Workshop Practice Series 35 - Milling, A Complete Course

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Holl,hosestoblished o reputtionforintrV ucing theNro modelengineerto a wide ronge ofmochine tx lo- rotions.In this im ok he introducesle milling mochine.

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users ofthe milling mochine i rou:h oIIofthe e hniques involved.W hilsfth deMile descriptionsinle G koreoimed primorilyoltbo- wishi '

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FirstpubIishedbyS.I.ModeIBooks Ltd.2004

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Preface

@ SpecialInterestModelBooks Ltd.2004

9

Chapter1

G etting S'taded

11

Chapter2

Tee Nuts

15

Chapter3

An Angle Plate

27

Chapter4

C lam ps

35

Chapter5

Parallels

39

Boring Head

46

Chapter7

Dividing Head

60

Chapter8

G rinding Rest

76

Chapter9

G rinding Rest-the m ain accessories

94

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Chapter10

The End M illSharpening Fixture

107

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Chapter11

Using the End M illSharpening Fixture

121

Chapter12

Tooland CutterG rinding Head

128

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The rightofHarold Hallto be identified as the Authorofthisworkhas been asseded by him in accordance withthe Copyright, DesignsandPatents Ri ghts Actof1988. AIIillustrationsand diagrams appearing in thisbookhave been originated by the authorexceptwhereotherwise indi cated.

AIIrightsreserved.Nopartofthisbookmaybereproducedinanyform byprint, photography,microfilm oranyothermeanswithoutwrittenpermissionfrom the publisher .

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ISBN1-85486-232-4

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The main purpose ofthisbookisto assi st wellashaving the projectstocomplete. the newcomerto the mill ing machine to become an experi enced beginner.Thi s is

Com ing to terms with operating the m iliing m achine is qui te di fferentto thatof

achieved by providing a range ofprojects using the centre Iathe.In the I attercase : .

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usingthe centre Iathe,then the sisterbook to thi s itLathework,a Com plete Course -

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of detail for com pleting the turned after m achining, is what creates the components.However,should the reader probl ems which have to be resol ved.The

feela need fora greaterunderstanding of projectsinthisbookaim togi vetherequired

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thecentre I athe(themainmachine i n most operation varies Iittl e.However,the wi de workshops)and givesa minimum amount variety ofcomponentshapes,before and

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the range of m achining processes is com parativel y Iarge, outside diam eter turning,boring,screw cutting,parting off, high precision work,etc..W hen using the milling m achine the actual m achining

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to com plete which togetherw illgive suffici enttime spentusing the m achine for this to be accomplished. The book assum es thatthe reader already has a good grounding inthe use of

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Workshop Practice Series No.34''would m ake usefuIreading.

quantity and variety for the newcom erto be very much athome using the machine.

Whilstjustreadingthebookwi llprovide much usefulinform ation this willbe a poor

W ith the three main projects being substi tute to actually making the i tems qui te sizeabl e,and the item s produced of described. The reader is therefore considerable use in the workshop,the encouraged to make atleast most ofthe

bookisnotjustintendedforthenewcomer i temsdetailed. to the m illing machine.The experienced usershould also find the book beneficial, Harold Hall no doubtal so gaining some usefultips as M arch 2004

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sizeable projectsratherthaneachdealing

Having pai d some E600 fora I otof

wi th a particularprocess. W hen Ipurchased m yfirstmachine,a mi d size mill-drill,i twas in the earl y days of these appearing on the m arket. Isoon found thatthe accessoriesprovided were farfrom adequate.

machine,i tseemed outofproporti onto pay E100 plusforsuch a sm allitem asa milling cutter chuck. Today a chuck can be purchased a Iittle more cheapl y,butifyou wantimperi alandmetriccollets,and orup to 16m m/5/8inshankdiameter,you wilstill be paying a I arge amountwhen compared

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; M illing cutterchuck L

to the costofthe machine.Unfortunately, the bad news i s thatitis quite impossible to m anage withoutone. An al ternative i s to use cutterholders, these consistofa tapershankbored totake a singl e size cuttershank,butas a num ber ofthese are required theircostwould not be that much di fferentto a cutterchuck. They are also theoreticall y Iess accurate, being unable to compensate for di ffering cuttershank sizes whi ch occurdue to the

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m achining was notprogressingwell,surely the m achinewasnotthatinaccurate.Itsoon became apparentthatthe m i lling cutterwas being pulled outofthe chuck due to the spiralform ofthe cutter.Only i fItightened the drillchuck excessivel y,and then onl y if 1 took very Iight cuts, could I m ake sati sfactory progress.

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m aking som e $ T ''nuts became the first

w hen using the centre Iathe as the machining proceqsvaries li ttle from taskto task.W hatdoes vary is the shape ofthe partbeing machinedcreatingproblemswi th m ounting, m achining in the required position and measuringto ensure a correct partis the result.Forthis reason the book attem pts to create progressively m ore

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Usingthe m illing machine does noti nclude

the range ofoperations thatare available project.Immediatel y,Ifound thatthe

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The machine was provided wi th drillchuck, tilting vice and a sizeable face cutter' , apparently,even now,thisis the kitofpads mostoften provided.The absence ofany $ T''nuts,afundam entalfixingdevice forthe m illing m achine, prevented m e from mounting my vice,a peculiaromission, especi all y as Ihad also recei ved a small selection ofend mills.However,with some temporaryfixingsthevi cewasmounted and

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2.An end m j/!can only plunge by a VeW Smajjam ognj due jo j ys jpa:jjjjY jo Cutto the COl'lX . Thl s m akes it ''

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Cuttlng enclosed slots.

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range ofshank diameters and types.Itwill

1 l s ui s zei sub c t e t e sr t ,r p ee sr e hr a vp es da fo1 r6 mmom unt s ih na gn ak nw yh oe dn d al soH pa r o vv i n i dgeo vb at l ui a an be l e dt y uo r n ui n rg cu et x te pr er c i e hn u cc ek. j! onlya12mm colletchuckisavailable , r

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making the remaining essentialitems can

l . The Mill ingvice nom s weco cu mt m t ee rs nc ae n. dYa ou fewi l ot oh fec ros um rs a eln to eo el d s y vice Ireceived was robustand proved thatIwillnow dealwith. '

thin its capacity, to adequateIyhold parts wi

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accuracyIeftm uchto bedesired.Beingof Basiccutterscom eintwoforms,endm ills substantialconstruction there was scope and slot drills.These have a m axim um forre-machining which Idid.However, diameterof14m m fora 12mm shank and because of its tilting facility,it was an 20m m for a 16m m shank. The m ost involved task.Aswillbe seen,a vice i s not comm on form has a threaded end to the as essentialas i s often considered and shank and requires a colletchuck system

al though itsoon became apparentthatits M illing cutters

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thecostwhi l ststi laccommodati ngawi de i fonl yI i ghtl yti ghtened.Oneexcepti oni s

thi s form .Plain shank cutlers and suitable collets are becoming more available but they stillIack the absolute certainty ofthe cutternotbeing drawnfrom thecollet,even

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On the right is the two cutting edge, slotdri llwhere i tcan be seenthatone edge is m uch Iongerthan the otherand passes centre.This perm i tsthe cutterto cutto the centre and can as a resultbe plunged to permitthe cutting ofenclosed sl ots. In the m i ddle is a m inim illthat has three cutting edges,aIIofwhi ch cutto the centre and can be used both as end mills and sl otdrill s. Recentdevel opments in cutting tools

using replaceable tips (thathave been widelyavailable foruse in turning formany

years)arenow becomingavail abl e asend

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m illsand face cutters foruse on the m illing m achine.There is though a Iim i tto how smallthey can be m ade and conventional cutters in the sm allersizes,especially slot drills,are stillrequired. A face cutter,often supplied as an beingplunged (ascanbeseeninPhoto2) accessorywith the m illwhen purchased is by very m uch so their use for m aking usefulformachining I arge areas.They are notthough essentialand Iwillcom ment enclosed slots i s impracticable.

more willbe said onthe subjectthrough tosuit.Iwouldstronglyadviseyoutoadopt

the book. If9ou wantto minim ise expense then the miling cutterchuck described in the sisterbook W PS 34 willconsiderably iimit

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the 6m m shank cutterthatis notintended for re-sharpening and does com e with a plain shank. End millshave fourcutting edgeswhil st slot drill s have onl y two.As their name i m plies,slot drills are form illing slots;in padicularclosed end slots and whilstata push end m ill s can be used forthe process this is farfrom i deal.Both forms ofcutter should therefore be obtained. The 6m m shank cutters are di fferent and have 3 cutting edges and function adequately as bothend m illsand slotdrills. These are known as dm inimill s',Qhrow away mills''and othersuch names. The three forms can be seen in Photo 1 thatillustrates the basic difference.The end millon the I efthas fourcutting edges, aIIofequalIength butstopping shod ofthe centre ofthe cutter.Thispreventsthe cutter

1.The three comm on torm s ofcutters ,leffto rightend m III,m lnim illand slotdrill. permitted tolerance intheirdi ameter.Their

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square (two insome cases)i s also useful

f orposi ti oni ngpart sonthetabl easwi lbe seen through the book.

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Measuri ng parts being made onthe m illing machine i s far more difficul t than sim il ar Rem aining essenti alitem s tasks on the Iathe,and largerdim ensions The remaining essentialitems,clamping arealsoIikel y.Therefore,a150mm verni er accessories,an angle plate and parallels, i s essenti al,Iikewise a dialtestindi cator are quite sim ple and Ipropose thatthese foraccuratel y placingthe parton the table, shoul d be the basis ofthe projects in the and relati ve tothe cutter. An engineer's early chapters.

