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... - - j , . ,..M. *IIIe - k r--Through the Nges of I Engin-rs' Workshop mogozine, oulor Horold , )

fo intrV ucing the Nro model engineer to aHoll, hos estoblished o reputtion rwide ronge of mochine tx l o- rotions. In this imok he introduces le millingmochine. '

ie millin: mochine ond IThis O k ossumes no previous exmrience of usingirough the medium of four minor ond four moior proiects will Iecd prospective 1sers of the milling mochine irou:h oII of the e hniques involved. W hilsf thudeMile descriptions in le G k ore oimed primorily ol tbo- wishi

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Harold Hall

SPECIAL INTEREST M ODEL BO OKS

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IThe right of Harold Hall to be identified as the Author of this work has been

1 asseded by him in accordance with the Copyright, Designs and Patents RightsI

Act of 1 988.T

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AII illustrations and diagrams appearing in this book have been originated byl the author except where otherwise indicated.

; AII rights reserved. No part of this book may be reproduced in any form by print,I photography, microfilm or any other means without written permission from ther publisher

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C ontents

Preface

Chapter 1

Chapter 2

Chapter 3

Chapter 4

Getting S'taded

Tee Nuts

An Angle Plate

Clamps

Parallels

Boring Head

Dividing Head

Grinding Rest

Grinding Rest - the main accessories

Chapter 5

. Chapter 6#Chapter 7

9

1 1

1 5

27

35

39

46

60

76

94

107

121

128

Chapter 8

Chapter 9

Chapter 10

Chapter 11

Chapter 12

The End Mill Sharpening Fixture

Using the End Mill Sharpening Fixture

Tool and Cutter Grinding Head

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The main purpose of this book is to assist well as having the projects to complete.the newcomer to the milling machine to Coming to terms with operating thebecome an experienced beginner. This is miliing machine is quite different to that ofachieved by providing a range of projects using the centre Iathe. In the Iatter case

: to complete which together will give the range of machining processes is. sufficient time spent using the machine for comparatively Iarge, outside diameter

this to be accomplished. turning, boring, screw cutting, parting off,The book assumes that the reader high precision work, etc.. W hen using the

. already has a good grounding in the use of milling machine the actual machining: the centre Iathe (the main machine in most operation varies Iittle. However, the wide

workshops) and gives a minimum amount variety of component shapes, before and.

' of detail for completing the turned after machining, is what creates thecomponents. However, should the reader problems which have to be resolved. Thefeel a need for a greater understanding of projects in this book aim to give the required1

.: using the centre Iathe, then the sister book quantity and variety for the newcomer to'

to this itLathework, a Complete Course - be very much at home using the machine... $

l Workshop Practice Series No. 34'' would Whilstjust reading the book will provide'î f I reading

. much useful information this will be a poormake use u) With the three main projects being substitute to actually making the items

quite sizeable, and the items produced of described. The reader is therefore.. considerable use in the workshop, the encouraged to make at least most of the!.

, , book is not just intended for the newcomer items detailed.. to the milling machine. The experienced'

' user should also find the book beneficial, Harold Hall

. i, no doubt also gaining some useful tips as March 2004

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!h Using the milling machine does not include making some $T'' nuts became the first

the range of operations that are available project. Immediately, I found that thetwhen using the centre Iathe as the machining was not progressing well, surelymachining proceqs varies little from task to the machine was not that inaccurate. It soonètask. W hat does vary is the shape of the became apparentthatthe milling cutterwas

) h part being machined creating problems with being pulled out of the chuck due to the,' mounting, machining in the required spiral form of the cutter. Only if I tightened: position and measuring to ensure a correct the drill chuck excessively, and then only if. 7

part is the result. For this reason the book 1 took very Iight cuts, could I maker attempts to create progressively more satisfactory progress.): sizeable projects rather than each dealing Having paid some E600 for a Iot of':; with a particular process. machine, it seemed out of proportion to pay1

W hen I purchased my first machine, a E100 plus for such a small item as a milling' mid size mill-drill, it was in the early days of cutter chuck. Today a ch uck can be:7

these appearing on the market. I soon purchased a Iittle more cheaply, but if you1 found that the accessories provided were want imperial and metric collets, and or upt. far from adequate. to 16mm/ 5/8in shank diameter, you will still! be paying a Iarge amount when comparedL; Milling cutter chuck to the cost of the machine. Unfortunately,'' The machine was provided with drill chuck, the bad news is that it is quite impossible;

tilting vice and a sizeable face cutter', to manage without one.apparently, even now, this is the kit of pads An alternative is to use cutter holders,

) most often provided. The absence of any these consist of a taper shank bored to take' $T'' nuts, afundamental fixing device forthe a single size cutter shank, but as a number

milling machine, prevented me f rom of these are required their cost would not.

1.

mounting my vice, a peculiar omission, be that much different to a cutter chuck.especially as I had also received a small They are also theoretically Iess accurate,

' selection of end mills. However, with some being unable to compensate for differingtemporaryfixings the vice was mounted and cutter shank sizes which occur due to the

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1. The three common torms of cutters , leff to right end mIII, mlni mill and slot drill.

permitted tolerance in their diameter. Their range of shank diameters and types. It will

use is best reserved for mounting any odd also provide valuable turning experience.1 l size cutter, perhaps a 16mm shank when Having obtained your cutter chuck,j ! only a 12mm collet chuck is available

. making the remaining essential items canr ;

now commence. You will of course needl . Milling vice some cutters and a few other small toolsy The vice I received was robust and proved that I will now deal with.' I hold parts within its capacity,to adequate y

although it soon became apparent that its Milling cuttersg accuracy Ieft much to be desired. Being of Basic cutters come in two forms, end mills' substantial construction there was scope and slot drills. These have a maximum1 for re-machining which I did. However, diameter of 14mm for a 12mm shank andt

f its tilting facility, it was an 20mm for a 16m m shank. The mostbecause oinvolved task. As will be seen, a vice is not common form has a threaded end to the

i as essential as is often considered and shank and requires a collet chuck system1I more will be said on the subject through to suit. I would strongly advise you to adopt1

the book. this form. Plain shank cutlers and suitable' ' If ou want to minimise expense then collets are becoming more available but91 the milling cutter chuck described in the they still Iack the absolute certainty of the

; sister book W PS 34 will considerably iimit cutter not being drawn from the collet, even

the cost whilst still accommodating a wide if only Iightly tightened. One exception is!12

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the 6mm shank cutter that is not intendedfor re-sharpening and does come with aplain shank.

End mills have fourcutting edges whilstslot drills have only two. As their nameimplies, slot drills are for milling slots; inpadicular closed end slots and whilst at apush end mills can be used for the processthis is far from ideal. Both forms of cuttershould therefore be obtained.

The 6mm shank cutters are differentand have 3 cutting edges and functionadequately as both end mills and slot drills.These are known as ddmini mills'', Qhrowaway mills'' and other such names.

The three forms can be seen in Photo1 that illustrates the basic difference. Theend mill on the Ieft has four cutting edges,aII of equal Iength but stopping shod of thecentre of the cutter. This prevents the cutterbeing plunged (as can be seen in Photo 2)by very much so their use for makingenclosed slots is impracticable.

On the right is the two cutting edge,slot drill where it can be seen that one edgeis much Ionger than the other and passescentre. This permits the cutter to cut to thecentre and can as a result be plunged topermit the cutting of enclosed slots.

In the middle is a mini mill that hasthree cutting edges, aII of which cut to thecentre and can be used both as end millsand slot drills.

Recent developments in cutting toolsusing replaceable tips (that have beenwidely available for use in turning for manyyears) are now becoming available as endmills and face cutters for use on the millingmachine. There is though a Iimit to howsmall they can be made and conventionalcutters in the smaller sizes, especially slotdrills, are still required.

A face cutter, often supplied as anaccessory with the mill when purchased isuseful for machining Iarge areas. They arenot though essential and I will comment

13

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t j ' more about them Iater.1 '! Measuring equipm entr

Measuring parts being made on the millingI' machine is far more difficult than similar

tasks on the Iathe, and larger dimensions. 1 are also Iikely. Therefore, a 150mm vernier- is essential, Iikewise a dial test indicatorl

for accurately placing the part on the table,l and relative to the cutter. An engineer's1rrr

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square (two in some cases) is also usefulfor positioning parts on the table as will be t Fseen through the book.

Rem aining essential items ',The remaining essential items, clampingaccessories, an angle plate and parallels, 'are quite simple and I propose that theseshould be the basis of the projects in theearly chapters. '

:

As milling machines vary in size so the :T'' close a fit in the slot as small fragments ofslots are bound to differ in size, it is swarf will make it difficult to slide the nutimpossible therefore to quote into place.dimmensions. You may Iike to do some W anting to machine some ..T'' nuts butresearch to establish the particular sizes without any initially available presents a

r to suit your machine but that is far from problem.-rhere are various ways round this,essential, a Iength of nut at Ieast equal to but making two nuts by hand (hack saw andthe width across the 'dT'' should be file) would be the simplest way out. If you

. satisfactory. Also, do not make the width already have some RT'' nuts available, I' and thickness of the arms of the NT'' too would still ask you to consider if you have

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minimum. I would also suggest that someli are made with different thread sizes

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tvoicallv M8 and Mlo. This mav seem a lotl 'b 'ut as-will be seen, they wi-ll find uses

r IC beyond what is normally considered to beI k ! their purpose. where space is Iimited, it is1 .'' occasionally helpful if the clamping stud

could be moved over a little. This can be!done by having a few which are tapped off

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i centre, see SK 1. If you consider that you1. I 11 have su#icient, please do read this chapter'

carefully as it deals with the milling. operation in more depth than elsewhere in

! the book.

t ! Making the 1'T'' Nuts! il .ç ,j ! Make two temporary r nuts with a threadI size one size smaller than that chosen forl the nuts to be made, typically, M8 if M10

nuts are envisaged. Cut a Iength of material

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for eventual cutting into individual nuts. Thematerial used should obviously be at leastas wide as the chosen width and as deepas the total depth of the nut. lt is likelyhowever that the material will have to beover these sizes and the sequence thatfollows, provides for reducing thesedimensions as required. Mark the materialout for drilling and tapping, rememberingthe 2mm allowance, and drill the tappingsize holes, Photo 1.

Mount the material as shown in Photo2 using the two temporary nuts. W hiIst thisappears to be a simple operation, itimmediately becomes apparent that thereis more to it than first appears. Theclearance of the ttT' nut in the slot and thescrews in the holes, permits some variationin the position the part takes up. Obviously,the Iength of material must be true to theaxis of the table otherwise the width of themachining will vary end to end. Forprecision, a dial test indicator in the chuck,or a purpose made mounting, testing alongthe length of the part as the table is movedis the way to proceed. For this situation

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move the table forward as it takes up theplay in the Ieadscrew. This sudden forwardmovement will give a dramatic increase inthe depth of cut with possible disastrousConsequenceS.

W ith vertical milling, the Iight cuttingload relative to the table stiffness makes

2. Positlonlng the material on themilllng machine table.

tl'f 5. ''' %'')7t)k ) ik recommendation. However, in industry,'

' , '? Up and Down milling where modern machine tables can be? x ) . .= 2 .

' VUCII Writtorl Work 0r1 t@1c milling PFOCOSS backlash f ree, moving the table with thestresses that the movement of the part rotation of the cutter is preferred as it givesî'ntn .?. ? ). .. . ..

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' 7 ' ' being machined should oppose the a better surface finish. The reason for this1L vglxx.t u.. . j . direction of rotation of the cutter

. Such terms is that a cut starts at full depth and reduces1 ite is the''t,,., - ,. as Up milling (Climb milling), and Down to zero whilst in reverse the oppos.. . zkI) jq milling are used and emphasises that the case, SK 2 attempts to illustrate this.

requirement initially stems from horizontal This is due to the difficulty of making' ; milling. The problem is that when the action very Iight cuts unless a cutter has a very

of the cutter is attempting to move the parl fine edge, a situation which would soon be' forward in the same direction as it is being Iost with a new cutler even after a small

. fed, a heavy cutting action can suddenly amount of machining. Obviously, after a

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the possibility Iess Iikely. Even so, asconfidence grows and heavier cuts aretaken with Iarger diameter cutters, it maybecome a problem, so if no overriding factorexists it is better to conform to the

though, high accuracy is not that importantand a rule dimension at both ends off thefront edge of the table will suffice. Note alsothat the material has been packed up fromthe table using some thin (0.2mm say) card,the purpose of which becomes apparentIater.

Even though you will not be machiningmore than a few millimetres in width, douse a cutter with a diameter at least threetimes the width of the cut to be taken; moreabout the reasoning behind this Iater.

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L i I 3. Finlshes obtalned e/tll Up and Down m illing compared.î .k li milling cutter has Iost its initial fine edge coolant, etc.. Also, the Ievel of rigidity of

! ij asking the cutter to stad cleanly with a the part mounted on the machine table isj , ! minute cut cannot be expected. SK 2 also an important element. This combination of! attempts to illustrate this. factors precludes the provision of precise

W ith the question of up and down rules. W ith experience it will soon be found$ jl milling in mind I decided to carry out a test, that there is more tolerance to the speedl 1, making a cut of about O.1mm depth on a chosen than one is often Iead to believe.l piece of material lomm thick, doing this in As a starter I would make the followingl '1 b0th directions. photo a shows the result, recommendation; at 1 2mm diameter,f i! (on the right), performed using the down machining mild steel, set the speed at 500

'i .' illing process', it is much smoother than rpm. From here, the important point tom;

i that on the Ieft using up milling. In the flesh, remember is that cutter peripheral speedthe part feels almost glass smooth if a finger should be the same for aII diameters, so atnail is run along the smoother end whilst it 6mm make the speed 1000 rpm and atk

j has a rather corrugated feel at the other. 24mm diameter 250 rpm. For aluminiumYou will be given an opportunity to try out double these speeds and for cast iron andthis test for yourself Iater in the series. bronze halve them. Of course these speeds

: will not be exactly available on youril Machine speed machine so select the closest possible

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. Before stading, machine speed must be W ith experience you will no doubt be happyset. As in turning, the acceptable speed is to increase these values, probably quitedependant on many factors: size and substantially, although for smaller cutterssharpness of cutter, type of material, the top speed of the machine will be theIrobustness of machine, use, or not, of Iimiting factor.

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4. Taking the first cut along the Iength of HT'' nut material.

Machining com mencesW ith the machine running, slowly Iowerthecutter onto the top of the material until firstsigns of machining appears, move the tableto clear the cutter from the part and lowerthe cutter by around 2mm. Now bring thecutter up to the side of the material, againuntil first signs of machining are apparent',do this on the visible side of the material.Marking the side with marking blueimproves visibility. Move the table Iengthwise to clear the cutter from the end of thepart being machined and stop the machinerunning.

Knowing the initial width of the materialand also the width of the 1'T'' nut to be made,calculate the width of the cut to be takenfrom each side. Set the cut to reduce thewidth at one pass, providing this is no morethan one third the diameter of the cutter

being used. Also check that you will beobserving the rule regarding traverseopposing the cutter rotation. Start up andtake the first cut. Slowly traverse theworkpiece taking the first cut along thewhole length as shown in Photo 4. Nowreturn to the start, Iower the cutter by afurther 2mm and repeat the cut. If you feelvery much at home with the 2mm depth ofcut this could be increased to 3mm forsubsequent cuts. This assumes a cutter ofat Ieast 12mm diameter.

As guidance to width and depth of cutusing an end mill, consider maximum widthof cut to be 1/3 cutter diameter and at thiswidth, depth of cut also up to 1/3 cutterdiameter. The depth can be increasedsomewhat if the width of cut is reduced.These figures do though assume a sharpcutter and a fairly robust machine, typically

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/ 5. Finish machinlng the first arm of the 'fT'' to the correct thickness. j ..v, to size, the card provides a safety marg/nf l : 7. SWD#fD# the Gidlh BCf**@ the

! 11: the Iarger mill/drills. For a smaller machine Still working on the blind side traverse the ï between the botlom of the ctltter and the table face. Below: 8. Reduce the height'! I something rather Iess will be appropriate, table by the projection of the $$r' nut arm '( of the nut over half /ts length to the required Wze

.l,. reducing depth rather than width, and lowerthe cutter until it just touches the makina contact with the machine table see CrOSS feed table when setting the previousI ' experience will confirm what is possible. card packing and machine along the outer jatercWomment reoarding machining the nut Position. At this stage reverse the feedContinue with fudher cuts until the edge of the arm. Now traverse the cross . d surface. Thi-s time you have reversed handle until resistance is felt, (which takesen$ I j thickness of the first arm conforms to the feed byan amount equal to the width across direction of cross feed so taking account of tlp the backlash), then note the feed dial1 t l

size required, Photo 5. Now machine the the T, plus the cutter diameter, (again see ' backjash is a must. An easy way to do this reading, loosen the table lock and feed by! 'r I sK 3) and similarly machine the visible side, bsolute accuracy is not a the amount as above.other side using the same process here aI w'

1 ! remembering to machine in the opposite Photo 7. If you are concerned about irement, as in this case, is to Iock the NOW to reduce the height of the nut,h. recurI1 direction. A Iittle more care will be needed '

.. re-fix the nuts to the table using two fixings, ' )) Njyf 3.6 YOU Will bo machining On the blind Side . s yaking a witness cut to check that $, .* J ' . ) iïh One hasf Of the material length . This willTo set the width traverse the table by a ty- at, conkorms to that required. f''' . :: '''X9'>':îi Perm it half Of the nuts to be reduced inee

distance of (wlidth of centre portion of nut s, ''* t,,. ;;.;q(.(.. heightatthefirstattempt. Remember, width' . plus (Dliameter of cutter, see SK 3. Take a .f' '' ' ' ' ''''''',.,)Y' y.*...;3. .. $ of cut should not be greater than one third, . . . j. g -., .y js wouldtjt shallow and short witness cut to check the .. ,,, g y.;., . cutter diameter. In practice, and thI idth of the nut being produced conforms è), t.v .'' ...') / : be an excellent test to carry out at a Iater:1 wj j .. ..u, .. .,,.4 y, ,,, ,îj.j,, . ... . j., , tjme, jt wjjj ue jound that, at an appreciable. . to that required Photo 6. Follow this by t tt w E , ,, î ' . .#, ,,s.. 7 . îî. ' .b$)(. : - '' '' ' ' ' ' ' '

' repeating the process used for machining ' ,q, . .. depth of cut, traversing requires MeW much% . . . . .the first side. A small mirror, perhaps a $ . .) s .

'' more force on the Ieadscrew handwheel as7 . . . . y 'krs- .dental mirror will be useful to inspect the ' '

t. .f.î(1.*' ). .. xs. .. '''. . ' the width of cut approaches half cutter! -kjjjj' ' , L.. '

.. . . . . 'oopa , j x. t.. j,jt ; b I i n d s i de , B U T O N LY W H E N T H E ...r. . ' %.Li.L y.j..'y,'y'.,t.:ty,4ozy.,ys wpyy. , diameter, or greater. As I see thls, aIInOUgs <;.sk y.yt(# .jj i ii CUU ER IS NOT ROTATING. ' ty

, 1 have never seen it explained this way, it. 71

,#' Next stace is to reduce the widtia u , ; <z,?.. ,., is because movementof the cuuer s cutting- -

'' '- to that required. '*g ' '''''r''''' ., edge at one point is at right angles to the,1 across the arms of the x. x .q.fY'.! !; .

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9. An engineers square /n an excellent! aid to positioning items on the machine

table.il direction of traverse of the part being

machined (SK. 4). In theory this isimpossible but can occur if the cutter ismomentarily def Iected, hence theincreased force required at the feed

. handwheel.After one pass return the cutterto the beginning, place on a further cut andrepeat the process. Repeat the procedureto complete the machining, Photo 8.

lf you are being ambitious and making' a large number of nuts, it may be safer to

) first clamp over two thirds of the Iength1 l 1 I and machine one third at a time. An'

alternative would be to use side suppodsbut, in theory at Ieast, you have no d'r' nuts

f ' to hold these. Remove the part from the' machine table and refit to enable the other

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end to be machined in a similar fashion.Finally cut the Iength into individual

nuts and machine the ends. Of course, thenuts will work perfectly adequately with justsawn ends, but we are in this for theexperience. Clamp the first nut to themachine table, again using thin card aspacking, and using an engineer's squareto position the nut accurately as shown inPhoto 9. Using a square in this manner isa very useful aid to positioning items onthe machine table, two squares are evenbetter in some cases, Photo 10.Progressively machine the end by steppingthe cutter down the end face as was donealong the Iength of the nut. This time widthof cut will only need to be sufficient toremove any saw marks, probably only inthe region of 0.5mm. Bearing in mind thatthis is the first of many ends to be similarlymachined, do set the depth stop just shortof the table surface! This will avoid thepossibility of hitting the machine table in amoments Iapse of concentration, easilydone when many similar parts are beingproduced. At this early stage in yourexperience with a milling machine, you mayIike to err on the side of caution and set thestop with the cutter a Iittle higher, say0.1mm. The very thin web Ieft will easily beremoved at the deburring stage.

Now the end will still show thatmachining was done in stages and whilstthis is of no real consequence, eliminatingthese marks will be useful experience.W ith the cutter still in the Iower positionset on a further cuts of say 0.1mm, andsurface the complete end at one pass.Machining the complete height (probably15 to 2Omm) at one pass may seem that itwill present too much side Ioad on thecutter, however, due to the spiral action

10. Two englneerssquares can be used toposition Items fn Iinewith table travel.

the actual width of cut will be much Iess.For the mathematically minded SK 5

shows that for a 12mm cutter and a depthof cut of 0.1 mm the width of cut will only be2.3mm. Ideally, a relatively new cutter withits cutting edges still in good conditionshould be reserved for such applications.

Vford of warningAs a word of warning, swarf produced bythis process is needle sharp with obviousdangers. W hiIst in warning mode, 1 will alsoremind readers that milling cutters,especially when new, have razor sharpedges. Because of this they should be heldin c10th when screwing them into threadedcollets which can be a Iittle sti# if either thethreads in the collet, or those on the cutter,are not scrupulously clean.

Finishing offW ith the machining stages now complete,iiberally chamfer aII the edges using a fileand finally tap them with the requiredthread. You may chose to leave the nuts inthe raw finish or, for a professional finish,oiI black them or black them using one ofthe chemical methods available.

Ideal practice would be to first finishone end only of each nut. Then, use Iocatingfences (see Photo 3 Chapter 4) to positionthe nuts for machining the second end.Using this approach will make it easy toensure aII nuts are the same length, notessential but good for experience.

Screws, studs and washersThe ''T'' nuts must of course be

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.Jkkj I 'r' l sKs.' i .1 rt complemented by a supply of studs

,f11 screws, nuts and washers. Screws arel l easier to use than studs with Ioose nuts,

you will though need screws in Iengthincrements of 5mm and this is obviouslyimpracticable, therefore studs will bel

ired and could be used exclusivelyrequ

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instead of screws if it was considered aneasier option.

Screws, if used say for shorter sizesfor holding such items as a vice or an angleplate, should be high tensile. Studding isnot Iikely to be high tensile but providingyou have chosen either M8 or M10 thisshould not be a problem. This is easilyavailable in 300mm or IM Iengths, eitherfrom mail order outlets or your Iocal D1Ysuperstore; it can then be cut down toIengths required.

W hen using studs that have acontinuous thread they can pass throughthe $T'' nut and hit the bottom of the '6T' slot.W hen tightening the assembly it is possiblefor the stud to turn attempting to jack upthe side webs of the ''T'' slot. Somecommentators have stated that this cancause the webs to fracture. Personally,Iooking at the robust nature of the 'T'' slotson modern machines l find this improbable.As a precaution though the followingpractice should be adopted. Run the studinto the dT'' nut until it bottoms in the fc'l'''slot, then wind it back a couple of turnsmaking sure it does not once more bottomin the slot as the nut is run on. The use ofstuds being threaded from either end withone just sufficient to enter the RT'' nutovercomes the possible jroblem. Thesecan be purchased at a prlce but with thewide range of lengths required, makingone's own would be a wodhwhile exercise.

The use of screws however needsmuch more caution as whilst the above canstill arise, there is also another potential andmore serious problem. If the screw is muchtoo Iong it will be obvious as the item willremain Ioose on the table when it bottomsin the ffT'' slot. It is though possible that onthe border line itwill clamp the part sufficient

to appear adequate but will move when thecutting forces are applied. This could havedisastrous consequences and apparentlyi n s o m e m ac h i n e s h o p s t h e u se ofscrews is taboo. Used with care though,there is no reason for this if the followingis adopted as standard practice. Placethe screw into the f'T'' slot and move itclose to the item being clampedobserving that the head is lower than theitem. In this case adequate clamping canbe guaranteed but do also ensure thatthe screw is not so short, that only a

thread or two will engage with the nut.As angle plates, clamps and Other

items will f requently have slots, largediameter heavy duty washers are a must,as these are not that easy to come bymaking a small quantity would be a usefulexercise on the lathe. Nuts should be hightensile.

Having considered 'rr' nuts and theirassociated pads there remain three items:clamp bars, an angle plate, and pairs ofparallels in a range of heights. We start withthe angle plate in the next chapter.

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s Machining an angle plate impodant; do not use a precious high speed.).ê Introducing the manufacture of an angle steel tool as one hard spot and the tool will' plate at this early stage may appear need sharpening, so this is really a non-

. premature. lt is though an essential item starter. Start machining using an elderlyfor much of the work that follows and this cutter that you will not be too concernedè

t dictates that it is covered now. W hen the about damaging.subject has been f ully studied, and Alternatively, an end mill havingt;

E hopefully made, I think you will agree that replaceable tips, as mentioned in Chapter,'

it is not as daunting a task as may first be 1 , would be an excellent choice (if available)' thought. but do ensure the tips are of a suitable

. ) j tjje ptjsose., grade ort Machining cast iron Having mentioned the casting's hard'

? Machining cast iron falls into two stages. surlace that can destroy cutters, of any' The outer skin can be extremely hard and type, care has to be taken to make sure'

without proper precautions can easily that the method used to machine thedestroy the tool being used. However, with component attempts to overcome the

.t the outer skin removed machining is as problem. It is not an inevitable problem as, easy or even easier than mild steel. It does many castings will machine with ease. The

though machine quite diflerently and it is a method is to make the first cut su#iciently. javery didy operation. Do therefore use a deep to get below the outer skin where t e?L. good barrier cream on your hands. possible problem Iies. However, with/ Choice of tool type is especially castings being of irregularshape, a cut that;

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1. The angle plate casting with the cylindrical squares and clamp bar necessary to 2. Rem oving any hard spots around the edge by machining the edges ffrst.

eomplete its machining. .

