VERTICAL `

ARNC .Ə THROP

MILLING IN THE
HOME WORKSHOP

uuuuuü inn mm |

WORKSHOP PRACTICE SERIES 2 )

VERTICAL MIILLING
IN THE
HOME WORKSHOP
Arnold Throp
C.Eng., F.I.Mech.E.

ARGUS BOOKS
Argus Books
Argus House
Boundary Way
Hemel Hempstead
Hertfordshire HP2 7ST
England

First published 1977

Second impression 1979
Second edition 1984
Reprinted 1986, 1988, 1989, 1990, 1991, 1993

© Argus Books Ltd 1977

All rights reserved. No part of this publication may be

reproduced in any form by print, photography, microfilm
or any other means without written permission from the
publisher, 7) =

ISBN 0 85242 843 x

Phototypesetting by Performance Typesetting, Milton Keynes

Printed and bound in Great Britain by

Biddles Ltd, Guildford and King’s Lynn
CONTENTS

Chapter One EVOLUTION OF THE VERTICAL MILLER 12

Early history of industrial machines: milling in the
early small lathes: milling attachments for lathes
circa 1920s: E.T. VVestburys experimental machine
1964: the Dore-Westbury machine 1968: currently
available small machines and attachments.

Chapter Two MILLING FLAT SURFACES 27

Surfaces parallel to table: simple fixed-radius
flycutters: variable-radius boring head flycutting:
multiple-tooth face mills: work holding: multiple-
pass milling: surfaces square with table: using side
of endmill.

Chapter Three SLITTING AND CUTTING 35

Use of slitting saw for cutting through machinery
component bosses: eccentric sheaves and straps:
marine type big ends of connecting rods.

Chapter Four KEYWAY CUTTING 37

Endmilling round ended feather’ keyways: keyways
on taper shafts: use of disc type cutters for plain
sunken keyways: Woodruff keyways: making
Woodruff cutters in the home workshop: table of
suggested sizes of Woodruff keys and keyways for
model engineers.

Chapter Five FLUTING COMPONENTS OTHER THAN

TOOLS 43
Correct form of flutes in loco connecting and
coupling rods: mounting rods against angleplate for
fluting: parallel flutes: taper flutes: preferred type of
cutting tool.
Chapter Six BORING 45
Dealing with parts too large to swing in lathe:
trepanning large holes.

Chapter Seven ‘JIG-BORING’ 46

Using the miller as a measuring machine: drilling
holes at one setting of work and precise centres:
engine beam: back-lash precautions: trip gear com-
ponent: multi-hole boiler plates.

Chapter Eight PROFILING 49

Curves on parts too large for lathe: loco frames:
smokebox castings: machine pad bolts: loco con-
necting rods and coupling rods.

Chapter Nine END-ROUNDING 52

Use of hardened filing guides deprecated:
mounting work on rotary table: standard size guide
plugs: anti-slip precautions: direction of feed for
external and internal surfaces.

Chapter Ten DIVIDING HEADS 54

Simple ungeared dividing heads: using change
wheels as index plates: examples of dividing work:
hexagons, squares, dog clutch teeth: avoiding odd
numbers: the Myford worm-geared dividing head:
avoiding back-lash errors: packing block for
bringing to lathe centre height: universal steady
stand for Myford head: three further dividing heads.

Chapter Eleven DIVIDING HEADS AND GEAR-CUTTING 62

Limitations to straight spur gears: simple head:
Myford worm-geared head: tooth cutting on
integral pinion: use of home made fiycutters:
Brown & Sharpe disc type cutters: selection of
cutter to suit number of teeth: cutting a large
coarse tooth gear: anti-slip back-up devices.
Chapter Twelve DIVIDINGHEADS AND TOOL MAKING 66
Fluting taps: example 5-flute Acme tap: producing
a small fine tooth milling cutter with ball end: use
of table stop blocks: combination of rotary table
with main table movement: large 60 degree coun-
tersink fluting.

Chapter Thirteen DIVIDING HEADS AND GRADUATED

SCALES 71
Cutting graduation marks: use of rotary ‘engraving’
cutters: use of non-rotating planing type tools: use
of table stops to control line lengths: graduating
cylindrical scales: graduating flat angular scales:
checking correct way of figuring when stamping
scales.