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As m illing machines vary in size sothe : T' slots are bound to differ in size, it is im possible therefore to quote dimm ensi ons.You m ay Iike to do some research to establi sh the parti cular si zes r to suityour m achine butthat is farfrom

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essential,a Iength ofnutatIeastequalto butmakingtwonutsbyhand(hacksaw and the width across the 'dT' ' should be file)would be the si m plestway out.Ifyou

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sati sfactory.Also,do not make the width and thickness of the arms ofthe NT''too

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AIII?IIFIECE kIIhILJTE SIAZTINC CIJT Njjggjjjjsjjjjjc g(;y. --------+- MOVEMENT

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already have some RT''nuts avail able, I woul d stillask you to considerifyou have

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close a fitin the slotas smallfragm ents of swarfwillmake itdifficultto slide the nut into place. W anting to m achi ne some .T'nutsbut without any ini tial ly available presents a probl em .-rherearevariousways roundthis,

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foreventualcutting i nto individualnuts.The m a t er i al us ed s houl d obvi ously be atl east , ' as wi de as t he chosen wi dt h and as deep i ' . . y . ' ) y . : t ? y ? è . . : ' A z v l x ' . ' ' . , ( L . , L . r i . j yy k h j .. j yjjq;. t y t .j yy yy , VLt. y jj,j y, jy -j sx yysx . as the totaldepth of the nut.lt i s likely Lj) jy.) t y ) j ) , > . y . . . , . y . . . . .. .- ? : y a y o y . ; , y' ( . ï . ' ) ' . î L j p y i t q t t j k ) . t . . ) ' . ) . ;' y.. .j. j ) ; . t k . . n . k. , y ) . . y . . ' howev er t hat t he m a t er i al wi l l ha ve to be & ':'ï? p ? . . -'; ', '. ' ) j,...:.4.'.' . ij , t j ? t . .y 'j -I ./ over t hese si z es and t h e sequen ce that . ,..,. ) jt kt , ) . ; .) j .t. lt4 ! )L ) L T1 . L l q ) v' 4r . follow s, provides for reducing these i ) . !. di m ensions as required.Markthe material :( ,. . ... .q$) outfordrilling and tapping,rem embering .'? kq.. ) ..> the 2m m all owance,and drillthe tapping si ze hol es,Photo 1. Mountthe materialasshown in Photo 2 usingthe two temporary nuts.W hiIstthi s appears to be a sim ple operation, it imm ediately becom es apparentthatthere :,/ ' *t is more to it than first appears.The < clearance ofthe tt T 'nutin the slotand the 1.Drilling a Iength ofm aterlalto m ake screws i n the hol es,perm i tssome variation 4 yyp ,Nstsi n the positionthe parttakes up.Obviously, almustbe true to the sufficient; 8 woul d seem the absolute the Iength ofmateri mi nim um .Iwould al so suggestthatsome axis ofthe table otherwise the width ofthe are made with different thread sizes, machining w illvary end to end. For precisi on,a dialtestindicatorin the chuck, tv b 'ut oicas' all vwi M8 andseen Mlo,.T hi sma vlsfiend emua lot orapurposemademounting,testingalong llbe they wil ses beyond whatisnormall y consideredto be the length ofthe partasthe table is moved t heirpurpos e.wherespaceisIimi ted,itis is the way to proceed.Forthis situation occasionall y helpfulifthe clamping stud 2.Positlonlng the m aterialon the could be moved overa little.This can be m illlng m achine table. done by havi ng a few which are tapped off tl'f 5. '''%'' centre,see SK 1.Ifyou considerthatyou 7 t)k' ) ik ') have su#icient,pl ease do readthischapter ? ,)'? .. =2. x ' carefully as it deals w ith the m illing operati on in more depth than elsewhere in î'ntn.?.?). .... the book. '7 ' ' 1Lvglxx.t u.. j 1 Making the 1'T''Nuts 't,, . ,- ...,.zk .ç , I) Maketwotemporary r nutswi thathread si ze one size smallerthan thatchosen for the nutstobe made, typically,M8 ifM 10 ' nutsare envi saged.Cuta I engthofmateri al )

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fn i oc rlu mdainkgina gnta hl elow nu am ncbeersay ofn utsre qui red, 2mm per nut

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recommendation.However,in industry,

Up and Dow n m illing

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m ove the table forward as i ttakes up the play in the Ieadscrew.This suddenforward m ovementwi llgive a dramatic increase in the depth ofcutwi th possible disastrous thetableusingsomethin(0.2mm say)card, ConsequenceS. the purpose ofwhich becomes apparent W ith verticalm illing,the Iightcutting Iater. load relative to the table sti ffness makes Eventhough youwillnotbe machi ning the possibility Iess Iikely. Even so, as more than a few m illimetres in wi dth,do confidence grows and heavier cuts are use a cutterwith a diameteratl eastthree taken wi th I argerdiametercutters,itm ay times the width ofthe cutto betaken;m ore become a probl em ,so ifno overri ding factor exists it is better to conform to the aboutthe reasoning behind this Iater.

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though,high accuracy is notthatimportant and a rule dimension atboth ends offthe frontedge ofthe tablewillsuffice.Note also thatthe m aterialhas been packed up from

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TFAkEqSE TiIkEqSE ICIVEiSE Tq W 1 0 Ii = TA 1 2 TALE NOTE OF LEAZSCFEN EICrLASH AFEF kOyISG FFO: ï 10

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where modern machine tables can be

VUCI I Wri ttorlWork 0r 1t@1c milling PFOCOSS backl ash free,moving the table wi th the stresses that the m ovement of the part rotation ofthe cutteris preferred as itgi ves being m achined should oppose the a bettersurface fi ni sh.The reason forthis direction ofrotationofthecutter. Suchterms isthatacutstartsatfulldepthandreduces as Up milling (Climb milling),and Down tozerowhilstinreversetheopposite is the m iling are used and em phasi ses thatthe case,SK 2 attempts to illustrate thi s. requirementiniti aly stems from hori zontal This is due to the di ffi culty ofmaking m illing.The problem isthatwhentheacti on very Iightcuts unless a cutter has a very ofthe cutteris attempting to move the parl fine edge,a situation which would soon be forward in the same direction as i ti s being Iostwith a new cutlereven aftera small fed,a heavy cutting acti on can suddenly amount of machining.Obviousl y,after a

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4.Taking the firstcutalong the Iength ofHT''nutmaterial.

factors precludes the provision ofprecise rul es.W ith experience i twillsoon be found

M achining com m ences W iththe machine running,slowl y Iowerthe cutteronto the top ofthe m aterialuntilfirst signsofmachining appears,m ovethe table to clearthe cutterfrom the partand lower the cutterby around 2m m.Now bring the cutterup to the side ofthe m aterial,again untilfirstsigns ofmachining are apparent' , do this on the vi sible si de ofthe material. M arking the side with m arking blue improves visibility.Move the table Iength wise to clearthe cutterfrom the end ofthe partbeing machined and stop the machine running. Knowingthe initi alwi dth ofthe material andalsothewidth ofthe 1 'T''nutto bem ade, calculate the width ofthe cutto be taken from each side.Setthe cutto reduce the wi dth atone pass,providingthis isno more than one third the diameterofthe cutter

makinga cutofaboutO.1mm depthona chosenthanoneisoftenIeadtobelieve. piece ofmateriallomm thick,

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M achine speed

machine so sel ectthe closestpossible.

Before stading,m achine speed m ust be set.As in turning,the acceptable speed is dependant on many factors: size and sharpness ofcutter,type of material, robustness of machine, use, or not,of

Wi thexperience youwillno doubtbe happy to increase these values, probably qui te substantiall y,although forsmallercutters the top speed ofthe machine willbe the Iimiting factor.

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being used.Also check thatyou willbe observing the rule regarding traverse opposing the cutterrotati on.Startup and take the firstcut.Slowly traverse the workpiece taking the first cut along the whole l ength as shown i n Photo 4.Now return to the start,Iowerthe cutterby a further2m m and repeatthe cut.Ifyou feel very m uch athom e with the 2mm depth of cut this could be increased to 3mm for subsequentcuts.Thi s assum es a cutterof atIeast12m m diameter. As guidance to wi dth and depth ofcut usinganendm il,considermaximum wi dth ofcutto be 1/3 cutterdiameterand atthis width,depth of cut also up to 1/3 cutter diam eter.The depth can be increased somewhatifthe wi dth of cut is reduced. These figures do though assume a sharp cutterand a fairl y robustm achine,typically

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to thatrequired Photo 6.Follow this by repeating the process used formachining the firstside.A smallm irror, perhaps a dentalmirrorwillbe usefulto inspectthe

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size required,Photo 5.Now machine the the T,plusthe cutterdiameter,(againsee m il arlymachinethevisibleside, other side using the sam e process sK 3)andsi r ing to m achine in the opposi te Photo 7. If you are concerned about dem irecember tion.A Iittle more care willbe needed

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end to be machined in a similarfashion. Finally cut the Iength into individual nuts and machine the ends.Ofcourse,the

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10.Two englneers squares can be used to position Item s fn Iine with table travel.

sawn ends, but we are in this for the experience.Clam p the first nut to the machine table,again using thin card as packing,and using an engineer' s square to posi tion the nutaccurately as shown in Photo 9.Using a square in this m anneris a very usefulaid to positioning i tem s on the machine tabl e,two squares are even better in som e cases, Photo 10. Progressivel y machinethe end by stepping the cutterdown the end face as was done al ong the I ength ofthe nut.Thistime wi dth ofcut willonly need to be sufficient to remove any saw m arks,probabl y only in the regionof0.5mm .Bearing in mindthat this isthe firstofmany ends to be similarly

machi ned,do setthe depth stopjustshort

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of the table surface!This willavoid the 9.An engineers square /n an excellent possibili ty ofhi tting the machine tabl e in a aid to positioning item s on the m achine mom ents Iapse of concentration, easily table. done when many sim il arpart s are being direction of traverse of the part being produced.At this early stage in your machined (SK.4). In theory this is experiencewitha milling machine,you may im possible but can occur ifthe cutter is Iike to erronthe si deofcaution and setthe m om entarily defIected, hence the stop with the cutter a Iittle higher,say increased force required at the feed 0.1m m.The very thinweb Ieftwilleasily be handwheel.Afterone pass return the cutter removed atthe deburring stage. tothe beginning,place on a furthercutand Now the end will stillshow that repeatthe process.Repeatthe procedure machining wasdone in stages and whilst to complete the machining,Photo 8. this isofno realconsequence,elim inating lfyou are being am bi tious and making these marks willbe usefulexperience. a large numberofnuts,itm ay be saferto W ith the cutterstillin the Iower posi tion set on a f ur t her cu t s of s ay 0. 1mm , and f irstcmachi l ampo ver twothi thi of hte Ieng th surface the complete end atone pass. and ne one rr dds at at ime. An alternati ve would be to use side suppods Machining the complete hei ght(probably but,in theoryatIeast,you have no d ' r 'nuts 15to2Omm)atonepassmayseem thati t to hold these.Remove the partfrom the willpresent too m uch side I oad on the machine table and refitto enable the other cutter,however,due to the spiralaction

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the actualwi dth ofcutwillbe m uch Iess. Forthe mathem aticall y minded SK 5 shows thatfora 12m m cutterand a depth ofcutof0.1m m the wi dth ofcutwillonly be 2.3m m.Ideall y,a rel ativel y new cutterwi th its cutting edges stillin good condi tion should be reserved forsuch appli cati ons.

Idealpractice would be to firstfi ni sh one endonlyofeachnut.Then,use I ocating

fences(see Photo3 Chapter4)toposi tion the nuts for machining the second end. Using thi s approach willmake i t easy to ensure aIInuts are the same length,not essentialbutgood forexperi ence.

Vford ofwarning

Finishing off

Asa word ofwarning,swarfproduced by thi s process is needl e sharp with obvious dangers.W hiIstinwarning mode,1wi llalso rem ind readers that m illing cutters, especially when new,have razorsharp edges.Because ofthistheyshould be held in c10th when screwing them into threaded collets which can be a Ii ttle sti# ifeitherthe threads in the coll et,orthose on the cutter, are notscrupulousl y cl ean.

