reaso nably good nish. Th dept h of cutt Thee rat ra t es of of feed and dept of cu w hich are com co m monp which mo np lace on industrial mach ines are quite machines quite out of of order in the home worksho p. N ot only are industria workshop. Not ind ust ria l machines rk machi nes heavy and rigid, so are the wo work holding dev ices, and the work ititse self devices, lf is much more robust and rigid. Also, and th is this app lies particu larly when applies whe n cu tting tt ing stee steell,, these machi nes can machines ca n usually usua lly flood flood the cutter with coolant aki ng away the coolan t , ttaking the heat gen erated he cutt ing ope ratio n,, and generat ed in tthe cutting operation that is no ally nott norm norma lly possible on m achines in tth he me wo rkshop . So Table III e ho home workshop. II I has been piled to giv e som e gu idance in been com compiled give some guidance the the kind kind of opera opera tions ti ons which have been described in the k. It is based on using t he boo book. speeds w hich wi ess which wi ll conserve conserve the t he sharpn sharpness of ly to t of the the cutters like likely to be used. For For flycu flycutte rs, commercially lls . and ters, commercially made endrni endmills, and Brown he tools Brown and and Sharpe Sharpe gear gear cutters, cutters, tthe tthemselves wil willl be properly properly hardened high high speed l. Fo speed stee steel. Forr the the Woodruff cutters cutters itit is based e made cutt ers based on these these being hom home cutters duced from carbon stee eell pro produced steel or or 'silver' 'silver" st stee (w hich is (which is aa carbon carbon stee steell with w ith about 1.2% 1.2% carbon o re than carbon and and no no alloy) alloy).. M More than one one
article Model Engineer Engineer in in years yea rs past past has has article in in Model described descri b ed methods met hods fo fo r making maki ng gear gea r cutters the Brown Brow n and and Sharpe Sharpe type, type. and I cutters of the have hav e some of of these these myself, myself, made mad e from from plain plain carbon stee st eell of about abo ut 1% carbon . Such mo re slowly slow ly Such cutters m ust be run more tha n the high com than high speed spe ed steel cutters of commercial m ake, le that ake, but it is possib possi ble that a w ider s w ill ide r variety var iety of tool tools il l in future fut ure be made e home work shops, ma de in in th the w orkshop s, as a bette bett err ng and th e conunderstanding understa nding of tool too l maki making con tribution he verti ca l mill er can hic h tthe vertical m iller t ribution w hich provide gnised pro vid e comes com es to t o be be reco rec ogn ised . The The cutting it h su ch tools cutti ng speeds sp eeds to t o be used w with such will he tool w ill need to be arranged to t o suit sui t tthe materials m ateri als and the w ork they are doing. The proper mounti ng of ttools ools in tthhe mou nt ing e
miller miller is is a matter matter of of great grea t importance. im port ance. Reference Reference has has already already been been made made to to tools t oo ls which which screw directly di rect ly on on the t he spindle spind le nose nose , and another boo k will w ill give anothe r chapter in this book descriptions of the milling chucks which w hic h are currently ava il able availab le. ers It will be found foun d that some of the m ill illers at present on offer have have speed spee d ranges ranges which e wh ich do not go low enough enoug h to match mat ch th the bottom comm ended speeds botto m end of the re recom mended on e Ill. te, but on Tabl Table II I. This is unfort un fort una unate, bu t it is a fact of life, and one mu st do the t he best one on e ca n with can w it h it it,, even it it means me ans occasionally occasional ly borrowing bor row ing the use use of a friend's friend 's machine. Natura lly it will Naturally w ill tend t end to infl in fluuence ence the decision hinking of purchasing decisio n w hen he n tthinking pu rchasing a machine machine..
75 75
TABLE III
TABLE TABLE III (continued) (continued )
FLYCUTIING . Flat surfaces surfa ces as as in Fig Fig.. 16, H H.S .S. cutters, easily sharpened. sharpened. FLYCUTTING. .S.S. Dep th of cut: cut : Depth Mild steel .0 30 in in.. .030 Brass .0 4 5 in. in. .045 Brass Light Alloy A lloy 60 in. ..0 060 (inches) Diam eter of Diameter cu tt ing : cutting: Speeds r.p.m r.p.rn.:: Mi ld Steel Stee l Mild Brass Ligh t alloy
1
150 2 30 23 0 57 0 570
KEYWAY CUTIING. With H.S.S. H.S.S. dis disc cutter Fig Fig.. 26, 26 , or slittillg slitting Fig. Fig. 23. 23 . KEYW AY CUTTING. (inches) (inc hes)
It 11
2
21 2 l2
3
31
4
4t
5
100 150 3 80 380
75 1 15 115 28 5 285
60 90 90 230
50 75 75 190
45 65 65 165
38 57 14 5 145
34 34 50 1255 12
30 46 1 15 115
Cutter diameter diameter.. Speeds r.p.m . Mild steel stee l Brass Bras s Light Alloy Al loy
2
2t
3
31 3 2'
4
65 115 1 15 190
55 95 95 155 15 5
45 75 125
38 65 110 1 10
33 55 55 95
GEARCUTTING. S. Brown i in. GEARCUTIING. Commerc ial H.S. H.S.S. Brown & Sharpe Sharpe cutters 2 2~ in. diameter di am eter. Fig Fig.. 42. 42 . Speeds Speed s r.p.m. r.p.rn. 48 M ild steel ste el 80 Brass 110 Light Light A lloy 11 0
Sp eeds may well be lim it ed by the exten sw arf throw n abou abo u t the workshop can be Speeds limited extentt that swarf accepted.