Chapter Fourteen CUTTER SPEEDS FOR VERTICAL MILLERS 74

Speeds affect time occupied on job: speeds too
high may cause excessive cutter wear and chatter:
rigidity of work, cutter and machine inferior as a
rule to industrial conditions, dry cutting instead of
lubricated: Table Ill gives speeds for cutters in
different kinds of tasks: machine speeds may not
always be suitable.

Chapter Fifteen WORK-HOLDING WITH DIFFICULT

SHAPES 78
Comparison with full scale engineering: use of
chucking pieces on components: thin components
and use of adhesives: advisability of making fixtures
for difficult pieces: three-sided angleplates.

Chapter Sixteen CHUCKS FOR MILLING CUTTERS 81

Never use taper shank tools or chucks without
drawbar: chucks for screwed shank self-tightening
collets: Clarkson chuck: Osborn Titanic chuck:
Chucks for tee-headed locking cutters: Clare
chucks: use of small end mills and D-bits without
locking features: philosophy of ‘throw-away’
cutters.
List of lllustrations

Abwood milling attachment of the 1920s

E. T. Westbury s milling machine
Dore-Westbury machine
Dore-Westbury Mk II machine
Rodney attachment
Rodney machine
Amolco attachment
Amolco machine
Mentor machine
Maximat attachment
Astra machine
Twin machine
Senior machine
Set of three flycutters
Flycutting a bracket
Flycutting connecting rod ends
Flycutting tapered bar material
Flycutting cylinder soleplate
Facemill
Milling flywheel joint face
Milling crosshead slide
Milling bearing jaws in bedplate
Slitting boss of casting
Milling feather keyway
Milling feather keyway on tapered shaft
Milling keyway with slitting saw
Set of four Woodruff keyway cutters
Milling Woodruff keyway
Fluting locomotive connecting rod
Drawing of steam hook (lever)
Photograph of steam hook
Profiling pad bolt
Profiling coupling rods
End-rounding with rotary table
Cutting teeth in dog clutch part
Drawing of steady stand for Myford dividing head
Steady in use on a gear cutting operation
Throp dividing head
Thomas versatile dividing head
Kibbey/M.E.S. dividing head
Close-up of fiycutter and pinion
Gearcutting with Brown & Sharpe cutter
Flycutting 10 d.p. gearwheel, front view
Fiycutting 10 d.p. gearwheel, rear view
Fluting Acme thread tap
Cutting teeth of ball-end cutter
Close-up of ball-end cutter
Gashing flutes in large countersinking tool
Rear view showing steady stand in use
Cylindrical machine component being graduated
Close-up of previous operation
Graduating part-circular arcuate scale on flat surface
Tape-held workpiece being flycut
Hemingway three-sided angleplate
Two of the three sizes of Hemingway angleplates
Clare milling chuck
Clarkson milling chuck
Osborn milling chuck
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Preface
In the engineering industry the vertical
miller is very widely used, not only for
batch production, but also for tool making
and the ‘one-off’ jobs which are so
common in general engineering. In the
home workshop, where most jobs are
‘one-off’ the versatility of the machine
makes it an important companion to the
lathe. This book describes many of the
infinitely wide range of operations which
can be done, and all those described are
illustrated by photographs so that under-
standing of the methods is assured. These
cover work on parts of model locomotives,
stationary engines machinery, cutting
tools, gears, clutches, etc. Full information
is given on the machine accessories which
are required, such as various types of
cutters and the chucks needed for their
mounting on the machine spindle. The use
of cheap home-made cutters is shown
and encouraged. Guidance is also given
on the work-holding devices such as
clamps, packings, vices, angle plates,
dividing heads, rotary tables, and which of
these are needed for particular kinds of
work.
CHAPTER1