Starts sufficiently deep may subsequently plate may seem Iike asking the impossible. 1) is precisely square to the base. This is squares. A thin piece of card could also bejust scrape the surface as the machining The method makes use of two precision ' covered in much greater detail in the WPS used to protect the squares andprogresses', a sure recipe for a damaged squares, a posh name for a round piece of .' 34 in the Workshop Practice Series. compensate for any very minor errors intool. Under these circumstances the metal having its diameteraccurately parallel l The two squares, already mounted, flatness.process should be halted and the tool along its Iength. The diameter of the @ with the angle plate casting (Ref. 1) and anreturned to the staë and a deeper cut set. squares is not critical, neither do they have ; essential clamp bar (only the centre hole Face one' r

'

Having totally removed the surface skin to be the same, but to ensure they sit is required) are shown in Photo 1. With the casting mounted as in Photo 2?tthe remaining machining can proceed with accurately on the machine table a diameter First dress the main faces of the machining can commence. First completelyease using a newer cutter with very Iittle of no Iess than three times the idr' slotwidth ,. casting with a file to remove any minor machine round the casting as shown andmore caution than with other materials. should be aimed at. projections and test each one on a surface by going round anticlockwise the cutter willIncidentally, it is normal to machine cast iron Cylindrical squares should be turned ' plate. My casting sat on the plate without be breaking out at the casting edge ratherdry. parallel , certainly within O.005mm, '

. the slightest rock and this was chosen to than cutting into it. This will have the effect

preferably better, and their bases faced mount against squares on the machine of chipping away at the outer face causingCylindrical square immediately after machining their outer ' table. If this is notthe case some additional it to break away rather than be cut andMachining a precision angle plate from a diameter without removing them from the filing may be necessary or possibly some having much Iess drastic effect On theraw casting without access to a second Iathe. This results in a pillar where the side packing between the casting and the cutters cutting edges. Follow this W taking

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3 and 4. (Above and Faclng Page) Rough machfnfng the flrst face.Iengthwise cuts to completely machine thefirst face as in Photo 3 and Photo 4. Setthe tool just a Iittle deeper, say O.O5mm, soas to skim the face created by the initialmachining.

Should the cut, due to the irregulars u rf a c e of a c a s t i n g , b e c o m e t o oshallow to remove the surface skincleanly, stop the process and repeat thecut made a little deeper as in Photo 2.Then a further attempt can be made tomachine the first face completely as inPhotos 3 and 4. This repeat operationapproach may be required with any ofthe machining operations that follow.

Face twoRemove the casting and reposition againas in Photo 2, with the now machined faceagainst the squares there should be noproblem regarding flatness, a check first onthe surface plate will be worthwhile though.

Rough and finish machiningI would point outthat, after rough machiningthe casting fully on a1l the required suKaces,it will be necessary to essentially repeat thesame operations as a finishing stage. AIIthe photographs were taken atthe roughingstage but are equally applicable whenfinishing the casting.

Repeat the process used on face one tomachine face two. Incidentally, if you makethe squares taller than the casting it will benecessary to pack up the casting from thetable, this can be seen in Photos 3 and 4.Any suitable piece of metal will suffice, theprecision of a genuine parallel in notrequired.

the faces butt accurately with the squares.Lifting the casting off the machine table willensure that this third face in no wayinfluences the attempt to achieve this. W iththe first end completed, turn the casting andmount again in the same way and machinethe second end. You may ask why take somuch care with the ends, why do they needto be square? It can be seen though inChapter 7, Photos 9 & 10, that it is notunusual to mount an angle plate onto themachine table, end on.

Some question the use of toolmaker'sclamps for work holding on machines, butproviding they are robust enough, and set

EndsNow with the two main faces machined,mount the casting between the twosquares, Photo 5, and machine the endas shown. To ensure the ends are perfectlysquare with the two faces it is essential that

30 31

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!. I 5. The cylindrical squares are also used when machining the ends. .. 6. Machinlng a long edge. 7 (Right) After rough machining the required faces the

'I' ! l setups are repeated for final finishing.' t . . . . î11 I correctly, there is no reason why they Flnlsh machlnlng ' machined faces using the same sequence no need to be precise. Just a single turn of. should not be used. The subject of clamps AII materials contain within them stresses . and setups already used. Problems with the Ieadscrew, or 1-1/2 or 2 whatever suits

is discussed in detail in Chapter 6. If you that have been introduced at the 3 hard spots at this stage are much Iess likely the situation.I do not posses toolmaker's clamps then with manufacturing stage. W hen sections of the ' and finishing cuts of say 0.2mm deep will1 . x & , , *.

care substantial G clamps can be used, material are removed, this destabilises the be sufficient to give a good surface finish. End m llls versus face cutters.:I otherwise, the clamp bar used in the internal stresses and causes the material Do though use a sharp cutter, cast iron at You may ask why have we machined this, original set up, together with a second bar to distort. This situation is particularly this stage machines very easily. You could angle plate using end mills when Il could be employed. prevalent with castings, though the effect 1 speed up the process by working clockwise. commented in Chapter 1 that most MiII/

is not always immediate. It is therefore, 7 gradually working to the middle but I prefer Drills are supplied with a tungsten carbide,I The Iong edges preferable to Ieave the rough machined working in straight lines as this gives what face cutter. Theoretically, the face cutterj Finally, at the roughing stage, the two long casting for at Ieast a few days before final l consider to be a better appearance, see would be ideal for roughing cuts but I wasedges can be machined by the method finishing. Photo 7. For appearance sake each pass concerned that the rather heavier, cutting' shown in Photo 6. W hen considered ready, re-machine aII should be at the same spacing but there is action would be too demanding for the

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) squares mounted on the machine table.' This would be the case particularly if they.1!' were on the small size in respect to

diameter, as were mine.' At the finishing stage the reasons

are more obscure. It is easy to assumethat the m illing machine is perfectlyprecise in alI aspects', they are made toIimits though and deviations from theI Iperfect are the norm. Even in toolroom-

I : quality machines, deviations exist,although of course they will be less.

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Rather than attempt to go into detail in thetext I have produced SK 1 that attempts toillustrate the effect of a cutter spindle thatis not at 90 degrees to the machine table.The sketch shows that the surfacedeviations from the flat, depend on whetherthe error is Ieft to right of back to front. Moreimportant though, the Iargerthe cutter used.the greater the e#ect. In theory thereforethe smaller the cutter the flatter the part, inpractice though a compromise choice hasto be made. Attempting the task using a4mm end mill would be Iudicrous whilst a50mm face mill would give the greatesterror. An end mill 12mm diameter andtaking Iight cuts of about 4mm wide, wouldbe a good compromise.

Finishing touchesUsing a file Iightly chamfer a1l edgesproduced by the machining operations andclean up the slots and their edges. As faras is practical, clean up the remainingunmachined faces of the casting and givingthese a Iick of paint will give the angle platea professional appearance.

ln the next chapter the subject isClamps followed by Parallels in thefollowing chapter, after which we get downto some substantial projects.

ReferencesThe casting used in the illustrations isReference No. 5O1 from The CollegeEngineering Supply, 2 Sandy Lane,Codsall, Wolverhampton, W V8 1 EJ Tel/fax01902 842284.W ebsite: www.coilegeengineering.co.uk.Many suppliers to the modelling andeducation establishments have similarcastings available which would be equallyappropriate.

C hapter 4

C lam ps

This chapter concentrates on an essentialitem for use on the milling machine', clampbars. It would be tempting in the case ofthe clamps to cut a few shod Iengths ofsteel, drill a hole forthe clamp stud, deburr,and call it a day. We are in this though forthe experience so will aim at a moreprofessional and useful result.

The dimensions on the drawing are forguidance only as size of machine, maydictate the size made. Do though ensurethey are su#iciently robust. lf in doubt becautious and use a thicker material, 8mmwould seem the minimum for use on themilling machine. The slot and hole will ofcourse have to suit the clamping stud size.

First decide how many are to be madeand cut off this number from the bar ofmaterial adding 1 - 2mm forfinal machining.

1. Machining the first end of the clamp,do m achlne towards the cylindrlcalsquare for added security. .--!111111

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As to quantity I would suggest 6 as a 3. With the clampI'' 1 inimum

. This may seem more than is s, ' havîng been marked .,.m , y .Iikely to be used at any one time but as we . With the p/lflfol' of è.T, .; Y'' ?shall see through the book other uses than ' v ' ''' )

the WOf, Retting the *''tè' Y. c.' ' . .. L . - y yjyystlj' -'f direct clamping do frequently occur. ' .. f. table stops for .

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. . . . . ytt . . .. f Njp/s the s/ot in - . .. : mac g'! .1 Manufacture . ...

the first and V ' ' 'i '. , . ;. 1. . ' - -?' i I--t!,p 1-),,, k!Ep jrj,jp jpjrjp ,!;,, t:l jrkg)r jrj-l!jr;p :!;, jrt!;y .

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' M o u nt th e an g Ie p I ate a n d on e of th e 1 ) . t'tttta ... . ) ys,yyy. .),)?. kys#.. .;.' . .I . . s,.yyyy : sy 0. .) y j y (yy . . .' i' ! cylindrical squares and first clamp as in .î3 :' ea8Y. 'ysyur. ..,,j.).h, ..;..?. .l r ! : $'- kjqq y. . . . .' - L . t: . , . . .?. . .. , L t:. . - . .. .: ; 1 Photo 1 . You will need to make a simple .. ' ; J ) )(j.., k,.. .y ,.. .... .. . y ....yg. . .1 . p . .y y) ? - . - . .. . . . .. jyyjjysy. q-. ., .. -t k.! ! clamp with a single hole if you do not have ' ',. j ' tv,î.qlèntl'îï . .. .' .. .. --0e '-' ' - %. 'ùlixfL1 . ' t ,? >r. . .. '

!! . .. one. Use one of the other pieces of clamp ). (....)..-...-', ' ! '> . )-.;j.);'$L1). > '' ) ,' koyl .-...; :' . . . .

. ,, .. . ,material as packing for the clamp though it .,v.,.b1)'1 ss .. ., ... . . ! a. , . :.. . , y . . .. jyytyy.t.j.,....,,....?' ' i ' is best practice for the packing to be just ' .

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' . ).y''. 11 . I t, , y, y. ,j . oyy- j))y;., . y ,y.h li'l ! ': : higher than the part being held. I normally f'è ) jE . . ...ùù,z.îj, stu,lujes:rsi.aè +, : I . . . t j( Ij ' I.

, achieve this by placing a thin piece of card rt ) t, )I I '' ..7,4..! jl under the part being used as packing but è të I I ? ;. 4.,-.s4. kï) w ,.-.. . .. . I appear not to have done so in this instance. ,.t.) ) ) ' .y u..;.. . 'r ! ' . y ,

, . .. ;v-è-Machine the top face of the part and, , y , .' ' l Iess you have a Iarge diameter cuqer, , ) 1 t . ,i'l.1 1-1 yy : . . . .y .y . . , -;z..- ):.. . - j)... ,; : . . ,' .

. . . . : .. . . ..; ) . . -L. I two passes will be necessary. In aII milling / o .., . î, . .. .,, .

' '''' ' operations it is highly desirable to machine C Sè 1 C ' . o . ' #';'èu2''?'4t'::'.'' 'èë?.. . . ê .. .j ; . . ' ry .. - . .. . -. :. ... -

towards the supporting items, in this case ' m Jthe cylindrical square. If machining was 2. The positioning screw below the k' ders may observe that the clamp stud identical to Photo 1 but closer examinationrea

from the square, that is from right to clamp piece enables all the clamps to ),aWay could be higher in the angle plate slot. This shows that the part is being supported by a

I left in the photograph, the single clamp may be easily machined to the same length would ensure that the clamp held the part screw screwed into a ur' nut, illustrating a' )

not adequately hold the part. Eagle eyed when machinlng the second end. t nearer the edge being machined for point made earlier that there are uses for5 )

improved security. This is not the case KT'' nuts other than pure clamping. W henk . , h; ; 4 , ,

.! , , though, as I find that using a T nut in the fitting, turn the screw until it contacts theij $ slot enables nuts to be tightened without bottom of the 6T'' slot and very Iightly tighten.'

tI I I l ) the need for a second spanner, and often This then supports each part as they arel j u . . - q..xa -- '' a third hand. The ''T'' nut does though fitted onto the angle plate so that each new' * ' e''D ' t the screw from being close to the part can easily be machined to the same- ..

y preven; . . . .

,' slot end, and I intend to make some with Iength, without recourse to measurementi ' l I 1 ) the tapped hole nearer the end which would or reading Ieadscrew dials. A real timeL.

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tj - - - r '. also be radiused, as in SKI, for use in this saving benefit when a number of identical1 U 1 3 . jjke to do the same

. parts are being made.,, way, you may' . 55 - 8 = 'l

.t70 = , T Nuts, other uses Secure clamping!j SUGGESIEZ SIEE 08Lï, DIREhSIO8S kAt CFIAhCE 10 StlI1 Having trimmed the first end of aII the Next mark out the pads for drilling the holes' RACHIhE AdD CLARF SIU2 SIEES. ' clamps

, machine the second in a similar and just one with the extremities of the slotSLCGESTEZ CLAHF IIIkEhSIOSS manner, photo 2. At first this may appear tobe madeiwidthand Iength. Drillthesingle

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hole in each one and use this for securingto the machine table as in Photo 3. I cannotstress too much, to err very much on thesafe side when it comes to securing partsformachining; onetoo many aclamp is verymuch better than one to few. W ith that inmind, placing support pieces which do notactually grip the part will give addedsecurity, often in places when an additionaldirect clamp cannot be applied, typicallycases Chapter 6, Photo 9 and Chapter 7,Photo 4.

ln this case a single screw fixing wouldprobably suffice, especially as it is a slotbeing produced that will not tend to placeany side load on the item. The supportpieces in the photo do though perform avery important additional function. Mountthe clamp that had the slot positionsmarked onto it and position it using anengineer's square off the front face of themachine table. Clamp it in place using thesingle screw then add the two supportpieces as shown in the photograph. As youbecome more involved in milling machineactivities such additional aids to completingthe task will become necessay so do makea habit of keeping these bits and pieceshandy for possible future use. Of coursethe clamps now being made could performthis task for future operations, hence mycomment regarding making sufficient.

Fit a slot drill of a size that will cut theslot at one pass. If however a sufficientlywide slot drill is not availables then widenthe slot using an end mill as slot drills aretoo fragile for cutting on one side only. W iththe machine stationary, Iower the cutter soit is almost touching the workpiece. Then,with the cutting edges in Iine with the crosstravel use the cross feed to align the cutterwith the marks on the workpiece. Lock the

38

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cross feed in this position. Now rotate the :cutter ninety degrees and traverse the table y'until the cutting edge lines up with the end 'mark and set the first table stop (Photo 3)at this point. Knowing the Iength of the slot A set of parallels are almost as essential 1/2 to 1-5/8in and at a very reasonableset the second table stop with the gap . as the clamps in the previous chapter for price. However, many of those available arerequired, and traverse the table to check , use during milling operations. These could only 1/8in wide, which is on the thin sideagainst the other end mark on the clamp. be commercially made items'

, ones made especially as some vices have a smallStartthe machine and plunge the cutter by the user

, or, as so often is the case, just grove in their bed adjacent to the fixed jaw.into the workpiece, say by 1 mm, and make off-cuts from mild steel bar. W hiIst in many You will also have to trawl the cataloguesthe first cut. Slot drills can be used in either cases the Iatter may be adequate

, to find them. Making them still seems adirection, so plunge the cutter by a further especially when used as a single parallel

, good idea.1mm and take a cut in the reverse direction. , two pieces of bar

, especially if taken fromGontinue until the slot breaks through on '' different lengths of stock material

, may not Parallel, how ?the other side. As the slot aligns with the ' have identical widths

. On the other hand The aim will be to create parallels in pairs$$T'' slot there is no danger of the cutter the hardened and ground commercial that are both parallel along their IengthLdamaging the table su/ace. The positioning variety will be of accuracy rarely required and of exactly the same height

, at leastpieces on the table, and the end stops and be a Iittle on the expensive side

. Of within good home workshop standards,having been set, will make machining the more significance though with these

, is that say within 0.002mm. At first sight thisi bt forward. he will not be available in a sufficiently may appear a standard that is too closeremaining clamps very stra g t y

. (.You may consider that the single hole wide range of heights if the cost is a to be achieved, especially with regard!i

n the clamp is purely f0r this machining '( consideration. Making your own is a to being parallel. How, after machining

operation but We Shall see later in the book worthwhile option as the cost will be the first side, is the parallel positioned

that it has a very important role to play. minimal and a wide range of sizes will accurately enough for the second to beGenerously deburr aII edges and the present no problem

. It is possible to buy machined parallel to the first? This is theclamps are complete. t, sets of parallels in 1/8in increments from secret behind the method proposed.E.

' (, 39

t

SK1

mount these onto the angle plate atapproximately the same height. See Photo1. Very Iightly machine over the top surfaceof the posts to give two Iocating faces forthe parallels to sit on. The small, reducedend to the post avoids having to machinetoo close to the angle plate face. It will benecessary to mount the posts towards thetop of the angle plate for the smaller sizes,say 10,15 and 20mm and Iower and re-machine them for the Iarger ones.

The screw seen in the centre slot actsas packing for the clamp when holdingthe parallels. See Photo 2. This shouldbe set at a height just greater than thethickness of the two parallels, say plus0.5mm. This would seem to be a goodtime to discuss good practice in terms ofclamping and rather than going into greatdetail in the text, SK2 should Iargely coverthe subject. However, in this case, if theclamp is not positioned suitably theparallels may tilt with obvious effects on

The heights of the parallels are notcritical providing each pair are accuratelythe same; I would suggest nominal valuesof lomm, 15mm, 20mm, 30mm, 40mm and5Omm and say 8mm thick and 100mm Iong.Having cut your Iengths of material, invarious widths, machine the ends using thesame set-up as in Chapter 4 Photo 1 andgenerously deburr the ends. Also removeany blemishes along the Iong faces andedges that could affect the mounting of thepieces for machining.

Make two posts as SKI, (as you willsee the dimensions are notthat critical) and

40

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.@ ,'. the helght of these, as illustrated 'In 3. and once more fit in place making sure that' ith the first pair of parallels mounted the mounting surfaces are scrupulously' machine the f'Irst side, remove and ve clean. achine the second s'lde, Photo 3,

I'Ightly deburr edges and ends. urn over the piece of packing seen below the clamp

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F holds this at just the right height. Finally, be susceptible to damage to their edges,remove, deburr, and the first pair of parallels though if treated appropriately this should

FA 4- woqx- AOiCFIECE CLAkFISG are finished. Photo 4 shows the use of ddr' easilybeavoided.AsmallwoodentraywithIhG ?IEgE FIGFITS A$2 AFOSGS nuts with the angle plate as mentioned in separatorswould helpatthestoragestage.

! Chapter 4. This avoids the need to use two In any case, damage is Iikely to be Iocalspanners and frees a hand to help and can easily be removed with a file

SKZ '' elsewhere. without affecting their overall accuracy.'

W ithout hardening, these parallels will This now completes the basic kit

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' without further equipment. major problem, even for the novice, but ,

In the next chapter we make a boring provide su#icient milling involvement forthe1 head, the first of three substantial projects newcomer to be well at home with the 10.' that bring the book to a conclusion. Even machine, by the time the three items have '

) !though the projects are quite sizeable the been completed.

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. yc..$,44 . jyy xyj completion. In the same way that the simple simultaneously. This will enable a particular1>L,)v lyt. . .. jjhvygyj), j): jtems thus far produced are essential fOr set-up to be used whilst available for parts$$. c?7t#?.w$' 'L(2$. y.''. ... ' :kq:)- ... . . . ' $Lï1' é.. ..k7j.sy., yy ,,, u .... ..j,y.y.

.. . . .) the manufacture Of these malor items, so in more than one project, red ucing the) . 7 . ' u .... u

p.x yyye, y tjjs jtem jn tjjjs chapter WiI 1 be essential f Or overall time taken quite appreciably. I wi 11'. jy .. . 7 . )î.jy qy , .. k. y jjje constructiorl Of thc SCCORY . UikcWiscj Oj COurSO doscribc CZC; itcm ZS if it is bCi rIU,p u . 7 .jj y s .). tjje second iS PSSOQtiZI fOr the third item . made in isolation. By now the process Oft , ''y

.. ytr j) They are a Boring head, a Dividing Head material removal by the milling methodïl . . '. . .. .

' . L .:. , y. . . . .klt(. . . ...y . .7 î . '. nhtjnj.xy. ... p . c .. ...?j and a Very Versatile G rinding Rest. should be reasonably weI I understood and. . ) . ' l y. :) . .rs. . . : . : ... .. .. . .t ty.s '. i-tchïs : ..a c ,d ?.,kt . '. t ,, : c.,. ., .... .. .. .. . ïk .t'#.c..:s;??- 'è;.kî;. .twy,. - ' ' - ' .. . .

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.v ,,. Materlal These final chapters are backed up by a

i Onerous number of photographs toI To simplify material procurement the 9E i. i ' three items have been designed where illustrate the actual machine set-ups.

I I possible to use the same material sizes'' for their major components. Secondly, to The Boring Head

ease the machining processes, material Body (7) and cuuer carrier (8)' Sizes that can be obtained free cutting Cut two lengths of 50mm square, 75mm

(230M07) have Iargely been chosen. This long, plus an allowance for machining.limits rectangularshapesto squares only. Mount an angle plate and cylindrical

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A$2 FULL $UT 2 0FF15 M4 ï 12 SOC4EI 2AF SCCEA 1 OFFH6 k4 ï 8 SOCKET C8U8 SCFEA 4 0FF

1. Machlning the end of the main body.Note the use o/ the cyllndrical square toposition the parl. Below: 2 Marklng outthe pads for drilling and slotlfng.square, clamp the part ensuring it isaccurately in contact with both angle plateand square. Machine the end, Photo 1,reverse, then machine the second end to75mm. Repeat for the second part. This set-

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QUXNTIU 0FF O JGIB STRIP 2

BORING HEADASSEMBLY

up ensures that the end faces are truly atright angles to the side faces and parallelto each other; a requi rement for asatisfactory conclusion to Iater operations.Mark out the positions of the holes and theextremities of the slot in the Cutter Carrier,Photo 2. Actually, my photograph showsthat l did this after reducing the thicknessof the carrier to 30mm as detailed Iater.

48 49

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. ï yj . y . tjje cross feed SUCh that a flat of aroundI j ' . ..,. ,. @ J . ) = ( : . .. . p . yjty.. k .1 :. .,. . ' ' ..t.. sj ;.c y yy . . ..y .. . ..y.( / j t (. g.5mm remai NS alol-lg 1he Iength . lf previousf x./w, tzjgro? t ..rt yy. syso .y. . . . ),. mach i n i n g j and the Setti ng Of th e angle! ! ' j , . s,yn . ..,g y > . . . ... . . . . . , . '1j!l) q, . . xz;y . . . .I ,

'fijlt . . s ( .: t . a ..4. q,jj,e< ' ' .u,. 'k q'v- k . 'k1 1 . .y, . 'wr' ,' r..a.a.z.- . ..' # ' .' y, .. . ,...,.'?t . ,,. ' . .. ,..x .,.. piate at this time is accurate, the flat should11 ' 't . . '' . .. Ek.';2 >' 'T ' c '. . '.% ) . : ) .... ty . , q ,*'è ...,. ' ) ;(. jjo. .. . . ' be a constant Width. If , an appreciable errorj . L. . . 4jj1k jj.. yyy u yy ... . . . y. .At ,....) . y . s. : )y. y. jqj yj . o! ' I 1 . evk. h . .. y, ,ys$ . .. ' ? . x, . o. . .'. .v. ' t . - exists it wi l I be n ecessa ïy to i nvesti gate thej ' .. . . . ?@ . Lt y ( . ..4j j . j g / y . .

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. Lower the cutter 2mm at a time untily

' . v:ê '4.' s ' bq .,y , s.. . . k, . s.t . . jjae f uI1 depth has been achieved. Follow

'. ?/ . . : '. ) . è L.g , , yytk ' .4 f eed of 0 . 1 m m , each ti me taki ng a ski mj I . . 7). l k jy. .. s. . . 2 yy a .. . .

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vq . ) . . ;#$ . yj L.'' '&ê' ' . . ... . . . 74 qa y?.. . : ' . '. .

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; a..' 4k. .... . u.',.,y,.., *j .c'',;.tv.s:.. '' ,...... . k , , ,< disappears. This is a case where direction,

..4:.. ,.,,y()p ... .. ,j . j yraverse can correspond to cutter rotation.. .

o' 4 11 Either method is acceptable but do take Left: 3. sor/ng the body for the arbon s. An alternative approach to using a to achieve the best surface finish, (see14 Right: 4. prevm /nary machining of t,e dovetail cuaer. chapter 2, photo a)' , note of the eventual reduction in thickness

' !1 if marking out the carrier at this stage. bodyprior to mactdnlng the dovetalls. Remove the part from the angle plate,'' Body (7) turn end on end, and repeat the process,

Drill pilot holes for B and C. Mount on the method. Note also the use of a substantial the workshop kit, so another method of Photo 5. Remove and place two pieces ofIathe faceplate, bore to take the arbor, washer over the slot. creating the dovetail is proposed. Even if rod (about lomm diameter) one on eitherPhoto 3. A tailstock centre located in the Loosen the part from its clamps and 0ne were to hand, using the method side of the dovetail and measure thepilot hole C will accurately position the part rotate through 90 degrees, this time described would be excellent milling distance between them at each end. Even

. . on the faceplate whilst clamping. Return the allowing the clamps to fall into the recess experience. if an appreciable error is apparent it is ofj .

I il part to the milling machine and mount just made. skim the slide faces to achieve Mount the angle plate onto the table no consequence, as the Gib Strip will

(1 ! dovetail side up. use an engineer's square the 8mm dimension. face end ways on, Iong clamping studs will compensate for this. It will though be nicer 1 off the table front edge to accurately Turn over to machine the two lomm x be required. (See Iater Photo lofora better to knowthe results of your eflorts and if theIij . position the part. Remove the centre podion 6mm slots. Lower the cutter into the 25mm view). Again use an engineer's square as error is less than O.1mm you have doneII to a depth of 8.2mm, working to the hole and whilst on the 37.5mm centre Iine, accuracy isvital, (using a dial test indicator very well.I !

. r dimensions of lomm and 26.5mm. See advance the cross slide until the cutterjust would be even better). Take a Iength of steel Finally, at this stage, drill and tap holesphoto 4. contacts the bored hole. Lock the cross say 12mm square, though not critical, and A and finally drill holes B and C.