'Hom e-m e made' produced steel '., ade' cutters prod uced from 'silver steel'
ENDMILLING . Sp ute H.S.S. ill s. Dept h of iame te r up ENDMILLlNG. Spiiral ral flflute H.S. S. endm endmill Dep th of cu t up to to ~ of cutter d diameter ter. Wid th of step be ing cut to 3/ 3/1166 in., then up to -i- ooff diame d iameter. being cu up to } o f d iameter. iameter. (inches) (inches) Cutt er diam et er 1/1 6 3/32 1/8 1/ 14 3/8 1/2 3/32 5/8 3/4 Cutter diameter 1/ 16 1/8 3/16 3/ 161/14 3/ 8
Cutter eter. Cut te r diam eter, Speeds r.p.m r.p.m..:: Speeds M ild stteel eel Brass Allllo y Light A
t
Spee dss r.p.m .: Speed r.p.m.: M ild steel Mild Brass Bra s Ligh Lightt alloy
18 0 0 15 0 0 12 00 800 1800 1500 1200 800 65 65 0 2500 2000 1600 160 0 11 50 850 1150 3500 30 00 2 500 17 00 14 00 3000 1700 1400
450 650 120 0 1200
2 50 350 8800 00
18 0 180 250 25 0 70 0 700
KEYWAY CUTIING ted endm s or CUTTING.. H.S.S. spiral spi ral flu fluted end m ill ills or slot slot dr driills. ll . Fig. Fig . 24 24.. (inches) (inche ) W idth ooff keywa y 1/ 1/ 2 32 1/ 8 3/ 16 1/4 3/8 Width keyway 1/ 16 3/ 3/32 1/8 3/16 1/2
5/8
3/4
Depth of of cut: cut : Mi ld steel Mild stee l Brass Ligh Lightt alloy
100 100 140 140 13 5 135
00 2200 250 300
2250 50 3300 00 3350 50
350 350 450 45 900 900
250 250 350 350 800 800
18 0 180 250 250 70 0 700
Speeds r.p.rn.: r.p.m.: M M ild ild steel steel Bras s Brass Light Light alloy alloy
76 76
3350 50 450 00 9900
(thousand ths of of an inch) (thousandths
10 10 12 15 15
15 17 17 18 18
180 0 1800 2500 2500 3500 3500
1500 1500 2000 2000 3000 3000
25 27 27 330 0
30 40 45
445 5 60 665 5
70 10 0 100 1110 10
450 120 0 800 0 450 1200 650 800 65 1600 11 50 850 650 1150 850 650 2500 0 0 140 0 1200 1200 1400 2500 17 1700
(inches) (inches)
1.t 1t
1q2t
2
2t 2}
60 120 180 18 0
50 100 10 0 150
338 8 75 110
30 30 60 60 90 90
may be be I:ulters. maade' de' silver steel cu KEYWAYS, Using 'hom e-- m WOODRUFF KEYWAYS. tters, Speeds may cutters. commercial H. .S. cu incr ased by one third th ird for f r co increased m me rc ial H,S.S. tters. (inc hes) 1/2 3/ 8 1/2 1/4 3/8 5/ 16 1/4 Cutter diamete r. r.p.m.: Speeds r. p.rn .: 200 300 200 250 30 0 380 Mild steel M ild steel 450 580 3350 50 700 70 0 Brass 650 650 1000 800 10 00 900 Light All Alloy Light oy Cast iriron unless exceptionally har . may may be cu t at th the same revs 'INS.. as mi mild steel, Cast on,, un less excep tiona lly hard, e same ld stee l, but for on carb carbo steell ('silve ('silverr stee steel'). steels. CUlling stainless work on onn stee l'). alloy stee ls, and free CU ll ing sta in less reduce revs. one third. For non non-magnetic stai nless by half. half. by one - magnetic stain less reduce by
77 77
CHAPTER 15
Work-holding with Difficult Shapes Problems arise from time to time Pro blem s do arise regarding th e m met reg ardin g the ethhods ods o off holding work in the milling achine. In I n fu ll sca le engi engineerthe m illing m achine. neer these p ro blem s are not nea nearly s acut e ing th ese problem rly so components more clam ps as compon ents are m or e solid and clam can be app lied w ith out crus hi ng the applied without crushing pieces. Often with wi t h model mode l parts it is gett a hold sufficiently rmly diffi culltt to ge di ff icu sufficien tly fi rm ly withoutt m mo re or or less mutil muti lati ng the t h piece. withou ore ating One m eth o d I ofte n use bo th for castin gs often both ca tings ethod materiall is to arrange fo forr an and bar materia chucki left on the accurate chuc ki ng piece to be left component operations co m p one nt unti l all operati o ns are co o rem co m p lete and th en tto re m ov ovee th is. Generally piece made of Gener all y this this p iece is m ade to su it one of' the M yf ord coll et s, from t in. diam et er Myford collets. diameter downwards. the co collets dow nw ards, since the lle ts do hold the with accuracy. and after turn turning part w it h great accuracy, ing transferred operations it can be tra nsferred to the with collet placed divi ing miller w ith the coll et pl aced in a di viding done., head ; even if no indexing has to be done the head act tive vice. actss as a very very effec effective thin presen Som So meetimes times thi n compo nents prese ntt lems holding thee m milli ng prob le ms iinn ho ld i ng on th ill ing m ach ine. If one e is already flflat at one can machine. one sid side use do ub le- side d sticky ta pe, available double-sided tape. ff ice supply shops and from drawing o office so me stationers. If tw o or some two or three strips can be used ly firm grip used., an astonishing astonishingly ri p can be obtained, hich w ill stand obtained. w which will stan up t o shea shearr forces induced by m illing. illing. I have also in an