Evolution of the
Vertical Miller

The horizontal milling machine evolved lathes were provided by different makers,
naturally from the lathe in the first or and the great versatility of the lathe
second decade of the nineteenth century. created in itself a tendency to make the
Eli Whitney (U.S.A.) is said to have had lathe do every operation that arose. This
one in use about 1818, and in Jools for was enhanced by the fact that many
the Job the late L.T.C. Rolt recounted how modellers were working men with very
the young engineer James Nasmyth (later little cash to spend on their hobby. Many
to become famous as the inventor of the were the ingenious attachments devised
steam hammer and other appliances) to enable the lathe to carry out work it had
fixed one up and milled the flats on never been intended to do. Such makers
hundreds of tiny hexagon nuts for a model as Drummond Brothers modified their
of a Maudslay marine engine, while lathes with tee-slotted boring tables to
working for Henry Maudslay. Drawings of help in this work, and even brought out
the early horizontal millers show such a the famous round-bed lathe, which
resemblance to the lathes of that period although intended for a cut-price market,
that almost certainly they were in fact also had built into it the ability to do a lot
lathes which had been adapted to milling. more than just simple turning. But as the
The cutters were really files, made by the years went by it became ever more
file makers of the times, using the ‘hand- apparent something better was needed
cutting’ methods (really a hammer and a for milling operations. None of the small
special chisel) which were the only millers produced by the machine tool
practice available at that time. industry were oriented towards the home
The evolution of the vertical miller workshop.
came naturally after the horizontal Then in the 1920s the Abwood Tool
machine. 1 have not found any reliable and Engineering Co. produced an excel-
reference to a date by vvhich the vertical lent vertical milling attachment for
miller had appeared in industry, though mounting on small lathes, especially the
this must have been well before 1900. popular 34 in. flat bed Drummond, though
When model engineering started to adjustable features made it applicable to
become an established hobby at the turn other lathes too. It had a No. 1 Morse
of the century quite a variety of small taper arbor which fitted into the lathe

12
Fig. 1 Abwood milling attachment of the
‘920s

13
spindle, and bevel gears with keywayed the Drummond lathe. Although out of
shafts took the drive up to the vertical production for many years now, it was in
cutter spindle, which had a No. 1 Morse its time a courageous effort, but belonged
internal taper. All the gears were equal to the age when most home lathes were
ratio mitre bevels, so the cutter rotated at driven by flat belt from a treadle or coun-
the same speed as the lathe spindle, and tershaft, and the cost of electric motors
all the six speeds of the lathe were usable. made the independent motor drive
The work was mounted on the lathe uneconomic in home hobby applications.
boring table, and power feeding in one But the need for a handy vertical
direction came from the lathe screwcut- milling machine had been recognised, and
ting gear. A photograph of this unit set up in the early 1960s that very good friend of
on a Myford Super 7 is shown in Fig. 1. It model engineers, Edgar T. Westbury,
was unfortunately a low-volume, labour completed an experimental machine,
intensive unit with vee slides needing which he described with drawings and
hand scraping, but was selling in 1930 for photographs in the Model Engineer
7 guineas, about a quarter of the cost of during 1964. That too was a very labour

Fig. 2 E.T. Westbury's

milling machine
 intended to make economies or improve
the performance. This new design was
discussed with Edgar, who agreed to the
use of the name ‘Dore-Westbury’, the
machine to be sold as a kit of semi-
finished components by my existing firm
` T
Dore Engineering. | was able to place the