'

i In photo 4 we now see the purpose of slide and reverse the handwheel until about 75mm Iong, drill in the centre with a Leadscrew bearing plate (4)I the hole in the clamp, that is to take a stud resistance is felt to take up backlash. hole to take a clamping stud. Fix this onto Cuta piece of steel allowingforsubsequent

1 to act as packing. The stud is threaded into Release the cross slide and feed by 7.5mm the angle plate at an angle of 30 degrees, machining, machine the ends, mark out and!' ' a ..T'' nut (another use for a ''T'' nut as ((25 - 10)/2). Take a very shallow cut and using a stud Iong enough to also clamp the drill holes A and B. IT IS IMPORTANT toI' intimated earlier) and Iocked with a nut as check to make sure no error has been part. make B, tapping size for M5 at this stage.I 1. seen. A nut on the stud below the clamp, made, make the two slots at 2mm depth Fit a 6mm end mill and set this to take Cutter Carrier (8)

not seen, sets the packing height to just increments. Being an open-ended slot an an initial depth of cut of 2mm maximum. Having previously machined the ends, cutI Ihigherthan the pad being held and afurther end mill can be used ratherthan a slot drill. Remember, at this small size of cutter a the 50mm square to 50mm x 30mm plus tonut placed on top make the assembly At this point it is assumed that as a high spindle speed will be required, say allow fOr machining to the 30mmsecure. This is an excellent packing novice a dovetail cutter is not yet part of 1000 rpm plus. Take a first cut adjusting dimension. Mount the material onto the

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. tjj J#y:u. . .,, yyy..1 () 1---' 15 ----1 1-.*. j * ' v .. *% ' ' ' ' > . t.....h/gïtL'lf 25 . T ' '> e''- .' A n - -r-- .-.- = X .j 1 ....l t * . . y, ? . .z.I *îJ ' ... -.1 .v f:a q- 'a - v - v - - u. -''. . ' I y

.. ttcs v. '. ... ! F1 0 LE S I 1 El S ):! z! ' ''''j . u ' .. . , )) s%ï; yx y .

;. .;y . .I ! /$ .$. ;! r,-d r,-, . . - ' . '' '''..- ,t) kqîq; .. --Liî. ... b/- . .s- -- -: ! ' I i - : () 1..-. u'a - . . . - . 4.- :), ' - 'h ty),. . : . . . .. i I c/ 8OiE 7 m m 4m m ZE E F 2 OFF . .. ..s a . t.st'.) '.t, t . -?. .. . ku, .x.. . -. .. :? ë$ .. ' ..t2,)r4,tv ;;j) .!!l 84 r'l llr! E3 (:2 - ' ' -,-717/j4/,' ' - yltyyjts t , , . ...

-b$1%.n.j,;-kkqL è.y )' j ;y..l), ' .. 'c'ït ) 't: ' . . . ' .I ' tt () %* v . )))j)) .ky z:r - q ) # 4,7- . . . .t- ?.o .. . .).' . Aa u?.+t,hsè- '71t1$1t),' stk). b c $ :. .-7:. . ?. .4: t- ..: ; 7 .8-1 (:) L. il tEk l ;!: EE 15; ,2 ' qrttct.-è''p. lztk., jjy4qtzy t'?v.-rty.,,: ':.c??,

' ',:J '. -:L r'' .:yg. . y;. r? ., . . .I HATE 21 AL 50 ï 8 STEEL ()8()A 1 b ty . ,. s,,L L.jv... ..t? . . L.1

......,a A b.5mm C/80FE 1 4mm 6mm CEEF '. .x/b.,nks, . . .u .. î.î ) . o-' I . gAjilry g oFr O L..1 8 k4 x lokk OEEF 2 0FF sand 7. Thicknessing the Cutter Carrier angle plate as in Photo 6, sawn side up.. Q c k4 4 0FF. !gq having made ff from 50m m sq. Note the Again it is necessary for the angle plate tog 12mm ZIAkE1. ' RING E TO EtJIT SI'E OF CIJTTEES TO 82 (JTEC Cylîndrical SVllare 'S nOt part Of the be aligned with the cross feed. With theI LEADSCREW BEA

, teftinptace fora future task. ends accurately machined, the part should. .: setup, on y' ' l PLATE 4 NNTEFIAL 50 y 50 klL2 STEEL 2:50k07 (50 / 50 IS Below.

. 8. Positionlng the ctlller Carrier automatically be parallel with the table'sI 1 7). NoT PAILA8LE IN FqEE suTIlNc 250:0 dovetails

. surface Iengthwise but needs also to be-....a /or machining t,e' 1 ' O t.-l arallel back to front. Because of this, the: p.1 CU ER CARRIER 8 uSe of parallels is essential. lt is unlikely; i I : . .:.:! '' .' ,y $.t that the parallels will be firmly held after

. . ..s.. y y tj jj k tjjat tjae part. c Clamping the pad but O c ecwyttt: j . y sits accurately on them and then remove.I ! j . .I rj u j o s n u $ n y j q n ;- r p y XI/FE i AS VlJ I R LU M I t# n 1 h; ud ==' 7 % VZCII irlo to 30C151 di IXCRSiOR j Photo 7 .I . 5t:,..;!.

I = . 'W - - ( x Drill and tap aI1 holes where required: n-

.j Lc : t y. jjt tjjo searing pjate. Mount thej .... j -y. -nzc excep ,1 ! art on the machine table, accurately. AF T0 SUIT 21?1: 8àF ... . rh

. . , .

sl . '.. . positioning it aided by a dial test indicator.I ' l X'V <

j I 1 ? . 22 50 ' ( .2 M ac h i rl e th O 1 0m m S I Ot g u id ed by theVATEFIAL 7 -' 'w,,' .. ''''.

'' 38mm ZIAMETEi STEEL 250k07 1 0mm x 1 0mm STEEL 080A1 b. .. ,j)o , ..'.'.- ')' .'. markings previously made, Photo 8.

,. . . , . . .. .? . 4.,..:..,.,4 j vounting the dial test indicator on some. .: ljsr ? y. 2è' .

.. .

; ,... :. . .

. - : .. . .y . )jjQtJANTITt 1 cFF O C1 .,

v.î.. - . . 4 point of the machine, rather than using the. . y . . ... ..,; ) ) . î. ySè # éyjjj or qutjgr cgjtjckj Nag advzRtzgos ZS it

I FOIE kAt iO1 8E iEû0liE2 IF t0d FIVE Ah E/ISTISC Ai80i. t ' '! x.

' . .yy.. . ; ...., avoids removing a drill Or cutter f rOm ther t ) Ctt .t' . y . . cplji ! k

sj: . .. k .s.,

' '. ...0

. 't. . jjjjjjjj)jj.jy) o.. ch uck th at may sti 1 I n eed to be u sed .' AR B O R 6 k,' .

'

,.7..i.k.). . j, ' . .''.. yzjcqyv,y)ynnn.L)i. ' '.' ... ' 'L ' ' M ach i n e th e edges as shown i n P hoto: .

r

'

.

' ! iI ;' 5352

I

I I.. . .-....- ..- = .

. r

.!; .

; !..1'/

Y X 9 i n 9 ro Pa rat i O n f O r m ac h i n i n g th e 1 '/- Using a. .f '

' '' dovetail, work to the 9.2mm, 31 .smm and micrometer andI j I y. . to csecg1 r ' t 1 ' 7.5mm dimensions. Byway of explanation t-o rods

I I ,). jx..yk. if tle dovetail .l ! !' , -.,

'.'vt.tt:.)) of the photog raph , the clamps were .j I .w.q . . . t. jjej . .I ,,, actually made from l-l/4in material and sides arepara .

I j . . .:.'.g were therefore just over the 31 .5mm width.. '. .

' . '.. 'k'.'./ The pieces of steel either side Of the'. ?' ..-. :k: L.kzi; ..,)t.-.. . . it th e cl am ps to be .... ' ' î' . ... . . . . -. . ' ., '';.i,).',.....

'.. .

. .

-.,..

.)v; ... .y .. wo rkp i ece pe rm t . .. . .-... .. ...... .- .2 . . & . . .. ..s)(, j) # t , joosened and moved to Qormit thO SOCOnd ' '..... . 7: t . .' '* Qkhk. . ' >wl . ) ' jù z . . . Li..:.awt ,z. . ' . ' .. . . ... .. . . .' w . . '' . . . . .: t '''.t. . u % yt) . - ' ' . ..A..- ... 4.,..7 side to be machined, withoutfearof Iosing ''

, 'exc'>4 '. . Lbit, r ' '). accurate positioning of the part. Note also 1 'I y m' .. . . y)%) $ ' ' t L j,' 1 ''' ''' thatthis necessitated the clamps to rotate,

1 . j . t:. ' . .j , Lq è s

v. c'

. jjj o. o . . j jttj. m aki n g it i mg racticzb 10 to IOCatO. . : ... ( ;. o. . . . . t: .L 1E51,. , . ,j' $.. the packing stu nu ,'

. ' ' . . .. .x = : ,s a. s. w w j .. ...... yy. g . .s''. . '. yjs ' qt . ' ''? q . 4. Using a ScreW ntlltotl I n tO tl'le UIGIHP , .' ' g Note that the Carrier is additionally held by%' ,.1. 's- .)).) ,.. .)'( y. . .,

,, '.v,. C). ' . 7:- . and with its head on a piece of packing jty ( k ? , the inclusion of a toolmaker s clamp,.. -...c (. . . . . 't(.j)) . . .Nt

.t kè to overcome the problem , in f act, where LLL œ:- y clamping the part to the suppoding bar.. N'4t 'p. o . !y jjjs ))))). . #. wjtjj tjje cuqer Carrier and Bearing Plate- ' x ' . . 4 * ' N:'':- . t h e h e i g h t O f t h e p a c k i n g i s s h o r t t . ../ . ... + , )F w. z . . .. . . . tjyyy )) '.y )/.,/ .. .. . t)))) . .yIi -f. is probably as good a method. iC) ?? , '

) dovetails completed, check the assemblyIjjg Reinstate the angle plate on its end, ,..-w 7 .,'

.,-. ' as in Photo 11. In this case the sides shouldl . g. Preliminary machining the Cutter y '

.1 carrferprfor to machinlng the dovetails. togetherwith the support bar at 30 degrees, ,l, be parallel, at Ieast within 0.05mm, as the. ' ' j1. machine following essentially the same ' . ;,( ' Gib strip will not compensate for any error.

911 rocess as for the body, see Photo 10. )77' îfL in this pad. ldeally the rod should be at Ieast' pi Ir1 I ë:yty -. !. - iy -.-.'' S3-/LL. . ' '

t. .:7. )t.: lomm diameter so that it rests on the two' 1 h 41' .,$ib').))' ,y,''' .. jjdjng faces of the dovetail. Corrections. . ) . , .y. y jj . , s. i èy.- .. . . .. ...

.)yy) #jj iï-;. . .I I ( i ')..f . . ., t .)j .y. 2 .t .. ... with a f ine file and/or a scraper may be1. .

. ... : k),).. : . . y ,. needed on assemblV.'

. : r. < t . . ... . 'î :.')4k. yt ' ). - ..

.' j' ?/y' . ' 'y .. . . .tx . . . . t Havi ng shown a tool make r s cl am p i nj j .. ..... . . . . . j y ,js . yj . .

; . ' .y %,17 s, :, :);î L Photo 1 0 this would seem an appropriate..(' :hp,. -#j? tv'... . ,!!?- ,) yc .il .).ù .. . time to discuss their use in machining': 1 . . k . '$ y . 4 . : .. . .' yj . ( ,2 ' o.y y . . :g o y . . operatjons. W N jjst jt js CORSiYCSCY CSSCRIIZI. :' . . y): . ; t . . '- .. .. . pc.g. ? .r tlxltytyl ).u

.),x'?4.) . . . .z.. . . for the packing used with a clamp to be justi 1 ' .y jyj ' '-'.y, k .z ,...)...:....ï w'yo ,u . . - . uj .. . , ,

'

.....

. ,. jjjgjjsy tjjas tjje pay.t yojng jyejtjj sucja thatI ;, ,krr- ,1l),'tt?,t.yyj,.'. ;)- - y. . ..,.?t 'tlls '' ë,,

x . .. .. .. ' ? ; y, ..k.t , yyt y . y . c j a m j) i R g tz kCS 4) l ZCO Z1 t q1 O O rl d Of t/j Oe' ); . t)' tttc C , . 4 sz uxqyxoyj.y. . - . l t c 1 a m p t h i s i s n O t s O w h e n u s i n g at:.tt tj ) - . .. -

I . z) A y . j ). . '' j k e r , s c I a m p . W i t h t o o I m a k e r si .. î . t O O m aI I . .y tj ty .

' ! , . . (

'

. .:.

,$) r . ''c?! .. .., accurately on the faces of the two itemsI y y;)y .yyt . , . ,jjj . g yyyosyk' ,g: :1 . , ye gpjjpaajajjy ggsembled, the being held, SK1 seeks to make the position.':. jt;) . , k ) 12. Gfth tI I () . 't: . t V 'jjzw' jo Mak/ng the Leadscre - Nut is drilled with a tapping clear. The essential requirement is that theI . --. yty. -kt@)? L;;;; ; .-r yj . .. . . s$;)- è-. . -' I t z,!,,,-. : dovetaits on tNe size hole using the assemble parts as a distance between the two arms be. sjt. .. ' ,'j?jï j .t cutter carrier

. gtl/ee to onstzre augnment. accurately set using the screw nearest theI . %%.I I

54 55. .

,jr .,hsI . k.gl (.

k< .

! ' I I .- ' .

:(II

I . -1 I

13. Machining ''j.t ;I %' I ! s ;) A the Ctlfler Carrier . 'y y') ) jjy

y :?,l I r- - 25 for weight ' ..'V 4, '' ! c.u . . àljltll . .

.t ' I .- j- duction and . ' , . ,L,,;,,y;î);j . . , . ,h . re c , . y ,1 - . . T ôetter visibility ?2k.',.' .'? '' ' ' 72) ' ) , . .. .. .... q,.pty,.. '' . >'. ; .4:.1 ! - .

.. y.. . .1 ' ! t. when in use. '..L ':.

' . .: ,.. 7 r '. , .:!; (E) 1 (E) i---''--' '1k '.t ' . . *-'k3b;., ,.. 3)-.,.,.yk

q . ' .

1-1 (E) 1.. !: 15; - -. ks. '-. '' rrtt yùt :-..- ''C$#-.:t t$. - 'kiL.L)j'ï)L?.;,jj? l tqh ttt.., . j.,. a'tyjyjjyjjjjjjyt,x.ss' jz )(jA 4mm ZIRFLE F0F GFtJ8 SCFEA HOLES 4, )l b

. 2 m m C / 8 0 F E 8 . 5 m m b m m E) E E F Yk '8 k 5 è .. t , ,' . . î.. (tL ) 'C k 3 j 1 2 ZEEF. ..

.. . .

'. . .,.. '' '. ,.ss.@0SI1lO$ A 1$E) 8 051 ASTEQFLï MITEFIAL 2ûmm OIAMETEF STEEL 230k07 ; .,j. ? j' 7 - %''').C -'--141111144'. . llqt -; . . . ., . .q

' '

,

' '. . .) .FI 0LE C T0 Al () Ik EkOVAL OF FAF-E .t?klyt)) o .

TI1ï 1 0 F F (1 C 'X ) 'AFTE F ISSE k 8Lï . û (JAF y- ; yyf ... .. j i gjjj y x

FATE AITFI 42 ZIVISIO8S ' ' ' ' * 'kATEFIAL 1 2mm IIIAHETEF CALl8 .s't .?,. .. ..

STEEL 250:07 .,.. . ., .

. '..> ' ..

.00 C DIAL 3 + ',k -' '0tJ,sTI:t ! oFFs .we ' '..f' .

. LEADSCREW NUT 1 supporting the other with the tailstock (2) and assemble together with the Body

centre.Turningthetaperatthetailstockend and the cutter carrier. Fit the Gib stripl uEAoscnew s and the zsmm diameter with a Ieft hand screws and tighten. uoosen screws,I .

g knife tool will achieve this. remove the Gib Strip, centre punch in thei kj.

. .-. y The remaining turned items need little marks made and drill the dimples 4mm

'1 ' ''u' -- a comment. Note that the Leadscrew Nut (1) diameter to take the end of the screws.II j

, !2 @ holes A and B are drilled on assembly. The Reassemble and fully tighten the Gib Stripj11 1 p 8 8mm Iength on the Leadscrew (5) should screws. Fit the Leadscrew Nut through the

, 1E1 '- '-- 5 55 be just Ionger than the thickness of the hole provided for this in the Cutter CarrierI ;. ; o re s uq y q.m nrrp Bearing Plate to permit rotation with and tighten its fixing screw (H1). Looseni FULL-J '* '?-Z n u''''- ---' Q0 C inimal backlash. Calibration of the Dial (3) screw, remove Leadscrew Nut (using a Iong1 ! m

MATEFIAL 1 2mm ZIAMETEF STEEL 250907 DIAL CALIBRATION may be a problem due to the absence of a Ma screw to achieve this), centre punchijo sK2 dividing head, in which case use SK'? as a where marked and drill 4mm dimple. RefitA

ûCJASTITt 1 0FF temporary method asfollows:- Markthe sloping the Leadscrew Nut and fully tighten its fixingface Of the Dial with marking blue, centralise screw ensuring that it is Iocated in thethe Dial Over the sketch and make the dimple just drilled.

ing point. The Outer screw is then The turned items calibration Iines using ascriber. Final calibration N ext task it to d ri I I th roug h theclampd to apply the clamp force. Some You may, as I did, use an existing arbor in can be done when the Dividing Head (that assembly with an M5 tappi ng size dril IuSe

reservation though should be considered which case dimensional changes are follows in the nextchapter) h% A n œmpleted. as seen in Photo 12. Ensu ring that thehen rough Castings are being clamped, probable, Otherwise make the Arbor (6) as machine table is clean and the CutterW

h in the case of Photo 5 chapter 3 per drawing. The essential feature is that Final assem bly carrier is standing firmly on the table,thougthe fact that one surface was a round pillar the 25mm diameter and the taper are cut a Iength of lomm x 3mm steel, 75mm will make certain that the hole is! I . made it a SPOCial Circtlmstance. Concentric. Holding One end in the Chuck, long and trim the ends to make the Gib Strip aligned accurately with the dovetails.

1 I !1! 5756i

J1

----- -.--.-.-. x ! .x.. W.

!r' j I! !

,hi, ik - 1- 'i!1.!

Open up the hole to 5.5mm through both . .

! I . the bearing plate and the cuttercarrierand.1 ' I bled tap the ueadscrew Nut

.

'' C'''-. ... ,.. .. z.-,..,... , '...,....,.q.f .. . .. .-... .,.-,.. .,..,,. . ,.,..., -s.... ........' whist still assem .!. i .. tt..' i r Ms. Dismantle, make the 1 4mm , .,>.,:. cutter carrier and open IOOLMAKEF S CLAMF #ILL i01 FIVOT. . . . . w, . counterbore in the ) . .,

. . ). i jate.

ESSEFTIAL F09 o .t) ', : ' ' , - ' ': . ' . )y .j , j up the hole to 8mm in the bearing p g! tk' , ..., . .. . u . ,. .I . kACHININ .i .. ... , . . .

- . .

' ' Assemble once more and, with the Gib Strip ,..j ,' ' , '

. .- . ' !; . .. ). y ,. .. - .

. .

. .. ...-I screws preliminarily adjusted, check that .. . . ù. a,( , I ., . the slide works satisfactorily when turning i

.). . .. '

. . - '

. .

' ' '

. .'.:,kyo.... ..1)y'

.. ,.,. ,: . the leadscrew. i ' . ' ;.-.,. '''t

r7. . . . . .) .'. r?y r! Some scraping of the slide surfaces may y ..o t yk. . . . . . . ' . - .... ' .

' ' . '' ).t . o,,,,s.x.' .1 be required. lf everything is as it should be, t

. .. .'.y . .... )' p;. . . . 'ty . jî!

da i l::)- :iE!;;l: '-' i I::)- ' : -L'LïL3L ' ' ' ' . -. .. ' . .. ...- ' - -;t - iïï '' '''' ' ' ' .' . ---7''-.'% ' ' .?'j Iock the slide by fully tightening the j u.. .. t. . . . - - - - - - - ' $ y , . ....s. x . .N. . . . .( yscrews and Once more return to the milling ...-s------ ', 4. ,. ... .. - '''z ) .. . ) . ,hine as in Photo 13 and machine the -X-- , w --- ----- : 'axjl '.,.L ' ' , ' .,s 1,

edges of the Cutter Carrier as per drawing. . zr.---

' ' '' - '- .l' .. .. z: 1. .. . . . . . . / .. z ' ' ' ' ' . it.y.,' . . ' t k . , ,This reduces the weight of the unit and -- - , y . .r I improves visibility of the cutter and TOOLkAKEF'S CLARF WILL Flibl #T %. 7 ?t' o4 . . . t ,N yI . ' 20 NOT USE 1$ o

, :. ). ).)è% . -.,.I Workr)ioco . ( '.., . ' . . ' . '2

' 111 S AAï ! 7't . ) 't'1 r 1 was pleasantly surprised how accurately .,t#.. .

' I 14 skimming the sides to level ll# the . '' ' ' ' '---*' a'w'' '''''e'' ' ' - -' '-''-- '' $ ' Improve appearance. js

. vtte spa,ee sorfng head but sftl, wîtlt temporarily cagôrafee feed efa/.l t.o parts and1 !: .. .y y

! : I . ' ? . ' jjk j ; .' .. .Iy , . .,, . . . sytwt.,,,tysskok ,. the sides of the cutter carrier and body especially sliding surfaces, reassemble? 1 .

' ' C''-''''>.t).. '',-,'*, k>.è '4,t,,.stx-..., .,,.. .

.......-,j,

Iminaecdjlujope, stej; Pshjyoetojal 300, sbuftosrtl' doEidod to With a touch of oiI where appropriate and!.

s .f '' axw. s.. ' . )), --..uz --------- ppearanco the boring head is finished, Photo 15,

. j .p , u ....., oaysy./koa.j. -.-- , - - ---- -...... ..-.

-.-.

.

.

- purposes. This is shown being carried out except that is for the temporarily, calibratedj j yjj ---;z qv.-u' -- - in Photo 14 whether you do this yourself dial which can be seen in the photograph.. . , ' * ---.w ...

l.(' ).) ; ---.-- - - t the option is yours. If you do, parallels are ln the next chapter the project to beV

. TIIIII-kAKEq'S CI-ARF AILL FWOI Ai !'. required under the assembly. Finally, started is a dividing head, this immediatelyI ' go tko! t)SE Iy

o djsmantle, deburr sharp edges, making this making use of the boring head justj . nr , y .ryjls AAy!: , y.. .. a generous chamfer on the prominent completed and being used tor the dial justl j . ''t edges when assembled. Clean aIl parts, mentioned..

., . y7. . . .. . ; .., 7. .r'1) jjj . . . ) L. . - î, ''': '

. J ,/ .1. 1

k .:. ' . .. . , qi-Chllls AN2 NFIONCS1 '.: gg CgI/kG -riojkjxjrj's

, . ' ' S$ . . ...

r, ctxk?s j;q NAO,.I.j.;-

SK1

58 59

*1 I1! I 1*- 1 .I .1 I ('

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-:' - 11

. ! 1. ' I I' f I *.' i ' 1 .

7 (. . . . . . î)L '66j'.7: $.. q ...)y.j) . j... jw. nr'.; iyk ..2 :;t y . . . . )y) s g.. y ya4' :jj,. . . . .;. . . ')t.

' (jJ:.. . . Tjikut) . . . L. L: . t z cj. .. . ' C ï4 ? L wst( ' . c' . . . rp .'? f ' . ' .. è#ôr:.. - p s . ,, .. . ?1L )(' )..'(..J)/1.. ') ' . L.. è V. ) .;.( .myk . . . . . . . ; . 7 . . ' è. . ky. èë . . ' . : . . 7 .. . '

I 71.: . ' ' . L ' ' . ' . Jt. ! (). t ' ' . . . L2.. .z Ljj ; S .). ::''zqj, yy yltyLst . j))L; ' ' . ' ' ? 7:. é js ;;,j. r . . ) yy . . . . , . . .y4. . . q.,z. jlll 1111 1111. . I y . . . . .

. . . . .t;; . .. . : s .. I . i .

'

t . . . y . zyjj . . .. . . S,t. 1. j LijLL. .. . . . . . . ' ' ' ' . .,;.. , . . ,. . . L s . . .. . . . ...tyy,

I I = .) . . . . . . . . . . t! . ) .: ? ytl..tyte.$. t . s ; c:! ; ' )'' . . . . .. è. ' '. . . ' .'j j I j l j' .y . . . . ' '. . . ' . ' . . . L. ''a' . ' ' ' . . '. ' . '.u)' .'.: I 1 C:. ' . ' . ''. . ' ' '' 7. . . . . '

t St' '

Iy y , j ' ttt)lFjg. .t. . .

.

. '

. . . . ' ' ' ' 77L .

.. .. .. ' ''

. . tj IL'LIL;L

. 1. .1 r 1. wsk. ' l ' ' '' 1' l ' ' L. 'î; ''''':t%è '2. . . . )'j i ! j ,yj . . 7 .I ' I I . ?'' . ' . '' .. ''. I j . Jf 'l. qè . . .. . .. '' .... q f .;>ktL ,:?' L : <'..?tr .>zLqj,

nt . .. . . . . - ' . ' ' C r'-1 ' ; 1 --. - ..- --,/. . - '. . . . . ....

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.

'

. .. . . .: --- . - . .. ' . . .. .

-. %'b è. è. ' 'rpë;.' ,,,jj-

-

v'

;,' .j ' y;y r): . . .':1 . . jij. : ' . a .. .t

I ! I .. . .13, t)ï.

:'j .. . ' wt ). n. ' .' tjf? ''j i . . ,,:$). , ) . . . . . . ' - ' . '. . '. , . j,,.jj. > . ' '' ' . . .' 'lï. '# ' 4 . : l - .z'ï tcl . ..' . )C. . . L . z . . . . . E.q . L . . . . r >' jt' y. .

4/, ,. . . . . . .... . .j));I 11 yy. .ï , yy we now come to the Second Of the major and machine the ends to a dimension ofyi ,: . . s. . .y àv. )(.,tj , ' j ys. . .. ..a . . . x . . p, , j (jam m using the set-up Of an angle plate' 1. $.' . .'. h y j1' itoms doscribod irl this book thzt Stil I USOS '

I I ' 7 è 7: ' ' ''' ' 'Ii I , . . .:..y'. .ttly .j . ...,'1. ....... .. ' .. k'è Iargely basic milling operations but provides and a Cylindrical square. Mark out the, 1 ..,.:,)..jt .,t .# . . .t jtjon for aII holes

, and width of 20mm. 1. . ;. ', ,4..y>f,. uih-. -t. . ..,. è,.v . a chance to use the boring head made in 9OS1 ''k

L'jîL;ï;.'')'.î-L'..-zb-t Q*.k %...k .