78
stuck metal industrial p lant stu ck down m et al which way across had to be tooled to oled all th e w ay ac ro ss th e piece. false wiith h woodw woodworker' p iece, on a fal se base w ork er'ss of new new spaper. paper. A After he and a sheet of glue and fte r tthe operations leted operation s are comp let ed a fine chisel is knocked in betwee n the th e part partss and tthe he be tween pa perr ttears ith in its its thick thickness. 0 the pape ears w ithin ness, so th e apart withh some pap paper rt wit er pieces come apa sticking ca n th en be washed st icking to each . This can off w with water. There nothing off it h hot w at er. Th ere is not hing very orig his, origiinal n al abo abouut tth is. of course, course. it is an age agepattern m akers ' m method prod ucing old pa t ter nrnakers' eth od of pro duc ing a pattern which patt ern wh ich has eve ntua lly to be in hal ves , but t hod not halves. bu t it is a sound me method no nea rly wel l known as it sho should Fig . 5 53 so well uld be. Fig. 3 b ing faced shows a light alloy casting being ith r. the rig ht across w it h a flycutte flycutter, th e cas ting bei ng stuck to the t able wi with th sticky tape nothing else. and no th ing else. However. ariou exam pl es give n How ever, tthe he var io uss exampl th roughout th the should throughout e book shou ld serve to show o undert unde rtake of how tto ake a really wide range of jobs.. A Att the risk of seemi seeming repettitive itive I jobs ng repe wo uld agai again stress that worth would n st ress th at it is often wort h w hile to m ak e a jijig g fo din g or loc ating while make forr hol holding locating th ake sure it can be held thee work work., j ust to m make fifirmly rmly enoug h without da mage ht enough m age in the rig right attitude nd of ji gs and fixt ures atti tude . The ki kind and fixtures neede d in m od ellin g se seldo m involve mo r needed mode ll ing ldom more tthan han a few few mi nu tes or pe rhaps an hour minutes perhaps hou r to make, rds the co mpo make. and if this this safegua safeguards compo
Fig. 53 Tape-held workpiec e being fly flyccut ut Fig. Tape- held w orkpiece
angleplate vee-blocks Fig. 54 Three-face ang leplate used to align vee-b lo cks
79
CHAPTER CHAPTER 16
16
Milling Chucks Chucks for for Safe Cutter Holding
Fig. 55 55 Three-face Three-face ang ang lepla leplates used as as m main p acking acking Fig. tes used ain p
nen toolss and nentt,, as as well w ell as as the t he tool and machine m achin e.. it it is time well spent. If a duplicate is ti m e we ll spe nt. If a duplicate co co mpom po nent nent is is ever ever needed neede d tha thatt wi w i llll be be produced produce d expeditiou sly w ithout risk t oo. exp editiously w it hout risk t oo. Angleplatas A n gl eplates s been A A new new type type of of anglepl angleplate at e ha has been introduced by Hemin gway. This has int roduced by Hemin gw ay. This has three three faces m achined at 90 degrees to on e faces m achined at 90 degree s to one anothe r. I have found over m any years ano the r. I have found over many years that -in th at cas castin slots slot s in in anglep ang leplates lates never never seem to be In the rig ht pla ce fo seem to be in the righ t place forr any any job, job, and and itit seems seems better bet t er to to just just drill drill aa hole hole where wh ere itit happens happens to to be be needed. needed. These Th ese
80 80
an gl wh i c h a rree sent out g l e p late l a t e s, s , whic un mach ined in ligh oy. are in three unm achined lig htt all alloy, sizes sizes very convenient conve nient for use in in ho me me workshops wo rkshops and can easily be faced up on late. the Myford M yford lathe lathe bo ring rin g table t able or o r facep faceplat e. Fig Fig.. 54 54 show show ss one on e of of th them em se sett across across aa mi -b lockss in milller ler tabl tabl ee ttoo loca locattee the the tw twoo vee vee-block in which ti ng . Fig. w hich the th e work w ork is is res resting. Fig. 55 55 shows show s another ed as anot her pair pai r uused as main main packings packing s w w ith it h Pica dorr stepped Picado st epped blocks blocks oonn top t op to t o give give the th e he clam last ment last bit bi t of of height heigh t adjust adjustme nt for for tthe cl ampp an y sizes plates. pl at es. So So m many sizes are are available ava ilab le by by ecting different sel selecting di ffer en t attitudes atti tu de sof of these the seblocks blocks that tha t they they are arevery very usefu usefull indeed. indeed.