Zə ,
machining of the components with a
number of firms already known to me, and
the first sets of materials began to go out
to customers early in 1968. Since that
time many hundreds of sets have been
distributed, all over the world, and are still
being made in ever greater quantities by
Model Engineering Services, of
Chesterfield, who took it over from me in
1971, when | wanted, on account of age,
to reduce my commitments.
Castings to the original design are,
however, still available from Woking Pre-
cision Models of 16 Dovecot Park,
Aberdour, Fife, Scotland KY3 OTA, and a
machine from these is shown in Fig. 2.
The Dore-Westbury machine is depicted
in Fig. 3 and the similarity between them
Fig. 3 Dore-VVestbury machine
will be at once apparent. During its
entire life the Dore-Westbury has been
undergoing small improvements, and the
intensive machine vvith vee slides, and the present suppliers have now decided that
main castinqs were much too big to be the modifications are sufficiently
machined in the average home vvorkshop. Stabilised for the present version to be
At that time he vvas unable to find any titled the Mark l| model. From now on all
engineering firm vvilling to take it over and machines supplied vvill be of this form,
manufacture it, or even to do the machin- though still subject to certain optional
ing on a contract basis at such a price as it variations which customers will be able to
was thought model engineers would be select as they wish.
vvilling to pay. The more important changes include an
Three years later | found myself with increase in the quill travel from 2š in. to
the opportunity to take a fresh look at this 41 in. Extra pulley steps with a new type
design, which he had discussed with me of belt extend the speed range slightly
during the experimental period. | evolved from 32 to 1880 r.p.m. with more inter-
a new set of drawings for a similar mediates, providing for boring head fly-
machine, but using flat slideways more cutting on large radii right through to
economically constructed, a reduction keyway cutting with 1/16 in. cutters. The
gear for lower bottom speeds, hollow reduction gear system now fitted has
spindle for a drawbar, and other changes helical gears which run in an oil-bath,

15
16
Opposite, Fig. 4 The Dore-Westbury Mki/ Fig. 5 Rodney Attachment

17
 Fig. b Hodney machine

sealed against leakage even when inclined standard. The down-feed worm has for
away from the vertical, and is quieter than convenience been transferred to the right
formerly. A larger table, 20 in. by 6 in., can hand side of the head, a coarser pitch rack
be had as an optional alternative to the is now used, and there are a number of
normal 16 in. by 54 in. The column and other minor improvements.
cross tube are steel, as always, but now š
in, thick and enormously stiff. 2} in.
diameter micrometer dials are now Opposite, Fig. 7 Amolco attachment

18
 Although colleges and commercial No doubt the most important improve-
workshops will probably wish to use the ment is the (optional) provision of power
all-over belt guard, it may be debatable if feed for the long movement of the table. À
the cost of this is justified for the solitary small motor with a 4-step pulley and
mature modeller alone in his home enclosed worm reduction gear provides
workshop. An alternative belt guard which feed rates of .5, .62, .85 and 1.1 inches
covers the spindle pulley only and does per minute.
not impede belt changing so much is A number of attachments similar in
available and is shown on the Mark Il general concept, though much different in
machine in Fig. 4. detail, to the old Abwood, have come on

Fig. 8 Amoíco machine

20
Fig. 8 Mentor machine, now superseded by the
F82 and Maximat attachment

the market in recent years. Tew

Machinery produce the ‘Rodney’ to suit
the Myford ML7 and Super 7 lathes, and
this is marketed by Myfords. İt is shown in
Fig. 5 and the complete vertical miller
based on this attachment is that shown in
Fig. 6.
Another attachment, the “Amolco is
supplied by N. Mole & Co. Ltd. and
appears in Fig. 7. This has its own motor
and attaches to the top of the lathe bed
also. It is made as a complete machine,
shown in Fig. 8.

Fig. f 1 Astra machine

21
 machine vvhich is floor mounted and
shown in Fig. 13.
So it vvill be seen that there are novv
many machines and attachments vvhich
are of suitable dimensions for inclusion in
the limited space of most home
vvorkshops. İt vvould be useless to give
any details of prices in a book of this kind,
as such information would probably be
incorrect by the time the book was
printed, and readers are therefore recom-
mended to enquire of the various adver-
tisers.
A summary of the leading particulars of
all these machines etc. is given in Table 1
Fig. 12 Twin machine but again specifications are amended by
makers as time goes by, and it can be no
more than a general guide.
A brief word must be said about foreign
machines, particularly those coming from
Elliot machine Equipment supplied a Far Eastern countries. It would appear
continental machine, the ‘Mentor’ which there are several factories producing
was available both in bench and floor machine tools and accessories. Some
mounted forms. The bench machine is appear to be quite good, but others are
shown in Fig. 9. They also have the definitely not good, and | do have personal
‘Maximat’ attachment to suit the lathe of experience of some of these. | have not
the same name, which fits on the back of had the chance to see one of the milling
the lathe bed and has independent motor machines working, but those | have
drive (Fig. 10). This is also available as a inspected in exhibitions have some cheap
floor machine, the FB2. and nasty features, although the main
Other complete machines include the items such as spindles, bearings, and
‘Astra’ supplied by Scot Urquhart, which slidevvays may be excellent. Some of the
is really a horizontal miller with an extra machines are more suitable for com-
vertical spindle with its own motor. Made mercial factories than home workshops
in several sizes, the small one is shown in but there are others of modest dimen-
Fig. 11. sions. To anyone contemplating buying
Twin Engineering Co. introduced a one of these one can only suggest that a
bench machine illustrated in Fig. 12 and close inspection should be made by a
also a floor mounted machine of similar knowledgeable engineer, and that a
size but slightly different design. working demonstration should be
Finally the old established firm of Tom requested, of the actual machine which is
Senior Ltd. now produce their type E to be bought.