. .,.yt'y?- . ze previous chapter. grove, drill and tap holes C, a tapping size. ikL ). . .' I I ' - .. . . ?I : ,. -' ..

'. s. uuyt) . ' ...:

? ,,')) hole for D and a Iarge pilot hole where the! ' ..

. u yyy. gk' njiv..zi . . . . . . . . ; jy x ..1 ' . I . . /.,)tt. -)t)X,''t. . . . ....), ..'.... 3.,.,?,t ''-' ''' The deslgn Spindle is to fit.

1 1' , ' I 1 '-' $(,( -,')'.,','' -''' 'C.t.Y,,- ''.:'y';.,'..':,..?t,.'.,s',.;,..

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rî''.' This is a simple dividing head based on Position the par't using an engineer's

suyl).l' ' w è;l. r.)t,),è .') >.t ..:tt r.t.,jttytlyyjt.- jng a single gear, photo 1 , and more sq uare , P hoto 3 and , afte r add i ng1. I ... '''?,')t#)t,è?#jp?)st?y?)...ry.y..)j complex dividing using a gear train, Photo additional support to the machine table, milli i I ' 1, '7C ? 'c . ).) j yjiyl't )y.() tj ) y .t1. . -t> .7.$ jt..yyt), ttlyt. 2 yjje yjvjdjng head may find a multitude the 20mm slot to the depth of 8mm using. I I . I . .. è )'.

'kïztl 'lkt/lytq '.

' 'f.>'i?> of uses, such as cutting gears, drilling holes the marks to position it, photo 4. It will ofI . - .. s.. ,s.tt,I . . y course be necessary to make a number ofI ' I .

. . . . .. .t..,..... ' ,.........t.'.C. t?'''t.', . on a pitch circle diameter, milling squares31 . . . . . sj' I ''

- Axritt.'-': ' ',.-...'''','(,''.'b''b'î.,'î$'î,;--b$b.1.1'1'i$2' and hexagons and marking divisions on a passes to mill the slot to the required depth.

i,1 . t, v . . .? ,è) t,.;ï,,.,j.;;.,,,,.;,).;;-. machine slide dial. The single gear could If you do not have a zomm end mill or slot. . '.ypy!jj6ilk#s)jt;p,.))qy):jj L . yjy . .

.. . .. . y. zj y ,.j.. .

.

. y j-.) y..y:,yjt. ,,. .

. .t , y : . j j, .yj t y . - . . y, . y j, ,yy y,.. .... y .' blL.))jtyyhj( s.v . .,... . . c. . , . ... . ..:,j.,y..,.,.,j.. ,. y yy y y. tj yj-jo yrjjj you wilj have to make the slot in two1 1. :-%. lkyjphj y. .u' . . . . ..- . n,)i..j. ., . .'. .. .. ,. ,

'

, .y,..t...y,. .. .,:.?,,...

,. ,: l,.(.j,yyj.y.y,l be replaced with a dividi ng plate anil . )..;p,;j. zyyr ). .,.....y, ,,. .. . . . , . , . ., ,jy...,, j ;y.y. t ,,. ,.j, .y.y y yjyjs stages. I n this case do not use a slot drill.1 .zojjïlilbfhq ltytyy

,- . . . .,... ..

.j...,'..:t. .. . .. .

.. ,. . .. ..

.. ....

. .y,,.. . ..,,,,ày. .y:.,.,,j..,,..ys.,.,#,,,,y,,y.y,y.y. yjy pj unger assem bIy mod if ied to suit.' I i . rjy èjrtjltxhyvttlt))s'yg?)t. ,y4. .44 . . y- . .yyj,,:.... .. sy.o. . . . . . ..... . .. . .... .,. ,. ..,,,jj...y.. yyty.t,.,,y..,y jvj ,,y,. wjjen widening the slot as this is best done. I $,. . ).).'.trs.è..q:à)tjyt)y.js:z.,jyA4 y- Lz .. j)j.:#J..).., ,.. . . . . . . . . .

.. . .. .. , . .., ,.s . . .. ,.. à t: :, .:,,,), would increase the number of divisions.jI ktjtitn )..' ,.jy./j jy .ryylysyyjyxyyy) yjyyy, ,.....

. . ),j.)J.,.,y...,. .... . . ..y . ... ,. ... ... ,. .,. .. . . ..., .., . . ....,y.,y...,.., ....;,..)..j,,...v jn an eny mjjj. Reposition on the table' ' ' i)1)). :d'-g;!ë@èî;-.:t-..-.''.-.-.-- -i- )rt,-- 'j,@-'.tq.

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y . . j y y xysyy .. y . . . . .. y . . . . y. y . . y .y . . ..g .. . .. y ojjy a josgjj.y oy gamm sg jjare steoj j cgm m as it breaks th rough .I # 'k;'.W..'. #. . . y .',

::.*..,,,7. .lR....tt$.z9.j.'W'.,... Tl'#.?,' .'#) .'.?.*b,.L.,?.)j;)..j.)j),j). yt Iong, (plus an allowance for machining) , Now is the time to bring the boring head, jjy. y. . . . . .. t . .. . . . .. . . , y . . , . . . L. . , j y) . ;q . y? ));.)..; .,j , Lc yt ..y..' %C'1'C1 1 hC''' '' % 7% ? ' '''' '' ' ' '' ' '' '' ' ' ' ' ' ' ' '

61! 60

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FAqZAAFEH1 k6 NUTS 2 0FFH2 k6 ï 20 SOC/ET CS4 SCqEA 1 OFF85 kb ï 12 SOC4ET CA? SCqEA 4 0FFH4 k4 ï 6 SOCKET GCU8 SCFES 4 0FFH5 SFFING T0 SUCTH6 k6 ï 25 HEï HEAg SCFES AN0 NUT 1 0FFH7 k6 ï 16 8Ek 8EAg SCFES AN2 AASFEF 1 OFF

4 10 11

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1. N I N r N r N

NOTj. 1HE DETAIL FACT ZIMEhSIONS5/8 AIOE, SFACEF AAShEFS kAt 8E FECUIFEO WFEqENAFFOAEF GEAFS AqE 8ElhC LSEZ.

SUIT GEAFS WFICF A8E

DIVIDING HEAD, SINGLE GEAR DIVIDING

62

j' ,.

-,tyj,tpjjy., -. j., ... tt ) ;, ..'zt,jy.L. ,

.) . .*1) .

. . . itgt.. . !,. -'

t((q..y,!k$;:. .'è )î NOTE. N0 ZEIAILS AqE GIVE. F08 T8E MEIl1OZ 0F COLFLING)'l;p IFIE T:O GEAES TOCETFEq (ï) AS IT IS E/FECTEZ TFIAI TFIEî$ kETHOZ )h11) Fq08A8Lï THE FAFTS (JSEZ AITFI IFIE AVAILAELE

.#: t (j jIE' LATHE FIANGE AHEELS WILL 8E US 2.

, ..) t - - - . . -l)J DIVIDING HEAD MULTIPLE GEAR DIVIDINGy

2. Fitted w/fll gear train for more complex divlsions.Below Right: 3. Positioning theBody on the machlne table

..3 r@*W* *p...- - u -G E A @ S * * ' ' *w '11 I

@ o: 4 I 1 . .za I I- - qyo---rjj-l l V ''' '''' '''

- v . a L .- .

; '* T -l j I

. A.. m* < .-- ; 4& ... ..% '-'K - Yx * 1

63

4 1 ' ( I I 'l rl kt'' . .

. .

- . - I ppI I I p ys , J

I i I .

I * 14' HQLES j-! . . '

( A 6 . 5 m m 2 O r r - - - , r - - - o.. ,...

, j, . .8 k 6 y 1 5 DEEF 2 OFr l : ' .. . . '

s. C k 5 ï 1 2 ZEEF # 0FF : l ' . .'' .

D k 6 F 1 4. D E E ? 1 O F F l l . ' '1'., '.

' ' ?t-S LOIS 1 .5 : 1 () E ' r

j u . .. , . ). . ., V-- - - . è '2.50-1 ' . ''kATEEkIAL 10

.

50 y 50 STEEL 250k07 A

. QdANIIT? 1 0FF 21 8 '.. .8 ' .. ' '(-2 b-j s '' . ) .jt.,. . . .j I l - . ' .

' * . . . ot'k.s k :.% f .

I 1:I p J ' : : : '' r : : . -. ' . . kr . - - ,- .-. . . -. . . q..- . yy .' -- --- I l l : 1 : : ' ..6.,.$: -') . .- ' 'r . .,1 ' f ,

l ::::12 j- ... ....14..... ... - : : : :- : . . ,. . ,. , . y-. , . -. - . . r, )- . . -l

L..- ' '- j ;. - - .1 j. .f . 2'. ..s .. ...p . ' t1 . j. j u u j

.

.

,; - y .4 g+6-, , : , yj ) - .

.:1, * x Y * w ay .; .i)

, ;. *

(7(:8 ,.' ,.' ::L -:)h :lt. p .. . . w . t op' .-. 1 ; j IN . '.tz'ttiâ=ï-u:vt'ka''' j .; I j ; s 8 h 4. Machining a 5101 in the Body. BeingI

rn m x n g an open ended slot an end mill can bep t ,,, t p ! j -, . , used. selowz 5. using a Iarge drfll to .

.,1 +-l the Body for bor/ng. Right: :- , ... . . . ., . ...,1 () .50-1 1 0 3 Pëeqare5 C jg Fyplra/ set of bpring head too/s

. .

,k ' , .

i f :! IMFOFTANT COTE

FIT 8EAZINGS (14), tJSIiG AZFIESIVE, FFIOF T0 . '/ - easily be bent if the tool is fed too deep' . ag . jj., * . 2j4

. III?ILLIF: Flot-Es A 182 8 AkE) kAïIN: SLOTS. . . '.'. into a blind hole. Boring will be a slowjob? I Fl'I 8EAFlNcs, ZFILL AN2 IAF FIOLES, .., , -,. ,.... , ,, as Iwouldsuggestinitiallythateachcutbeh

SALL.Y NALE st-o':s O E:l --, .. 'imited to around o.amm maximum; tsat! rl

I jbj. . would be so cuts to get from 24mm to., ,.y -- rl,tllt . 44mm. vou may as your confidence grows'è.>. k ' u

into use. Photo 6 shows a typical set of three, support pieces against the Body, one ' feel able to increase this to 0.3mm, maybe' . )..borirlg tOOIS thal CaI1 bo Obtainod

, Qtlito On Oach Side and One at the end aS Can ' more. Use the fine down feed to feed theeCOr1OmiCZlly irl Sets, f rOm many Of the just be Seen in the photograph . WhiIst ., . tool. The speed should be set on the Iow1

-suppliers to the home workshop. W ith a suppoding the part during machining they side, say 250 rpm, but as in aII cases there' suitable holder they can also be used On have another more important function as t'ir is justification for some trial runs at higher

the lathe. Will be seen Iater. speeds, especially if you have obtained free

' Fix the part to the table, Photo 7, taking Starting f rom the hole size already cuqing, 230M07 steel.

note that the clamps used to hold the part drilled gradually increase this to 28mm and After having made a few cuts, m easure

will need to be as Compact as possible to to a depth Of 35mm. It is essential that the the distance between the inside of the boreavoid fouling the boring head. Also place depth stop be set, as the boring tool will ' and the outside of the Body

, the two sides

64 65I

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j1 I ,1 ' j .l p . ,

;.. ,

j%

t(, .I J j , '! ,

.', ,

1 ': . 'r

'

I . .

'

. - andtoo should beeoual.Aszamm isaverv l

'

I ' ener'ous clearanc 'e on the spindle gre Jt BEARING 14pjj p ..

- g js unnecessary so a rule qA.rgyjAg

o: I I I

k aCCUraCYI - --r measurementwillsu,ice.lfthereisane-ror.

j . ,.. . .,...,-..,. ., .',.,, repositi-nthetableleqtorightand/oruack s0mm ZIA.ETEF cAs, Iqoy:1 I I j y ggjg yg kjgk jyjjj yjyyjjg y; gipy' ' '' to front to minimise the error. To avoid the1 . ? - :. . # cutbecomingtoointermiuent, makeasmall --- IFITIALLY 8o2E 29:: PIAVETE8 ,. .j, .. j. .y

1 j . ' it adjustment only; bore to the Iarger size, j-. ...j, the table 24 QgAy.rjry 2 OrF.l ! .. .t't.'',?.- ... ..-. ,,... ,.' make a further adjustment to jy . j g ,' ' ' position and bore again, repeat as ., , l * .

w,. necessary.! j 1jI .1 ..y .. . '

.... , w hen the hole reaches 28mm set the step measurements with the anvil and the

r!p ( ' p;,.;ty , deptjy stop to 18mm and bore to 44mm cjamp removed.

'.

71 . ''

1 I . djameter. This bore Should be central to w hen the 44mm bore is f inished, tj.' 'y . a h igher degreo SO When the hole gets to Ioosen the clamps and turn over the Body t '

,,pr j ' m' ugjng a VO rrl icf. lf the 9OCkOt Will rtl n to it, urpose Of the th ree, support pieces nOw f. 'J :Ax.; ,> xk '

.0 j o jy' j ; y j s k y yj jy o w rj j rj p g j g s s j y u j j j j u y s y . . + s pj 1 tjje m j CrO mc wC r w .. v .. .. . - . weCOmOS OwVIOUS ZS KIICX WII1 ZVOIU tII6 zt '

1 ; ' . . '''. - ; ' è , v ,y .' .jj. . I .' .. , . # . permits measu rements f rOm Concave two bores will be reasonably concentric ) ' ' .'t l.,y' .'''I . g,.')j. v .%. ' 1 j.j j n anvi 1 enab Ies

ajthough as will be seen this is not crucial. 7. 'î,.''4 /& '. t ' su rf aces . Th e tt '')

, . / . s;' l' i '7 m easu rements f rOm narrow Slots and Bearings (14) ' '' '.. t('$b(L... 'I . . $ ' y s kk lly/yjpjgjjjj. ;t.' borîng headgets fts first task lo cast iron has beenchosenforthe Bearings ' . i- ' '1

.. . 7. The è t;'

. z' ertorm. Below: a A usetul m icrometer as the dissimilar metxs, cast iron and mild .

',lf .

. . .' ' .. à . ujy jjllll yj . . o .

. (; . ./ I ; q.'' '.'k' ,or measuring from concave su,aces, steel, will enablethe spindleto rotate easily, .., . .. .t.. .l . /. -,,.. . . . . .,. . z aao ,rom s,ots and step measurement. e

ovnetnhewhtje

gnutthseiyBee.

avriangkjsna

grethaedjsuesaterdjntgosbjes ly.

,,.y ,,. ,.,

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,,ify.,;! sqkjj j.,,j i f-j 1., jjf: f-j y.k,k, ,:, ,. f-l ,:, r.y ,-j ,.. t:b d:p 4-4 ,:: ,-, d-,j f:d ,.r r-j 1 ,;. ,-1 ,:. ,. i d-h l q )- -

. ' '

. #:y) to the Body. Fit the Bearings to the Body1( 1*:' ''t using a two-part resin adhesive and Ieave ,, ' '

jo set.I . M4IAOw ) Again we set up the angle plate endI I ,1,, #. - :p,t,',,,,, 4:, . t:sf 'ryrt- .. ,- ? , .W .. ..

. .,.. on as seen in Photo 9. The engineer s t

I paraljel to the Dividing Head base. Both inserts fitted.jq jl Bearings are bored at this stage so the ,!!l !

66 67i :

..'. / /. . .. .! . .'

j . . pr I .1 I . , . . . ,.' J .(: I I ' ,

. I p

'

I

. ' '

. cutter will need a projection of at Ieast: li t ?' 52mm. Do pay attention to ensure that the A 2 CI

. v.4k jouj with any of 2 52gzr11 revolving head does not 1 --r. r-a h ,'

..

'

ï ':V..,.'

, the assembly, studs, clamps, angle plate, '-*- - I - ,

- - -

l t j l -1 0 1 b,t )'? : ''

etc. Bore completely through in stages to ..-j ..j ).. ..t.w.-. ' o .. . ht y.,y .t., .. ' . () ;y jj j jj24mm, Photo 10. Accurately measure the 42 6 $è

c'ù'' 7/7. finished diameter of the bore, possibly st) . 4ag . ) wt .

., . ,.w .....v...- . . . ?pty making a plug gauge to confirm the figure. 1 22+ *'v. . .. ,.,.... k:.7.. Make a note of this for use when turning HOLE SIZES MATEFIAL. .. . aj.g ,' ' L

. )4.,,.,,7. J# j) jes A and A 6.2mm 2 0FF 1 6mm DIAMETEF STEEL 2.50:07.. ., s the Spindle. Next drill and tap o

').j. #? . 7K....:. . : A mjljing machine accessory, not yet E IFICEAC 10 Stll1 GEAC COUFLING USEZ 2mm CIARETEF STEEL 230k07I . ..

, y ) . y . $ jyr ' x 1. . x .y * g j s m $ j g j j ( (; y. .. -., .,.

,. ...

. mentioned, is a sliuing saw Arbor, whilst'

J 7 ' ' ' ' .t.'' ''''''t?'> - . . ' not in the essential category, it is an item VATEqIAL 2g y 2 STEEt- gggAls DFILL AhC F11' ARk 0d ASSEMELth

! - . .. ... j r q j go g/ t. . that will be difficult to do without. lf you do (ILIAhITITY 1 oFFê

' ' ' not have one then it is time to break of from QUA8IITY 1 OFr C)0 CI . ' !,. --. --.-p.- -----.--, ----- ----..-- oEvExv wsu a uocx.xo HAxouE la

' . ''j. ë' ' : . . . j . . . ' '& . 1:f . . .

. situation in the home workshop, this time? A

.. ?''' to make such an arbor. Forthis task at least' t%t

C?q)'ttk' . ' a loomm diameter saw is preferable and I jLLî . () ... ;jj jjy( .(xL would suggest 1 .5mm thick. C/ 1- -1 j g g E) E5Mount the Body onto the table but

..j jy yjo j yy j ; sj .. .. .....4. . . - . . . - - ..

10. Final boring the Bearlng fnsertl. jjcu sI2gs y5 ----- -----ï--..-.- -. ..Below : 1 1. Slfttlng the S/dy to proWde A 6.2mm 2 0Fr 1 V j'

v' '

xt t#e individual adjustment of each 8 6.2mm CS4 ljmm ZIAkETEF 2 0FF I g j 20 : S1 j.Bearing. DANGER, KEEP WELL CLEAR. 5- kAlgqjAg 2g y g slggg gggAjj Js .. ) y. le . >

1:* .. '

$ 't t . oEvExv AsM supponT 2 8 CIAMEIEF AN2 SLOT T0 SdIT GEAFS LSEZ>. .

. ,

glos. . . . . . 1 . . . . c () A N g g A g g g j ( g y jj g g g j N g j g j () s g. w ?j . : t ; ' . jt2 . z ' '''* ' ' '1 . ' ' I''C 1s . .r. ,j. -. . : . t . . r) '.( '''' , ... ,. . .w.,, MATEZIAL 38mm STEEL 250:07

,, ..),. . ,.,- ;. . ,, r . , ()o :1è . . ) 2 ; ka.jj)' ' ' . . . j g k 6.

. , w . ..

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1 saw, whilst stationay till it just touches the pitch of the slots, do make a couple of these parallel. To do this place a parallel Wbetween . .,/ :'

, top of the Body, move the saw from the and keep available for future use. them as they are being positioned and 'F. 1l Body and Iower by a further 21mm plus half Spindle (12) Clamped. Include a clamp in the assembly ' ' ' , 'I

' J the thickness of the cutter. If as suggested I am not going into detail regarding turning as shown in Photo 14.The Spindlecan now '' ' '.'

this makes 21.75mm. the Spindle as I am assuming that you be placed between the two pieces of '. ',the saw is l.smm,Having made the first already have a good understanding of material and clamped in position, Photo 15. .

? ') '' q *'Make the f irst cut. y)y ;.,. , . . , .t lowerthe saw a fudher 8mm and make operating the centre lathe. lf hesitant, then Remember this assembly, as it is an ' '''' '1 ),z,

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d, photo 11 . The additional the W PS 34 in the W orkshop Practice excellent method of holding round parts on t .''.,e. ''

.- /the secon' support shown on the right is probably series would be helpful reading. Essentially, the machine table. Machine the keyway ' . -r

diameter and spindle nose taking note that with such a small cutter, .unnecessary but I cannot stress to strongly turn the 24mmto erron the side of caution when mounting whilst suppoded with the tailstock centre, the machine speed should be set at itsitems for milling. Actually, the ease with then fit and adjust the fixed steady whilst maximum, hopefully 2000 rpm plus. î C

C iwhich a slitting saw cuts through a piece of still suppoded by the tailstock. Remove etent (5) .. ..Photo Turn the 4mm diameter and make the M4 ''sj.. . . ' ' ' 'steel is perhaps surprising and illustrates tailstock and bore the internal taper,

the danger present when such an item is 13. Do take note that it will be necessary to thread. Reduce the 12mm outer diameter 'used. Do bear this very much in mind and set the top slide to the required angle before to lomm and part off. Using the four-jaw ' . . ?c,.

i this sequence. Chuck and gripping the 4mm diameter set ' ' 'keep well clear whilst it is running. Photo start ng , , ..

12 SNOWS the Set-up f Or maki ng the Mount a piece of steel on the machine the lomm diameter to run true and turn the - ,.LL--horizontal slots. A small piece of hack saw table using an engineer's square to ensure end as shown at S1, drilling hole also. This

'/IiI blade might be required to complete the the right face is in Iine with the cross feed. Sequence ensures concentricity. ;,:y . . . .. .; , . , . yyy), .. ,k ' . II1

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j jo :4 . -.j . , ssys, mark out holes A and B and drill andp a 1.: , I .. sTggg zlgkgyl 3 I f y ----L (...$-2: -1 12V oo (j tap' Votlnt On machine table as shown int- pk- - -a 2 g ûgAjkrlly 1 gFF photo 16 and using a slot drill make the8I 5 44 a 6mm wide slot. The cutting edge on the

RAIEZIAL C- S 1j : I 1 DETENT KNOB 7 cutter l used became blunt on the very first' ' p 1 2m m 2 lAH ETEF - . . - . . - - - - . . - ...11 2 t-.. gggg zjgkgyI Jg .- @ klou slzEs cut, and got progressivelyworse, hencethel & 4.2mm 1 oFF on the milling macnine or mounted in theS'AFE To FIT EEIwEEF poor finish in the slot that is evident. This

' I T:o TEET8(y) AN!) 52 g lgm. 1 oFF four jaw chuck. Mark out holes A and C.' 71 Drill hole A fully through the part. Mount in rosulted despite it being a brand newcutter.I 1 àcqoss A SI8GLE TooTFlt . . -I E IEyI Asn s!-4 - ' ' - ' ' - ' ' - The Iesson to be Iearnt is to buy the verySE

c :6 1 oFF the four-jaw chuck using hole A and theFo2 qoqE nETXLS . @ best cuxng tools you can afforu thinkingI ' E,IAkEIECS I)! AN2 2smm y 25mm tailstockcentre to position the part and bore'II l 22 &iE ho1 CFITISAL SJ MAIECIA: twice about buying economy versions.! SIEEL 250:07 lomm hole as a close, sliding fit on the. i - . . - . . - . . - . . - oetent. Drill and tap hole c, ueburr edges. Base (3)

lomm EIIAVEIEi To 8E s o (:) cut a Iength of somm x amm, Iength to suitQtANTITï 1 oFFcosE SLIZING F1T , o

1: FAFT 5 yurned ltems the mounting conditions you wish to adopt.1'6î' S1' Tbe remaining tumed items are simple and M

reaqcubiriele ends, mark out holes and drill as. (XANTITy 1 oFF

'' DETENT 5 DETENT CARRIER 6 need no comment, except to recommend '! I o :1I that you drill and fit the arm in the Locking Assem blyj , : j j sarjtjjs ajter assembly when the best cjean aII parts, deburr where required andd Using a file. Fit a file the outer edges such thatthey clearthe

shape the detent en ition for this can be chosen.file teeth on either side when the detent locates POSwasher on diameter 02 to prevent the generously chamfer corners that areh S4. Detent Arm Support (2)larger diameter. Shape as On the central toot , prominent in the assembled state. W ith thed

amaging the cut a Iength of 20mm x 8mm, 75mm Iongil it just breaks into the hole D1 . File Detent Carrier (6) spindle in situ fully screw in the stud and52 unt Ius an allowance for machining. Machine. that the Iarger end Cut a piece Of 25mm square 14mm long P jock it home. Add the two nuts; adjust andj a triangular groove sO d k out drill and countersink.1 1 S3 Finally,

and face the > 0 Sides to give 12mm, either en S, mar ,isjust larger than the hole D1 as . lock them together such that the Spindle' ;.I'

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I I becomes a Iittle stiff to turn. Screw in the 'Ao, ,.v,

't ' Locking Handle and tighten, mark the V AbOVe: 18. A Wpical set o/parts forj jysssg j.. gaays, gequyey .j.,,I . osition where the Arm is to be, probably A 8 , ?t

.2 p , in up t,e dwidinq Neaw as inI ..$ as in photos 1 and 2, remove and drill, see .,y. - , . . ,) . , . spetltogp ses: .3y. ssosg tt. scwsgI ,. oI '

,. : photo 17. Fix the Arm using a two-part n n -j , .' 1' () ! I ,.o .,a

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; '?. No method of coupling the pairof gears . - ; - - l .)' ''1 ? '. è .él ' ''' ...1... shown in euoto , has been detaileu, it '#' s t. . '). ' )l

' ''à being assumedthat, using the lathe change :-.5 ,. . s. t , ,; ' .wheel gears, the parts from the Iathe will I tjy' . 'g ;

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.? j be used. Photo 18 shows a typical set of ' ' --T ' xx , >' ';parts. FIOLE SIZES ' ; .

' Finally check the engagement of the A 5.2mm 4 0FF ', f ' ' '''1 ,Detent with the gear wheel. If having C/80qE 9mm b.5mm ZEEF 3: '. ' w.. ' èè ...: ' z. . ' ' yjjktg 'I Iocated the Detent in 0ne position the gear

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mOVOS, When the Detent is rotated 1 80 8 SIZE AhI) FOSIIION, A8!) FACI .. %'' .1* '' . ,.tc ., 'i . '

1 degrees and re-engaged, file a very Iittle LENCTFI, TO SUIT kOlJ8TlhC'

he error indicates. carry CEQtJIFEREhTS .off one side as tl t this test both with the Detent between . . ... .- ...vv)..'v.'. : -':. ' ,

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two gears and theforkacross asincletooth. RAIEFIAL 5ûmm y 8mm ,*'*' ' In the following chapters w J discuss SIEEL 080/15 .