W ith the machining stages now complete, iiberall y cham feraIIthe edges using a file and finally tap them with the required thread.You m aychose to leave the nuts in the raw fini sh or,fora professi onalfinish, oiIblackthem orblack them using one of the chem i calmethods available.

Screw s,studs and w ashers The ''T' ' nuts m ust of course be

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to appearadequate butwillmove whenthe cutti ng forces are applied.This could have disastrous consequences and apparently in som e m achine shops the use of screws is taboo.Used with care though, thereis noreasonforthisifthefollowing is adopted as standard practice.Place the screw into the f' T''slot and move it close to the item being clam ped observing thatthe head is lowerthan the item .In thiscase adequate clam ping can be guaranteed butdo also ensure that the screw is not so short,that only a

instead ofscrews ifitwas consi dered an easi eroption. Screws,if used say forshorter sizes forholding such itemsas avice oran angle plate,should be high tensile.Studding is not Iikely to be high tensil e butproviding you have chosen ei therM 8 or M 10 this should not be a problem .This is easily available i n 300mm or IM I engths,either from m ailorderoutlets oryour IocalD1Y superstore;it can then be cut down to Iengths required. W hen using studs that have a continuousthread they can passthrough the $ T ''nutand hi tthe bottom ofthe '6 T 'slot. W henti ghteningtheassemblyi tispossible

thread ortwo willengage with the nut. As angle plates, cl am ps and Other items willfrequently have slots,large diameterheavy duty washers are a m ust, as these are not that easy to come by m aking a smallquanti ty woul d be a useful exercise on the lathe.Nuts shoul d be hi gh tensil e. Having considered 'r 'nuts and their associated pads there remain three item s: clamp bars,an angle pl ate,and pairs of parall els ina range ofheights.W e startwi th the angle plate in the nextchapter.

forthe stud to turn attempting to jack up the side webs of the ''T' ' slot. Som e com mentators have stated that this can cause the webs to fracture. Personally, I ooking atthe robustnature ofthe ' T ''slots on modern machineslfindthis improbabl e. As a precaution though the following practice should be adopted.Run the stud into the d T ''nutuntili tbottoms in the f c' l'' sl ot,then wind i t back a couple of turns making sure itdoes notonce more bottom in the slotas the nutis run on.The use of studs being threaded from eitherend wi th

one justsufficientto enterthe RT''nut

o vercomesthepossiblejroblem.Th ese can be purchased at a prlce butwi th the

wide range of l engths required, making one'sown woul d be a wodhwhile exercise. The use of screws however needs com plem ented by a supply of studs m uch more cautionas whilsttheabove can , stilarise,there isalso anotherpotentialand more seri ous problem .Ifthe screw i s m uch you willthough need screws in Iength too Iong itwillbe obvious as the item will increments of5mm and this is obvi ously remain Ioose on the table when itbottom s impracticable,therefore studs willbe in the ffT'slot.Itis though possible thaton twillclampthe partsuffi cient required and could be used exclusively the borderline i

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Introducing the manufacture ofan angle plate at this early stage m ay appear prem ature. ltis though an essentiali tem form uch ofthe work thatfoll ows and this dictates thatitis covered now.W hen the

steeltoolas one hard spotand the toolwill need sharpening,so this is really a nonstarter.Start machining using an elderl y cutterthatyou willnotbe too concerned aboutdamaging.

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M achining cast iron Machining cast iron fall s into two stages. The outerski n can be extremel y hard and without proper precautions can easily destroythe toolbeing used.However,wi th the outerskin rem oved machining is as easy oreven easierthan mild steel.Itdoes though m achine qui te diflerentlyand itis a very didy operation. Do therefore use a good barriercream on yourhands. C hoice of tooltype is especially

Having mentioned the casting' s hard surlace that can destroy cutters,of any type, care has to be taken to make sure that the m ethod used to machine the com ponent attem pts to overcom e the probl em.Itis notan inevitable problem as many castings wi llmachinewithease.The method is to make the firstcutsu#i cientl y deep to getbel ow the outerskin where tjae possible problem Iies. However, with castings beingofirregularshape, acutthat

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2. Rem oving any hard spots around the edge by m achining the edges ffrst.

plate mayseem Iike askingthe impossible.

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is precisely square to the base.This is

squares.A thin pi ece ofcard could also be

justscrape the surface asthe machining The method makes use oftwo precision

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covered inmuchgreaterdetailintheW PS

used to protect the squares and

process should be hal ted and the tool along its Iength.The diameterof the returnedto the staë anda deepercutset. squaresisnotcri tical,neitherdotheyhave Havingtotallyremovedthesurfaceskin to be the same,butto ensure they sit

@ withtheangleplatecasting(Ref.1)and an ; essentialclamp bar(only the centre hole Face one r i s required)are shown i n Photo 1. Wi th the casting mounted as in Photo 2 t ?

progresses' ,a sure recipe fora dam aged tool. Under these circum stances the

the rem aining machining can proceed with ease using a newercutterwith very Ii ttle

squares,a posh name fora round piece of metalhaving itsdiameteraccuratelyparall el

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34 in the W orkshop Practice Series. com pensate forany very m inor errors in The two squares,already m ounted, flatness.

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accuratelyonthe machine tablea diam eter ofnoIessthanthreetimesthei d r'slotwidth

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more caution than with othermaterials. should be aimed at.

First dress the m ain faces of the machiningcancomm ence.Firstcom pletely casting with a fil e to remove any m inor m achine round the casting asshownand

projectionsandtesteachoneonasurface bygoingroundanti clockwi sethecutterwill

Incidentall y,i tisnormalto machi ne castiron dry.

Cylindricalsquares shoul d be turned parallel, certainly w ithin O.005m m , preferabl y better,and their bases faced

' ' .

Cylindricalsquare

immediately aftermachining theirouter

'

Machini ng a precision angle plate from a

diameterwi thoutremoving them from the

raw casting withoutaccess to a second Iathe.Thi sresul tsinapillarwherethe side

plate. My casting saton the plate without the slightestrock and this was chosen to m ount against squares on the m achine tabl e. Ifthis isnotthe case some additional filing may be necessary orpossibly some

be breaki ng outatthe casting edge rather than cutting into it.Thiswillhave the effect ofchipping away atthe outerface causing i t to break away ratherthan be cutand having m uch Iess drastic effect On the

packing between the casting and the cutterscuttingedges.Follow thisW taking 1

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3and 4.(Aboveand Faclng Page)Rough machfnfng the flrstface. Iengthwise cutstocompletel y machine the firstface as in Photo 3 and Photo 4.Set

Rough and finish machining

Iwouldpointoutthat,afterroughm achining thetooljustaIittledeeper,sayO.O5mm,so the casting fullyon a1lthe required suKaces, as to skim the face created by the initial itwillbe necessarytoessentiall y repeatthe machining. same operati ons as a finishing stage.AII Should the cut,due to the irregular thephotographsweretaken atthe roughing surface of a casting , becom e too stage but are equall y applicable when shallow to rem ove the surface skin fini shing the casting. cleanl y,stop the process and repeatthe cut made a little deeperas in Photo 2. Face tw o Then a furtherattem ptcan be m ade to Rem ove the casting and reposition agai n machine the firstface completely as in as in Photo 2,with the now machined face Photos 3 and 4.This repeatoperation againstthe squares there should be no approach m ay be required w i th any of problem regarding fl atness,a checkfirston the m achining operations thatfollow. the surface pl atewillbe worthwhile though.

30

Repeatthe process used on face one to machine facetwo.Incidentall y,ifyou m ake the squarestallerthan the casting i twillbe necessary to pack up the casting from the table,this can be seen in Photos 3 and 4. Any sui table piece ofmetalwillsuffi ce,the precision of a genuine parallelin not required.

the faces buttaccuratelywith the squares. Lifting the casting offthe machine table wil ensure that this third face in no way influencestheattem pttoachievethis.W i th thefirstendcom pl eted,turnthecastingand mountagaininthe same way and machine the second end.You may askwhy take so much care withtheends,whydo they need to be square? Itcan be seen though in Ends Chapter7,Photos 9 & 10,that i t is not Now wi th the two main faces machined, unusualto mountan angle plate onto the m ount the casting betw een the two machine table,end on. Some question the use oftoolmaker's squares,Photo 5,and machine the end as shown.To ensure the ends are perfectly clam ps forwork holding on machines,but squarewiththe twofaces itis essentialthat providing they are robustenough,and set

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.. .. correctly,there is no reason why they Fl nlsh m achl nlng should notbe used.The subjectofclam ps i s discussed in detailin Chapter6.Ifyou do notpossestool m aker'scl ampsthen wi th x& ,, care substantial G clam ps can be used, otherwise, the clam p bar used in the ori ginalsetup,togetherwi th a second bar could be employed.

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setupsarerepeatedforfinalfinishing.

î ' machinedfacesusingthesamesequence noneedtobeprecise.Justasingleturnof . and setups already used.Problems with the Ieadscrew,or1-1/2 or2 whateversui ts 3 hard spotsatthisstage are muchIess likely the situation. ' and finishing cuts ofsay 0.2m m deep will

AIIm aterials contain within them stresses that have been introduced at the manufacturing stage. W hen sectionsofthe materialare removed,thisdestabili sesthe internalstresses and causes the materi al to distort.This situation is particularly preval entwith casti ngs,though the effect is notal w ays imm ediate. It i s therefore,

. be sufficientto give a good surface finish. End m *l lls versus face cutters

Do though use a sharp cutter,castiron at this stage machines very easily.You could 1 speeduptheprocessbyworkingclockwise. 7 graduall y working to the middle butIprefer

You m ay ask why have we machined this angle plate using end m ills when I com mented in Chapter1 thatmostM iII / Drillsare supplied with a tungstencarbide, working in straightlinesasthis gi veswhat face cutter. Theoretically,the face cutter

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The Iong edges

preferabl e to Ieave the rough machined

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l cons d7. erFor tob eabeance tterasak ppeear ance, see wo uld eidtehat alfo rroru hingheavi cutser bu Itwa s Phot oi appear each pass conc erb ned the ag ther ,t cu ting

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shown in Photo 6.

should be atthe same spacing butthere is

W hen considered ready,re-machine aII

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Finishing touches Using a file Iightly cham fer a1l edges produced bythe machining operationsand cl ean up the slots and theiredges.As far as is practical,clean up the rem aining unmachined facesofthe casting and givi ng these a Iickofpaintwillgive the angle plate a professi onalappearance.