22
Fig. 10 Maximat attachment

23
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26
CHAPTER 2

Milling Flat Surfaces

Of all metal-working operations the shown in Fig. 14. Each is just a Morse
production of true flat surfaces is perhaps taper arbor with an enlarged head having
one of the most difficult if reliance has to a slanting hole drilled in it to take a cutter
be placed on hand tools and hand bit (+ in. in these samples) with a screw to
methods, for it depends just about com- lock it in place. The head diameters are 1}
pletely on the personal skill of the in., 12 in. and 2? in. so the faces that can
workman. But a point offset from the be machined at one pass are roughly + in.
spindle centre of a vertical milling to + in. wider in each case. They were
machine must when rotated describe a made by boring through short pieces of
flat plane in space if there is no axial steel of these sizes to suit the parallel
movement. Therefore, provided the parts of Morse taper arbors. It is not
spindle is truly square to the table, an perhaps widely enough known that tool
offset cutting tool must generate a flat merchants can, if they will, supply Morse
surface on a work-piece attached to the taper arbors of this kind, which are a stock
table. Model engineering, just the same as product of the large drill makers. This
full size engineering, demands the produc- method of fabricating flycutters by using a
tion of a great many flat surfaces, so the ready made arbor with a head Loctited on
ability of the machine to perform this task saves a good deal of time and some heavy
in a simple way, without expensive steel. The effectiveness of tools made in
tooling, is extremely important to the this way is beyond question. Fig. 15
home worker. shows a bracket clamped against a large
angleplate and being milled with one.
Fig. 16 shows one working on a steel
FLYCUTTERS connecting rod which has to be reduced
The cheapest tool for the purpose is the from a circular section at each end. The
flycutter, usually consisting of a small rod is about 9 in. long, so it is held in two
toolbit set in some kind of holder. There vices at the same time, and each end is
are commercially made holders available, taken down to finished size before it is
but it is quite easy to make satisfactory turned over. Packings are used, different
holders at home, and they serve just as at each end to ensure the finished. surface
well. Three home-made flycutters are is above the vice jaws, to avoid cutting

27
 Fig. 14 Set of three flycutters

into them, and these packings ensure the Owning two vices alike may at first
rod is at the right attitude for keeping the thought seem something of a luxury, but
milled surfaces parallel to the axis. as soon as long articles have to be dealt

Fig. 15 Flycutting a bracket

28
 Fig. 16 Flycutting connecting rod ends

with the benefits are at once apparent. reduced to a tapered section to cut up into
Another fiycutting operation is shown wedge blocks for connecting rods of the
in Fig. 17 where a steel bar is being type in the previous picture. These wedge