Th e newcom rtical ng m The newcomerr to to ve verti ca l milli milling may ay wo nde r w hy there wonder why th ere should should be be any any need need for for special ch ng cutters, ch ucks ucks for for m milli illing cutt ers , and and especially especial ly w w hen hen he sees that tha t these these are fairly expensive accessorie s. may be accessories. tem pte d tto o make do w itho ut one. tempted ithout on e. But first of ssary to realise at tth he of all itit is nece necessary re alise th that e force miilllling ing cutters in use forcess acti ng upon m are generally e diff erent from those generall y quit qu ite different act ing on dr il lss in a drilling mach acting drill dril li ng m ach ine or The usually subject ed,, except lathe. Th e drill is usua lly su bje cted m ent com plet e penetrat pe net ration at the mo me nt of complete ion ., to axial fo rces only, on ly , which whi ch press press it more mo re and axi al forces in to the t he Morse M orse t aper ho hole in le in m ore firmly int the spindle. spindle. Even Eve n if it is is held in a drill drill the chuck and has has aa para para lle llell sha shank, t he same sam e chu ck and nk, the thi ng applies. applies. thing Butt the th e mi m illing cutt er is is subjected subject ed to to Bu lling cutter transverse forces, for ces, across across th thee axis, axis , and and transverse unless itit is is screwed screw ed on on the the spind spindle, these unless le. these forces have have aa componen co m p on entt which wh ich is is forces pressing against against the t he in inside of the the Morse Morse pressing si de of tap er ho holle, e, and and thereby thereby trying try ing to to cause cau se the the taper cutter to to slide slide ou outt of of the the sp spindle Each cutter indle.. Each ti me tthe he spindle spindle rotates rota te s the the pressure pres sure isis time transferred to to the the opposite opp osite side side of of the the transferred hole, e. and this wagg waggles the tool tool out out of of the the les the hol nd this tool mounted mounted spind le. So first fi rst of of all, all , any any tool spindle . So by aataper t apershank. shank,whether whether itit isisaachuck ch uck or oraa by MUST be be solid endmill endm ill with w ith taper taper shank, shank, MUST solid
pro vided w ith aa drawba with drawbarr through th rough the the provided spindle is ten spi ndle to to stop stop th this tendency ency to to w w ork ork out. out. For cutt ing tools w hich in ope rat ion For cutting tools w hich in ope rati on prod uce no no end end forces forces that that precau precau tion tion is is pro duce suff icient. e spiral suffici ent . But Bu t all all th the spiral flfl uted uted end end m mills ills and slot dr ills do gene rate end forc es, and slot drills do generate end forces. tending e holding to screw screw tt hem hem out out of of th the holding tending to device. lies to device . (Strictly (Stri ctly speaking speaking this this app applies to cutt ers w at ion, like ith righ ri ghtt ha ha nd nd rot rotation. like a a drill, drill, cutters w ith and right ha nd luting also like like a ri ght ha nd fflutin g,, also a drill. drill . But But and as it it w w ould ould be be re rem ark able for for any othe rs, m arkable any o the rs, as tho ugh m anuf actured, t o be fou nd in a tho ugh manu factured, to be fou nd in a home works wo rkshop thee others others ca can we llll be be home hop., th n we disregarrded. ded.)) So So spi spiral ed cutters cutt ers w w ill ill ral flflut ut ed disrega try t o work ou t of a chuck, if parallel try to w ork out of a chuck, if parall el shanked, and m ust be fo rcibly prevented. sh an ked , and mu st be fo rcibly preve nted . It is is not not good good enough eno ugh to to ho hold ld them th em in in aa It thre e-jaw e-jaw lathe lathe ch chuck, uck, especia especiall since llyy since thre mo st of of these th ese exert exert more mo re pressure pr essure at at tthe he most in ner end end than tha n the th e outer, out er, th through wear inner ro ugh wear existing in th the jaw slides slides,, in in effect eff ect giving givi ng existin g in e jaw them aa slig slight t aper.r. them ht tape This isis where w here th thee specially specially designed des igned This mill ing chuc k com es int o its ow n. Ther Th ere milling chuck comes into its ow n. are tw o bas ic types, but each is arranged are two basic types, bu t each is arranged to grip the cutte r firm ly on it s paral lel to grip the cutter firmly on its para ll el shank by a split coll et clo sed by a screw shank by a split collet closed by a screw thread forcin g the collet into a conica l part th read forcing the collet into a conical part of the chuck. In addition one typ e uses of the chuck. In addition one type uses cu tt ers formed with a specia l shap ed end , cutters formed with a specia l shaped end ,
81 81
Fig. 556 Clare milling milling chuck chuck Fig. 6 Clare
and the the ot other type uses cu cutttters with and her typ e uses ers w it h aa of tthe he short screw th thread at tthe he end end of sho rt screw re ad at shank. The The first first of of these, these, the th e Clare, Clare, has has aa shank. forr the th e cu cutter, and this this rectangular end fo rect angular end tt er, and end is is undercut undercut by by m mill ing. After Aher passi passing end illing. ng itit rectang angu lar slo slott in in the the co collet, llet, the the through aa rect through ular cutter is is turn turned hrough smal angle, so so cutter ed tthro ugh aa sm aill angle, the pa part not und undercut overh angs the t he end end the rt not erc ut overhangs slide out. The The of the the co colle t, and and cannot cannot slid of ll et, e out.