. . an adaptable Grinding Rest together with c;o c . -' accessoriesto maximisethe potential ût;A$1l1t 1 OFF .'. someof the item. In thisthe Dividing Head is used '' ''

h icrometer dials and at 'to calibrate some m BASE 3the same time. final calibration of the dial .l on the boring head.

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K''.... , % ..z .:t7,tf .. ., , , This final item is comprised of two sections-. the item being ground has to be held in an' ) ; ' '1 ê' ' W Y'?' '3$'*1 Xè. à ) 'Q.%y ' öI r !!j ' s'lty. y. ., . 1 , A grinding Rest (this chapter), and 2, appropriate accessory rather than ground/J ? p ffl ''/4t)y y '. . .' . Accessories for the rest that enable items totally free hand.l i

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oj tooling to be sharpened, typically end. I , .. # .u .,. .2 ' . . .. ' ' .. s.

I ' è.L ' ''') . y, . ),' ,j such as screwdrivers. The 32/50mm Square itemsl ' II. .: C '' . . ' ,.-.:4ky/1t' ,, .y,.tj)kf.) L$q$, @- y? . ..

I , .y . . ...1'. ..).),.. '. . j.,.zyè. tyj' , . Of aIl items of machinery bought, the To economise on effort, f irst cut the materialI .... .: ,. > .jj. 2 .k( . . . .

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.,,r '. r.qy). .tt .... . .. bench grinder almost certainly falls shod for parts 4, 8, 9 (2 00, 17 and 18, machining(41 '- ,. ' ).')) . . .',/sy',k, y,y ' ... . .... .. ,

, of that required in the home workshop by the cut faces of these as in Photo 2. Thist . :q.... ' (.34 y ...'r , .

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rk,' ' 1' ) . . more than any Other. The rest supplied is set up Of angle plate and cylindrical square,I 1 . : 'L. è 1 .1ï ' ;r : )j ' à''' '' ' '. ,, ' - . '.

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: always too small and f requently is one with that by now you should be veryI l .k) ' / tp.,.. ..., . . insufficiently robust making it totally much at home. However, machine one sideI t f.. . .' t .e. ' '. .. .

o .y. jyw,... s,... inadequate for serious use. Only of items 9. Use 32mm square materialg y . . )).IIl ? . . ' t,. , . The significant feature of the rest seen for Item 8 to benefit from free cutting

! I ? s . , : ,ï' jn photo 1 js that it gives f i ne adjustment material 230M07j . . ytj . .: y

y.);? , .I I t . . . ? j) tjj to and from the front face and to and Slide Swivel Pieces (9).'.y:) .. . ,. . . ), O

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'. ) f rOm the side face of the grinding wheel. Drill hole A and use this to mount b0th' I f ') .bikb.k. trtk' s , j yjjjs makes it possible to remove very small pieces as in Photo 3 use an engineer'sI 7?>.14)t1: ' ' ' ' . . .:à7c /7 '), . . .; . è t)t. ,

I - ( , ?z , .') amounts whilst at the same being able to square from the front edge of the table to(-. (b, .

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,..)y , adjacent cutting edge, without any fear of operation. Machine b0th edges, 16mmI ' 27 Indlhg damaging it. To make use of this feature thick and about 14mm wide. So as not toI .L: . . ;; . 111;1! ip'- . .j . , . ... . )y. y. .. y. s . . 7) . . ; g ) ),j. . .y .1 .$'. ' . . .. ' '' '' l$' ' '' * '

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Ilose position, clamp to the machine table widen to give the dimensions of lomm and dovetail, doing this in stages until a flat of only 0.1mm for each pass, continue untilas in Photo 4 before removing the screws, 26.5mm. about 0.5mm remains along the top. the flat is machined away. Leaving theand also add end supports. Using a Iarge I am assuming that by now your Repeat this on the second side. Next Iower cutter set at this height repeat the processslot drill, mill a slot down the centre to a confidence in using your milling machine the cutter and skim the base of the slot to on the first side, Photo 5. Mark out and drilldepth of 7.9mm. An end mijl is also is sufficient for you to justify the purchase establish the 8mm dimension. Using the and tap the remaining holes.

' acceptable as the slot is open ended, of a dovetail cutter. lf not, you will have to same process as for the top half of the Lower Slide (4)although I preferto use a slot drill. However, follow the method used forthe boring head. dovetail, machine the lower half until it Position the part on the table using a dial

L! .'4i q r do not use a slot drill to widen an already Lower the dovetail cutter into the slot by becomes Ievel with the half already test indicator to ensure that it runs parallel' . I ' formed slot, so change to an end mill and about 4mm and start machining the produced. Now, moving the cross slide by with the table traverse and securely clamp:! I

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... ,. . , . jj;y jjr jjg jj;y .(. . .. . . . tt .''' ')' -- ' ' d es o' the slfee dovetails fn the t,'t' .'''/*' l 1 .r%',.:.- . .a. .. . jsl jjjy . ,))))qvjg))jjy . yy. w . ., . . (qk /)të:. . ..-' ' ' ' ivel pieces. slfde swlvel ' ' ' Y'.'s.

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ii I 1p! 1 .11 '' . .. , . .q .I I!' ')4k 8 cutting the 't -)' ' ':s ,. : , . 'ly4' 6. Positioning the - . , ;

. . y ) dovetails fn the -' . :. . a t, .. Lower slide pr/or r . , 4,l ) ' .

* tp. A. to cutting the Lower sllde. . ' ?) ; ' ,,, '' 7 1. t '. : ' ) ,. * , s'ir' . ' - -1p4944,,7.' '

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i in place, Photo 6. Do equip yourself with the distance pieces for the second stage,

thickness of second side; do not alterdown it only remains to mark out and drill holes.' someform of mounting adial test indicator, and not one stage as photo 7 and 8 feed between machining the two halves. Side Arms (20). I

f I such as seen in the photo, as it is so much inrlifmtn nn ihiq iw firti aninra okorxex exrxex Mnnhininn thiK is now almost the eaual of Position a clamp on the angle plate using! ' ' ''' '''- ' ''''' '''''b '*''''@' * '*''''' 'h'' *'' ''h' *'' ..'p ' ' ' 'u' %' h'fh'''' b:r 'i'.a tKiit

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brlq> :.,.:1117 '-'-' ''-'' -'' ''' ' - ' ''' .1.:7 - - ' ,! moreconvenientthan mounting it inthedrill on b0th sides followed by settinn the full machining the Iowerslide sowill notgo into an engineer s square as shown in Photo' 0r cutter chuck. set the height of the depth as in photo 7 and then fini-shing the detail.The slotgoes completelythrough the 11 using this to support the arms whilst

dovetail cutter using a stack of distance dovetail on both sides. This will ensure thev part SO make Sure yOu align the part with machining their ends. Remember to

pieces, 20 + 3 + O.5 giving 23.5 as seen in are both at the same Ievel.

* the ''T'' slot or use packing to raise it from machine towards the support as shown inPhoto 7. Produce the dovetail as in Photo Fit a 12mm slot drill and machine the the table. Again, hole A should initially be Photo 12. However, the photographs show8. ldeally though, do this in two stages as slot

, Photo 9, do not forget to set the table tapping size for M5. that I had second thoughts having movedwas done for the slide swivel pieces using stops

, (seen in the lower picture), when Upper Arm Spacer (17)7 ' . machining closed end slots. Having Set this up as shown in Photo 10, only a .: . ; 01**-.,

' -. ks j(.Jj. . yj )! '- '' :' positioned one end, distance pieces to the single clamp has been use' . 1. t'

' ' ' Value of 14mm will enable the other stop to insufficient space to take a second. .: (4

' -'q . ;''., be easily set. Mark out and drill holesAand Because of this do use a substantial clamp ;.p;- z ? ) kv.qytjg.. ' '1 j à.- t'.i:'-'-''tt . 7: .t' .'. i n skkjl yyty ., . . ...). t. -.,j-

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.. . ..r k7'- . .-t , ,1. >,-'- . :- * '': B but making B tapping size for M5 at this and position the part close to the clamp . ,! . t2 ' t .'e ' ' /1. . , . . . .,!1 Stage. stud as shown. The support pieces are also . . . r ''y.... . . . . .jk.y.) ..'

. ' '') )>. TOP Slide (8) absolutely essential. Mill the step as shown . ''' '' ,, t', ).'' ....$' ' jjt y)tt) tky . / . ' . .: .. . : jkj @y . ,. . u j . ''.ft''it' 't Z '7-: To reduce to 12mm after sawing to 12mm ensuring that you cut towards the support. ' r,f ''' !47Vx z ..

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-j; .L;yh4. yy $:r .. '' ' t '-'-V .. '.4/t' 7 . tl .'. plus, clamp to the machine table with Then mount onto an angle plate an ..t.> . . ., +. ' .

.è .. . ? $) ()y) '. ' gè ' o ' )' .?''.,

'' ' ''''' Iamps on one side only and reduce half machine the two angled faces. Mark out -, . ' ,.'#,.. . tltlst. . c .

. , .. . . .. ctî? 7 . .i).ï , ' . t the width to lzmm. Before removing clamps and drill and tap holes A and B. ' ' . mx rj.)j,t.. . .Q. t ...w'-,e -,c.:'#.l. .k. .'

, ;- .. )2''t' '' ) fit fudher clamps on the already machined .. Lower Arm Spacer (18) . .-.- T6--;y. / *ijt'k''îtlq î;.î , ' . / J :'. . ),..t gr q . @!. .è# .'rt'ltltiAw)) t t' half and then remove first clamps. Reduce '' After machining as indicated on Page 77, . . ''# .-+. 1î' s, .. .>. b . . . . $. . .. jtrr . ,.;). , . .;),bbb . ., , . . .)) .

3, . . )7. ' . '7 Setl/ng the depth o/ dovetall va/ng ' ' ''< -' 'Qx.w . .. distanle pieces. ' % CNWXV the SlOf In the lOGW Slldee .

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. y j yj . >n s. .' p, 't.., '.. v . ' ' '' . . ' < o. .'! . - 'ê' : Above: J1- Settfng up a support for vice far outnumber the advantages

, but it base and that the face on which the jaw 1 3. Yodfffed drilllng Fkel mlke'

1 E ! machinîng the side arms. Above Right: depends on how much emphasis you place slides must be parallel to the base of the adequate WOOS fx Vertical milling.f . : . , 12. Machining the ends ofthe sidearms. on each factor. The major advantage of the vice

. The reason forthis requirement is that owe their design to their intended use on

. Som e second thoughts obviously milling vice is speed of use, but only where this face is often one on which the the horizontal mill where loads will often be1

resulted fn the set up being changed positioning the vice is not critical and workpiece rests, either directly or with much greaterthan loads present in verticalbetween Photos 11 and 12. positioning the part in it is straightforward

. arallels interposed. milling.Amilling vice isthereforefrequently. 11 p11 Its disadvantages are cost, time consuming 'rhe next requirement is that it should more robust than required. My approachI I

' ,1 j the angle plate and the clamp is fitted to position it accurately on the table and be sufficiently robust. Most milling vices was to modify a pair of the cheap and

( higher. This does though remind me to difficulty in many cases of positioning theI It ' comment that much mounting work on the part in the vice, especially for batch )

angle plate can be carried out remote from production. For many, the disadvantages )' y -- ------the machine. This can be on the surface will be outweighed by the advantages even ' M

. . . . . . . .

plate, or even mounted in the bench vice if its use will be Iimited to a small fraction of é o' with the working face horizontal, making the work undertaken.m first, for Iimited use, ' g j gjAkgl'gjk

positioning parts very much easier in many it may appear that a vice from the cheaper - ---- -- ---- -f-.s ------------------ 'CZSOS. end Of thO market Will suffice, these will --- S K1

normally be offered as drilling machine g -Milling Vice - required or not? vices. without doubt the most Iikely limiting - sK3

You may have become aware that we have f actor regardi ng these is jaw I ift, asalready carried out a wide range of milling illustrated in SK1 . ln the case of the milling

' : activities, yet still without using a vice. I have vice this problem is Iargely eliminated byl deliberately done this to highlight the fact fitting a much longer moving jaw. SK2. O1! that a vice is far from essential, it would Next requirement for a milling vice is1' though not be appropriate to overlook its accuracy, with two factors being particularly -------------r3--------LJ-----------h use. important. These are, that the vertical jaw ---------- SK2 SK4; Numerically, the disadvantages of using a face must be truly at right angles with its

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l/'èt cheerf ul drilling vices by skimming alI' )ty . relevant surfaces to improve accuracy and 1 2 1-..-1 8

' :7'' Y b adding a much Ionger movingjaw, photo ' 1-

cx,i

- 55--1 -161-7 ) y g( : . . . .. I - *13. These vices, available for Iess than a --7-

-1 ,, 2-1j C A - - - , --E10, Iook fragile but their Iarge footprint, '1ow slung design and four widely spaced gjckE glgls 27 I j1$. )11.V* 'i

tt) tt' ' fixings make them more than adequate for A çmm 1 OFF 8 kb 1 0FF -!- - :- -f7 ' C the task

, if modified as suggested. When ''-. l r.- Si!$ . .. vxvasseoyq . . t. . . . w. w. ..t,p oks 6.

.1 ' g Lyl' .x :: '; y re-machining them the front edge Of the g 5mm ZIAkETEF DIMFLE 1 0FF - * j') '') ' ;, 'r. ,.,v. ...- base was also machined parallel with the 1'-j i ,6t .. '' ) -.-.....--'.

.jj);î )q:. :. .. . . - . . :;(kE ,: .(yj) , ylypgàvg fixed jaw face. This makes positioning them FOSITION 8 AND C 0$ ASSEHELï 1 - - - - .

': ' s. on the machine table an easy task, Photo '. I I 1! 14 : VATEFIAL 12mm DIARETEF r

. !6 4gPhoto 15 shows the smaller vice being STEEL 230907 ëg - yused to hold one of the side arms for ! qcg

zs,.. z.t , slotting, though the task could have been QLJAFTITï 1 0FF C)0 Q (;o (j, yjou sjygsù done more easily with the part mounted on

7:1 * 1 ' the machinetable.Theparallelswould have LOW ER LEADSCREW NUT 16 ) 4.2mm CS4 9 mm ZIAkETEF 2 0FF;1k.) .' ' '''/JM' :)

, .)L yyyt (j;. .. .,,.j; yysyt. been slid out before the cutter broke fully A co kA-ggqjAj j ggmm j çmm STEEL û8ûA 1 5. . - . ) k x.; . j'' t h r o u g h

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7 y ....z . .. ,, plus an allowance for machining and place TABUE j. t (7 ; tt '' . ,'..u J'''t , -(i this on the machine table as shown in FIOLE SIEES))'f'#

., '

A k5 Fcsl-rjcN ON AssEkgl.y, . tt . Photo 16. Line up the edge to be machined' . ' '- ttjfbf-kiiiqLt.. : ,

t . with the gap of a $-1-* slot so that the cutter'

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j)t c will not damage the table and machine the VIIEFIAL 1 2mm ZIAkETEq, 4.' *), t?.'èj d puoto 17

. Back in chapter 2 SIEEL 230k07 I ': : ' Lî , -) , . . g tL . (E)) j; 4E2). t . . .c.. .j. t. / . y jyggy jgj lj qa q:' regarding tfT'' nuts I indicated that an (/)() C -1-improved finish can result if a Iight finishing QUAiIITY 1 0FF s ycut, say 0.1mm, is taken where the traverse R UEAOSCREW NUT 15 3 5:UPPEdirection and cutter rotation are the same. kjogg SIZESThis is a chance to try this out for yourself, A gqjkk glkggls AFIEydo remember that you need a sharp cutter Ayove Left: 14 Having 2s front edge ISSEM8Lï T0 JA4E Ek2

. t' ))$ w.'

for this process. jje, wit. t,e vice jaws enables the OF AZJLJSTI $() SCqEASjLIL. t .t.t , . . .-.L:q...t). . ... .vs 4..-.. . ., jrljly/eljl

7 à.: yoyxw)yk v.

' .xv...- jj j tj osce more aCCU rztojy @OSitjOr) jj....v' ..-... o es an Mjjjjpg t#e glots in the Side al'ms (thOU9 k AJ ( jl A L 1 0 m m y ! m m

wx-px, ''

w>p 7. jhe pad on the machine table. This time j) enxw s , j uogja gasjjy ygve e gjg jg y jyA j j. ), ' . . 't z 4L$4 thls D#el'at On

,-.. o .. jjxgg.gl . packed up to allow for milling the through aone wkth the part. m ounted on the,.s. .?s - . . .x ss.-* slots, Photo 1 8 . Set the table traverse Njne table)

. Note the cross feed (10 C. >w..:+.A. .' ' - stops, and cross feed stops if your machine m*C i1AF1l1ï 2 0FFr , u ,,, stops at tlw botlom of the photograph

r ;)))),).L' . has them, (typically as seen at bottom of set up to control the Iength of the slot. GIB STRIP 12. .. . c . . . yy. . ,zu

l 88 ê 89l

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1 . aos 'r+' 16. posft/orgng the Table fn 18. M/ll/ng the )?,n' ; ' .) i' .' ' l )'' , .ê' .,I; , ,,, ,).,,,.,)v, preparation for machining its edges. Table slots. . t,. ) ; . . ,. L$: . . . : g., : ..ïL . . . .$è. 11y . .- g. . ..'j . , jfj.: . . . . '' u. t , .<tps. 2 . xtps..yk ,( .>... a. ôs ,.. ..jivàk., NqLI.Stt.... .,.pgy>'i; Lock Screws (5 and 19) 7 't7' P)-. '3X . ''*'t'X''' : . vii. ' .

The turned parts are aII quite simple and ' . .. . '.. ' '

'''' ' ' therefore I do not intend to go into the .,h . -)y' .t)X'''''Q.''''' ' '' 'I j '.. , ' y . . .

. j!i . . . Iathework involved in these. However, the .''.... ' . , ., tksysy. v'''', ; I . . yj . . ëq$ . i '' Lock screws do have a little milling activity ' - ' ' . ''s:. ,'. ,.ty.,,.,) .,,.,.. j. .!' . .,: . ' ' yj h. ' . ..;;qôv...s,..s.. . .' .

' ...... that could present a problem to the novice . ' ' 7'7)y?.'.'' t)7yt)y),):è77.J7tCt-''Cê.-'..@):; ' . . . à'C..y. y 2i ' .

' ' '''t The Iesson here is that what may seem to , ' '' t1 1 '' I ''''''' ..,.,:','t':,.-.'.4.' be a problem when attempting to use tiae ..;)). -t,. -,, ,.,.,.

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qjjqj.qjjjjj.. s jj,;yy,yy.jj.jyy.. jgtys.stjjxyjyy yysj yyy. . .. . y.y. . . ... . y y. . yyzyxysyy; tvy..jj)j.q,,vc yyysysy ..jy,,. ,j yy..,., .s...... ... . . :. .?y... ...'.) .r)ït. .... .

I ' t . nvt. - uo.oy. . . . . . . a v a' .. ? t:if' ) n%=' :2 .'ykt>'7' .,... . ,k 2.4.. 4 u y. ,.-t77' ' ' ..'..ï ' - ..r-- .?.> p I ate vice etc . ) can beco m e a ve ry ' < . .4 . .. : yjj; fèi - . :.. jjjjjk):. ' awsm- ..tys%t% , , yt ' .,t. vw o w. ... .' . . :. c.ï2 w. v,:o js)rt y ;q. . .I .: :

' '' , . . .

.. ' . zqf)+$*1. . ' ,,vx.s ogza' , . (... s t ra i g h tf o rwa rd o p e rat i o n i f a i d e d b y a Belo > Right: 19. VtX).'' , , )) ))')) '' oo .7 . . . . u -% zt.% . . . ..... -.qo.. w ou:t>. ) ''' ' x œmqe wZ:G . . . ' 1V4 . . .)ky(y$yYy2k*'.&. . k

. ..# .' )v...- ss.xtvT- ' Slmple home-made f ixture. Milling the slot in àyta ,,,, : 7 ': '

. : . y y . . ..jt>-; ; . y , ... ' ,., a .- Make the two items shown i n SK3 the Base angle. .' . : ' . ..et$1Iè. . ,' 0' .jz 4k4' '.'' il il EI' ' taking note that the hole must be central inI ;

ï Photo 15) enabling the slots to be cut item A, aII other dimensions can suit the remaining two screws, a very simple mount this on the Iathe as shown in Photot ! without continual reference to the table available material

, a Iength of tube will also Operation. 22.( I6 '' i traverse dials. At 6mm diameter you will be required. set these up on the mill table Gib strips (12) This is your first opportunity to check2 I .

need a speed on the high side, say and with a 4m m mini mill running at These may appear to present a problem if the accuracy of the Dividing Head mandrel.' 1000rpm plus. maximum speed mill the flat as shown in a tilting vice is not pad of your kit, you have Set up a dial test indicator on the surface to;

Base Angle (7) photo 20. Now turn over the Iock screw though already made the ideal fixture for be calibrated and rotate the Dividing Headt . Bythissugeoftheseries, machiningthebase complete with holder A and relocate holding these. Clamp one of the Slide by hand noting any deviation present. lf the

j ' ' 1. ' ''. '

::(1 ?.. angle should come as second nature. Photo against the stop in part B making the Swivel pieces to the machine table and with dial runs perfectlytrueyou have indeed done

1 1 'i'''i1I! 19 shows the set up for machining the slot. operation of milling the second side, and a round rod and a piece of packing use this Well but some small error is likely which inj i, j ; j'

! l '' t0 hold the Gib Strips for machining, Photo most most cases, even when making aI . ' ' ' N '

' iig' 2 21 . Turn strips over and machine the ,.',. .r... .',,, ..'.,)tI )j;.t '. ))#k':#rv tàj /))t)jjj)-; ' . . , .w ., Second side. W hat appeared a problem has )y 4:)tt.. . y . . îjLlt-q. jyjj, . ,j ajj )))))L..qjj))py-. .,,,. . :, I L( ..,. tu rned out to be very si mple. When on you r yottktk.y' y ypytyy y.f I yt, . jact tjaat a part .' '. ' .

' 'tiixv x. .i . E , ... . . . .

''. . . .... OWn, do nOt Iose sight of the, , I I . , . . . . . : : j.o : : . xj;ty y .!' , . I ',thst .''' t''t already made Can Often aSSISt I n maCHI N1 rlg X *7.: '7 ' <'..>'

. :'' . lkL cqî- -1/ ' ''

y. .,,'Lî '' other parts that follow. 5. .t7' .jl . . . ht' $- ' ' yeed Knob (1 0) 76.:) .'. . . 4. . . . . u..k s . m..x. . .' ' -. o-ray-sy *p.z.?.p 'b$î'%î/: ' '7'-M. . .. ,..,k I ; ;.s j; : jy j.v I::y ,.k Iar I.,- ;. jj j. jF ; jj . .a. .

I I I uaallkpratlrlg tHO r-OOu INROIJ CZr1 kJO kllc I I rSt N 2k E , . '),,''?'. task for your recently made Dividing Head. - -.'?.)' '...,t4-?.?.,.

'

I I . jkùiLyk yklt: . . fvgv, y., ' .. , yy.;,yo?o-... '' ' Ajter uoring and making the knurl whilst '''Y'' f-' '''''' 'l l j . . 'tlyyy -,.:.gb() . yyytk. L); è .. t:.. . . . :. . ztjy. ;sxy.s. L..q:. yyyg sg, yyjjj.. cjqvlly.j; . .. kjj..s.. .v; .tf/,, - :. mounted in the chuck, mount on a taper k ,$

î' 7 .' .. i -.. stub mandrel and turn the portion to be 'k

. . -=' . wy . 'j a .. . . ' ' ' ' v î ' . .. . .

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CZI ibratod . DO ORSU ro thzt the knob is MeWj . ...........aw # . 2. . . jj)(v s yj ym jy y; 4j , jy otj o yjjo jjj o mau tj y. j . w jtjj o (jt ..! . .. .. . .

trj)(jjpjgy.. . . ..;bï)?'b3L; ... ...I i Ii ' ryyr/ttt'. Ltyk . jz. uachining t,e removing f rom the chuck, transfer chuck, i ,11 -v- ...tr:ctp$p?)j.)'t k j;. g.,- m' r' sy j-. I Table s edges. mandrel and knob tothe Dividing Head and .

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m.. àk:. .îx ... . .'t 4 .. Sgt' , '. of''. x %c. . p 4 k $. . 4. t 2 .. . w. ?Jt . à> s. . ' '' ' é e. .. o lk gz :7 tqàt. .. . .. &. .q:). s.. ...? , . ma . k. zgj z .'q o Ak . . ?.' ' öhqr. .) p, bblg... . xlpa.. o:V. . s . . xstwcz . 97 . . w. m . . . X.. '.. .. Vy..ç 'S . . p.'. .% . . .v . . .. '. LL.R4y . ... 3' 4) . JYAr . 'y .... w ... . ; ny%n( .. x . . .u, g.)Ty 6.. % . . .

gear,It is easy to fall into the trap of thinking

that a pointed cutter should be used tomake the Iines on the dial. However, anerror in concentricity will cause the Iine tochange in width as the dial rotates. Make acutter as SK3; I would suggest a tip widthof 0.2 to 0.3mm. Depending on the error inconcentricity you may still need to makeslight changes in the depth of cut as thedial rotates. I would suggest you find themid-point of any error and set the depth ofcut at this point to be 0.1mm. Make sure

will not be ofany Consequence.

21. Uslng one of the Sllde swlvelpieeesas a fixture for holding the Gib strips formachining the angle on their edges.

AssemblyFirst, assemble both items 9 together withitem 16 and fit and lightly tighten the screwH5. Take apart and drill dimple C in pad 16as indicated by the mark made by thescrew. Reassemble with items 4, 8, 12, and15 added

22. Calibrating the Feed knob using theDividing Head made in the previous parlof the series.

adhesive. You will see fromthat I chose to fit the top Locking11 on the Ieft rather than on the

the Photo 1Handle

the tool is firmly clamped on the top slideand use its calibration to set the Iine Iengths. three centre punch marks in some obscureW ith an Msthread having a pitch of 0.8mm, position, such as on the threaded ends of40 calibrations will give increments of the lock screws. Assemble for the Iast time0.02mm. applying a Iittle oiI in appropriate positions

You can now go back to the dial on the and the Grinding Rest is complete, only nowboring head and calibrate this also. You will Assemble the parts involved in using Waiting the arrival of its attachments forthough need to mount it on a taper stub the Locking Handles and mark the sharpening various metalworking andmandrel and re-machine the sloping face, preferred position for their arms

, remove, Woodworking tools. These will be describedeven if you had nottemporarilycalibrated this. drill and fix the arms using two-part resin in the following chapters.