Fig. 17 Flycutting tapered bar material

29
 Fig. 18 Flycutting cylinder soleplate

blocks are needed for adjusting the being used to face a cylinder sole-plate for
bearings in the rod ends. The rectangular a slide valve engine model of 24 in. stroke.
section bar is held in a vice on a tilting
angle-plate which has been set at 6
FACE MILLS
degrees to the table of the miller with a
Starrett combination protractor. The Of course, multi-cutting-edge face mills
tapered form will be seen on the end of permit machining a surface quicker than a
the completed piece lying on the single point tool can do, and with less
angleplate. This is an easy way of getting snatch and jerking, but commercially
a special section which cannot be bouqht, made they are very expensive, and in the
and which would, to say the least, be home workshop the greater productivity is
tedious to make by filing. not usually of much consequence. Never-
These flycutter holders do not allow theless, for anybody willing to spend the
much adjustment of the radius of the time needed they can be made in the
cutter bit, but with some makes of boring home workshop, with several cutter bits
head there is quite a lot of adjustment. For mounted in one mild steel body. Fig. 19
example the Dore boring head permits of shows a face mill of this kind, which was
using a cutter in a $ in. diam. bar at any made originally to screw on the spindle of
radius up to 24 in., and by setting the a Myford lathe to do some repetitive
saddle in or out on the slide body the milling of a fairly heavy nature, now no
radius can be adjusted by fine amounts to longer required, but it is still a good
suit any job within the range. Fig. 18 general purpose tool. İt has 12 tool bits +
shows an old type, pre-war boring head in. diam. set into flat bottomed holes, all

30
 Fig. 19 Facemill

ground off to the same projection, and stationary engine. The casting is suppor-
sharpened to a diameter of approx. 21 in. ted by a special angle plate type of fixture,
In Fig. 20 it is shown milling the face of the pattern for which was made in an
a half-flywheel iron casting for a model hour. Without this fixture the operation

Fig. 20 Milling flywheel joint face

31
 Fig. 21 Milling crosshead slide

would be somewhat difficult. If the parallel passes with an endmill much

casting was held in a vice on the table the narrower than the face required. Apart
point of cutting would be a long way from from taking more time than a too! with a
the holding point, and movement of the wide sweep, minute ridges tend to be left
casting under the pressure of cutting where the passes overlap, and these may
would be not easy to prevent. Vibration have to be removed later by filing or
and chatter would be more likely. It very scraping. So while this method is feasible
often happens that the only way to get a the flycutter or boring head is better
satisfactory job is to make some equip- where there is room to use it, and the
ment specially for it. This is not usually cutter bits are cheaper than endmills and
wasteful, especially if a duplicate compo- easily sharpened like any lathe tool.
nent is ever required, but the equipment is However, an example of work where a
usually found adaptable for some other small cutter and successive passes must
job later. Doing metal cutting by ‘knife- be used is shown in Fig. 21 where a flat
and-fork methods can soon lead to bedplate slide for the crosshead on a
disaster. The other half of the wheel model stationary engine is being milled.
casting, with the cast-in teeth for the The surface being cut is in a recess š in.
barring ‘rack’, can be seen in the bottom deep and the corners cannot be dealt with
half of the picture. The wheel is 93 in. by a tool cutting the full width, as the
diameter and has 96 teeth. radius left would be too great. Note the
Broad flat surfaces can be, and some- stop bar bolted to the table. Accurately
times have to be, produced by successive squared with the table it provides not only

32
correct location for the casting (which was head could also be swivelled so that
followed by others) but also insurance angular faces could be planed also.
against slipping. After the planing of crosshead slides
In the full sized engines these slides they were tackled by the fitters and
were always planed, and every engine- scraped to a portable surface plate. This
building shop had planers for this kind of was coated sparingly with a mixture of
work. In the one where | worked there lamp black and oil, slid to and fro on the
were several of different sizes, and the slide, lifted off, and then all the black
largest, built by Joshua Buckton of Leeds, marks scraped away. The surface plate
could plane any casting up to 20 ft. long, was then put on again and a fresh lot of
12 ft. wide and 12 ft. high. It was said at marks made, which in turn were scraped
that time to be the largest in Yorkshire, away. This work went on for many hours,
and certainly it often did castings for other indeed on a big slide two men could
firms. Cutting could be done in both direc- spend two or three days. For such work
tions of the table travel at equal speeds, or the surface plate would be so large that
in one direction with a quick return the two men could not lift it without the use
other way. Each of the four toolheads had of the shop crane. Eventually after a long
power operation independent of table time the finish obtained would be
movement, so that cross-planing could regarded as acceptable. İt then consisted
be done through bearing recesses, etc. of a very large number of extremely
One of the pictures shows this operation shallow depressions between the marks,
on a model being done by milling. Each and each of these proved to be an oil

