It is done by a rotating tool, the rotating side of the cutter, known as a drilling drill. In this operation, The workpiece is revolving in a chuck or a faceplate and the drill is held in the tailstock drill holder or drill chuck. The feeding is adopted is affected by the movement of the tailstock spindle. This method is adopted for the drilling of regular-shaped workpiece. Reaming is the operation of finishing and sizing a hole which has been already drilled or bored.
The tool is used is called the reamer, which has multi-plate cutting edges. The reamer is held on the tailstock spindle, either directly or through a drill chuck, and is held stationary while the work is revolved at a very slow speed. Boring is the operation of enlarging the hole which is already drilled, punched or forged. It cannot produce a hole. Boring is similar to the external turning operation and can be performed in a lathe. In this operation, the workpiece is revolved in a chuck or a faceplate and the tools which are fitted to the tool post is fed into the work.
It consists of a boring bar having a single-point cutting tool that enlarges the hole. It also corrects out of the roundness of a hole. This method adopted for boring small-sized works only. The speed of this process is slow. Counterboring is the operation of enlarging the end of the hole through a certain distance.
It is similar to shoulder work in external turning. The operation is similar to boring and plain boring tools or a counterbore may be used. The tool is used called a counterbore. The speed is slightly less than drilling. The principle of turning a tapered hole is similar to the external taper turning operation and is completed by rotating the work on a chuck or a faceplate. The feeding tool is at an angle to the axis of rotation of the workpiece.
A boring tool is mounted on the tool post and by swivelling the compound slide to the desired angle, a short taper hole is machined by hand feeding. Tapping is the operation of cutting internal threads of small diameter using a multipoint cutting tool called the tap. In a lathe, the work is mounted on a chuck or on a faceplate and revolved at a very slow speed.
A tap of the required size held on a special fixture is mounted on the tailstock spindle. Undercutting is similar to a grooving operation when performed inside a hole. It is the process of boring a groove or a large hole at a fixed distance from the end of a hole. This is similar to the boring operation, except that a square nose parting is used. Undercutting is done at the end of an internal thread or a counterbore to provide clearance for the tool or any part.
Milling is the operation of removing metal by feeding the work against a rotating cutter having multiple cutting edges. For cutting keyways or grooves, the work is supported on the cross-slide by a special attachment and fed against a rotating milling cutter held by a chuck. The depth of cut is given by vertical adjustment of the work provided by the attachment. The depth of cut is given by verticle adjustment of the work provided by the attachment.
The feeding movement is provided by the carriage and the vertical movement of the cutter is arranged in the attachment. Grinding is the operation of removing the metal in the form of minute chips by feeding the work against a rotating abrasive wheel known as the grinding wheel.
Both internal and external surface of a workpiece may be ground by using a special attachment mounted on the cross slide. For the grinding external surface, the work may be revolved between centres or on a chuck. Use brushes and a vacuum, not compressed air. Chips may be sharp; use a tool to remove them. Clean up any coolant spills. Put away tooling, drill bits and tools. Recycle scraps and put reusable pieces in the storage bin in the metal shop.
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MachineryHouse AL Other lines m a y be marked in by t he same mark on the threading operator as needed. The setting of the compound rest feed is changed only after each of the four grooves has been cut to the depth of setting. The cutting operation is the same as in the preceding paragraph.
The sett ing of the compound rest feed is changed only after each of the four grooves has been cut to the depth of setting. To cut multiple threads by slipping teeth on the compound gear: cut the complete first groove to a minor diameter dependent upon pitch of the desi r ed th r ead. The change gear train should be arranged for the desired lead. It is important to use the same o point of reference to cut each thread - be sure to remember this point during the cuttin g operations.
Refer to the table on page , then slip the r equired number of teeth by marking adjacent teeth on the compound gear and the gear meshing with the compound gear.
Drop the entire gear bracket low enough to disengage the gears and turn the compound gear forward the proper number of teeth by rotating spindle by hand. Raise the gear bracket so that the previously marked gear tooth meshes with the newly selected compound gear tooth. Place 64 tooth gear in front position on screw stub. Place 56 tooth gear and 20 tooth gear on bushing in Position D, with 56 tooth gear in b ack position.
Tighten so that 20 tooth gear meshes with 64 tooth gear on screw stub. Place 24 tooth gear and 48 tooth gear on b ushing in Position A, with 24 tooth gear in back position. Tighten so that 24 tooth gear meshes with 56 tooth gear in Position B. Swing entire gear bracket upward and tighten so that 48 tooth gear in Position A meshes with 16 tooth compound tumbler gear. Place 64 tooth gear in front positIon on screw stub. P lace 20 tooth gear and 40 tooth gear on b ushing in Position D, w ith 40 tooth gear in back position.