92 93. '.

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making sure that screw 1.15Iocates in the dimple and tighten Gib Stripscrews so that the slides are firmly fixed.Drill through items 4 and 8 into theLeadscrew Nuts (items 15 and 16) usingan M5 tapping size drill. Open up holes initems 4 and 8 to 5.2mm diameter and tapthe Leadscrew Nuts M5 through the holesjust drilled. This will ensure satisfactoryalignment. Dismantle and drill the dimplesin the Gib Strips as indicated by the screwmarks.

right asshown in the assembly drawing. This helpsto make them both more accessible. It isimportant to take note that items must returnto the same position as variations in theposition of their threads will also causehandle arm positions to vary. I wouldsuggest marking them with one, two and

. 11 q .I . ! 7i ' .

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STOF SCFEA CAN 8E

FIITED EITHEq SIZE . .81 t1 1 r I IO Jh Jh

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In o r CCeS SO rIe S82 1

8AZDAAZE81 kl j 10 SOCKET CAF SCFEA 1 0FF82 :4 ï 1û SOCKET CAF SCZEA 2 OFF

FENCE AND STOP ASSEM BLY AS1

In the Iast chapter we completed the * Due to the item being ground oftenadjustable o#-hand grinder rest, the full being unsupported close to the wheel

2 1 22 extent of its capability will though only be when using the accessories, only takeach i eved by th e add ition of various very Iight cuts. The depth of cut mustaccessories, these being the subject of this be controlled by the fine feed and theand the following chapter. fence rather than manually.

At this stage, description of the * Make multiple passes where more1, H ù h manufacturing processes will be kept to a material has to be removed than can be

- -x- - - - -)1-):-.--.s- mjnjmum, as by now these should not taken safely at a single pass.present a problem. Making them will though * Keep the overhang of the tool, fromcontinue to provide valuable necessary the accessory holding ft lo a minlmum.experience. Much of the chapter will centre * ln view of the overhang do ensure theon the use of the accessories and includes accessory Is held firmly down on thephotographs to illustrate the operations that rest's table.S G n be performed. First however, very * Keep the table and the sllding1 ca

'' '' '' '' important safety considerations must be surfaces of the accessory as free ofaired. grinding dust as possible. This will

result in easierhand feeding and makesFI 1 1 2HAFZAAqE IMPORTANT SAFETY forsa/er working.H 1 *4 k 1û SOCKET CA? SCqES 2 OFF REQUIREM ENTS * when the grinder is running do not

* Do wear safety spectacles or make adjustments to the rest, otller thanCLAMP SCREW ASSEMBLY AS2 facemask. using t,e table's '/ne teeds.

94 951

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F()I? SHIiFENINC SIrE AS() T0FANr FELIEF.F0q SHAZPENING Fi?O8IAND FELICF.

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7.5mm y jmm ZEEF 8018 SIZES41 42 kATEFIAL

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, ' y' . ' , that both be mounted on a very robust base.' ' ' I ' , ( lf this is not done the rest will be able to ' aa rr.jj i ) i, j . . ?r . .yy. . y; s.y .. ...: ' '-'r Iative to the off-hand grinder when. rlrl (2hhkr(2h f-t!l . 11 ,, ,,' best this may result in inaccurate ''. A --1 5 ,-ot : . , .,

., in use. AtI . , '' -- ' results but much worse, be the cause of a j 35 2 r- I 6 ! - u.n' l ''/ ious accident. '

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oi 1 ' ., ', The accessories '

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, '',ë'',. ?) This is an essential part of the system being B j' . .k7 )k ' t.., . . d to accurately guide the part being , 25 25 '-use

', k HOLE slzEs A. :5 1 oFF 8 :4 k 8 DEE? 2 oFF' 7.' ground, either across the face of the wheel ç

., ''

.;(%: o ''tt or down its side. A stop screw can be fitted Sî v , / :nk . ; NA'gEjkIAL 1 2 m m SQUAqE STEEL 250907! T .'i . L,v when required to ensure that the part being 6'' I ' . I :1 L'ë' - -' 6 . sy' : -. ' çI . t*4. , l)jl ground cannot pass beyond a certain point.

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, '' , vw----s--. .w- i---w I p---- QUANTITY 2 OFF ADJUSTABLE FENCE 11! 4. 9 j 1 9 - ' ' , . . '.' . '''. , '.. '', ) ' . . e m p ',, ''a 's -'i s-e/d -t I -at tm J ''c I m i7 I -'i n-g - 'wo r 'k c ''a ; i-eI . I : u' '' J .t ! !! >> '- carried out without using a vice as the work 'q I j r w. ,,l . ' I I la' e hojdi ng dOViCO, Porhaps t0 the point Of 5I I . .

* y . . .. j j .'< N. $ .. . . N. giving the idea that it is not an essential. u ,0 o a, . o

' requirement. W here a Vice comes into its '1. Milling the >eb on the fence. own is with the smaller items

, which are '' '' '' ''i k 5more difficult to hold by other means. The Jo 5 ç !- Un. ..j a jj m - 25 m1

Make sure that aII Iocking Ievers are Adjustable Fence (11) is a Wpical instance. =- an mli firmly tightened before stading the grinder. Machine Iower web Photo 1. Turn over, -K*' MATEFIALI : A * c-.u 25mm DjAkgl'gj SJEEL 250k07The rest Can be Used aS a Convontional Off- hold On web just made, and machine top

hand Grinding Rest in which case ensure Surface to reduce thickness to 6mm. Drill o :: :1 5mm DIAREIER STEEL 230k07that the front edge of the table is no more and tap holes. Radius web ends using a 1than 1mm from the grinding wheel and the file. j l --1 1 g FABCICAIE FqOk 25mm AND 5mm' j j item being ground supported by the rest's The assembly also requires some ?- : 1 0 l - 20 MAIECIALS' ( ) : (j washers

. However, where simple - 40 (ltjArjyjyy r crg C

,

' i table. turne! Due to grinding dust getting into the parts are rejuired throughout the rest of HOLE SIZESIocking lever assemblies they can become the book, l wlll not comment on them in the A. k5 1 0FF 8 94 X 8 DEEP 2 0FF CLAMP SCREW 21

difficult to undo, but becoming free quite text, the drawings should give aII the ms u d de n I y as m o r

keoftjoorkcej o si S awjtql i eudn. kj oh iasslll i R f O jmjtot itlozrsltlwi 1 tl' e f e n ce f itted , t h i s can : V % 'f E 2 1 A E 1 2 m m S Q U A Ii E S 1 E E L 2 5 O k () 7 z j '

mounted off the bench grinder it is essential of the rest. You may find it easier to fit the

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. '' .. . y( g jjg jj é g j m yyj jo . jy g g g k jt $ g y) ,L1' t ' . q '' ( . #lî 9: qttljqljlvyjytt $L. @'07. '?t. ' çqy ).' lqqtitjk; ). . - s . .... )..- -j). )t ;, . . : .. -.

-., ry' (iq.. #( ,,; , ,j,)7 . ,,;., j, () tl A tk 'I' I T ï : o F F' C)0 C1'onwjlt. . ! A s . 7) .. w,(

,v . '., t 'f,

LEAF SPRING CLAMP 53 LEAF SPRING 52.

. . i ,( l .j , . . , . ')t .. jtyy,. . - ...,) . . ;. 'k . t),1)1. lj.,(. t . . ; : . .f I . .

' . ' ' ). ) :. .. j , . . t))t .z. , j. .;(jy))v,p .,), , ., y ,:

. .... . ' l /;x ( '. kj . t ,. 1 y I g I.' fence (and clamp screw assembly AS2) to other uses will surface. The Base (31) is l - . --

the table if you remove the table (2 screws) used for setting the angle of the workpiece ' ' --.-- . - .cc-lae ..-I from the remainder of the rest. When fitting relative to the feed direction and is also

I I 1the fence in either of the side slots,it should used with many of the remaining - - - .cmg... -IWaYS be fioed Such that if the base moves accessories. For simplicity it is not shown r , j 6 7I Z.

. Ili ,1 aWay f rom the f ence , the item bei ng on their drawings but can be seen in the - - -t-EL- - HOLE 6.2mm 1 0FF' 11 Sharpened mOVeS aWay from the wheel, not photographs. '. I 1

towards it. To machine the square w orkpiece L62. - - - -LT-1-: - OIARETEF T0 SIJIT

swivel Base clamp screw, AS2 Holder (32) mount on an angle plate using - - ' SLITTIhG SAA 808EThis enables an accessory to be fixed to a parallel to ensure the part is parallel to l

'' the rest's table where the accessory itself the machine table. Commence machining ' ' HAIEiIAL STEEL 250907; I1: feeds the workpiece', typically when using groove with an 8 or lomm slot drill, working EE I35

Fcqr the end mill sharpening assembly as will to the 5mm dimension. Open up to 13mm QtJA$1l1t 1 0FF= 50 '> I 6: be seen in the next chapter. using an end mill. Drill and tap holes. Cut a FOLES EACFI 80FE SIEE (Do ((ji

facture of the Clamp Screw length of 50 x 6mm forthe Swivel Base (31) : A k6 6 0FF AT 1 ûmm FITCH. M an uj Mount (22) follows very closelythat for item Machine ends to 75mm, again using the .) 8 k,'s ï 8mm CEEF 4 OFF. 11 above. angle plate for mounting. Drill and tap holes. .

Square w orkpiece Holder and Swivel To sharpen a lathe tool, mount the . RAIEFIAL 5ûmm ï 6mm STEEL û8ûA1 511 ! ! qI Base, AS3 holder on the swivel base at an angle to4 ! The main purpose of the holder is to mount suit the tool's side relief with the rest's table Q'AFTIT/ 1 OFF CO C1 square section lathe tools but no doubt angled Ieft to right to suit the tool's side ' swlvEL BASE 31 PIVOT 51I t

. d' 100 1011 .

I q .j'j . '

jr'

4 i : ' . ....y 1

! h' l 'j . '' r

.:I ' 'I ' . I .

' j)tj.)

, . J

. . VV7J % *. 7 >2Y ''..' ' ' 't a sharpening a sectlon lathe tools, etc. . sy ? ),..,.....v ','w '7 . Ty. . . . . );' ' .

' '''%'bz. c .o,-t.''' 4t..... e ,y? ..A..s square lathe tool. C Ut tWO l en gth s Of 25 x 1 6 m m , o n e ' wt4) k k. '.'.) '' ....c. .. ...sp. y .C+:. 'îï. yq . . * 7 L t . .. p' ?. î' j f y)jt . '. f: . . j. ' .. . . .

:. 7 ' . ; . . . qqt o )). .. . k. :

I j') tC',71 .' ..t;,'.. . , .' . .. .. . .

. t? each for Slde One (41 ) and Slde Tw0 (42) . .i.by. mo. ,.,.y.. (: ,, . e:. . .. ... .:s .. :. . . . ...L. . . : .. u L s. . . ' >.:..:')r.'' 7r'.':'...'.'.è, .s .?.y'''tp x U sl ng an an gl e p l ate f O r s u ppO rtl n g Rarts , . .

''. z- ''-'> . > ' ''C: 'r. .'% .'' .. ' ...' 'è'L =' .)' ' ' ' '%.,,L ''. ' w p2. . . 'k.2. .. . j.) .. . .j.. g. 7 .. . . yk. . ) . . . w. . . . . yL) . . . . k. ;.:î. y . . ( 2. .%k.. i . . . . ' . . .. .. . . tj jj rooves G XOVOS RIUSt ''t. . '. . . ..' - -

. -. .--. t.. L..) ( . . .. t.è.- z. ..5 - vsltt. (t:- .t- . ;-: .. .. . . .

. . i . . . . î . -.. .

't)'.'y-. z 1-11-11 IEEIk d::l 1-1 1 1--1 dEs,h d!ë,h 1-.1 IEE; IEE'- 1,-1 6) . .-?; .#:..

é.'.qy..: . . xcmo,kc'ss. tk .è hyy F. : v ;j: . . . . '/, .? . . 7 . . . . . . . ? L '.-y, ye ce nt ra 1 Oth e r-w1 s e t h ey w I I I n Ot a I I g n 1 f . '' 3 -' 2 J t Aq ) ' wk .. k , . L '. ' ù tu.1 / . ).? è '' ' ' '.' . . . ' . )d i ? Jr J'v: = . . 7 . . -r.. $1 . :. ,.. ... . . .. .: . t. . '.!. , . . L$t, .

. . ... : k's'v'î'' .j;-'*2% >()$rà'k.c -' îî .'. k,j) - zqly)?/rl --L)L . ,''f.#,t.'? '7?y#jj.t. ytqj, y' y . , .

') , . 'ysshy;'yj ):. ....sy)k (:) t-l (E, r:l 15t 1-1: 1 t!l 1k t.l r. y-l (E) (:j (:) hjl (E, r- r. (!) I 15t 1k I hkr fëh 1t (:) 1: i-l (!, (:) 1k i-l (E, r'. ' '-(g jjxyyyojyye,ttjnj'/é'kgtyty 6'j.î àL.sy. .)) '. jîî . ). . .y .. 2 . . jj;j j. j j j jj jjj

. jyj tjjj j-j (yj jyi jyl (.j y-j jy (gj y. jyl (y;j y. (jj .. ' î/ï'ï . jyt.wut llvc,-. - -y.t.. : ... /.'. -.. L.- è(.. ëj L); y: .. .c).? ,. . :$t).L L ) jLtév;î j: ., o . j .. . . t,. y y :.,..,.j, ...., ... w..yyy . , j-y y- jg;j y-y yyjt tjy ya j- jgyj jjjkj (yj y..j pkjr jg;j y. .,y .yy. t..! ! . û:')'y;!t.).4k . . ;qb'L. 4T.JtikfC' ,; yp'' . ..ijjî, .y ,.c j. . .) ..yj. .: !i/!$jr j-l 1:5, 1-1 l.1 1: I r-l (; 1 1k 1k (:;) 1E9 Ijlk 1:)I

> s- îî '? t,:. . ' -. ; tikxtctq : )t-? .k- : jt/à.. ? ?t' : . .,f... kjy . j:r)j jryjy . . ;.:.l j i ')( . . .: )( ) ( j yty. . . .... p jj o t o 4 ) t h e h o I d e r W 1 I l n e e d t O .' I . ! .()J)lèïkit)jky,- . k-. - -vî kd?k . '''l?)j?y)Jy,?#j bt.:îiqq.bjîy (: . . .l . xctjj;. )y . . . ., î :, y jj .y jjj j.. , jyjj jkjr jgyj j. .. . . jptc . . y...I .,bî(%iqg. .o< . -?t .,.y.. ktsl)t. sstyykts removed f rom the swlvel base, turne o , ..I ''Jlt nn. 'yy j.tt;.. ï. z'3ïkkî;: . . .. y. rt)..: ; . sjjy . .. . ;. .I I . ., . .

$.v. èu..w. . ' yswy. yljjjyy tj t j.j o s e c o n d s 1 d e g r O u n d . T h *1 S W 1 1 l . '' ''''''- ' ' ' .' '.,. . .,. :33. . . ..,-,,. -'. -j;)j;)( t, j, îjjj . ) yyyyxy ;jy. 1j,k y-l . . . . .. . i : .. ty ,qî., . --- ' ' .. ' . ty . fjt ,? .. . t ?j... . 'yk. lyyl . .)y ;(( j . .t, .tate t h e f .1 n e 1 eft to ri g h t f eed b e '1 n g # ' '' ' ' -11 ' I ');) ' s î ' (y . :î:jL y . . ? . 7 ?,. qs èt y . 1-1 (!j (:) 44j 12; jëi 1'1 ' . . c '((.)(j t'kc , . AJ ' ' .. . .. :). . t ' Liltt. yy kytjy jt/qyzyli?: '.' I . . .j) jy..t L ?' ty .j t . îî .?' ïî . . )# . . . . . .- .- .. .. . .

'

. .. . . ''''@,?-. .#$1- C'i 's.

'. à'''. ..' .' ..-'

,----.

. .

y î '. ' '.):y .. ;. . -.

.f'.'- --t''c. ?',/tè(.$--'t-'.t...*-,')+.,'-?--. - 1E5t. .::11 jl 1.-1 tEr 1t d!!,' 4::1 IEE'. tëklp IEE!L I I-'k 'ESIL 'EE; I 1l: I t!!i 1.-1 1--1 I I 1-42 .E!,, I !h?!' 1t: 1-'1 lisl.t 1t 1-.1 dE!,' l-''ii:' t!!i 1.-1 I lt: .bi . bLikps @sr

s). .. . - . . . -. . -. . - --.,-- - . - . -. .-,- -,,----,,----,.-. - -. . . . , . , , . -..- ------. ... .- -- .1 --,-- . . - -.-

xz. ..,- .- - -,t.k,). l,t -. t. . . . - .-v- . 4::, 1-, j:;p (:;p !t I.1 ,!y 1 ç:jl 422, t!i ,k,k, I I 1 1:2) (E2, IE l-) 4E2, t!i 1E1. I-lr) .E), ,j,k( l 1r I-) 4::. t-l 1L 1k @.1 l :Ey : :. y,y qo . .. .,t.-tttqk.tysw- .jt j)j;L;);.. . ....114 <n.t#)rj). à j)g: e zs'jjlqlq. ... : . jjty j -,r4tyL .,-w. . VC.LL.. . . .. . ,j . jyyjytzj yy . . . . z:.w jj. xk yjjyyy. jat..yyu. ., y .,1 : ! r ..,>, .. n%%' 9'û7: ' ' ' ' k xfj .. w . .,s . ' ' c b k :)j .?yg...r7 j:l (!j 1 r-l j:j (:t (:) 1*1 (Ej . ..)(y. s '..I

. '': . . yè ' .nqy.rùy. l'phksy*:,s <k --' , . 1 . w.t1 I :1 Ii . '. . ' .' . The screw drlver end W1II nOW requlro 'I g . 2 , yjq .L . >' , ...j . j... , jj. j... j; j,.. . j.. jy jj j,.u z..u jj, .'! i V .. . 6 ;.?...L g rl rl U I n g to L; rl 11 @ tHO l H IC Nl'l OSS to tll t;1 t '

7 1: W ' '. ' rCQ U 1 rCd . R 0 IMOVO th O h O I d O r f ro m thO. î ' ' ', UF ?sq x. . ) .. . . , , ... ..y y. ... 2. L 7/4 . . o î. , . ja'' ' èt tl't)'.Y.7Q ' SWIVOI base ttlrn On ItS Slde and grlnd t e. L . ? . .' gî.jqlntjj). , . , , 4 syarpenjng a screw drl*Fel''

'''.','

. bz..;. .''''è.')>.Vy')ïV..'t>..:y' ' eNd to establlsh the requlred blade Wldth. @. ' . . ..b.3L. j : . . .' . . è . . j ï .,. .î.'h.,..3 ''. '.h.tt/ts), , ? .k hjjq . '..../#,(....),.;. zyotltp. ..-. Due to the ove rhang Of the screwd nve r f rom.'. . :' 7 :. v>lpt . 2. x. jjj . . .. . .?2(j;;y... .qjjjvil.oyv. q..y.. '' . y. . (y(. .. . ,y. jjj y.' . . 7 )7.16 ' .. c uqhxenwqx. M:'. '' . r T 77. cpki k y. . . . . .

. . n .7 'y $s . a. )L.:ïîî .. w. y . 'z;L y&p.''')):. : (:.44) îtltanj) 4; t: ?q $7t ),:b.?*L2 # è)) '2T ?ZqJILJ' .ï qy ; q) ? (lj%j >y)). ?qysj (?qq()ïà11). . o pikojl..' w . . . ?' % y . . . ' F . . . ktvakx w. . . ' ' 7 ' ' ' . ' ' ' & A w - w. # # w I w - A : Cl %. ' : ' ' t . ' l ' ' ' '. ' ' L ' ' ' . . . '. . . 7 . . %Jk%*.**1. . 2 ? 7 ; L w '

. . - ' . . ''ï %*. 7 f'ta wî ' .

%'e-xwb. x vtjh.'.' . . . . ::7, j!'qi j!:lp iùtr lr itlp 1r lr 12,7 lr 1k17 lrl 1k1r . : j J : . ' j ft '.èy5y t crbdk x)p' .z/. rf ' jtttqy :'4.y<#!. L'' .....-...-.-' ' . . t . )q ' ; . . . .. .: 's f . èjttf pr' . .1 . . .. . . . <:.. w nhj su . ''' k$-' .. . . vx .. jo the screw 7. t ' .. '.'(L'j;)). ojytv -' .

' . ' . ' ' : ''

..'eV vs.L6Ijbz' ' .'j r ... .. .. )'' ' ' . . . ''

. ., .. q .

'....y.jty' s jcln yjoxRw 1>. o ... . L . ' . ''''$fbq)Lg..Lq;jk. . . '. . . ..t . . jyj .qL ;y .;b ., ., jjr . ... ; ; y . y y. y .j...y ..,))j, , . :jygu.yyjrjy,. . .. ' , yy. '.)k r1y.. .. . nîyîuxqh?. . dnver lS easl y . . . t L u ..x (t x. <' i 7 .'. 'V= -' '''1llqt''èc ;r' . . .-s-. ïàz. J:.. . ' '.'.. ''

. .. . ., jt:,jr jj.l jg:;j jjk .' t ;' L . . ' . ) è j'. .. :... y. y'. .'y

3j'j, '?j L=fby' . -. ':y. 'achleve , , u, , ,.4 sIj . . j j yt .t,. .: ét@'.j/' :t'. . . . . jjy j!jj jgiykjjj jjjy jjgj jjjjjrjjgj jjjj jrgj ... l.. y t't. . . (p t (j..j wt $ Llb Altytjq. , clearance. Photo 3 shows thls operatlon. Is dellberately set to an angle to the slde of t .. .; .. .....v.;.,.'.....L,'.ï'''', . ........... .

7%

' '' If you have studled the Gnndlng Rest the wheel to avoid this possibility SKZC. ;, RHemP&lHM 1H1+ ? N . . ,. - ' ' jyjt.' IIj. . . . t .. : ..1'. '' .. . ' . . . . jt,1 ! In detall you may conslder that the angle This may seem Iike a procedure to bY &DaS*lStOd ? , '.' C ' (;#)è/'' ,>: j 24 j .g ( . . .. . . .. .; t . g t''

' t using the swivel base would actually overcome the accuracy I'Imitations of the ' 0// hand ' ''V' N '>-' ' ' f'/v '.;I Se yk.. xk . y . . ... jty-: .,?. .... .

' be achleved uslng the rest s swlvel faclllty. home wo rkshop , It Is though standard 9fln 1D# ' . tqzyn ''ttyj . . à. L LqlijjjLn.' ., .,,'.,'. ,. y..j . , , . . , . , .. z,tkprït .. .asszlky -.- - (t j,.). :,? -- -- - . - . - - ...,. è,,. Thls Is not so, Its use, wlth a few exceptlons, practlce In lndustry. D, E and F show the .i k-k4qtha.tg. t ... .. .)'y.t'')#xs - ,. , .. ?. ... . ;'.' , ,

' 4. jjjk . à . ) ' 't . jn ) j) ? L j . (. . t 7 )c.1 Is purely to set the approach angle of the same s'Ituations relative to the front face of )' -::C.1..' ' ' '. ' ' s ''(**. % ' V' ''''''' ''' ', >I i' : . , . . ;(j . jkkL . . I.. ' . '. , . . ï' . . ' j'jèzI ' '' tace being ground to the wheel. the wheel. This angle set by the rest's .'. .th%'' '.' ' . -?'''''è'''Ltt;''7 ' ''' '' '' ''''?''''''.v:I.,i î.ç. . . . jt. . , .,. ..., I , , . . : . ... OL y.). tî . j: ?. y. :. . . t. .. .. .. ètyt.I . . . . , , . . , .) çty àt . ., . . .. . . .) .. #) ttyx. .. yt . ,. . tj .j' W hen grlndlng a podlon f rom the slde swlvelllnn facllltv

, should be a maxlmum of ':. 'lt..tt.t.J.@.''... . , ,sthye,s.ttttzul4c... o q..'îs',....'. .yh.,

h.. .' 'otkti '

. , x-' - , . yy g( .. . t . .2 y, s. y,f?.jxj) xjtx.yps;uu ks : yjyy q yy t . . . ; ,2 y.... .q .jr' of a workplece It would seem obvious that a deg ree or two. ., '.,èL''î .q ...',.' 'lttkv.' --::.1 'np%t-z.;v. -.,s.t)yt..t,'?ty .....,. , y .y..j)t?g)y'.,... y... . ..

' . . .,

,,' ..'y. . .

. . jy. . . q . . ... yjty yjjyxjyjjjy yjy . yy. y,yyjyz, qqj. yy . . )),.y y..y y y. , ,.. j . y . . . . jjthe feed dlrectlon should be parallel to the Round Workplece Holder AS4 '' ./..'... . >. ' '. .'. . ..k;.,î(ï2-';i'1l'$A+%b/L.I%Lîîïî.),,,,,,'

,L,Lï, '.yv.yt.''t.J. ,..) '.,...) '.,.. ,,.. ...'.....t '..' . '.. .,..t. j).;) t. .. y . x;y . . . .... . jy 2yy.j j))g.;yj.jyX.' gg jj

jjqejjqlnqj. jtj. èty

'.. jyj y j .. . 2 .; .. . y : y . . . . . : j. z. jsside of the wheel , SKZA. However, any This is normally mounted on the swivel ,

, 1,)77... .. ' '

, tc'' . ' c..?è' fxkf7'xykvvjt);)') ;à (.èt.L'... .. . ,. , .. . . .;..

' îè'r'k;L -è4y j ... ' .. ', b .

t ' .. ....... fL.)y'û bk'2L3ï,1Ljï-' yyg!). 1ty) Lklàslbkî é è' .... è: ,. .. '

: ...: , . . . .. .- . . ' ?'ssmall error in the approach angle could base, s'Imilar to using the square workpiece ''.

' ' t . . . .. . ,.,., . fkb3L1.zhïy1bLLï1;jb.$;.L;î)ï.kï.'î'ï,LïL...L'.',.b,.

''c. . '. ): .'.'. '? .''...' 'k .. ' . .

'

..'....'...,..vv

'..'.1'n.t,t.(l ' . è. - . .. ' ' : j) :f) Llqjqkkl)t ?cy- s , syt)- ..;t.i'(î?Lb. : :. .... :. ... ï, . ...s .y,t, ..;,zè..î:.-...ï-. ..- ws :.. .-.: . ..C a u s e t h e pa r't to be ad d 1 t 1 o n a 1 I y g ro u n d o n h o I d e r

, a n d 1 s u s e d tv n 1 c a I I v f o r h o 1 d 1 n a ;, '.(t' ' . .