collet is is no nott only only retained retained in in the the ch chuck uck collet body by by all an int intern ally screwed capp w w hich hich body ernal ly screw ed ca fi ts on tthe he bo body. is also also closed clo sed on on the the fit s on dy , bbu utt is shank by by it. it. The co collet screws intoo anot another shank llet screw s int her re ad in in tthe that it th read th he cap, which en sures that en requi required, small spanner loosens lo osens wh en red, aa sm all span ner being prov provided the m makers fo r tthi being ided by the akers for hiss of chu chu ck w ill in fact purpose. This type of pur pose. This tters w which do not not have the the 'tee' hold cu tters hold hi ch do
Fig. 5 57 7 Clar Clarkson milling chuck chuck Fig. kson milling
Fig. ill ing chuck Fig. 58 58 Osborn Osborn m milling chuck
end, and have jus n rou nd shank, shank, justt a plai plain round rse the security fea feature tthough hough of of cou course t ure is then non-exist f orr sma sm allll cu cutt ers nt.. But fo tters non-existeent ill serve serv e very very well. we ll. will and light duty it w The other type type of ch chuck, m ad e both by uck , made Clarkson Osb orn , uses only a screwed Clarkso n and Osborn, shan k typ e of cu cutt er and cannot can not be be used shank tter exc ep t with w ith thi this. Th e screw thread th read on on the th e except s. The shan k, when w hen subjected subjecte d to the the torque shank, orque dr ive th e cutter, cu tte r, provides prov ides the the necessary to drive and th ereby grip gr ip force to t o close clos e the the collet and force the tool t ool shank. shank. A A centre cent re device device inside the t he the bod y engages engag es with w it h tthe he centre cen tre dimple dimple in in body the end end of of the the cutter cutt er to to reduce reduce friction fr ic tion the force s that that would w ou ld hamper hamper rotat rot ation of the th e forces ion of cutte r. TThhee Clarkson Cla rkson chuck chuc k needs needs aa cutter. spanne r, provided provided with w it h the th e tool to ol., to to release release spanner, t he co co llet llet for for ch chang ing cutters. cu tt ers. The T he the anging Osborn e uses uses aa finer finer thread thread on on tthe he Osborne sec ur ing sleeve . ttoge ogetthher wi th som some lost securin g sleeve. er with e lost motio n provisions, provisions. and and can can be be released re leased by by motion
82 82
hand w ithout th e use ner. There ha nd w itho u the use of of a a span spanner. There is provision w ith each each of hese for for using is provision with of tthese using 't hrow - away' aw ay' cutters, w hich hich are ade 'throwcutters, w are m made to :l- in in.. Th These have a a cheaply sizes up up to ch eaply in in sizes ese have plain shank. unscrewed, unsc rewed, of of in .. diameter di ameter pla in shank, in w hate ver the the size size of of th th e e cu cutt ing portion. whatever ttin g portion, w hich has a a sma sma llll fla flatt in in one one place. place . They They wh ich has are set set in in an an adaptor adapto r w w ith ith a a small sm all screw screw at at are the side, sid e, which w hic h bears bears on on the the flat, fl at , and and this t his the is sufficient suffic ient to to prevent preven t their t heir working working out out of of is the chuck. chuck. The The idea id ea of of these th ese cutters cutt ers is is that tha t the they are are made m ade so so cheaply cheaply that that in in aa comcom they m ercial engineering eng ineeri ng shop shop itit wi wi llll cost co st more m ore mercial t o re-sharpen re-sharpen one one than th an to to replace rep lace itit by by aa to new one one .. Whether Whe ther or or not not that t hat is is rea really true new lly true will depend depend on on the t he parti par t icula establish will ularr establishment in in wh w hich they are are be being used,, but bu t in in ment ich they ing used the home hom e workshop. worksho p, ifif there the re is is aa Quorn Qua m the grinder. itit will will be be feasible feasible to t o re-sharpen re-sh arpen grinder, them m at at aa worthwhi wort hwhile cost in in time tim e and and the le cost t roubl e, for for aa wh w hile until aa certain cert ai n amount amo unt trouble. il e,, until
t
t
83 83
of shortening shortening has has taken taken place place.. of cutte rs with with screwed screwed ends ends to to All the the cutters All suit the the Clarkson Clarkson and and Osborn Osborn chucks chucks have have suit Whitworth form form threads threads 20 20 pe perr inch inch Whitworth irrespective of of diameter. diameter. On On in . shanks shanks irrespective in. conforms to to B.S.W B.S .W.. and and on on tt in. in . this conforms this shanks to to B.S.F. B.S.F . for fo r both both of of which which dies dies can can shanks readil obtained . But But for fo r other other be read i lyy obtained. diameters, ifif one one needs needs to to make make aa special special diameters. cutter in in the the home hom e workshop. screwing aa cutter 20 threads threads per per inc inc hh is is not no t aa difficult difficult shank 20 shank specia for the Clare task. Making the spec iall ends for cutlers is not quite so easy in my view. but cutters the Clare Clare chuck chuck has has the t he advantages advantages of of a a the sho rt overhang and a smaller sm aller diam et er of short iameter body, Th This is particularly part icula rly useful useful when when body. is is holding work wo rk in in a a 3 3 or or 4-jaw 4- jaw chu chuck on a a holding ck on dividi ng head head ., when when sometimes some times it is dividing it is difficult to to cl clear th e chuck jaws. But But all all difficult ear the ch uck Jaws.