Tight en so t hat 20 tooth gear meshes with 64 tooth gear on screw stub. Place 48 tooth gear and steel spacer on bushing in Posit ion B, with 48 tooth gear in back position.
T ighten so that 48 tooth gear meshes with 40 tooth gear in Position D. Place 44 tooth gear and 20 tooth gear on bushing and mount in Position A with 20 tooth gear in back position.
Tighten so that 20 tooth gear meshes with 48 tooth gear in Position B. Swing entire gear bracket upward and tighten so that 44 I tooth gear in positio n A meshes with 16 tooth compound tumbler gear. Gear set-up for. Place 64 tooth gear and 20 tooth gear on bushing in Position B, with 64 tooth gear in back position. Place 20 tooth gear and 56 tooth gear on bushing in Position A, with 20 tooth gear in back p osition.
Tighten so that 20 tooth gear meshes with 64 tooth gear in Position B. Swing entire gear bracket upward and tighten so that 56 tooth gear in Position A meshes with 16 tooth compound tumbler gear.
Place 20 tooth gear and 56 tooth gear on bushing in Position D, with 20 tooth gear in back posit ion. Tighten so that 20 tooth gear meshes with 64 tooth gear on screw st ub. Place 52 tooth gear and 20 tooth gear on bushing in Position C, with 52 t ooth gear in back position. Tighten so t h at 20 tooth gear meshes with 56 tooth gear in Position D. Place 36 tooth gear and 64 tooth gear on bush ing in Position A, with 36 tooth gear in back position.
Tighten so that 36 tooth gear meshes with 52 tooth gear in Position C. Swing entire gear bracket upward and tighten so that 64 tooth gear in Position A meshes with 16 tooth spindle stud gear. These threads and all others must be cut in the same manner as metric threads See Page Extra gears available from the factory at nominal cost. When the material or job requires a certain feed, refer to the table below.
Extra gears are available from the factory at nominal cost. Each stud assembly has an outer gear bushing long enough to accommodate two gears. Cross section of change gear stud assem bly. Notice that in order to make t his assembly complet e, two gears must be mounted on the gear b ushing at one t ime. W hen bot h of the gears on a gear bushing mesh w it h other g ears in the train, they form a "compound" gear a ssem bly. W hen on ly one of two gears on a gear bushing m eshes with t he other gea rs in t he t rain, it is called an "idler.
A met ho d ofte n used to ob - FIG. A small amount of greas e, preferab le graphit e grease, ap plied to gear teeth will often aid in obtaining smoother , m ore q uiet operation. Whenever a new gear train has been set up, shift the tumbler gear lever to test the direction of the carriage travel. Because some set-ups are simple-geared and some are compounded, the carriage travel may be right for on e set-up an d left for another set-up, even though t h e l ever has b een shifted t o the same position in each case.
A lways test th e directi on of carriage travel before starting to cut a thread. Gear set-up lor 11 through 16 threads per inch. Place in front position of screw stub the gear listed in "Gear on Screw" column of threading chart. Place 20 tooth gear and 40 tooth gear on sleeve in Position C with 20 tooth gear in back position. Tighten so that 40 tooth gear meshes with gear in screw position. Place 64 tooth gear and spacer on sleeve and mount in Position A with 64 tooth gear in back position.
Tighten so that 64 tooth gear meshes with 20 tooth gear in Position C. The 64 tooth gear is an idler. Swing entire gear bracket upward and tighten so that 64 tooth gear in Position A meshes with 32 tooth compound tumbler gear.
Place on back position of screw stub the gear listed in "Gear on Screw" column of threading chart. Pla ce in front positi on of screw stu b the gear listed in "Gear on Screw" column of t hreading cl, -' r t.
P lace 20 t ooth gear and 32 tooth g ear on sle eve and mount in Po si t ion C with 20 tooth gear in back posit ion.
Tig hten s o that 32 t ooth g ear m esh es w ith gear i n screw p osition. The 32 tooth gear is an idler; th e 20 toot h g ear is a spa cer. Tighten so t hat 64 tooth gear mesh es w it h 32 toot h g ear in P osit ion C.
The 64 toot h g ear is an idler. Swing entir e gear bracket up wa rd s o that the 64 t ooth gear in P ositio n A m esh es w ith th e 16 tooth com pound tum b ler gear.