'' .' .. 27 . , ul ' 'ï''.''',11' ' #.î'q' t.:,.é,t.3,uf.'t.'...,t?.,.è'.. .' ' .... ..v'.,. ''' '' ' ' ' ''

. . . . . @ ' @ W ' 2 Q 4* . l 'V2'z ) J L%V6 V76 24.2 ' V . W '''' 'Wz'' Y.lts slde, SKZB. In vlew of thls, feed dlrection screwdrivers, a wheel dresser and round :

?j.103102 h

.j

i .

'

. . . j j ,

r = t=!=J=Z= - I

l jll ë' ! 1

. . ' ' .

Illdjh di 11 i ''-.--,-'', 4. 6 r,eaecessory f bending at ..x,, as shown, to improveh Ij ' ,.

' a ( (; jj jg j jg y jggg. used /or the serew '.Q. indexing on smaller t00th saws.

ï .>'#- This completes the minor assembliesdriver /s also used rgEg . - g1to hold t,e wheel - aI1 of which can be seen in Photo 8.

eresser. End mills and slot drills8! whilstmany items, typicallylathetools, screw( '

drivers, etca, can be shamened free hand withî this is almost impossible insome success

,' the case of end mills and slot drills. An

. ..t.y'..y 'C's '? ïï '< aCCOSSOW Crlzblix thOSO to bo Sharpened,

both on their end teeth and cutting edges, isx. '-'j'. 5 t:e subject for the next chapter.

7 ,q( d. j..

6 J..* 2 .%, . r , . oo t x :. : F 2 o))ètî .

x C n'' .6 'Y..- -C '-t)a N, x '

. . . . ko 5,5 xj- .>'j- ,>Jj-. ' OL - t--- - VY. -

' t y.y , . y 4 y 4 y yè. f SLIUING SAW SHARPENING

. thO holder, DO NOT be tempted to feed this absolute minimum, as it will reduce the ASSEM BLY AS5froo harld; OVOII fOr this Simple Operation it Width Of the wheel and the ref o re itsis Szfor to USe the fine feed, assisted by strength . RV hX. C.V

>J x ;>' x $ xthe fence, making multiple passes until the Slitting Saw Sharpening assembly AS5 # # à* *

A t'z. -' r'r- . t'n- -required blade width is achieved. This comprises the swivel base with a few --s-; ' . v - . . .-.

Sharpening a screw driver free hand simple pads (51 , 52 and 53) added. $. ' 7:1: . g E Fmay Soom Iike a Simple exercise but The method for sharpening slitti

ng saws h J s aar1XOr1O WhO haS tried it Will have should be clear f rom Photo 7. Do ' 1 I : 1110 F AFE 1FE COFFECT' h ' 71 AFFFCACF ASCLE 1C 1SEOxperionced the difficulty Of getting the two remember that the saw is fed by hand with

--$-a l jsides parallel. Photo 5 illustrates how a the swivel base held firmly againstthefence wORKPIECE APPROACH# ,-good result can be achieved, and simply, and the saw against the swivel base. Thei j..-j p'n ANGLE SK2With this accessoly The photograph also inward fine feed is used to control depth of

.- l y g ySNOWS a Centre pu nCh , wh ich wiI I be cut. W ith the Iarge teeth on the saw no stop g g 25diSCUSSOU Iater. is required. However, With an accurately HOLE SIZES

Other Wpical uses are wheel dressing, dressed wheel, saws with very small teeth : : :': A 6.2mm 1 OFF j j sI----------1 8 k, 5 oFF o Ea C v----------1 C)Photo 6, (note this still uses the fence and can be ground when a stop, fitted to the j --y

the SWiVeI base) and sharpening round fence, will be necessary to avoid the wheel I AATEIyIAL 25mm sû STEEL 250907 gg - I 1 2lathe/boring t0OIs. Note that, with the fence touching the adjacent t00th. In this case FIOLE s.2mm 25 gEE?mounted at right angles to that in the photo the Ieft to right feed would be used to 1 5 CUASTIT/ 1 0FF

jZRd thO WhOCI drOSSOr ttlrning through 90 accurately Set the stop position. The bush 25 'dOQrCCS OR thC SWiVPI basoj the right hand On which the saw rotates is drilled off centre oou a om woowojmor unI nwn LOCKING LEVER EXTENSION 1

ide Of the wheel can be dressed. However, to provide adjustment for differing saw GuhAmnu H h'nn' 'uh#** ''v-*e'*-ns sx, )dressing the side should be kept to an diameters. The Ieaf spring may require 32 y

h - .4 1c51 0 )

, 'F

q'I. i

' ' 11.1 IIi wwj..v l I 1 l 1 I I i 1..1 :. uzw v- ' - . . .- '. w.wm pmxzm m za- - . . . ... v . % -

106

Chapter 10

The End M ill

Sharpening Fixture 1

We now come to an End Mill Sharpeningfixture, AS6 by far the most complex of theaccessories. This enables both the end andside cutting edges to be sharpened but canalso be used where a round workpieceneeds to be rotated, typically a centrepunch.

The accessories thus far are quitesimple as can was seen in Photo 8 Chapter9; they will though dramatically improveresults compared to totally free handgrinding. The item shown in AS6 is thoughquite different with some comparativelycomplex parts to be made. It will thoughmake it possible to sharpen end mills, atask that is impossible free hand.Spindle (62)Cut a Iength of 30mm diameter, 105mmIong. Mount in the three-jaw chucksupporting the outer end with a steady.Face, drill and tap M8 15mm deep. Removeand firmly fit a short hexagon head screwin the tapped hole, and grip this in the three-jaw again supporting the outer end with a

steady. Face then centre drill the end,remove steady and support with thetailstock centre. Turn the 100mm Iength to24mm diameter, Ieaving the flange at thetailstock end. Check before reaching the24mm diameter that the result is parallel.This is essential so that the spindle slidesin its bearings without stiffness or shake. Asmall error can be eliminated by careful useof very fine emery c10th.

W hiIst still supported by the tailstockcentre, fit and set the fixed steady at theKilstock end. Remove the centre, settop slideto 5 degrees, machine the bore and leavethe top slide at this angle for making thecollets. Drill 8mm to a depth thatjust contactsthe end of the screw. Remove from chuckand screw from spindle and return spindle tochuck, now holding it on the 24mm diameter,(suitably protected), drill through 8.2mm.Collets (80)As these are used when sharpening thecutting edges of an end mill, concentricityis essential, as it is also with the 24mm

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, and bore 24mm diameter 18mm deep, use THls &SsEk8Lï c&N7 4.: , ' . kjjiggj roy jjot-gj NG -..... .......... ,.---..s. I . the spindle as a gauge. Face end, turn AESO 8E J -------------.- ------ , ,1 .

. t &. x ., q.. OTFIEy ITEVS uslqc ITE: 8! -. , czz <..- : ,l ' :) . 30mm diameter by 13mm long. Remove Ty?1cALL'f A SENTEE PUNSFI ='VXD O Izx.q --------------- --rar.- '-.....z'' , ; : . .' o. ''f% ';!y. ' Faq cyl NIIING, u-- -- -- --- - - - - -- - - ..xi . ,,g. ,$,,;...yj.j from the chuck, reverse, refit, make second. . .- . .

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'î with the jaws placed normally it should be'' acceptable to part the two bearings on the END MILL SHARPENING ASSEM BLY AS6Iathe. However if you are using the reverse

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jaws in the three-jaw I would be hesitant to' .. . . ,. ...s .'' recommend this due to their limited lengtht+04 <' . w.. s.)?a?.. . o. tz,? .

... m' ' pjy '' tr,. . v of grip. In this case remove f rom the Iathe, , &. . ) .y ()t .. .. .k jjs jathe mandrel bore from the. ' z- LL ' . . and saW in half, return and face sawn ends diameter. Place a short length of 6mm rod through t' ' ' *1b,/'/% 71) to give the 16mm Iength. through the two holes to align them and changewheel end, to make the short Iength

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5. Setting up the bearing supports formachining thefr base.

with the lathe stationary bring the tip of thetool up to the faceplate su/ace at someavailable point.Adjust the saddle stop, alsousing the top slide to make the finaladjustment. Make a gap of 0.05mm toensure the tool will not foul with thefaceplate. If you are not happy working thisclose to your faceplate when blind, youcould add a thin piece of card between thepart and the faceplate to give more Ieeway.Bore to a diameter about 0.05mm largerthan the bearing outer diameter, Photo 4.If you do not have a 14mm drill you will alsoneed to bore the 14mm hole in part 64. Fitbearings using two part resin adhesive.

To ensure the spindle rotates andslides freely without shake it is essentialthat both bearings be at the same height,the following ensures this.

Mount the two bearings on an angleplate using the spindleto align the bearings.

Do this with the angle plate mounted in thevice as in Photo sthis is much easier thanperforming the task with the angle platesudace vedical. This process may seem asimple, risk free task though there is onepoint that must be observed. The fixings inthe base of the two pads must be alignedcorrectly when mounting the parts on theangle plate, or the bearings will not be inIine when mounted to the base (70). Notethat the right hand hole B in part (63) is15mm from the edge whilst the lefbhandhole in part (64) is 20mm. This means thatthe pitch between them must be accuratelyset to the difference of 5mm. W ith this done,the bearings should easlly align, with a littiehelp from the clearance in the fixing holes.Machine the base of the bearing suppods,Photo 6.Indexing Collars (61)Turn one or more collars as required. Makea stub mandrel for mounting the collar onthe three-jaw chuck and mount on thedividing head for milling the ratchet teeth.Photo 7 shows a simple method of

Above Right: 7. Asimple, butreasonably

accurate, >ay ofpositioning a

cutter relative to around workpiece,

in this case anindexing collat

8. Machining theteeth on an

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's teeth. Clip the rule onto securely held. As mentioned in a previous (x) =-! j 2 ' 1..-1 jmilling the ratchetthe square at the required dimension and chapter do not Iose sight of the fact that jjgkg SIEEplace the square against the part being quite often another pad being made may j g A 4mm 2mm ZEEF, FOSITIOF ON ASSEH8LYmachined and the cutter against the end be able to hold a pad that would otherwise < c A

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W hiIst still mounted on the dividing s v, RATEFIAL 0.5mm SFIEET STEEL) ,:kàq.-- ). r V' . . ;) 'L;.head

, machine the recess for the screw ' ,, ,g:k . ', .. Q j A j y j y y 1 o r r Qo g((j o o T H R E s T $ u p p o R Thead, Photo 9. Marking out for drilling the ' T

, s-yïhi tapped hole can be a Iittle tricky but making t CLAMP RING 75, Ihih yooTH REST 73! ; I t.' a 6mm diameter bush, and using this as a )IIIj- - . -. : 1111. drill bush, makes the process simple, PhotoI I ! I : p

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10. Drill, tap and slot collar. .. 1 5.. . ..;( .. . js?l tisi

Remai n i n g pads ' t '; )) :L, 1 () C%A I 00. .g L u 2 . t syy . .? .The remaining parts are aII relatively simple

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out (not an easy operation) the position t tsjy'lfor t,e samping screw. ''''?''' TOOTH REST SUPPORT 72

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COLLET CLOSING WASHER 77 12mm ZIAMETEF STEEL 2J()kû7

5mm ZIAMETEF STEEL 259:071----1 O ûg,h,ITï oFFkkz t-'zt2

kATECIIL SPINDLE LOCKING LEVER12mm ZIAHEIEi STEEL 2J0kû7 69

INDEXARMOLASTITt OFFSUPPORTW ASHER 71

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holding item 68 easy.The 7-00th Rest Support (72) whilst

similar, is Ionger, and can b:tter be heldusing the method illustrated by Photo's 14and 15, Chapter 7.

The hole in item (78) is drilled onassembly using the spindle (62) as a guide.The purpose of this is, with a small barthrough the two items, to enable the screw1.12 to be tightened on assembly.

Having completed the assembly,Photo 12, there only remains a need foran explanation as to how this is used tosharpen end mills and slot drills. This,together with a few other operations, willbe covered in the next chapter.

12. The finished accessory togethercollets for various cuttershanksizes anda 6 Gay indexing collar.

11. The rear bearing support makes anexcellent fixture for holding the indexarm support while machining the flat.

klJE8làL 7bmm ï 6mm SIEEL 08(415

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C hapter 11

Using the End M ill

Sharpening Fixture

This chapter provides instruction for usingthe End Mill Sharpening Fixture detailed inthe Iast chapter.

of the wheel. Grinding on the face willthough only be used where a very narrowIand is being ground, typically, the end teethof an end mill. As a result, only the angle atthe point where grinding takes place is ofimportance, Provisionally set up theaccessory with the device being ground andmeasure the distance above the table thatgrinding will take place. Mark the requiredgauge at this height and use it to set thetable's angle such that gauge and wheeltouch at this point, as shown in SK3.

Sharpening End Mills and SlotdrillsEnd teethFit the end mill accessory with the fourtoothindexing collar ensuring that there is no endfloat and adjust the bearings so that thespindle rotates freely but without shake.Fit the end mill making sure that the endteeth are horizontal and vertical when the

Setting the anglesA necessary requirement for using thegrinding rest, is to be able to reasonablyaccurately set 1he angie between 1he rest'stable and the face and side of the grindingwheel. Using the protractor from acombination set or some other engineer'sprotractor may seem Iike the device to useto measure the angle but their bulky naturewill make them very inconvenient in practice.To overcome this, make some gauges, asper SK1 and as seen in Photo 1.

To set the angle relative to the side ofthe wheel, bring the table close to the faceof the wheel and check the angie as perSK2. Setting the angle relative to the faceof the wheel is more complex as the angleis continually varying round the curvature

121

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C'ANTIIY 1 OFF EACH IIIAkETEF IEEIILIIIkEZ G0O0 QIALITY CA8Zindex collar is Iocated againstthe index arm using the fine feed until the first sparks Oq AkgklNluk 1 - 2mm TFIICr

. and Iock the spindle. appear. Move the end mill to the right andE set the end mill accessory on the place on a very small cut, about half of one ROUHD W ORKPIECE ylr.y

. . ûUANj swivel base to an angle of approximately 2 division. Now slowly feed the end mill to HOLDER 81 1 oFF EACFI ANGLE FEQUIREZ

degrees to ensure that the end teeth will the Ieft until the stop is reached, ensuring' be slightly concave when ground. that the swivel base is being held firmly ANGLE GAUGES SK1j ' Fit the fence to the table with the stop against the fence and the tabletop during

screw at the Ieft-hand end. Set the table at the operation. Remove assembly from the CFINOISG WFIEEL qINZIhG AHEEL'., 'k 90 degrees to the side of the wheel and 5 ' , - z. ' %:! ! # . TEkFOIkAF/ . x .

. to 6 degrees relative to its face at the point , , , , w' inding will take place, see sxa. .,t...

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w ith the swivel base against the fence and ... '-' '-b

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iae stop, and the end mill veryclose to tiae tt' . ..- . t,' . ,;

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, adj u St the I eft ri g ht ? , .. ., . 't L'. ' 7'' 1A8 LE.. .

..y .. y. ssyzyy y ). yy y jj y j j yyyy yy-y j yy y jsyy1, traverse SUCh that, when g ri nding , the ''' ' ' . . . .. . .. '',)'1 : .

.. . ?j.t; jjij . I wheel will nottouchthe adjacentendtooth, AT A8lci?- 7-Rlsrl - .-' ehoto 2. Err on the side of caution, fine SK2 To-llx-E--..(Vsf, ,

, j . ' , . .I ! adjustment is carried out once grinding' : - - x. i takes place. At this stage the adjustments ,

are made with the grinder at rest. Do not1 1 1 4$'. forget to set on the angle of a degree or , ,

table, checkto see if the whole length of the position and grind the remaining three end .1E '; r' two using the rest's swivel facility and make ',''- '' , end t00th has been ground and the adjacent teeth. Inspect the result and if necessary, i!

'!. sure that aII adjustments are firmly Iocked. end t00th not touched. Make adjustments slightly advance feed and regrind aIl fouri isfactory result is ' 'ë Now with the grinder runninc and the to the Ieft right traverse if necessay teeth, reneat until a sat'

' held firmly against 'fhe fence Without making further adjustments, rotate achieve 'd.Adjust inteed by no more that half; 1 swivel basej ,1) and stop, vew slowly advance the end mill 2. sharpening an end mills ene teeth. the end mill ensuring that it is Iocked at each a division at each grinding.4

' I I' 122 123

3. sharpening an end m ills cuttingedges.

lf the width of the ground surface is greaterthan 1 .5mm then the secondary clearanceshould be ground. To do this repeat theabove sequence but with the angle set at10 to 12 degrees. Do this until the width ofthe primary clearance (that first ground) isno more than lmm. This will ensure thatthe primary clearance can be ground a fewtimes without the need to grind thesecondary clearance.

In most cases sharpening the endteeth only will produce a markedimprovement in the cutter's pe#ormanceand will be aII that is necessary. However,where the cutting edges are well worn,sharpening these will be beneficial. Thiswill change the outer diameter and willprobably be undesirable in the case of aslot drill. The outer diameter of an end millis rarely crucial and can be sharpened on

its cutting edges without causing aproblem.

CuleredgesSwing the index arm away from the indexcollar, which should also be Ioosened andmoved towards the end of the spindle. Fixthe collar at a position that will enable thespindle to move lengthwise, by an amountapproximately 5mm greater than the Iengthof the end mill's cutting edges. The spindlemust slide through the bearings easily butw i t h o ut a n y s h ake . A n esse n ti a Irequirement for this to be achieved is forthe spindle to be thoroughly cleaned of aIIgrinding dust. Do not be tempted toIubricate the assembly, as the oiI will onlyhold onto any grinding dust, which falls onthe spindle. Fit the t00th rest suppod tosupport the end mill at its outer end andadjust the height so that the end teeth arehorizontal. This can aI1 be done with theaccessory away from the grinding rest.

Set the table at an angle of 85 degreesrelative to the Ieft side of the grinding wheel.Fit the fence, with stop screw, in the righthand slot and rotate the table so that thefence is at an angle of about 1 degree tothe side of the grinding wheel. Fit also theclamp screw assembly.

Fit the end mill accessory as shown inPhoto 3 making sure thatthere is clearancebetween cutter and wheel. Make sure aIIadjustments are tightened and that thecutter's edge is against cutter rest, and thenstart the grinder. Using the Ieft to right finefeed, feed the table until the first sparksappear.

W hen I first attempted to carry out thisoperation I started at the outer end of theend mill, sharpening towards the shankend, and found it almost impossible to feed

124

the end mill satisfactorily. After manyattempts I began to feel that I was onto aIooser. Alterations to the end of the t00threst (73) had Iittle or no effect. Withoutreasoning why, I decided to attempt to startfrom the shank end and work towards theouter end, the difference was immense.W hat was beginning to Iook an impossibletask had now become a task that could becarried out with ease. W hy this is I am notsure, though in the first case the mill rotateswith the wheel and the operator has to keepthe cutter against the rest as well as feed italong the Iength. In the second it rotatesagainst the wheel which keeps the cutteragainst the rest and the operator needs onlyto make the feed.

Having successfully ground the firstedge rotate the spindle anti-clockwise andgrind the second followed by the third andfoudh edges. However any attempt to turnthe spindle whilst in the position for grindingwill cause the rest to be forced into the

wheel and ground away. The assemblymust therefore be moved away from thewheel but do not do this using the fine feedas back Iash, etc., may make it difficult toget back to the same position. This willresult in cutter edges being at difleringdiameters. Instead, Ioosen the clampscrew, move cutter assembly from thewheel, rotate cutter, replace and re-tightenclamp screw. The fence is fitted with thestop screw to ensure that the assemblyreturns exactly to the same position foreach cutting edge. Aftercompleting the fouredges, inspect the result and, if consideredappropriate, repeat the procedure takinganother Iight cut to each cutting edge, nomore than half a division, probably Iess.

If this results in a ground width ofgreater than 1.5mm set the angle to 10degrees and grind the secondary clearanceto reduce the land to no more than lmm.

For me, having staded the exercise withwhat seemed insurmountable problems, the

125

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j r ).!' ' ,.j 'h!k' Iity of the finished task was etremely completed. It is wodh highlighting that this W hiIst not evident initially it will be when new cutter, or even the used cutter if theI . qua. I ! I g

satisfying. W hiIst not appearing up to the is one application where the angle on the the cutting edge is honed on the flat stone. wear is not excessive, and try to replicatestandard of a new ctltter the difference was item being ground can be set using the For quality woodwork, both primary and these. Frequently articles, hobby orlnot that great. In terms of cutting ability the swivel facility of the grinding rest itself. This secondary angles should be honed the industrial, on the subject are far fromdifference would be hard to tell. is evident from Photo 5 Chapter 9 which initial concave nature of the secondary precise with good reason. The perfect angle

clearly shows that a first rate job can be angle will be removed. Keeping the is so dependant on many factors, such asCentre Punch achieved. approach angle as small as possible, material being machined, but fodunately

The end mill accessory can also be used without it being negative, will of course Iimit quite wide deviations from the perfect willwhen sharpening other round tooling, a Many Other uses the effect. still give very good results. There iscentre punch being a typical case. I The tasks possible will not stop at those This now completes the projects therefore no need to be unduly concernedconsidered that such situations might already described, others surfacing with included to provide a wide and sizeable regarding angles', acutterwith a sharp edgesurface overtime, many being of a different time. These using new accessories for the milling involvement. However, having butwith an angle which deviates a littlefromdiameter. The eflort of making a collet for job in hand or ones already made. One f inished with an emphasis on tool the perfect will still cut infinitely better thaneach one as the need arises would such situation is seen in Photo 5. The sharpening I am very briefly including in the a cutler with the perfect angle but a bluntprobably be a deterrent from using the set- swivel base together with half of the round final chapterdetails of how to adapt a basic cutting edge.up. Because of this I chose to use a simple workpiece holder is being used to grind the off-hand bench grinderforfltting cup wheelsadapter (Round Workpiece Holder 81), as secondary angle of woodworking chisel. and saucer wheels. This does not involve SAFETYconcentricity would often not be that The approach angle of adegree ortwo, any milling activity but very nicely l make no apologies foronce more bringingimportant. set by the rest's swivelling facility, will result completes the equipmentfortool and cutter up the question of safe working with this

Photo 4 Iargely shows aII that is in a concave surface, greater than on grinding. grinding rest. The rest, having many moreneeded in terms of how the task is previoustasks due to the width of the chisel. WhiIst I have covered the mechanics adjustments than a conventional, off-hand

of tool and cutter grinding I have included grinder rest and its method of use being so., .. .. .. .. . . ,.. . very Iittle regarding characteristics of the different, the safety considerations are also

t! ' b ) cutters edges, angle, width, etc. This is a different and more importantly, greater. Do) : ' ,'' y.''

. hby,:. vast subject and is more than can be therefore read and reread the safetyI yj, I . . ' . . . ' ..L.. ' .@y .' ) f y '.C''.: Q'iJj4y LjiLi?/ ( 747'7 211 .. . . .. . g ' .i : I Lq)' L' . , > k.))?),.l j ' y ,)y covered as part Of this book. A good stading comments, which were included at thei '' ..r). .; . .. . y'..syyy .).. . . ..s.,. ,, j oj

japter g.l'/ 'k'''' ' t.u ',')j :';A ''$fj.)......... ...ètv, t . . . ..,. .,j' , .>.

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yyy.(( The subject of this chapter requires no only minimal need of truing up. I have

! I I ,)jL?' !' qà.(tt(..t( ' ' '' r't)jr);tjgjjjjtj)y.. . . ..1 r y,; ,

#.,#.t .Lv, . . milling machine activity and because of this included dimensioned, part drawings4 1.2:.: -s't . ' ' f is not strictly appropriate to the purpose of though these will need to be checked forIi rI' ttstt-v-tzttj' , .- ï . ii l am including it because of the your own situation. The dimensions suit a1. '. yvlva-tt). v :,.sx.- V '.. this book.lI2 7?fR* *'$'î . C *,)y , ' . ? tion with the content of the last three 12mm spindle and a wheel hole size of. .1 :y)?#ja n'ïq't k . . ,)) ,'(y. o(. . .,. . . 4:) (:2/ 1,1 13 1E2) 4:2:( n)(

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.'tt#))'' -:? . L. p? ?7 .). ,.) . )'. ' .' -:z :u) kspùt kè: ws'g-es. . --:,v /-). ) 'tt M:-$' -#)'jy;z,tt.t ?-?,?-'-.i/c '%'- 7 4:) I-1 IEIL I:)p 1t dEzh 1- t!l . :E!1 :EE! I-lrll I-lrl .' '*1 i'''' **î't$*ï.' Having put to use the grinding rest The step in the spindle, against which?. îkttàîît, /t. :. . ,-. .' i xîtt-lsï. . x-t- ?-t- r- .. . .'

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. )?. ,,. .. . ')...., . . ' . ,,?.:, .,,..c).,,,. ,x.,..,.-z,- . described in the previous chapters I was the wheel flange adjoins, was not well made'' . .1ï)l . . . . s .' h ' ' +.. .'.L'oL )'.' .. . )'..-.. .'' ''. . . '' . '' ..,. ' toottt . mo re than de I ig hted with the resu Its . and more impodant only 1 mm high so wasj I I :t 4) yp yà j j . . . . . . . . . . y) gy wo .,q .l ' . 1 ' 1tl '.,v' jyt ;, ' )?) ê.l)s . y ttk. l.àfLjjb; ''' . . ' However, using a standard Off-hand grinder, improved by the addition of the Spindle'; j. so

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.. . x-qyywyy.. . . . . .).),k, wyyyy j soon became aware that having both cup Bush (1 )

. I did not though consider thisl ' . '))L.LL . . .'ajtyt .. - èîr':' ' 1:' *' . d heels available would improve alone was adequate and machined the'1 l I y y :. an Saucer W'E ' ' t Vttgy .. ooyjyy. . ,? its use still fudher. This is not surprising, bush's face, wh ilst i n situ , usi ng the' ! 11 )? ' (

.. . . .. . . : y .î. /''..r' ?-', '. . o, ,-,,'';t,.,,. . .