Fig. 22 Milling bearing jaws in bedplate

33
pocket. When the engine was eventually speed of about 80 r.p.m. would make
put to work, with the cross-head having approx. 3600 million cross-head strokes
had similar treatment, the result was that in that time! Not a bad performance?
the cross-head ran to and fro on a film of When flat surfaces have to be produced
lubricant which reduced wear to a very at right angles to the table it is necessary
small amount. Engines in textile mills to use the side of an endmill. This may be
would run 60 years and at the end you quite unavoidable on some components,
would find the scraper marks still there. such as the model engine bedplate shown
The oil was continuously renewed by in Fig. 22. There is not much choice about
brass combs attached to the crosshead milling out the jaws for the crankshaft
which picked up oil from a well at each bearings. This is an operation which the
end of the slide. An engine running night big planer used to do with the power drive
and day, as many of them did, with a on the heads of the cross-rail.

34
CHAPTER 3

Slitting and Cutting

İt is common practice to design machinery cutter, and a nut to secure it. Its a good
components with split bosses which can thing to put a pair of flats on the arbor to
be contracted with a screw for tightening hold it by when turning the nut. Fig. 23
purposes. The slitting can be done with a shows a slitting saw in use cutting
hacksaw, but if done in unskilful fashion through one side of the boss of one of the
will not look good when completed. parts of the Quorn grinder. On that
Slitting saws and many other disc type machine there are several components
cutters can be readily used on the vertical with this feature, so time will be saved if
miller by mounting them on a Morse taper they are all collected and cut through
arbor having a parallel portion for the while the saw and vice are in position.

Fig. 23 Slitting boss of casting

74 qa _

—s
-
m” -

>

35
 Many other jobs of similar nature will burrs to enable them at once to be bolted
come to mind, such as engine eccentric together. Not only are castings involved
sheaves, and especially eccentric straps, but also parts made from bar material.
which can be cast in one piece and then Marine type connecting rod ends are an
cut through, leaving two surfaces that example, and this method can also be
need only a touch with a file to remove used for producing bearings in halves.

36
CHAPTER4

Keyway Cutting

Keys and keyways are a very common engines, gearboxes, and other machinery
feature of machinery and naturally of components in the past have had wheels
models too. The common round-ended mounted on tapered shafts with the
keyway, for a “feather key, is easily keyways following the slope of the taper.
produced on a parallel shaft by holding the Modelling one of these would involve
shaft in the vice and using a small endmill, following the same procedure. One way in
or two-flute “slot-drill'. Fig. 24 shows the which this can be done is shown in Fig.
setup for this operation. 25. The vice holding the shaft is set on a
Various parts of car and motor cycle tilting angleplate so that the top of the

Fig. 24 Milling feather keyway

 Fig. 25 Milling feather keyway on tapered shaft

tapered part comes parallel with the thicknesses, and are always coming on
machine table. The shaft shown in the the surplus market at low prices. One of
picture is a simple one and quite short, these is shown in Fig. 26 milling an
and could have been just tilted in the vice ordinary sunken keyway, the shaft being
in a set-up like that of Fig. 24. But a long held in a vice with enough overhang to
shaft might well foul the table at its lower avoid the cutter touching the vice.
end so the elevation which the angleplate
gives could in such a case prove essential.
WOODRUFF KEYS
Small endmills are rather frail tools at
best and liable to easy breakage. The disc The Woodruff key is one widely used in
type cutter is more robust and a collection industry. This is in effect a slice off a round
of these acquired either as the need for bar, cut in half and set into the shaft in a
one crops up, or bought cheaply second- recess made by a small diameter slitting
hand, is worth while. Of course the disc saw. This is rather an oversimplified
cutter cannot always go close to a description, but it will serve well enough
shoulder on the shaft, and copying a as an introduction to the Woodruff key for
prototype may in some cases rule it out. those in home workshops without
For the work done in the home workshop industrial experience. Seriously, the
there is no need to insist on the relatively Woodruff key, which | think was of
expensive side-and-face cutters, (those American origin, has some very real
with teeth on the faces as well as the peri- advantages for the mass production
phery) because the slitting saw, with teeth industry, and some of these are of just as
only on the periphery, will do quite well. great importance in the home workshop
These are made in a very great variety of and the field of light engineering.