This chapterconcentrates on an essential i tem foruse on the m illing m achine' ,cl am p bars.Itwoul d be tem pting in the case of the clamps to cut a few shod Iengths of steel,drila hole forthe cl amp stud,deburr, and callita day.W e are in thi s though for the experience so willaim at a m ore professionaland usefulresul t. The di m ensi ons on the drawing arefor guidance only as size of m achine,may dictate the size m ade.Do though ensure they are su#iciently robust.lfin doubtbe cautious and use a thickermaterial,8mm would seem the m inimum for use on the m illing m achine.The sl otand hole willof course have to suitthe clam ping stud si ze. Firstdeci de how many are to be made and cutoffthi s numberfrom the bar of materi aladding 1-2mm forfinalmachining. 1.M achining the firstend ofthe clamp, do m achlne towards the cylindrlcal square foradded security.

ln the nextchapterthe subject is Clam ps followed by Parallels in the following chapter,afterwhi ch we getdown

4

to some substantialprojects.

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squaresmount edonthemachi net abl e. This would be the case particularly i fthey References

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were on the sm all size in respect to diameter,as were m ine. At the finishing stage the reasons are m ore obscure.Itis easy to assume that the m illing m achine is perfectly precise in alIaspects' ,they are m ade to Iim its though and deviations from the perfectare the norm .Even in toolroomquality m achines, deviations exist, al though ofcourse they willbe less.

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C hapter 4

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Ratherthan attemptto go into detailin the textIhave produced SK 1 thatattemptsto illustrate the effectofa cutterspindl e that is notat90 degrees to the machine table. The sketch shows that the surface deviationsfrom the fl at,depend onwhether the errorisIeftto rightofbacktofront.More importantthough,the I argerthe cutterused. the greaterthe e#ect.In theory therefore the smallerthe cutterthe flatterthe part,in practicethough a com promise choice has to be m ade.Attem pting the task using a 4mm end millwould be Iudicrous whilsta 50m m face m illwould give the greatest error.An end m ill12m m diam eter and taki ng Iightcuts ofabout4mm wide,would be a good comprom i se.

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The casting used in the illustrations is Reference No.5O1 from The College Engineering Supply, 2 Sandy Lane, Codsall,W ol verhampton,W V8 1EJTel/fax 01902 842284. W ebsite:www.coilegeengineering.co.uk. Many suppliers to the m odelling and education establishm ents have sim ilar castings available which would be equall y appropriate.

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one.Useoneoftheotherpiecesofclamp materialaspackingforthecl ampthoughit is bestpracti ce forthe packing to be just higherthanthepartbeingheld. Inormally

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underthe partbeing used as packing but appearnotto have done so inthisinstance. M achi ne the top face ofthe partand,

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operations i tis highl y desirable to machine towardsthe supporting items,inthiscase the cylindricalsquare. If machining was aWay from the square,thatis from rightto l eftinthe photograph,the singl e cl amp may notadequately hold the part.Eagle eyed

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. The ' T' 'nutdoes though preventthe screw from being close to the slotend,and Iintend to make som e wi th the tapped hol e nearerthe endwhi chwould also be radiused,as in SKI,foruse in thi s .you may jjke to do the same. way,

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identi calto Photo 1 butcl oserexam ination showsthatthe partis being supported bya screw screwed i nto a ur'nut, illustrating a pointmade earli erthatthere are uses for K T ''nuts otherthan pure clamping.W hen fi tting,turn the screw untilitcontacts the

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k ' readers m ay observe thatthe clam p stud ) could be higherinthe angle plate slot , .Thi s ) would ensure thatthe clamp held the part t nearer the edge being m achined for ) im proved security.This is not the case h; , though,as Ifind thatusi ng a ;4T,,nutin the

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fi tted onto the angl e plate sothateach new partcan easi ly be machined to the same Iength,withoutrecourse to measurement or reading Ieadscrew dials. A realtime saving benefi twhen a numberofi dentical parts are being m ade.

Secure clam ping

Ha vingtrimmedthe firstendofaIIthe Nextmarkoutthepadsfordrill ingtheholes cl amps ,

machine the second in a similar andjustonewi ththe extremitiesofthe slot

manner,photo 2.Atfirstthismayappear tobemadeiwi dthandIength.Dri llthesingle 37

(. l hole in each one and use this forsecuring to the machinetableas in Photo 3.Icannot stress too much,to errvery m uch on the safe side when itcom es to securing part s formachining;onetoo manyaclam pisvery much betterthan one to few.W ith thatin mind,pl acing supportpieces which do not actually grip the part will give added security,often in pl aceswhen an additi onal direct clamp cannot be appli ed,typicall y cases Chapter6,Photo 9 and Chapter7, Photo 4. lnthiscase a single screw fi xing woul d probably suffi ce,especi aly as i t is a slot being produced thatwillnottend to place any side load on the item .The support pi eces in the photo do though perform a very im portantaddi tionalfuncti on.Mount the clam p that had the slot positions m arked onto itand position it using an engineer's square offthe frontface ofthe machine tabl e.Clam p itin place using the single screw then add the two support pi eces asshown in the photograph.Asyou becom e more i nvolved i n milling machine acti viti essuchadditi onalaidsto com pleting thetaskwillbecome necessay so do m ake a habi t ofkeeping these bi ts and pieces handy forpossibl e future use.Of course the clam ps now being made could perform thi s task forfuture operations,hence my commentregarding making sufficient. Fi ta slotdrillofa size thatwillcutthe sl otatone pass.I f howevera sufficiently wi de slotdrillis notavailablesthen widen the slotusing an end millas slotdrills are too fragile forcutting on one side only.W ith the machine stationary,I owerthe cutterso itis almosttouching the workpiece.Then, wi th the cutting edges in Iine withthe cross traveluse the crossfeed to align the cutter with the marks on the workpiece.Lock the

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#8Eh LSING A T 8L1 WlT8 18E FACE FLAIE OR I8GCE FLATE, FLIS MADE AS FEq THE AZOVE F02R #ILL ENA8LE 8E1TE2 USE OF 1FE SLOIS T0 FE kA2(

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cross feed in this position.Now rotate the cutterninetydegreesand traversethe table untilthe cutting edgelinesupwiththeend

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markandsetthefirsttablestop(Photo3) atthis point.Knowing the Iength ofthe slot setthe second table stop with the gap required,and traverse the table to check againstthe otherend mark on the clamp. artthe machineand plunge thecutter into tSt he workpiece,say by 1mm ,and m ake the firstcut.Sl otdrillscan be used in either direction,so plunge the cutterby a further 1m m andtake acutin the reversedirection. Gontinue untilthe slotbreaks through on the othersi de.As the slotaligns with the $$ T' sl ot there is no dangerof the cutter damagi ngthetablesu/ace.Theposi tioning pieces on the table, and the end stops having been set,willm ake machining the remaining clam psverystraigbtforward. i You may considerthatthe single hole n the clam p is purely f0rthis machining operation butWe Shallsee laterin the book thatithas a very importantrole to play. G enerously deburr aII edges and the clam ps are complete.

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A setofparal lels are almostas essential asthe clam psinthe previous chapterfor use during m illing operations.These could be commerciall y made i tem s' , ones made by the user,or,assooften i s t he case,just off-cutsfrom m i ld steelbar.W hiIstinm any cases the Iatter m ay be adequate, especially when used as a single parallel, two pieces ofbar, especiall y iftaken from differentlengths ofstock m aterial,maynot have i denticalwidths. O n the other hand the hardened and ground com m ercial variety willbe ofaccuracy rarely required and be a I ittle on the expensive side. Of moresignificance thoughwi th these,isthat they willnotbe available in a sufficientl y wide range of heights if the cost is a consideration. M aking yourown is a worthw hile option as the cost w illbe m inimaland a wide range ofsizes will present no problem . Itis possibl e to buy sets of parallel s in 1/8in increments from

1/2 to 1-5/8in and at a very reasonable pri ce. However,manyofthose availableare onl y 1/8in wide,which is on the thin side especially as some vices have a small

groveintheirbedadjacenttothefixedjaw. Youwillalso have to trawlthe catal ogues to find them .Making them stillseems a good idea.

Parallel,how ? The aim willbe to create parallels in pairs thatare both parallelalong theirIength and ofexactly the same height, atleast w ithin good home workshop standards, say within 0.002m m .Atfirstsightthis m ay appeara standardthatistoo close to be achieved, especially with regard to being parallel.How,afterm achining the first side, is the parall elpositioned accuratelyenough forthe second to be m achined parallelto the first?This is the secretbehind the m ethod proposed.

39

mount these onto the angle plate at approximatelythe same height.See Photo 1.Very Iightly machine overthe topsurface ofthe posts to give two Iocating faces for the parallels to si ton.The small,reduced end to the postavoids having to machine SK1 too cl ose to the angl e plate face.Itwillbe necessary to mountthe posts towards the top ofthe angle pl ate forthe sm allersi zes, The heights of the parallels are not say 10,15 and 20mm and Iower and recri ticalprovi ding each pairare accurately machine them forthe Iargerones. thesame;Iwouldsuggestnominalvalues The screw seen inthe centre slotacts oflomm ,15mm ,20mm ,30mm ,40mm and as packing forthe clam p when holding 5Om m and say8mm thi ckand 100mm I ong. the parallel s.See Photo 2.This should Having cut your Iengths of material, in be setata heightjustgreaterthan the variouswi dths,machine the ends usi ng the thickness ofthe two parallels, say plus same set-up as in Chapter4 Photo 1 and 0.5m m .This woul d seem to be a good generousl y deburrthe ends.Also remove time to discuss good practice in terms of any blem i shes al ong the Iong faces and clam ping and ratherthan going into great edges thatcoul d affectthe mounting ofthe detailin thetext,SK2 should Iargely cover pieces formachining. the subject.However,inthis case,i fthe Make two posts as SKI,(as you will clam p is not positioned suitably the seethedimensi onsarenotthatcri tical)and parallels may tiltwith obvious effects on

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1.Machlning the end ofthe m ain body. Note the use o/the cyllndricalsquare to position the parl.Below:2 M arklng out the pads fordrilling and slotlfng. square, clam p the part ensuring it is accuratel y in contactwith both angl e plate and square.Machine the end, Photo 1, reverse,then machine the second end to 75m m.Repeatforthe second part.Thisset-

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the workshop kit,so another m ethod of

Photo 5.Remove and place two pieces of

Iathe faceplate,bore to take the arbor, washerovertheslot.

creating the dovetaili s proposed.Even i f rod (aboutlomm di ameter)one onei ther

Photo 3.A tail stock centre located in the Loosen the partfrom its clamps and pilothole C willaccuratelypositionthe part rotate through 90 degrees, this tim e on the facepl atewhilstclamping.Returnthe allowing the clamps to fal li nto the recess

0ne were to hand, using the m ethod described would be excellent m illing experi ence.

side of the dovetail and measure the di stance between them ateach end.Even i fan appreciable erroris apparentiti s of

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posi tionthepart.Removethecentrepodion 6mm slots.Lowerthecutterintothe25mm to a depth of8.2mm,working to the holeandwhilstonthe 37.5mm centreIine, dimensi ons oflomm and 26.5mm.See advancethecrossslide untilthe cutterjust

vi ew).Again use an engineer'ssquare as errori s less than O.1mm you have done accuracyisvital,(usi ngadi altestindicator verywell. wouldbeevenbetter).TakeaIengthofsteel Finally,atthisstage,drillandtapholes