t
84 84
recommended these chucks chucks can can be be fully fu lly recommended these as being be ing good good pr precision tools which as cision too ls which provide complete complete security security against agains t cutte cutters rs provide worki ng out out in in use. use. IfIf an an accident accident of of that tha t working not having having aa security security kind happens happens due due to to not kind chuck. aa spoil spoiled componentt is is certa certa in. in, aa chuck. ed componen broken cutter Culler is is possible possible., and and II hay have seen seen broken this happen happen on on a number nu mbe r of of occasions, occasions, So So this do be wa w arned don'tt think think the the cost cost of of do rn ed , and don' chuck too high high to to face. a proper chu ck is too Pho t og rap hs of the three t hree chucks Photographs men tion ed are shown shown in in Figs. 56 , 57 57 and mentioned shown 5 8 . The The Clarkson Autolock Autolock chuck shown 58. as in pictures in the the tex t, is here, as we ll as fitt ed wi w ith ring . After A fter the fitted th a damping ring, rse taper, tthis the Mo rse chuck is fixed in the his riring ng can be screwed scr ewed up to con conttact act the end of ca n be mach ine spi spindle, giv ing extra support the machine ndle, giving upport inst vibrati on. aga in st vibratio n.
A RNO LD THROP T HRO P was wa s an an apprentice apprentice then the n ARNO Outside Erector with w it h the the famous fam ous an Outsid engineer Cole. Marchent & Morley, Mo rley. engi neerss Cole, Brad ford. Produc t s: s : compoun compound rd , Yorks. Product d Bradfo Uniflows to t o 1500 15 00 hp, hp. engines to 2500 2 50 0 hp, hp , Uniflows engines Diesel oi l engi engines, Di sel oil nes, condensers for largest pow er sta stations. Lat er he held tech t echnica l tions. Later nica lpower inist rattiiv st s in i n high-tensio hig h - t en sio n adm in istra v e po sts swi tc hqear. mi ning ma m achin ery . st ainless swit hgea r, mining chinery, stainle ss fabrication. mac hine fa brication , machi ne tools, and m arking arki ng devices. A nt he was th Att his retireme retirement thee Dir ector of Ed w ard Pryor & Director of Engineering, Engi neering , Edward Son. So n, Sheffield. He has been an I.Me ch .E. in mo unting I.Mech.E. mounting seniority ing on several se niority over 50 years, ye ars, serv serving com m itt ees and one of mittees of B.S.1. B.S.I. He has read .E. and the me n pap ers rs t o 0 I.Mech I.Mech.E. th e Newco Newcomen pape Socie ty of hi ch he is a mem ber. e has Soci ety of w which membe r. H He worked worked for for half ha lf a doze n years as demon dem onst rator on orkshop Stand of E.E.. strator on the W Workshop of S.M. S.M .E.E at od el Engi ne er Exhibit at M Model neer Exhibi t io io n s, con co ntributed articles er fro m artic l s to to Model Engine Engineer from 193 2,. and an d having having been been in Sheff Sheffield 1932 S.M 7 has been s Presi S.M.E.E. .E.E . from from 193 1937 bee n itits President s. dent fo for.r. some some year years. Founding 633., he Fou nding Dore Dore Engineering Engineering in in 19 196 he redesig ned Edgar 's ve rtic all re designed Edgar Westbury Westbury's vertica m e Dore-Westbury as th the Dore-Westbury mille illerr and and sold sold itit as unti o Mod el Engin eering unt ill tra transfe nsferr tto Model Engineering Services 7 1. Services in in 19 1971. His tion ary His present present interests interests are are sta stationary ipment , gardening eng ines. wo rkshop equ engines, workshop equipment. gardening and ot ography. photography. and ph The author author The
86 86
87 87
Index illin g attachm attac hmeent nt Abwood m mill ing 12 Amo lco m i ll i n g atta chm e nt an ndd Amolco milling attachm en machine m achine 21 A ng leplat es Anglep lates 80 A ng leplate used as backst op Angleplate backstop 27 , 29 27.29 tt ing saw s and disc cu tters Arbors for sli slitting saws 3 5 35 As tra m ng machin e Astra mililliling machine 22 22 Boring operation s operations Bori ng heads Boring
45 3 0 30
Chuc ks, Clare, Cl arkson. Osborn Chucks. Clare. Clarkson, Clutch Clu tch teeth tee th Connecting rods Crosshead slides late bedplate slides., engine bedp
82
Divid ing heads . de s cr iption Dividing descr i ption principle Plain typ e. change el type. change whe wheel indexing Myford w orm -geared worm geared type type Use of ision plat es of div division plates Use of of locating blades blades Packing block for for centre height Steady stand for for extra rigidity Dividing head s and heads and gear-cutting Plain type type Pin ion cutting Pinion Large gea ng gearr cutti cutting