P la ce in b ack p osition of screw stub the gea r listed in " Gear on Screw" column of threading chart. T ighten so t hat 56 to oth gear m esh es with t he g ear in screw position. Place 64 tooth gear and 32 too t h gear on sleeve a n d mount in posi tion A w ith 32 toot h gear in back position. T ighten so that 32 tooth gea r mesh es with 56 tooth gear in P osition C. Figure shows the interm ediat e points between the four mainmarkings.
T h ese poin ts can be mar ked with penc il, or t he posit ions eas ily estimat ed. T o cu t the s econ d groove of a double t hrea d, the B FIG. The line and the "b" positions. Lin es for "A ," "B," and " C" p os itions ar e mark ed.
Set up the change gears for th e l ead in threads per inch 12, not Engage t he half nut lever for the fi rst cut wh en t h e stat ionary mark on the ou tside of the threading dial is in line with anyon e of t h e f our main marks on the rotating portion of t h e di al. T hen r eturn t o the start ing point and engage half nuts at any on e of the "b" positions, taking the first cut on the second groove of the th r ead.
The com pound rest feed remains at one s ettinJ! A s ingl e t h read of t h is lead can b e cu t only by engaging the half nut leve r at the "0" or "B " markings, on t h e thread ing dial. T o cut the second groove of th e double thr ead, the half nuts a re engaged at t he HA " or "e" markings, an d t he cutting operation is the same a s in the pr eceding para graph. Each thread groove is cut to its complete depth and finished before starting the next groove.
The feed in inches is equal to 1 For example, a feed of. Refer to the threading chart and the four following paragraphs when changing these gear set-ups. Table II on page includes gear set-ups for other carriage feeds. Tighten so that 32 tooth gear meshes wi th 64 tooth gear on screw stub. Tighten so that 24 tooth gear meshes with 64 tooth gear in Position C. Tables I and II give proper gear set-ups for a wide variety of special threads and feeds.
Most of these set-ups are exact- some are accurate to the limits mentioned. Table III gives set-ups for metric threads with pitch between 0. Thus, it is possible to cut metric threads very close to the standard metric pitches. Refer to page when cutting metric threads. A small piece of cellop han e slip p ed bet ween the jaw and th e w or k is somet imes u sed to a id in obtaining the proper bearing - advance t h e j aw u n til it just t ouches, t hen remove cellophane.
W hen the work is being held in a chuck, the jaws of the steady r est can be set more accurately if th e work is held between lathe centers w hile t h e jaws a re bei ng ad justed. Take extreme care in locat ing t h e tailst ock ce nt er see page F or jobs requiring maximum a ccuracy, check t rueness of the work with a dial gauge as shown in Fig ure 75, p age During th e cutt ing operation app ly plenty of lubricant on the work at t he p oint of bearing with the jaw s.
B oth t he follower rest and steady rest are often used to brace a slender F I G. Threading a long screw with t h e aid rod Fig. The cut-off tool must be set int o the w ork at an exact r ight angle and '"""1 with the cutt ing edge on dea d center see Fig F igures and 21 2 show t he t ool r ecommended for ,.
This tool is FI G. Cut-off Tool. T he blade must be at a right angle to the work. Do not use too slow a speed. W hen cuttin g off on a small lathe, the lubricant is usually applied with a b rush or oil can. S et t he cutting edge o f th e tool on the lathe center line-the tool blade should be at an exact right angle with the work Fig.
If the tool " hogs-in" an d s tops the spindle rotation, stop the m otor and reverse th e spindle by hand before backing out the tool with t he cross fe ed.
Aft er resetting the tool, feed in slowly and remove the bad s pots. Never complete a cut-off of work which does not swing free at one end. Cut off as close t o the headstock as possible. W hen c utting off soft copper or aluminum, refer to page S6 or To resharpen the cut-off to ol shown in Figure , grind the fro nt edge only, aIlowin g fron t clearance see Fig.
Fig ure 5 8, page Each groove is slightly less dee p than the finish-diameter-this simplifies the turnin g o peratio n by providing an easy stopping place after each cut.
Experiment to determine the proper spindle speed and rate of feed for the diameter and material being cut off-this is the best way to get the "feel" of the operation. When the work is held in a chuck, cut the knurl as close to t he headstock as p ossible. Advance the tool into the work with the cross feed until t he dial reading has been advanced about. Stop the lathe and without b acking out the tool, check the pattern produced.
When the pattern is not as desired, back out the tool and take a cut in another place on the work. After the correct desi gn is obtained the test cuts will be rolled into a perfect k nurl du r ing the final cutting process. When a test cut shows the proper pattern, engage carriage feed. Apply plenty of lubricant. At t h e end of the cut shift the reverse lever to "Neutral," fo rce the tool. Continue t he knurling operations until the desired depth is reached. A fter the knurling process is started, never back out the tool until the knur l is com pleted.