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say 12m m square,though notcriti cal,and

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a bout75mmI ong,drillinthecexntr ewitha Leadscrewbearingplate(4) hole to take a clamping stud.Fi this onto Cuta piece ofsteelallowingforsubsequent

toactaspacking.Thestudisthreadedinto Releasethecrossslideandfeedby7.5mm

theangleplateatanangl eof30degrees, machining,machinetheends,markoutand usingastud I ongenoughtoalsoclampthe part. Fita6mm endmilland setthi stotake an i nitialdepth ofcutof2mm maximum.

drillholesA and B.IT IS IMPORTANT to make B,tappingsize forM5 atthisstage. CutterCarrier(8) Having previ ouslymachinedthe ends,cut

higherthanthe pad being held and afurther end millcan be used ratherthana slotdrill. nut placed on top make the assembly Atthis point i t is assum ed that as a

Rem ember,atthis smallsize ofcutter a high spi ndl e speed willbe required,say

the 50mm square to 50m m x 30mm plus to allow fOr m achining to the 30m m

secure.This is an excellentpacking novice a dovetailcutteris notyetpartof

1000 rpm plus.Take a firstcutadjusting dimension.Mountthe materialonto the

a .. T'nut (anotheruse fora '' T''nutas intimated earlier)and Iockedwi th a nutas seen.A nuton the stud bel ow the clamp, notseen,sets the packing heightto just

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((25- 10)/2).Take averyshallow cutand check to make sure no errorhas been made,make the two slots at2mm depth increments.Being an open-ended slotan

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Leadscre-Nutisdrilledwithatapping clear.Theessentialrequirementisthatthe size hole using the assem ble parts as a gtl/ee to onstzre augnm ent.

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distance betw een the two arms be accuratel y setusingthe screw nearestthe

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and with its head ona piece ofpacking Nt (.... . .t k è to overcome the problem ,in fact,where N' 4t ' p . o. ..4* ! y'' ' x ' ' N: : . the heightOfthe packing is shorttjjjs ) Fw . z.. .

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rj' . accuratepositioningofthepart.Notealso ) ,' ''' thatthisnecessitatedtheclampsto rotate . jttj. making itimgracticzb10 to I OCatO 1E51,j

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the CtlflerCarrier

You may,as Idi d,use anexisting arborin which case dimensionalchanges are probable,Otherwi semaketheArbor(6)as perdrawing.The essentialfeature is that

the factthatone surface was a round pill ar the 25m m diameter and the taper are made i ta SPOCialCirctlmstance. Concentric.Holding One end in the Chuck,

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hole provi ded forthisinthe CutterCarri er and tighten i ts fixing screw (H1).Loosen screw,removeLeadscrew Nut(usingaIong

maybe aprobl em duetotheabsenceofa Mascrew to achieve this),centre punch dividing head,inwhi chcase use SK' ?asa wheremarkedanddrill4mm di mple.Refit the DialOverthe sketch and make the dimplejustdrill ed. cal ibrati onIi nesusingascriber. Finalcalibration N ext task it to driII through the can be done whenthe Divi ding Head (that assembly with an M5 tapping size drilI foll owsinthenextchapter)h% A nœ mpl eted. asseen in Photo 12.Ensuring thatthe machine table is clean and the Cutter Finalassem bly carrieris standing firmly on the table, cuta Iength oflom m x 3mm steel, 75m m long and trim the endsto makethe Gi b Strip

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we now cometotheSecondOfthemajor a ndmachi ne the endstoa dimension of i tomsdoscribod i rlthi s bookthztStilIUSOS j(jam m 'using the set-up Ofan angle plate I argel ybasi cmillingoperationsbutprovides andta lin ichal squ are.wiMar koutthe jonCy fo rdr aII ole s, and dth of20m m a chance to use the boring head made in 9OSj zepreviouschapter grove,drilland tap holes C,a tapping size .

. The desl gn This is a sim ple di viding head based on usjng a single gear photo 1,and m ore , com pl ex dividing usi ng a geartrain,Photo 2'yjje yj vjdjng head may fi nd a mul titude ofuses,suchas cutting gears,drilling hol es

ona pi tchcircl e di ameter,milling squares

and hexagons and marking divisions on a machine sli de dial. The single gearcould -jo be replaced wi th a divi ding plate antjyj yjyj s pjungerassem bIy modified to suit. would increase the number ofdi visions 1 :) 4 . 4 :: , ssi . I k : ) k 1e, .

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Spindl e istofit. Posi tion the par' tusing an engineer's square , P hoto 3 and, after adding additionalsupporttothe machinetable,m ill the 20mm slotto the depth of8mm using the marks to positi on i t,photo 4.I twillof course be necessary to make a numberof passesto millthe slotto the required depth. Ifyou do nothave a zom m end m ilorslot

yrjjjyou wiljhave to make the sl otin two

stages. I nthi scasedonotusea slotdrill

wjjenwideningtheslotasthisisbestdone jn, eny mjjj. ' k . l t !; ( ë i Ian ' r'''' r :'' ' i ' / . ' i' t E '' l' ! s ' t '1aI r ' l t ï ; pe si ë ( ; z ! r ed :: . ll , r . i11:: ( , 1 4 : ) eI r . ' ,I . k k, . r : ) ,r I ë . I . , eI r : ) p i1d :) . , t : l 'E i '''

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Willbe seen Iater. Starting from the hole size already drill edgradual lyincreasethisto28m m and to a depth Of35m m.Iti s essentialthatthe depth stop be set,as the boring toolwill

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the lathe. Fixtheparttothetabl e,Photo7,taking note thatthe clamps usedto holdthe part willneed to be as Compactas possible to avoid fouling the boring head.Also pl ace

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4.Machining a 5101in the Body. Being an open ended slotan end millcan be

suitable holderthey can also be used On have anothermore importantfunction as

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into use.Photo 6 shows a typicalset of three,supportpi ecesagainstthe Body,one bori rlg tOOIS thal CaI1 bo Obtainod, Qtli to On Oach Side and One atthe end aS Can

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FIT 8EAZINGS (14),tJSIiG AZFIESIVE,FFIOF T0 I I ? ILLIF: Flot-Es A 182 8 AkE)kAïIN: SLOTS. Fl' I 8EAFlNcs, ZFILL AN2 IAF FIOLES, . Y NALE st-o':s O E:l rlSALL

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would be so cuts to get from 24m m to 44mm .vou may asyourconfidence grows feelable to increase thisto 0.3mm ,maybe m ore. Use the fine down feed to feed the

tool.The speed should be seton the Iow si de,say 250 rpm,butas in aIIcasesthere

isjustificationforsome trialrunsathigher

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speeds,especi allyifyou haveobtained free cuqing,230M07 steel. Afterhaving madeafew cuts,m easure the distance between the inside ofthe bore and the outsideofthe Body, the two sides

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step m easurem ents withthe anviland the cjamp rem oved. w hen the 44m m bore is finished I oosen the cl amps and turn overthe Body,

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purpose Ofthe three, supportpieces nOw s weCOmOS Ow sVI j OUS ZS y KI uICX WI jI j1 jZVOI jU uy tI sI 6

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permits measuremen frOm oncaIv e . jjntsanv i1 C enab es surfaces. The tj measurements frOm narrow Slots and

two boreswillbe reasonablyconcentric

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7.The borîng head gets fts firsttask lo ertorm .Below:a A usetulm icrom eter jll

castironhasbeenchosenfortheBearings asthe dissimilarm etxs,castiron and mild

Bearings (14)

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position and bore again, repeat as necessary. w henthe hole reaches28mm setthe deptjystop to 18m m and bore to 44m m djameter.This bore Shoul d be centralto a higherdegreo SO When the hole gets to

ven on

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the thickness ofthe cutter.Ifas suggested 75mm . the saw i s l.sm m ,this makes 21. Make the firstcut. Having m ade the first saw a fudher8mm and m ake cut,lowerthe d, t hesecon photo 11.The additional support shown on the right is probably unnecessarybutIcannotstressto strongl y to erronthe si deofcautionwhen mounting

asshown i n Photo 14.The Spindlecannow be placed between the two pieces of materialand clamped in posi tion,Photo 15. .? ')' y'''; , . . Rem em ber this assem bly, as it is an y) ' 1, ),. z , . ''' t , ' excell entm ethod ofholding round parts on t .''.,e . the m achine table. Machi nethe keyway taking note that with such a sm allcutter, . the m achine speed should be set at i ts

the dangerpresentwhen such an item is 13.Do take note thatitwillbe necessaryto used.Do bearthis very m uch in mind and setthe topsli de to the requiredangle before keep wellclearwhil sti tis running. Photo starting thi s sequence. 12 SNOW S the Set-up fOr m aking the Mounta piece ofsteelon the m achine horizontalslots.A smallpi ece ofhack saw table using an engineer's square to ensure

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Iam notgoing into detailregardi ng turning the Spindle as Iam assum ing that you already have a good understanding of operating the centre lathe.lfhesitant,then the W PS 34 in the W orkshop Practice serieswould be hel pfulreading.Essentially, turn the 24mm diameterand spindle nose whilstsuppoded with the tail stock centre,

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the angle plate and the clam p is fitted higher.This does though rem ind m e to com mentthatm uch mounting work on the angle pl ate can be carri ed outremote from the m achine.This can be on the surface plate,oreven mounted in the bench vice with the working face horizontal,making positioning parts very m uch easierin many

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MillingVice-requiredornot?

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the horizontalm illwhere loadswilloften be m uch greaterthan loads presentinvertical mi lli ng.A milling vi ce isthereforefrequently m ore robustthan required.My approach was to modify a pairofthe cheap and

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m illingvice i sspeedofuse, butonly where positioning the vice is not critical and posi tioning the partin itis strai ghtforward. Itsdisadvantagesare cost,time consum i ng to posi tion itaccurately on the tabl e and difficulty in many cases of positioning the part in the vice, especi allyforbatch production. Formany,thedi sadvantages willbe outweighed bytheadvantages even i fitsuse wi llbe Iimited to a smallfraction of the workundertaken.m first,forIimiteduse, itmay appearthata vice from the cheaper

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VIIEFIAL 12m m ZIAkETEq SIEEL 230k07

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direction andcutterrotati onarethe same. Thisi sa chanceto trythisoutforyoursel f, do rememberthatyou need asharpcutter forthisprocess.