88 88
5 5 55 43 30 an d and 54 55 55 57 57 57 57 57 57 57 57 56 56 62 62 62 62 62 64
Dividing Divi ding heads and graduated scales scale s ing/slotting Plan Planing/ slotting and rotating too lls Table Tabl e stops stop s and liline ne length control co ntrol Cutting/engraving le ng/engraving cy lindrical sca scale Cutti arcuate scale sca le Cuttiing/ ng/engraving Cutt engraving flat arcuate micro meter Conical Con ical m icro m et er dials Marking res of of scales sca les right way M arkin g figu fig ures Dividiing ng heads and tool-m tool - making Divid aking screwing Fluting screwin g ttap ap Cu tting ine tooth m ililliling ng cutter cutt er Cutt ing ffine countersink Cutting large co unter sink Speciall di division plate Specia vision pla te.. 2 5 hole D- bit forr hol hole centring drills D-b it fo e cen tri ng to start dri lls Dore-Westbu ry m ill il lin gm machine Dor e-W estbury ing achin e End-round End-ro undiing: ng : Filing coll collars ro llers Filing ars and rollers Using rotary tab table Using le for rot rotary Fittings for ary table Rounding engine cranks Direction of table rotation Direc tion of Locking precautions external Lo ck ing pre c auti on s ffor o r ex te rna l work Engine bedpl bedplate jawss ate bearing jaw Engine cylinde soleplate Engi ne cyli nderr solepla te E olution vertical miller Evolut ion of ver t ical mi ller Flut ing op era t ion s.. locom ot iv e rods, Fluting operations locomot rods. cor rec t fflute lut e form correc British Rods for Briti sh engines Rodss for for Ca Canadian American Rod nadian and Am erican engines
71 71 71 71 72 73 7 3 73 73 73 66 66 666 6 677 6 69 6 9 70 47 47 14 14
52 52 52 5 2 52 52 52 52 52 52 53 53 33 33 30 12
444 4 43 43 443 3
89 89
Flywheel (i n halves) joint joint face Flywh eel (in
3311
cutting Gear cutt ing engravi ng cutlers cutters and o DGrinder for engraving bits
62 62 71
fi cation of cutte cutters etc.. by mark marking Identi fication rs etc ing made whe n made
42 42
JJig-boring ig-boring : Measu ri ng by table screws Meas uring Written record of m measu remen Wri tten recor d of easurem entts s for model eng engine Example of beam for ine leverot mode l eng engine Trip gear lever of model ine plates Boiler tube pla tes errors Avoidance of back-lash back-l ash erro rs Jigs milling J igs for milli ng operations opera t io ns
46 47 47 47 47 48 4 8 48 4 8 46 46 78
Keyways for plain pla in sunk keys keys:: Endmilling feather keyways on plain shafts shahs Keyways on taper tilti ng taper shafts shafts wi thh tilting angleplate Disc cutter milling of keyways Loctiting Locti ting for permanent assembly Long componen t s, holding problems com pone nts, Machine Machi ne specifications, specifica tions. table tab le of Maximat M axim at milling attachment attachme nt
90
37 38 41
27 3 8, 8 . 49 49 24 22
ng ma chine Me ntor mi Mentor mi lli ll ing mach ine Mill ing cutters. lti -tooth : Milling cutters, mu multi-tooth Early e-cut' cutters Early (19 (19tthh century century)) 'fil 'file-cut' Facemills Endm ills End mills Slitting saws saws Disc cutters Woodruff cutt ers cutters Brown & Sharpe Sharpe cutters Tap flut ing cutters cu tters A ng le cutt ers Angle cu tters h: M illing cutters, single toot Milling tooth Flycutters Connecti ng rod fluting cutt er Co nnecting cu tter Profi led gear rs cutters Profiled gear tooth tooth cutte Engraving cutters Milling operation s: operations: surf aces parallel Flat surfaces to table surface s squa square Flat surfaces re to table cut ti ng Slitting and cutting Com ponent flut ing Compone nt fluting Tool fluting End rounding Gear- cutti ng Gear-cutting Keywaying W oodruff keys keys and Woodruff keyw ays keyways Bor ing Boring J ig-boring
22 22 12
30 338 8
3355 40 40 40 62 62 67 67 69 69 2 7 27 43 43 62 71
32 34
35 43 67
52 62 62 39 39
38
45 46 46 91 91
Profili ng Profiling Engraving Engraving Myford-Rodn ey milling m illi ng attachmen attachm entt and and Myford-Rodney m ach ine ine mach Myford collets co llets Myford Myford dividing dividing head head Myford Profiling Profiling:: Circular Circu lar arcs arcs Locomotive Locomotive frame framess es Sm okebox and linder saddl Smokebox and cy cylinder saddles Pad-bolts Pad-bolts Sma ll ar c s dder er ii ved rom ccurve u rve ooff Small arcs ved ffrom end mills endmills Quo rn grinder ning Quorn grinder for for tool tool sharpe sharpening Quorn nder , parts Quorn gri grinder. parts of of
92 92
49 49 71 71 21 21 62 62 57 57 49 49 4 9 49 4 9 49 49 49 51 51
83 83 35 ,71 35.71
Rota ry tab les Rotary tables Rotary e.. M.E.S. Rotary tabl table M.E.S.