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, as such wheels are standard practice for grinder's own motor for power. The spindle

11 '-.. ,?.'z'f''2 'k., '*'''' :?'.-.k,,.t.yyy). . .. - .--' ''. ' '.'t, serious tool and cuqer grinding. l therefore was also 1/2in diameter and l reduced this;

? 7/ i ' .v, ? % 'ih,3.. 'c obtained a small (125mm) off hand grinder to 12mm to ensure it ran true and both ends. . ).jyy .. (j' .jyjr u s! . .tt.k.tyys;:..ky:jj y,yr,x'-

.- i . t't, ,t?y:y . : .. c y b..t . . ...' ij .,ï /t. ,. ' .''t..,. , . which I converted to take the cup and were the same size. The following is the' ' X .. 1 '''I

!1 .,r .c. . ''> . '..'j %-f?z,?s, ,, . ...-.i , saucer wheels. suggested sequence to adopt.I 2 . '' ' . î.î '): t:t . .:. ! iI1 ' ,,, lgn',tljli..y ) ... jj) . Normal practice when using these,!j I 7

. rlle side arms peo /t , > to > move , ' : ;o# f/le bast aa jpy) y wjlich have Iarger centre holes, is to fit them Grinding m achine Spindlei. jj . '; 2 '' ; 2 . . ' .).j .),j ))j t y yuitt )jL)))j):),j) j j. ).. . . fjfjj g sjyyy yy y yy j. ,y..y y. .jy .yj '11 iI! but tl'e Feêtlral web o; angle preyenar ' , y? nt in t:e oc yjjyqjj)jj. ..

.,:yy, wjth permanent adaptors. These enable Make both Spindle Bushes ( 1 ). Cut a piecer 11 ' '.. ::. a',I!ir ,,,:.1.:,., L'ëâ'à''b j,,p . .

. ' '' ''. ' '. . :t' f?'5f.:#'' 3. ' ' .11% /@ .

' '' ' '' -'****'***''* V heels to be interchanged quickly and with of tube to Iength. Set up grinder on lathe) o )) t w; ':

; iI ' .1 ' 128 129' .

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I 2 . Alternatively, if the grinder has a two screw . cr wy .'- vy-' mounting, then a Iength of steel of suitable ry,.y.': ',%.' k .- +..-' . . .- ,. -, m...-.'''. ','--:'r'xy . ?-i.n''.c ... k. u. ' . t> C1 J 4,.. . . width could be tapped to take two fixing ''' . . wku... .. .. .>>.,w . i!

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'' ' screws as illustrated in SK1 or, if four hole ' - . è?)) ' ' 4) C,i l-I 1 3 . ' 'y$, s. . yyy )(g ,. . t. . , f i xi n 4:1 , with cl a m p ba rs as i n S K2 . l f th e 1 at h e . a, ityyzysxyyy. )h s. ,t,, ss. u ., . : . . yy. ';b.% '''' ' . .

. ':# . ' ''-'. vjb. ;. has a Vee bed format then probably these ' '',?.$ ).'1k ttt? .l-1 :E! . . ....... ...

. 'tt,d -,,b, .. )) .-,yy.. . t' '-' ... . .. ''''' .(, hj ypyyy y . methods Could be adopted usi ng some ' . : ..' 4t'z. .' .. .. , b't ) . v 7 . . , . .

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' .. . c t .' . ' '' k$> Y.:.t .. : C ' s. 'sux ossible damage to the Slide Ways Some ' 7 '. î'n, . àL' ) . . v . '' (L . ?) t '..Ji. . r:l jz. j;è''Y

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'' ') ' /'.' ,,(. f- . . t th i n ca rd packi n g wi I I e I i m i n ate th e ..

'. lg yy 2. y . y . j;1 t t . . jy . .

. . ,. possibility. Having said that the mounting . .- '

r . ) . . ..g . '

,'-7 will not be called upon to withstand heavy .. . : ''

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. .. j., joads do nOt bo Com/lacont. DO giVO thO t ' 12 1;. y .. % spindle of the grinder a good tug to check

. ystl?. ...;..' adequacy of mounting prior to machining. , . j,1. Machining the face of the addedbush w hen mounted the spindle should run à' ' .L'

powered by its own molor, the spindle parallel to the Iathe's axis. Using a surface .>as machlned in a s/mflar manner. gauge, with the two pins Iowered and

J F1 1 E/ISTING FLASCE ,bed (see Iater comments) and machine the against the Iathe s bed, check the position .82 k4 k 1 2 SOCrET .,.77first end to 12mm diameter. W hiIst the Of the spindle at both ends as seen in Photot CA8 SCCEA j)e

! grinder is on the Iathe, fit first bush using 2. W hen setting up for machining t' two part resin adhesive, holding this in second end, allowance must be made for: i . '' .' CUP W HEEL FLANGE place using the piece of tube and the the different spindle diameters, use feelerI (L.t;. . .. .l 1 spindle nut and Ieave for a few hours. gauges at one end to compensate for the . ;i. . ASSEMBLY semove nut and tube and Iightly machine . difference.. kl the bush's face, photo 1. Remove grinder, # . .''!i'. turn round, refit and repeat sequence on lnner and Outer Flanges (2 and 3) r, . ïs' '..î'. :. .. .

..1. ' the second end making sure that both ends The essential requirement for these is for +''-' . , ''''' (4, Ct Li,z!1 :.j ..,. face which contacts the . .

4.t.zp:t''..?' ,,..

)/.'lt'l'1' ''. . - # ----. are the same diameter. t; their bore, the. k . 'j-- -1- .. s heel and that which Iocates against the -'''.-..è'u..- ,... . .'':t',. ,.)t:)è).'iI . . i : c.u ' ; w , ., y

y ())1 !1 'X - X : Mounting the Grinder ' spindle bush, to be true and parallel and C.,j ! L, I %xx .''

- - --y j w - - - Mou nti ng the g ri nde r Wi I I depend both On th e 32 m m d i a m ete r co nce nt ric w ith th e . uytyyjyy ,. y y,ymy.y.. .

.1 , the type of lathe bed and the form the bore. '' t,,

' ' 6 rinder base takes, as a result precise Cut four pieces of 60mm diameter, ..''r ' ' .c-'y -' . .11). ! g -tl,. . -. qv. .:. .;

'

1 0 details cannot be given. On the plus side, place in the three-jaw and face one side of .'%--.,.jb'' ')r? -))?x. , ..

! i - jjjt-. -, .only very light cuts will be taken so the each. Then reverse, making sure that the k o'! kATEiIAL ityof the mounting will notbe severely 21 ' -'secur25mm CIAkETEF STEEL 230k07 tested. Because of this, no materwhat form Above Right: 2. Setlfng up the grlnder Cl

the bed takes, adequately mounting the on the lathe bed for machlnlng thei1A$1ITï L 0FF rindershould not present a problem

. If the splndleandaddedbush. Right: 3.A stub '7t'7 .g, . .

Lkbed ways are rectangular then four small mandrel fs used for holdlng the flanges ' . , ,SPINDLE BUSH 1 toolmaker's clamps make an ideal method

. for machlnlng. $t

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5 4 rNe dividing ,l y y . .. . . .,. . . ,s,. . .head described in ' ' ' ' '''' '' ' ''' '! . y ..

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5 , ( t.' chapter 7, ùy :;,L.t. . j j t , y . . . j . 2 , .. k . ..) ,. : k t 9% 7 . . t A) g . ( . c t:)4. 7. 4y x . . . .mounted on the '' '' j.. .. .

-. .tlathes cross slide r) '.y),jl cxa j for marking out the .; t

' - ' - - - - -G- three holes fn the . . ''1 jj .y qqgjg .' flanges. .'.>ttY .

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QUANTITY 2 0FFalready machined face sits cleanly on the to 12.5mm as perthe drawing. Drill, tap andchucklaws. Face the second side to 10 and counter bore as required. Using a centre8mm thick, also bore each to a Iittle under drill and the dividing head described in+ 812mm. It is essential that the hole in aII four Chapter 7 mounted on the lathes cross

! : .5 flanges finish up the same size. To achieve slide, position the holes as shown in Photothis, continue opening up the fourth flange 4. For this arrangement I added anj

----------- to 12mm diameter and Ieave the boring tool additional hole in the body of the dividingxeee Yx

.. -- -- x set at this diameter. Replace each flange head for easy fixing, see the single studi /- 7-...:.-.- ---- h in turn and open up to 12mm at one pass. fixing visible in the photograph.--i- 7 - . -

,' ,' -

, L Note tlnat the outer flange is opened up to@ st .+ - .?-. - - ) l 12.smm at a Iater stage. The wheels'.c' % -!-' . , , , ,

-- w! ', ' o ' ,' Make a 12mm stub Mandrel using a whilst not readily available from mostX ''2 '' -- .- .''

piece of material at Ieast zsmm diameter. supplierstothe homeworkshop, the wheelsc-a c'a , ---- --

-.- Face and tapthe end M8then turn a 12mm required are widely used in industry andM -------- stub 7

.smm Iong. The 12mm diametermust should therefore be available from your

be a close fit in the flange's holes. Do not Iocal (or maybe not so Iocal in remote! - FIOLE 5mm C/8 9mm 4.5mm IIEEF remove mandrel from the chuck until aI1 areas) abrasives supplier.Thefollowing are5flanges have been machined. those that l used though your supplier may

! MAIEFIAL Fit the first flange and machine to the offersomething different, albeitonlyslightly:. Cgmm gIAMETEq STEEL 259:c7. azmm and smm dimensions, make alsothe Taper cup wheel, Type 11, 125mm outerOUTER FLANGE 3 depth with a stated0.5mm deep recess, Photo 3. Repeat for diameter, 40mm outerQCJAMIIIY 2 OFF tjle remaining flanges. Return the two outer hole size of 31.75mm, grade WA60 KVI. 1j

Flanges (3) to the chuck and open up bore Saucer wheel, Type 12, 125mm outer

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5. The lwo heels are also Iikely to be much more.y. è .. W

2 2 : j gjjpàjpg wheelg t j v o a yj < m a y j) e m o r O d i f j i C U l t t Oj i7 ) t exg/rl Sy;î y. .(. . , . , ,t,., ,k ( and the flanges obtai n .. :' . : ut . ... ,7 . . ). L . .)qj( .p .'ï:' ' '7:...;?...;.7yyz2yg.(J..:y.'2 (tjttjj. . . . . jj:jr;j jyw kjgj jgijrkjjjjjgjj jjjpg jj.jjj jgjj .. (jjjt)'

. .. :?j )i7.. . . . '' :. ..t . . . 2 j . .t'

.... ..,.,,.vL.,,,,..,;, .,ysy .. , .'.)..j) . , ... . ....,. large hole in the Mountlng the wheels 1 Jt.t ps :, . yyx yy jg .$ ( y ajleejs opjo a ' y.j x tjj e jjan ges to the wh eels e ns U ri ng th atj'î lk y' ,yk.è/t.:./jf.'. ','.l.'

?ytkyyj . lt .. ) .,

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' ) Yn'qqjlkq '''..?'' L;g%q., -ë'*')u vc j;, . .. .. uvs..... .,..,.

.' smaller spindle . tjqe supplied paper disks, known as blotters, F1 1*Xù,..L;;.. . ... . .;.-.-t r tjjjsftj. .. .. . . C ... ..... .... .. . s' '' ' ... ..' . . . : yy:):, fj .y. Ly. . .. . . diameteK Se/o.;.h;..%;).(I'.,'î 'j ;(,j?k- '...,st. . . .. are used. MeW Iightly tighten each screw in h1 J%j

xhjîjtjlhlhkv. ''',,.,% .,. .. . 6. The rest and turn then gradually increase the tightness'!lk )', :.' éé#.. ' ' '- . - ... . .. ' . ' ' -;grinder mounted j each screw

, again in turn. They shouldoOn a PurPose be tightened sufficiently to securely hold themade base. For bjy together without movement

,assem. ?. safety a wheel is rtainly not as tight as would be done with

.ï ce.

mounted only at tal to metal assembly. Over tighteninga me

the end in use. must be avoided! Then, using one of the

flanges supplied with the grinder moun! thediameter, 13mm outer depth with a stated published in this chapter show the more bjy onto the spindle as shown in theassemhole size of 31.75mm, grade WA60 KVI. appropriate DIN ISO 525 shapes that are bly drawings

. Again do not overassemBoth stated a hole size of 31 .75mm but both available. .tighten, Just sufficient to ensure reliablemeasured 32mm). If you adapt a 15Omm grinder there tation of the wheel

. Photo 5 shows theroAs an alternative to the taper cup (Type 11) is no need to increase the diameters, two wheels

, one already fitted with itsa straight-sided cup could be considered, as both sizes will run at the same jlanges. 8 1 EïlSTl$C FLANCEthis would be a Type 6. The outlines Speed, around 2950rpm . The Iarger rI! k4 j 8 SOC4ET

'*%.Lx)%%' Vt'ltst4'',ytl'tï'x $îî ','?' '/j??)'@/)$,ëii))ît/l;:t$t:' t.' ' . M OU nti ng the g ri n der C l F S C i 1%

'YxWtvtqvv%vlltyywo.' ylllilt( y.4t':'/.)>)v4,)'?t)%). 'qkybgy 80th g ri nde r an d rest n eed to be m o u nted- ' -'7:77' . V, ... kqlx t,ûêpl . -- t . )),v;.). yyy: jjyyytjyjf.ys xjyh. ytt. Ly,.y,yy) ):q:))j;Lj)L ,:yàty:y' j)L.

1l(Lb)(kLL(. xllsygjjtyjysyjyyytllgj-yjjyt t>.-- ' - '

... )t>k- .) L,..;) y. L''o.2.:#'-).='vt.jA)4:4k-< on the same rigid base. Any flexibility willYbihLbbkh'y.*. oiw'ekok'ul' ;yyçï$1yL<L''ty.z2.u,yù;t,. cause problems with f i n ish and accu racy, SAU C E R H E E L F LA N G E. 2 L

,;(. y,t,.vx-v yvybj<vbvt .y4) (j mayue safe working. For this use ASSEMBLYhk 4ts,. x s. t tt sx ). yy a n...... v z,y,y s , yys y

.o... .yy 0..,.,. . zcîp s t t'Acsoxts-x. , g. , tq-sy. k . -. . .t t'xk X.x >*. : Melamine faced chipboard using two

. t' ' .î...g.... .c. ...,'#:'xu. boards Iaminated fOr extra rigidity. These fOr Cutter grinder spindles to be reversing.7wt : , yt.. .* Vs ' * ZrO hcld togothor Usirli WOOd SCrOWS f rOm This Catlsed diSCUSSiON On the advisabilitylî#.?J à,

. ,' below at the four corners, and with the of this when using a single central nut for' grinder's and rest's fixing screws also fixing the wheel as it may tend to come1

t '.. ' . . ' ''.. ..t.a....c ... .....cz...: :s., 'x...y...,..... ....p,..... ..,... helping. TO cope with the fixing screws and Ioose. In this arrangement there will be noèq.i? . . .. .. 7 :. ? : yjw . .... . .. . .. .. . . . . y. . . . : . . t ) ...yy)jy- . j y.j jrjj j jggj :gjt h . .k . js jjjaj would prqoct Ol1 thc Urldo rsido

j Mroblom RS , i 11 OPOCt, WO havo tW0 SP7: jj.) . . . . f'cy r-l t-l

l'' .% è' % 4.r''.). jjj s etj g os a re f i n ishod With Stri PS Of their direction Of rotation differing f rOm endj ' y .yyu ..') ) . . . :: t. ,.?.. :. v, .. . . ' ?lc. b,: k:7 .i...tî , ) 7 jjt. . y ... Tq.()j)J(j g ) . . j.j j jjj jkt tjjj y.j jgj',; '. ' softwood, these, being wider than the to end. As a result the spindle as

))ï. 4jy,. îj(J i? thickness Of the tWO boards, raise the right hand threads to cope safely with thisî y. 7). j: Ly) '' tt assembly off the work surface. situation.? . . 47. àsxy . . .i 6.?:.c. y 4. g,/ .* '''* '*i Direction of rotation Mounting the Rest. .. . . , ' '@' J ê ' ' '' ' 'ù-.

.$:;,'.X$s.-'.ïL.L',''n..%4',zï:y ' ' ''-' ' '- ' ' ' ' '- v... I have read articles, which mention the need Mounting the rest with the grinder follows

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'..IFIE SHAFES ILLUSTFATEZ AqE JUSI .;yy,.. . . . ,,ISSEFT TFIICKhESS EASE .' ,A FE% OF TFIOSE AVAILAELE

.

' I8Et AiE TFIOCJGFI , TFOSE HOST . . - . ' .'' ''AFFiOFFIATE 10 1HE F!0kE S 3 ' ' ''' ''.'?t-''' ''' '' ' '. ' .*. . t..)' .e... . . CA O Ik r S FI O F 't'>. &. ' .

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. qlib tt'' ''e y. . . ' ..C J)v . n?,qt. . . .!j ' '' ...'L . . .' . . . ? ) . . . .;' . '.l j)) . :j.. . . ' .. . ) 2 t . ' . , ? 7 . . . L ' ) ) s . . ?2E'$. 't x . .'' èè ' j i'q . .î g 7 2 . .lr 1. ) ' ''7 ' 5' . . ' L t ' ' . ' '? ' . 'Yi ' ' 4. 7 . ) u.. -- .. ?. . . c . ;1!j4Ij II4I:r .11 )... -.. ' è . : . kg 7. /je .tjjjytr jù .L' ' . . ... y:? ;..'t, ..... ,) .. y .:., ,. 7 y. . ) )' Is è 1 i S . . 4 z:.. . .j ) .. . î . . . . .. .. .. . i' ;)b)z:k3kï. -' ' ?- . è . è ' . . . .' ... .'-'' .' . ' j. . . ;.., . .. . y. ' l.. x) . )jj . '''îj . ' .. a.( ) 'x . . s tz fc '' L % ' .r 7 ' ) '' kl'' l '

LATFIE ' .. . . C ?. .. # . .. . (t ; .8 E2 kx .

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) z. 7 .y ' N ' y. L u . ,. . .. .. . . .. y. ..------.-....... t u .? ,thl t-i -r ' '$t7' '' rv ttlly' ->-'@dt ? .'- ''?i' 2 : ' s .', I . . 2. =. . 7.?J9 .sq .. .. . ..

,.)jn. ')j.y. ' $, ..tc . . . y) j y.,, ..jy y,z. . q . gy. s . wjy4 ' . j? . s '... . f t :. .( . jyytto .7 ''a 't ':' L1' m . .

.

1 : . . ;j. . ... Iqyë)j?.I I ; 'L(j.I ' ) '$'?: ,

i ' 8. Slar nlng the epd teeth of an . .. .>,.î ,i . ' ., . '!t' S 2 end m/11 wlth the rest mount at the '' '' t

: . CLAM? s f' , Mlde @/ the Ghn-l a at the Wghf ï.,î ' è

., . yFA Kl NG hand end. .

'. .l) )#2. . :)' ))r. pk.. . j. ...ryyt klyyyr ,' :, . . :. ' , jyy j.jrll4r .; . .s : j( .t, . . jy , $ k .., . : L . .. ? .. . . t:i j . ' .... . . v ...y cjjtj). zlt,s, .j . tt

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G8IN2l$() AHEEL However, the design of the rest does ': only provide for it to advance the table ' ' .'. .s#,.

in front of the base angle as can be 's e e n i n P h o t o 7 , Pag e 1 28 . S K4 .J' ??(,t)Vs ''therefore suggests a dimension relative . 1 : )''

. I ,?). êto the wheels. . et

:,' , .

. ' ' . (juG uard i ng ' .

' $%: 's' tl . a'..o. 'è -'I have, chosen to retain the guards that . : ' .1'7

.. . . ) 4 (. . . .j; . ' ' ' -'- : ' ' )were pad of the original grinder. These, I ' . ,SK4 f ,

suspect, could be improved upon but feelthat only with experience of use, will I ' ' . .. .

understand the Ievel of access to the .wheels required. I would though suggest ' ,, ,.,,3

. è2 ' .. .that as removal and fitting of the wheels is x . .easy, that only the wheel being used should ' ., v .be fitted. This leaves the second spindle ' yt ' . '

y.s. s.without a grinding wheel preventing the .... :.,ttl: .. . ' '.'' )TFIIS ZIkEhSION SHOULO 8E IN TFIE OI?2EF Possibility of accidental contact. jf ..... yy. ..'êè '- . '-$'),t),,- , , .,, . , ..

' ' -

0 F 1 0 () k k , E I 1 FI E 8 70 T FI E F LAT FA C E 0 Ik t . )Li;))v . tUsing the set up . 'ïlt .s , '?..''yt . , t, tCCJFVED FACE 0F T8E AHEEL ZEFEFZINC .;y k0$ TFIE FOSIIIOS TFIE ZEST IS MO(JhIIEI) Methods for using the rest will differ Iittle . t)). ) ,

. . w. .4 '1 . . .. .from those described in the earlier chapters ..,'?''&. :-' û .

, :.' '?, y). . (:;the same basic set-up as was illustrated in so have not i ncI uded any f u rther t'è2' f .the earlier chapters. However, a second instructions, I have though included two '- ' '=-. .' #position for the rest is provided at the photographs to show it in action. Photo 8 ' ' . , ...'...,., .., . wo' .? . . .

' ' )y. , .. .' ' . . .1(. . 'Jngrinder's side, as approaching the cup shows the end teeth of an end mill being ï;f ,. .

tx % ?.:,'

'(' '% ' cwheel from this angle will be beneficial in sharpened whilst Photo 9 shows its cutting ' t'' . ;'i. ) .y '% ' ''''A,

;' Ctlt .' ' (-)? . :q '.L.L. . . ''some instances. The mountings should edges being ground. One final comment .,

. )(...Lj )y. t v,(- f$'' '' ' . L..î.' :' ' ï'.''' .--'.'' --11..$ 711d1''. -- ' ..

' ' - .' '' 'also be repeated at the Ieft-hand end. regarding Photo 8, this shows the base ,

Photo 6 shows the set-up. For ease of use, angle mounted close to the boards edge , . 7f.ê ' f .y '.. :! ' .. .

push-fit inserts in the Iower board as shown enabling the Iower clamping arm to rotate . )ï L:/'''' '. .. t .

in SK 3 as this will avoid the need to gain a full 360 degrees. This makes it possible ' '' ' ' 27 , . ' 'to nuts on the underside. to remove the bulk of the rest from the base ' 9. Wlth the Ghe l m*V*d fO the left 7' ',lJ'aCCOSS ,.

If you obtain a 125mm grinder it is Iikely angle, making it easier to move the base . hand end Rnd th* reW în the /rODf , ''. .i . -..

that the rest may be a Iittle on the high side angle between the four, mounting positions. Posltion the J&tl*V *d9e* aF* heîng t '*'ïand may also be for a 150mm grinder. This Having come to the end of the book l . gl*und. . , .

can be overcome by using a suitable piece do hope you have found it useful. W hiIst .. t' oj ' ' '' tt .of wood as a packer. reading the chapters can do much to impad y uzi> ; y y,t iven dimensions for the knowledge actually making the items will 1 * )' ) >I have no g , j v) y .'

I as they will depend on the drive this home and help considerably to '';.,..,-..,,'.,.,t':'-.'.,?,,,..,. ... ....,...,.vv,;.. . ,.,.,..k, ,,. ,.,,,.. ' .,'î3.$.;i1''$'b' )ï..'assemb y

, .y,y. ..),> .)dimensions of the grinder being used. increase your confidence in using the ' 'milling machine.

1 39138

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: 140!

l

ALSO BY HAROLD HALL

Lathew orkA Com plete CourseIf fear of the unknown is all that ispreventing you from embarking on thesatisfying hobby of model engineering,then this is the book that will banish yourconcerns. Author Harold Hall hasestablished his reputation as a mentor totyro model engineers through the pagesof Model Engineer Workshop magazine,of which he was the editor for a num ber ofyears.This book assumes nothing and using themedium of twelve Iathe turning projects willIead prospective model engineers throughaIl of the basic techniques needed to tackleambitious projects. AlI of the projects areextensively illustrated and full working drawings accompany the text.Once followed through, the reader will have amassed a wealth of practical skillsand a range of useful workshop tools and equipment.PAPERBACK, 168 PAGES ISBN 1-85486-230-8

THE CO M PLETE S.I. M ODEL B O OKSW ORKSHO P PRA C TICE SERIES

W PS 1 W PS 4Hardening, Temperlng & HeatTreatment Foundrywork for the AmateurTubal Cain 0-85242-837-5 B.TerryAspin 1-85486-168-9WPS 2 W PS 5Vertical Milling in the Home W orkshop Milling Operations in the LatheArnold Throp 0-85242-843-X Tubal Cain 0-85242-840-5W PS 3 w PS 6Screwcutting in the Lathe Measuring & Marking MetalsMartin (78e7/0-85242-838-3 Ivan Law 0-85242-841-3

141

r

W PS 7 W PS 21The Art of W elding Adhesives & SealantsG A. Fatzse 0-85242-846-4 David Lammas 1-85486-048-8

l W PS 8 26.95Sheet Metal W ork W PS 22R.E. +a#//0r420-85242-849-9 W orkshop Electrics

g WPS 9 Alex Ge/ss 1-85486-107-7Soldering & Brazing WPS 231 Tubal Cain 0-85242-845-6 W orkshop Construction

W PS 1 0 Jim Forrest t: Peter Jenningsl Saws & Sawing 1-85486-131-X :6.95 jj Ian Bradley 0-85242-887-1 WPS 24 !

WPS 11 Electric Motors in the Home Workshop j!Electroplating Jim Cox 1-85486-133-6 jJpoyner 0-85242-862-6 WPS 25 l ,

I ('W PS 12 The Backyard Foundry' )I Drills

, Taps & Dies B. rerry Aspin 1-85486-146-8 $Tubal Cain 0-85242-866-9 W PS 26W PS 13 Home Workshop Hints & Tips .

I Workshop Drawing Edited by Vic Smeedl Tubal Cain 1-85486-182-4 1-85486-145-X E ' l

W PS 14 W PS 27 @Making Small Workshop Tools Spindles ' .

. ( .Stan Bray 0-85242-886-3 Harprit Sandhu 1-85486-149-2 ;.WPS 15 WPS 28 y.W

orkholding in the Lathe Simple Workshop Devices ')Tubal Cain 0-85242-908-8 Tubal Cain 1-85486-150-6 t

' WPS 16 WPS 29 t ''I . 'ty 'Electric Motors CAD for Model Engineers .

'' .

Jim Cox 0-85242-914-2 D.A.G Brown 1-85486-189-1 ' .Jl wps 17 wps ac .i oears & oear cuuing workshop uaterials ki

Ivan Law 0-85242-911-8 Alex Weiss 1-85486-192-1 'w PS 18 w Ps 31Basic Benchwork Useful W orkshop Tools f 'Les Oldridge 0-85242-920-7 Stan Bray 1-85486- 194-8 : , , ,

I WPS 19 WPS 32 ' : ' ;Spring Design & Manufacture Unimat III Accessories 7

., j.Tubal Cain 0-85242-925-8 Bob Loader 1-85486-213-8 J ! '.. t J !W PS 20 WPS 33

i I .EI Metalwork & Machining Hints & Tips Making Clocks ',' i Ian Bradley 0-85242-947-9 Stan Bray 1-85486-214-6 'J.' ;! .

143142 'k . E

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