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LOW ER LEADSCREW NUT 16 ) 4.2mm CS4 9 mm ZIAkETEF 2 0FF

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cheerfuldrilling vices by skimming alI relevantsurfacestoimprove accuracyand 13. These vices,available forIess than a

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uaallkpratlrlg tHO r-OOu INROIJCZr1kJO kllc IIrSt taskforyourrecently made Divi di ng Head. Ajteruoring and making the knurlwhilst mounted in the chuck,mount on a taper stub mandreland turn the portion to be

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by hand noting any devi ation present.lfthe di alrunsperfectl ytrueyouhaveindeeddone

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This is yourfirstopportuni ty to check

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holding these. Clam p one of the Slide Swi velpiecestothemachinetabl eandwi th

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These may appearto presenta problem if the accuracy ofthe Dividing Head mandrel. a til ting vice is notpad ofyourki t,you have Setup a di altestindicatoron the surface to

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aroundrodandapi eceofpackingusethi s Wellbutsomesmal lerrori slikelywhichin

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photo 20.Now turnovertheIockscrew

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the remaining two screws,a very simple mountthisontheIathe asshownin Photo

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Milling the slotin the Base angle.

com plete with holder A and relocate againstthe stop in partB making the

19 showsthesetupformachini ngtheslot.

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Slmple home-made fi xture. M ake the two items shown in SK3 takingnote thattheholemustbecentralin

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without continualreference to the table avail abl e materi al,a Iength oftube willalso traverse dials. At6mm di ameteryou will be required.setthese up onthe milltable need a speed on the high side, say and w ith a 4m m m ini m ill running at 1000rpm plus. maximum speed m illthe flatas shown in

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The turned parts are aIIqui te sim ple and therefore Ido notintend to go into the I atheworkinvol ved inthese.However,the Lock screwsdo have a li ttl e milling activity thatcould presenta probl em to the novice.

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Lock Screws (5and 19)

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gear,willnotbe ofany Consequence. I ti s easyto fallinto the trap ofthinking that a pointed cutter should be used to 21.Uslng oneoftheSlldeswlvelpieees m ake the Iines on the di al.However,an as a fixture forholding the Gib stri ps for errorin concentricity willcause the Iine to m achining the angle on theiredges. change in width as the di alrotates.Make a cutteras SK3;Iwoul d suggesta tip wi dth of0.2 to 0.3mm .Depending on the errori n concentri city you m ay stillneed to m ake slightchanges in the depth ofcutas the dialrotates.Iwould suggestyou find the mi d-pointofany errorand setthe depth of cut atthis pointto be 0.1mm .Make sure the tooli s firmly clam ped on the top sli de and use i ts calibrationto setthe Iine I engths. Wi th an Msthread having a pi tchof0.8mm , 40 calibrations willgive increm ents of 0.02mm . Youcan now go backto the di alonthe boring head and cali brate this al so.You wi ll though need to mounti ton a taperstub mandreland re-m achine the sloping face, eveni fyouhad nottemporaril ycal ibratedthi s.

Assem bly First,assem bl e both items 9 togetherwith item 16 and fitand lightl y tightenthe screw H5.Take apartand dri lldimple C in pad 16 as indicated by the m ark m ade by the screw.Reassem bl e wi th items4,8,12,and 15 15 added making sure that screw 1. Iocates inthe dimple andtightenGib Strip screws so thatthe sli des are firm ly fixed. Drill through items 4 and 8 into the

adhesi ve.You willsee from the Photo 1 that Ichose to fitthe top Locking Handle 11 on the Ieftratherthan on the ri ght as shown in the assem blydrawing.Thi s helps to make them both more accessibl e.Itis importanttotake notethatitems mustreturn to the same posi tion as variations in the Leadscrew Nuts (items 15 and 16)using position oftheirthreads willalso cause an M5 tapping size drill.Open up holes in handle arm positions to vary. I would th one,two and items 4 and 8 to 5.2m m diam eterand tap suggest marking them wi the Leadscrew Nuts M5 through the holes three centre punch marksin some obscure ition, such as on the threaded ends of justdrilled.This willensure satisfactory pos alignm ent.Dismantl e and drillthe dimples the lockscrews. Assemble forthe Iasttime ttl e oiIin appropri ate positi ons in the Gib Strips as i ndi cated by the screw applying a Ii andtheGrindingRestiscompl ete,only now marks. Assemble the parts involved in using Wai ti ng the arri valof i ts attachments for the Locking Handles and m ark the sharpening various metalworking and preferred position fortheirarms, remove, Woodworki ng tools.These willbe described drilland fix the arms using two-partresin in the following chapters.

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21

* Due to the item being ground often

adjustable o#-hand grinderrest,the full being unsupported close to the wheel extentofi ts capability willthough only be when using the accessories,only take

22

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very Iightcuts. The depth ofcutm ust

accessories,thesebeingthesubjectofthis be controlled by the fine feed and the 1,

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and the following chapter. At this stage, description of the m anufacturing processes willbe keptto a mjnjm um , as by now these should not presenta problem .Making them willthough continue to provide valuable necessary experience.M uch ofthechapterwillcentre onthe use ofthe accessories and includes

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fence rather than m anually. * Make m ultiple passes where m ore m aterialhas to be rem oved than can be taken safely ata single pass. * Keep the overhang ofthe tool,from the accessory holding ftlo a m inlm um . * ln view ofthe overhang do ensure the accessory Is held firm ly down on the

photographstoillustratetheoperationsthat rest' stable.

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can be perform ed.Firsthowever,very im portant safety considerations must be aired.

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IM PORTANT SAFETY REQ UIREM ENTS

resultineasierhandfeedingandmakes forsa/erworking. * when the grinderis running do not

* Do wear safety spectacles or makeadjustmentstotherest,otllerthan facem ask.

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be. ac hl eved u, slngther tsswlvelfacl llty. home wo rk shop,It Is though standard , .tes . , . , Thl s I s not s o, I t s us e, wl h a f ew ex cept l ons, pr ac t l c e I n l ndust ry. D,E and F show the ,

I s elyngtogr se tthetoap perowh ach angl eofthe t acp eur bei ound th eel. .ng a podl .on from the sl .de W hen gr. lndl . , ofa workpl ec e I t woul d seem obvi ou s t hat . . thefeeddlrectl on shoul d be paralleltothe side of the wheel, SKZA. However,any smallerror in the approach angl e could Cause the par' tto be add1t1 ona1I y ground on . . . . . ltsslde,SKZB.In vlew ofthls,feed dlrecti on

s ames' Ituationsrelativetothefrontfaceof the wheel.Thisangle setbythe rest's ,

,velll ,nn facl .ll .tv should be a maxl ,mum of swl x-' -, a degree ortwo. . Round W orkpl ece HolderAS4 This is norm all y m ounted on the swivel base,s' Im i larto usingthe square workpiece hoIder, and 1s used tvn1caIIv for ho1d1na @' @ W screwdrivers,a wheeldresserand round

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bending at.x, ,as shown, to im prove

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indexingon smallert00thsaws. Thiscompl etesthe minorassemblies

g1

aI1ofwhich can be seen in Photo 8. End m ills and slotdrills w hil stmanyitems,typi cal lylathetool s,screw dri vers,etca,canbeshamenedfreehandwith some success, this i s almostimpossibl e in the case of end m ills and slotdrills.An aCCOSSOW Crlzbli x thOSO to bo Sharpened, both on theirend teeth and cutting edges,is

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SLI UINGSAW,S. HARPENING

thO holder,DO NOT betemptedtofeedthis absolute minimum,as i twillreduce the

.

t:esubjectforthenextchapter.

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required blade width is achieved.

strength. Slitting Saw Sharpeningassembly AS5

* *

Thi s com prises the swivelbase wi th a few

--s-; ' $ ' . :

Sharpening a screw dri verfree hand simple pads(51,52 and53)added. may Soom Iike a Simple exercise but The method forsharpening sli tti ar1XOr1O WhO haS tried it Will have Oxperi oncedthedi ffi cultyOfgettingthetwo

.

saDo ws should be clear from Photong 7. rememberthatthesaw i sfedbyhandwi th

'h 1J I ' h'

sidesparall el.Photo5illustrateshow a theswi velbaseheldfirml yagainstthefence good resultcan be achi eved,and simpl y, and the saw againstthe swi velbase.The Wi ththisaccessoly Thephotographalso inwardfinefeedisusedtocontroldepthof SNOWS a Centre punCh,w hich w iIIbe diSCUSSOU Iater.

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HOLE SI ZES

:1::': A 86 k. , 2m5moF1 FOFF

fence,willbenecessarytoavoidthewheel touching the adjacentt00th.In this case

oEa

IAATEIyIAL25mm sû STEEL250907

the Ieft to right feed would be used to

15

Onwhichthesaw rotatesisdrilled offcentre

si d r d ess Oi fn th get w he hes ei l dc e an sh bo eu dl r d es bs edk. eHpo twto eva en r, d t oi ap mre ot v ei d rs ea djusIt men tfo rdmay i ff erin gsarw The eaf spr ing requi e .

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cut.W i th the I arge teethon the saw no stop is required.However,With an accurately

ZRdthOWhOCIdrOSSOrttlrningthrough90 accuratel ySetthestoppositi on.Thebush dOQrCCS OR thC SWiVPIbasojthe righthand

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,

ASSEM BLY AS5

froo harld;OVOI IfOrthisSim pl e Operati on it Width Of the w heeland therefore its

is Szforto USe the fine feed,assi sted by the fence, making multiplepassesuntilthe

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C hapter 10

T he E nd M ill

Sharpening Fixture W e now come to an End MillSharpening fi xture,AS6 by farthe mostcompl ex ofthe accessories.Thi s enabl es both the endand si de cutting edgesto be sharpened butcan also be used where a round workpi ece needs to be rotated,typically a centre punch. The accessories thus far are quite simpl e ascan was seen in Photo 8 Chapter 9;they willthough dramaticall y im prove results com pared to totally free hand grinding.The item shown in AS6 isthough quite different wi th some com paratively com plex parts to be made.Itwillthough make i t possible to sharpen end mills,a task thati s impossible free hand.

1

steady.Face then centre drillthe end, rem ove steady and support with the tailstock centre.Turn the 100m m Iength to 24mm diameter,Ieaving the fl ange atthe tailstock end.Check before reaching the 24m m diam eterthatthe resultis parallel. Thi s is essenti also thatthe spindl e slides in its bearings wi thoutsti ffness orshake.A smallerrorcanbe elim inated bycarefuluse ofvery fine emery c10th. W hiIststillsupported by the tail stock centre,fi t and setthe fixed steady atthe Kil stockend.Removethe centre,settopsl ide to 5 degrees,machine the bore and leave the top slide atthis angle formaking the

col lets.Dril8mm toadepththatjustcontacts

the end ofthe screw.Remove from chuck and screw from spindl e and return spindl e to Iong. Mount in the three-jaw chuck chuck,now holding itonthe 24mm diameter, supporting the outer end with a steady. ( sui tablyprotected),drillthrough 8.2mm. Face,drillandtap M8 15mm deep.Remove Col lets (80) and firmly fita shorthexagon head screw As these are used when sharpening the ll,concentricity inthe tapped hol e,andgrip thisinthe three- cutting edges ofan end m i jaw again supportingthe outerend with a is essential,as it is also with the 24m m

Spindle (62)

Cut a Iength of 30m m diameter, 105m m

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adjustment.Make a gap of0.05mm to ensure the toolw illnot foulwith the faceplate.Ifyou are nothappyworking thi s cl ose to your faceplate when blind,you could add a thin piece ofcard betweenthe partand thefacepl ate togi ve more I eeway. Bore to a diameter about 0.05mm larger than the bearing outerdi ameter,Photo 4. Ifyoudo nothave a 14mm dri llyouwillalso need to bore the 14m m hole in part64.Fit bearings using two partresin adhesive. To ensure the spindle rotates and slides freel y wi thoutshake it i s essenti al thatboth bearings be atthe same hei ght, the following ensures thi s. Mount the two bearings on an angl e 5.Setting up the bearing supports for plate using the spindleto alignthe bearings. m achining thefrbase.