The bar is bein g fe d t hrou gh the beadstoc k s pin dl e. T he carriage stop Fig. It is clamped on the front b ed way as shown in Figure The cross slide stop, combined with t he micrometer graduations of the cross feed contr ol handle on the lathe, a ssure an ac curate " z ero" r eading before the compound rest feed is advance d for the n ext cut.
Do n ot run the compound rest against the cross slide stop with too much force. The work is held in the mill in g vise ja ws. The e nd mills are s uitab le fo r milling slots, facing and ro u t in g small wo rk, s quar ing or splining shafts, cuttin g straight k eyways, and gene r al milling oper at ion s.
T h e primary use of the Woodruff cutters is the cutting of Woo druff keyways-ot her uses include the cutt ing of slots, groov es, T s lots, etc. Th e complete co llet set includes one arbor f or holding straight a.
T his set consis ts o f : draw bar. A collet b ushing or arbor is also required for a ll st rai ght shank end mills except the Yz inch diameter. P ass the draw bar through the spindle and tighten t h e arbor into spin dle taper by turning handwheel.
T ight en cutt er in arbo r by locki n g socket-head set screw. The draw bar, arbor, bushing, cutter shank and lathe spindle must be wiped clean and dry. When mounting the mi ll ing cutter in the coll et arbor, be sure t o select the proper size of collet bushing if one is r equired. Take light cuts and feed in evenly and slowly until t h e correct feed can be judged.
Never force the work into the cutter t oo fast. A D iam. Optimum key w idth is e qual to one-quarter the shaft diameter. Keys s hould h e c hosen to appro x imate this relation as closely as possi ble. This should nominally be eq ual to o n e-half FIG. If des ired. This dust is extremely harmful wh en allowed to fall and remain on the lathe bed ways and cross slide.
A lways c ov er the bed ways and the cross slide during grinding op erations. Paper, oilcloth or canvas makes a good cov er. When using a cloth, be sure it is closely woven. After t h e grinding opera t ion, clean the b ed ways and carr iage dovetails t h oroughly. Th en a pply plenty of clean oil. Figure shows h ow the dress ing tool is mounted in the holder which h as b een clamped to the lathe bed.
T he diamon d point of the dresser should be at an angle and slightly below center as shown in Figu re Wheel Dresser w ith Diamo nd Po int. At " AU it is necessary to r everse lathe spindle-at "B" the same effect is obtained by ru nni ng the lath e spindle i n a "Forwa rd " dire cti on. The work should be turned as close to t h e final fin ish size as possible before the g rinding operation is begun. With the w ork and the grinder mounted in position and the grinding wheel d ressed prop erly, ad vance the w h eel into one end of the work.
T ake light cuts across the entire length of the wor k. If usi ng the autom a t ic carriage feed, set up the change gears for the. Hand feeds should be very slow and even. The last finishing cut should b e less than. When hardened stock is being ground. T h e quill which holds t he grinding wheel for internal work is threaded and tapered to fit inside the grinder spindle after the external wheel is removed s ee Fig.
Mount internal wheel on grinder spind le an d align spindle with tailstock cent er pa ge W ith compound rest set at 0, dress g rinding wheel. Feed up to the cent er with the carriage handwheel, lock carriage in p osition and feed a cross center slowly with compound rest feed. Take light cu ts. See that the work is held rigidly- vib rati on ca uses poor w ork. No lubricant or cutting com poun d is n ecessary exce pt fo r production work.
Keep the tool post g rinder clean and w ell oil ed. T he bearings are grease packed at t h e tim e o f assem bly and need no furthe r attention. Th e too l shown in Figure has been found satisfactory by many auto repair mechanics. Grind the tool bit to the angles indicated-hone it thoroughly at regular intervals. Set u p the gear train for a fine feed-the three fines t fe eds sh own in t he carriage feed table, Section 7, Threading, are recommended.
Take light cuts with a surface speed of to feet per minute pages 45 and After t h e trueing cut, choose an u ndercutting saw which is t he same widt h as the commutator slot.
Mount sa w on cutter arbor. Adjust undercutter so that saw is exactly on the lathe center line and in position to take a cut of about the same depth as the wi dth of t h e slot. In the table below, tangent s are listed for every 15 minutes of angle. For example : The tangent of the taper in t h e example on page is. The exact reading is obtained as follows : [. The upper part of the tailstock is locked in position by tightening two headless set screws, one in the front and one in t h e back of the base casting see Fig.
Loosen the headless set screw on the side toward which the tailstock will be moved. Then t h e upper tailstock w ill move in that direction when the other headless set screw is tightened.
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