52 52 52 52
Senior ng m achine Senior milli milling machine Security ill ing cutters Security of of m milling cutters:: Forces ing upon Forces act acting upon drills drills and and cutters cutters Use Use of of drawbars drawbars in in machine machine spindles spindles Positive ing of Positive lock locking of screwed screwed cutters cutters in in ch uck s chucks Posit ive locking Positive locking of of Tee Tee cutters cutters in in chucks chucks Slitting cutting operations operations Slitting and and cutting Speeds illing cutte rs of m milling cutters Speedsof
22 22
Tapered Tapered sections Throw-away' cutters cutte rs Twin Twin milling mil ling machine mach ine
29 29
Vices. Vic es. use of two tw o together tog ethe r
27 27
Westbury. Westbu ry, Edgar T. Westbury m milling machine illing m achine Woodruff keys keys and and keyw keyways Woodruff ays Work holding fo r difficu difficult lt shapes: Use of of chucking chucking pieces pieces lat later Use er discarded tape fo forr t hin art articles Sticky tape icles Glue and and paper paper for for tthin articles Glue hin articles Specially made jigs jigs for for di difficul Specia lly made ff icultt shapes shapes
14 14 14 14
83 83 22 22
38 38
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8811 81 81
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ENGINEER ENGIN ER ",on't won't let
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PRACTICESERIES WOR HO PRACTICE WORKSHOP SERIES 1. IHardening. Tempering and and 1. fardenmg, Tempermg Heat Treatment Treatment Heat Tubal am din Tubal vertical Milling Milling In in the the Home Homo 22. Vertical Workshop Workshop Arnold Throp Th rop Arnold
in the the Lathe Lathe 3J . Screwcutting rewcutting m Milflin Cleeve Cleeve Martin 4 . Foundrywor~ Foundrywork lor tor the the Amateur Amateur 4. B. T. A Aspin B.T. pin Milling Operation, Operations In in th the Ldthe Lathe 55. Milling Tubal Cain Cai n Tubal Measu ring dnd and Marking Ma rking Metals Meta/~ 6. Mea~urin8 LdW Ivan Law 7. The Art of Welding 7 W.A. Vause Vause W.A
1II1 1I~I3'13I~1II'9525 111 1 1 1 ,11~11~1 1 ~111 W 111111 I I1I1~ 1 ~111 11001 111111 1117696 1 117696 illi 66 9525 001
8. heet heet Meta! Work 8. felal Work R.E R.E. Wakcford Wakeford 9 . Soldering Soldering and and BraZing Brazing 9. Tubal Cain Cain Tubal
Saws and ami Sawmg SawlI1g O. Saw~ 110. Ian Bradl Bradley lan y Electroplating 11I . Electroplatmg Poyner JI. Poyner
onn«
12 12.. Drill , T,lP; is» and ,md Die} Dies Tubdl Cam Cain Tubal
Wor kshop Drawing 1I J . Work hop Drawlnl{ Tubal Cain Cain 14 . Making Mak ing mall Work,hop Workshop Tool, Tools S. Bray
15. 15. Workholding Workholding In in the the Ldthe i.athe Tuboll Tubal Cam Cain 16 16 . flectric ElectricMOlOrs Motor" V.1. V.1. Cox Cox 117. 7 Gears Gears and and Gear Gear Cutting Cutting I.I. Law Law 18 work 18. BiHI< B""ic Bench Benchwork Le .. Oldridge Les Oldridge 19 prmg De"sn \1dnutacture 19. Spring De'ign dnd and 1\ t.mutocture Tubal Tubal aln ain 20 . Metalwork Mt't,l/work and Machlnmg Mac hining Hmt Hint dnd and TIp; Tip« lan Ian Bradley 21 21.. Adhesive Adhes ives and Sealants Sea lants Davld Da vid Lammas Lamm as
2. Vertical Milling in the Horn Hom W orkshop orksho appearanc of vertic, vertic I mil lin ling machines in model The increasing appearance g machines work hops has ha brou brought ver atil ityy of thi thiss engineers' and other small workshops ght the versatilit p t ntial type of machine to the notice of a large and growing group of pot users, but until the fifirst published 1977 users, rst edition of the book wa s publi shed in 197 7 there waas little easily available guidance guidanc for the average am amat ur or small user. w ateur third,, revi revissed d ed itio ition description of many of the very v ry w wide This third n incl udes descriptions ide range of op erations possible, wi th photograph ed examples, plus operation photographed piu infor informat ion on machines, acce cutters, chucks, mation acc sories, ori ,cutter, hucks, r quirement quirem ntss and methods of work-holdi ng. work-holding. and successful engine ngine ring ring care r Arnold Throp enjoyed a long and steam and and oil engines and including including high tension ten ion very larg large steam starting with very swit hgear, mining mining machinery machinery and and machine tool tools. hieved sw itchgear, s. He has aa hi eved over 55 years' echanical years' membership member hip of of the the Institute of of M Me hanical Engineers. Engineer.
ISBN 0-8 0-85242-843-X ISBN 5242-843-X
I £6.50 £6.50 net net UK UK
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