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Do this wi th the angle plate mounted in the vi ce as in Photo sthis i s m uch easierthan perform ing the task wi th the angle plate sudace vedical.This process may seem a sim pl e,risk free task though there is one pointthatmustbe observed.The fi xings in the base ofthe two pads mustbe aligned correctly when mounting the parts on the angle plate,orthe bearings willnotbe in

Iinewhen mountedto the base (70).Note thatthe righthand hole B in part(63)is 15m m from the edge whilstthe l efbhand

hole inpart(64)is20mm.Thismeansthat the pi tchbetween them m ustbe accurately setto the di fference of5mm.W i th thisdone, the bearings should easl ly align,wi th a li tti e help from the clearance in the fixi ng hol es. Machine the base ofthe beari ng suppods, Photo 6.

Indexing Collars(61)

Turn oneorm ore collarsas required.M ake a stub mandrelformounting the collaron

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Thischapterprovi des instructi onforusing the End MillSharpening Fixture detail ed in the I astchapter.

Setting the angles A necessary requirementfor using the grinding rest,is to be able to reasonably accurately set1he angie between 1he rest's tabl e and the face and si de ofthe grinding wheel. Using the protractor from a combination setorsome otherengineer's protractormay seem Iike the devi ce to use to m easure the angl e buttheirbulky nature wi llmakethem veryinconvenientin practice. To overcom e this,make some gauges,as perSK1 and as seen in Photo 1. To setthe angle relati ve to the side of the wheel,bring the table close to the face ofthe wheeland check the angie as per SK2.Settingthe angle rel ative totheface ofthe wheelis more com plex as the angl e is continually varying round the curvature

of the wheel. Grinding on the face will thoughonly be used where a verynarrow Iand i s being ground,typically,the end teeth ofanend mill.Asaresul t,onl ythe angleat the pointwhere grinding takes pl ace is of importance, Provisionally set up the accessorywi ththe device beingground and measure the di stance above the table that grinding willtake pl ace.Mark the required gauge atthi s heightand use i tto setthe table's angle such thatgauge and wheel touch atthis point,as shown in SK3.

Sharpening End M ills and Slot drills End teeth Fitthe end millaccessorywiththe fourtooth indexingcollarensuringthatthere isno end

floatand adjustthe bearings so thatthe spindl e rotates freel y butwi thoutshake. Fitthe end millm aking sure thatthe end teeth are horizontaland verti calwhen the

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using the fine feed untilthe firstsparks appear.Move the end m illto the rightand

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11 1 4 $ ' . f a ore ge mtat dese o wt i t o hnth t e h e ga ri n de g l ero af ta r ed st e .gD re oenor t E' ;r' twousingtherest' sswi velfacili tyandmake '

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wheelwilnottouchtheadjacentendtooth, takes place.Atthisstage the adjustments

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traverse SUCh that,when grinding,the

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wheregrindingwilltakeplace,see sxa. w ith the swivelbase againstthe fence and t'*i ae stop,and the end millverycl ose to ti ae faCe Of the WheeI, adjuStthe Ieftright

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lzgs ,6 H Es AOL TO StJll ZIAVETEF OF ITER T0 8E FELZ

degrees to ensure thatthe end teeth will the I eftuntilthe stop i s reached,ensuring beslightlyconcavewhenground. thattheswi velbase isbeing hel d firml y Fi tthe fence to the table wi th the stop againstthe fence and the tabletop during screw atthe Ieft-handend.Setthetableat the operation.Remove assembl y from the 90 degrees to the side ofthe wheeland 5 to 6 degrees relati ve to its face atthe point ,, , -'''-' -'.'''?',

adjustmentiscarriedoutoncegrinding

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indexcoll arisIocatedagai nsttheindexarm and Iock the spindle.

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endt00thhasbeengroundandtheadjacent teeth.Inspectthe resultandifnecessary,

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totheIeftrighttraversei fnecessay

teeth,reneatuntilasati sfactoryresul tis

W i thoutmaki ngfurt heradj ust ments,rot ate achi ev ed' .Adj usti nteedbynomorethathal f theendmillensuringthatitisI ockedateach adivi sionateachgrinding. 123

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its cutting edges without causing a problem .

Culeredges

3. sharpening an end m ills cutting edges.

Swing the index arm away from the index coll ar,which shoul d also be Ioosened and m oved towards the end ofthe spindle.Fix the collarata posi tion thatwillenable the spindle to move lengthwise,by an amount approximatel y 5mm greaterthan the Iength ofthe end mill's cutting edges.The spindle m ustslide through the bearings easily but w ithout any shake. A n essentiaI requirem entforthis to be achieved is for thespindleto bethoroughlycleanedofaII grinding dust. Do not be tem pted to Iubri cate the assembly,as the oiIwillonly hold onto any grinding dust,which fall s on the spindl e.Fi t the t00th rest suppod to supportthe end millatits outerend and

adjustthe heightsothatthe end teethare

hori zontal.This can aI1be done wi th the accessory away from the grinding rest. Setthetableatanangleof85degrees relati veto the Ieftsideofthe grindi ng wheel. Fitthe fence,with stop screw,in the ri ght hand slotand rotate the table so thatthe the primaryclearance(thatfirstground)is fence is atan angle ofabout1 degree to no more than lmm .This willensure that the side ofthe grindingwheel.Fitalsothe the primaryclearance can be ground a few clam p screw assembly. tim es without the need to grind the Fitthe end m illaccessory asshown in secondary clearance. Photo 3 makingsure thatthere i s clearance In m ost cases sharpening the end between cutterand wheel.M ake sure aII teeth only will produce a m arked adjustments are tightened and thatthe im provementin the cutter's pe#ormance cutter'sedge i s againstcutterrest,andthen and willbe aIIthatis necessary.However, startthe grinder.Using the Ieftto rightfine where the cutting edges are wellworn, feed,feed the table untilthe firstsparks sharpening these willbe beneficial.This appear. willchange the outer di ameter and will W hen Ifirstattem pted to carry outthi s probabl y be undesirable in the case ofa operation Istarted atthe outerend ofthe slotdrill.The outerdi ameterofan end mill end m ill,sharpening towards the shank is rarel y crucialand can be sharpened on end,and found i talmostimpossible to feed

lfthe width ofthe ground surface is greater than 1.5m m then the secondary clearance should be ground.To do this repeatthe above sequence butwi th the angle setat 10 to 12 degrees.Do thi s untilthe width of

the end m ill satisfactorily.After many attem pts Ibegan to feelthatIwas onto a Iooser.Al terati ons to the end ofthe t00th

rest(73)had Iittle orno effect.W ithout reasoning why,Ideci ded to attem ptto start from the shank end and work towards the outerend,the difference was im mense. W hatwas beginning to Iook an im possible taskhad now becom e a taskthatcoul d be carried outwith ease.W hy this is Iam not sure,though inthe firstcase the millrotates withthe wheeland the operatorhasto keep the cutteragainstthe restaswellas feed it al ong the I ength.In the second i trotates againstthe wheelwhi ch keeps the cutter agai nstthe restandtheoperatorneeds onl y to make the feed. Having successfull y ground the first edge rotate the spindle anti-clockwise and grind the second foll owed by the third and foudh edges.Howeverany attem ptto turn the spi ndle whilstinthe positi onforgri nding willcause the restto be forced into the

w heeland ground away.The assembl y musttherefore be moved away from the wheelbutdo notdo thi s using the finefeed as back I ash,etc.,may make itdifficultto get back to the sam e posi tion.This will result in cutter edges being at diflering diam eters. Instead, Ioosen the clamp screw, move cutter assem bly from the wheel,rotate cutter,repl ace and re-tighten cl amp screw.The fence is fi tted wi th the stop screw to ensure that the assem bly returns exactly to the sam e posi ti on for eachcutting edge.Aftercompleti ng the four edges,inspectthe resul tand,ifconsi dered appropriate,repeatthe procedure taking anotherIightcutto each cutting edge,no m ore than hal fa di vision,probabl y Iess. If this results in a ground width of greaterthan 1.5m m set the angle to 10 degreesandgrindthesecondaryclearance to reduce the land to no m ore than lmm . Form e,having staded the exercise with whatseemed insurmountabl e probl ems,the

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ity ofthe finished task was et remel y quaI satisfying.W hiIst not appearing up to the standard ofa new ctltterthe difference was

completed. Itis wodh highlighting thatthis is one appli cation where the angle on the item bei ng ground can be set using the

W hiIst notevi dent ini tially itwillbe when new cutter,oreven the used cutter i fthe the cutting edge is honed onthe flatstone. wearis notexcessive, and try to replicate For quali ty woodwork, both prim ary and these. Frequently articles, hobby or

notthatgreat.Intermsofcuttingabilitythe swivelfaci lityofthegrindingresti tsel f.This

secondary angles should be honed the

industrial,on the subjectare farfrom

difference woul d be hard to tell.

is evi dentfrom Photo 5 Chapter 9 which

initialconcave nature ofthe secondary

precisewithgood reason.The perfectangle

C

cl earl y shows thata firstrate job can be achieved.

angle willbe removed. Keeping the approach angle as smallas possible,

isso dependanton manyfactors,suchas

entre Punch

wi thoutitbeing negative,willofcourseIi mi t

when sharpening otherround tooling,a Many Otheruses centre punch being a typicalcase.I Thetaskspossiblewillnotstopatthose

the effect. This now completes the projects

consi dered that such situations m ight already described,others surfacing with surface overtime,manybeing ofa different time.These using new accessori es forthe

included to provide a wide and sizeabl e m illing invol vem ent. However, having

diameter.The eflortofmaking a colletfor job in hand orones already made.One

finished with an emphasis on tool the perfectwillstillcutinfinitel y betterthan

each one as the need arises would such situation is seen i n Photo 5.The probabl ybeadeterrentfrom usingtheset- swivelbase togetherwithhalfofthe round up.Because ofthi s Ichose to use a simple workpiece holderisbeing usedto grind the

sharpening Iam verybriefl y including in the finalchapterdetail sofhow toadapta basic off-hand bench grinderforfl tting cup wheels

a cutlerwith the perfectangle buta blunt cutting edge.

adapter(Round Workpiece Holder81),as secondary angleofwoodworking chi sel.

and saucerwheel s.Thisdoes notinvolve

SAFETY

concentricity w ould often not be that The approachangle ofadegree ortwo, im portant. setby the rest'sswivelling facility,wilresul t Photo 4 Iargely show s aIIthat is in a concave surface,greaterthan on

any m illing activity but very nicely compl etesthe equipmentfortoolandcutter grinding.

lmake no apologiesforonce more bringing up the question ofsafe working wi th thi s grinding rest.The rest,having many more

W hiIstIhave covered the mechanics

adjustmentsthan aconventional,off-hand

oftooland cuttergrinding Ihave included very Iittle regarding characteristics ofthe

grinderrestanditsmethodofusebei ngso different,the safetyconsiderationsare al so

needed in terms of how the task is previoustasksduetothewidthofthechi sel. .,

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The end millaccessory can also be used

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abl e would improve alone was adequate and machined the and SaucerW heelsavail its use stillfudher.Thi s is notsurpri sing, bush's face,w hilst in situ, using the as such wheels are standard practice for grinder'sown motorforpower.The spindle

seri oustoolandcuqergrinding.ltherefore wasalso 1/2indi ameterand lreducedthi s obtainedasmall(125mm)offhandgrinder to 12mm toensureitrantrueandbothends

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ncludingitbecauseofthe yourownsituation.Thedimensi onss ui ta this book.lam i tionwiththecontentofthelastthree 12mm spindle and a w heelhole si ze of 4 : )( :2 / 1, 11 31 E 2) 4 : 2 : 4 : )I1I EI L I: ) p 1 td E z h1 -t ! l. : E! 1 : EE !I l r ll I -l r l. Having putto use the grinding rest The stepinthe spindle,againstwhich .

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oftube to Iength. Setup grinderon lathe

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grinderis on the Iathe,fitfirstbush using two partresin adhesive,holding this in

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Mounting the G rinder

Mo unti ngthegrinderWiIIdependbothOn the type of lathe bed and the form the

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detail scannotbegiven.Ontheplusside, onl y very l ightcuts willbe taken so the

placeinthethree-jaw andfaceonesideof each Then reverse,making sure thatthe

the bed takes,adequatel y m ounting the grindershouldnotpresentaproblem . Ifthe bed ways are rectangularthen foursmal l

Above Right:2.Setlfng up the grlnder on the lathe bed for m achlnlng the splndleandaddedbush.Right:3.A stub mandrelfs used forholdlng the flanges

tool maker' sclampsmakeanidealmethod

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securityofthemountingwillnotbeseverely tested. Because ofthis,no m aterwhatform

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.. lnnerand OuterFlanges(2and3) ïs' ' r Theessenti alrequirementforthese i sfor + '' -' 4.t..zp:t''..?' ,'''(4 , C t L i , z' )/. 'l t' l ' 1 ' ., . acewhichcontactsthe . t ; their bore,the f '' : t' . , , wheelandthatwhichIocatesagainstthe -''.-..è'u.-,...,. ) . , t : )y è ). ' i) ' spindle bush, to betrue andparalleland y C(). , t he32mm diameterconcentri cwiththe .uy'tyyj bore Cutfourpieces of60m m diam eter,

SPINDLE BUSH 1

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kATEiI AL 25mm CIAkETEF STEEL 230k07

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1. Machining the face ofthe addedbush powered by its own m olor,the spindle >as machlned in a s/m flarm anner.

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8mm thick,also boreeachtoa Iittl e under drilland the di vi ding head described in 12mm .Itisessentialthatthe hole in aIIfour Chapter 7 m ounted on the lathes cross flangesfinish upthe same size.To achieve slide,positionthe holes as shown in Photo

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t j l er emai ni ngfl anges.Returnthetwoout er hol esi zeof31. 75mm,gradeWA60KVI. 1j Flanges(3)tothechuckand openupbore Saucerwheel,Type 12,125mm outer

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ASSEMBLY Thi s Catlsed diSCUSSiON On the advisabili ty ofthis when using a single centralnutfor fi xing the wheelas it may tend to come Ioose.In thi s arrangementthere willbe no Mroblom RS,i1OPOCt,WO havotW0 SPjy.jjrjjjgj:gj

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ojeach screw , again in turn.They should be tightened suffi cientlytosecurelyholdthe assem bjy together without movem ent, ainl y notas ti ghtaswould be done wi th cert a metalto metalassem bly. Overti ghtening mustbe avoided!Then, using one ofthe flangessuppliedwiththe grindermoun!the assem bjy ontothe spindle as shown inthe assem bly drawings. Again do not over tighten,J .ust sufficientto ensure reliable t at i on of the wheel. Photo 5 shows the ro two wheels, one already fitted with its jlanges.

boards I aminated fOrextra ri gi di ty.These fOrCuttergrinderspindlesto be reversing.

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Ifyouadapta 15Omm grinderthere is no need to increase the diameters,

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assembl yofftheworksurface.

si tuation.

Direction of rotation

Mounting the Rest

Ihave readarti cles,whi ch mentionthe need

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However,the designofthe restdoes only provide for itto advance the table in front of the base angle as can be

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Ihave,chosen to retain the guards that were pad ofthe originalgrinder. These,I suspect,could be im proved upon butfeel that only w i th experience of use,willI understand the Ievelof access to the wheel s required.Iwould though suggest thatas removaland fitting ofthe wheels is easy,thatonlythe wheelbeing used should

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b efitted.Thisleavesthesecondspindle withouta grinding wheelpreventing the

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the sam e basi c set- upaswasillustrated in the earlier chapters. However,a second position for the rest is provided at the grinder's side,as approaching the cup wheelfrom thi s angle willbe benefici alin som e instances.The m ountings shoul d also be repeated at the Ieft-hand end. Photo 6 showsthe set-up.Forease ofuse, push-fitinserts i n the I owerboard as shown in SK 3 as thi s willavoid the need to gain aCCOSSto nuts on the underside. I fyou obtain a 125mm grinderi tisIikely

thattherestmaybeaIittleonthehighsi de and mayalsobefora 150mm grinder.This can be overcome by using a sui table piece ofwoodasa packer.

Ihavenotgivendimensionsforthe

as sembIy,as they w ill depend on the di

m ensions of the grinderbeing used.

138

knowledge,actuallymakingtheitemswill drive this home and help considerably to increase your confidence in using the m illing machine.

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M ethods forusing the restwilldifferIi ttl e from thosedescribed inthe earli erchapters so have not incIuded any further instructions,I have though included two photographs to show itin action. Photo 8 shows the end teeth ofan end millbeing sharpened whilstPhoto 9 shows its cutting edges being ground.One finalcomm ent regarding Photo 8,this shows the base angle mounted close to the boards edge enabling the Iowerclamping arm to rotate a full360 degrees.This makes itpossi bl e to rem ove the bulk ofthe restfrom the base angle,making iteasierto move the base anglebetweenthefour,mounti ngposi tions. Having come to the end ofthe bookl do hope you have found i t useful.W hiI st readingthechapterscandomuchtoimpad

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ALSO BY HA RO LD HA LL

Lathew ork A C om plete Course

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If fear of the unknown is allthat is preventing you from embarking on the satisfying hobby ofmodelengineering, thenthis is the bookthatwillbanishyour concerns. Author Harold Hall has established his reputati on as a mentorto tyro modelengineers through the pages ofModelEngineerW orkshop magazine, ofwhich he wastheeditorfora num berof years. Thisbookassumesnothing and usingthe

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medium oftwel veIatheturningprojectswil Ieadprospective modelengineersthrough aIlofthe basi ctechniquesneededtotackle

ambi tiousprojects.AlIofthe projectsare extensivel y illustrated and fullworking drawings accom panythe text. Once followed through,the readerwillhave amassed a wealth ofpracticalskills and a range ofusefulworkshop toolsand equipment. PAPERBACK,168 PAGES ISBN 1-85486-230-8

TH E C O M PLE TE S.I.M O D EL B O O K S W O R K SH O P PRA C TIC E SER IES

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W PS 1 Hardening,Tem perlng& HeatTreatment TubalCain 0-85242-837-5 W PS 2 VerticalM illing in the Hom e W orkshop Arnold Throp 0-85242-843-X W PS 3 Screwcutting in the Lathe M artin (78e7/0-85242-838-3

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W PS 4 FoundryworkfortheAm ateur B.TerryAspin 1-85486-168-9 W PS 5 M illing Operations in the Lathe TubalCain 0-85242-840-5 w PS 6 Measuring & M arking Metals Ivan Law 0-85242-841-3

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W PS 7 The ArtofW elding G A.Fatzse 0-85242-846-4 W PS 8 SheetMetalW ork R.E.+a#//0r420-85242-849-9

W PS 21 Adhesives & Sealants David Lamm as 1-85486-048-8 26.95 W PS 22 W orkshop Electrics

WP S old Se9 ring&Brazing

AlexSGe WP 23/ss 1-85486-107-7

TubalCain 0-85242-845-6 W PS 10 Saws & Sawing

W orkshop Construction Jim Forrestt : PeterJennings 1-

j IanBradley 085242-887-1

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W PS 11 Electroplating

5424 86-131-X :6.95 W8 PS Electric Motors in the HomeW orkshop Jim Cox 1-85486-133-6

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TubalCain W PS 13

The Backyard Foundry B.rerry Aspin 1-85486-146-8 W PS 26 Home W orkshop Hints & Tips

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Jpoyner 0-85242-862-6 W PS 12 Drills, Taps & Dies 0-85242-866-9

Workshop Drawing

WPS25

1- 85486145-X W PS 27 Spindles

WPS15 85242-886-3 W Tubal orkho ldingintheLathe Cain 0-85242-908-8

HarpritSandhu 1-85486-149-2 WPS28 Si mpleWorkshopDevices TubalCain 1-85486-150-6

W PS 16

WPS29

wp s17 oears& oearcuuing

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TubalCain 1-85486-182-4 W PS 14 Making SmallW orkshop Tools Stan Bray 0-

Electric Motors Jim Cox 0-85242-914-2

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CAD forModelEngineers D.A.G Brown 1-85486-189-1

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Ivan Law 0-85242-911-8 w PS 18 Basic Benchwork Les Oldridge 0-85242-920-7

als Alex W eiss 1-85486-192-1 w Ps 31 UsefulW orkshop Tools Stan Bray 1-85486-194-8

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WPS 19

W PS 32

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Spring Design & Manufacture TubalCain 0-85242-925-8 W PS 20 Metalwork & M achining Hints & Tips Ian Bradley 0-85242-947-9

Unim atIIIAccessories Bob Loader 1-85486-213-8 W PS 33 M aking Clocks Stan Bray 1-85486-214-6

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