38
 Fig. 26 Milling keyway with slitting saw

For a start the key itself can be parted accuracy from the bright bar. The
off from a piece of round mild steel or thickness needs careful control, but if it
silver steel. So its diameter is settled with comes off a bit too thick it can be rubbed

Fig. 27 Set of four Woodruff keyway cutters

” ”

2 4

39
down on a flat file. It needs to be cut in key is made, with an integral shank of pre-
two on a line which is nearly a diameter, ferably some standard diameter which can
but the cut edge can readily be filed to be run true in a collet on the miller. So the
bring it to final shape. The keyway is made shape of the keyway profile — and its
by a simple cutter like a slitting saw, of the width — is settled by the cutter form. The
same diameter as the bar from which the cutting part of the cutter is set in line with

TABLE II

56 x20 BSF FOR F

CLARKSON & OSBORN CHUCKS.

WOODRUFF
KEYS & KEYWAYS CUTTERS
A BİCİDİE İF |e
% 1097073 "037 "100 "030
Ac

% |% 172 4125 (053) 129"045

2 |“$a1203155 (053 "87 (060
40
the diametral line of the shaft, then the teeth can be cut in two operations using
cutter is fed in by a predetermined an ordinary end mill; there is no need for
amount. angular cutters, as the diagram on the
The resulting keyway is deep enouqh to opposite page indicates. The number of
give the key a good hold, so that it cannot teeth is not important, but six is a con-
roll over, and yet the shaft is not unduly venient number for small cutters. It is
weakened. Normally the top of the key is possible to file the teeth if you do not have
just clear of the keyway in the wheel or access to a dividing head, as the spacing
lever which is being secured, its purpose is not at all critical, but it's a little more
being to provide either torque or angular difficult. Fig. 27 shows a batch of cutters
location, and some means such as a grub made to the sizes in Table Il and Fig. 28
screw may have to be used to prevent shows a keyway being cut. There seems
endwise movement. to be no place where sizes of Woodruff
Woodruff cutters are not very cheap, keys and cutters are displayed for model
but they can easily be made in the home engineers. Machinery’s Handbook gives
workshop, from silver steel. The process is sizes which are used in industry, but the
really quite simple. A blank can be turned, sheer range of sizes is itself confusing, and
making a shank to suit some standard of course the tables are liberally sprinkled
collet, then with the shank held in the with tolerances that modellers could
collet the working part of the cutter can be neither follow nor want. | have therefore
turned to its diameter, and thickness. The picked out a few sizes which 1 think will
sides should be very slightly undercut by serve our purpose, and as we don't have
setting a knifetool a little off square. Using to provide interchangeability in our
a simple un-geared dividing head the products, if anybody wants to depart a bit

Fig. 28 Milling Woodruff keyway

41
from these dimensions he can certainly do shown in Fig. 27 are stamped with their
so. Up to date of writing | have not seen size details. It is a good plan to have a set
any specification of Woodruff keys in of small stamps, say 1/16 in. characters,
metric sizes. so that appropriate identity can be marked
The cutters shown in Table Il have on all home made tools, jigs, etc as well as
screwed shanks to suit Clarkson and model components. The holes drilled in
Osborn chucks, which have collets that these cutters were provided for the con-
close on the cutter shank through end venience of the hardener. They were
thrust exerted by the cutter against the hardened for me by a firm where liquid-
inside of the chuck. If you are making salt baths are used for heating and
cutters for use in a Clare chuck or just to quenching tools. A small hole enables the
use in a 3-jaw, these threads are not tool to be hung on a wire in the baths
needed. İt may be noticed that the cutters without damage to cutting edges.

42
CHAPTER 5

Fluting Components
other than Tools
Fluting of locomotive connecting rods and progressively along the rod, leaving
coupling rods is an operation very similar behind the swept end. Where the cut
to keyway cutting so far as the removal of finishes there is also a swept end,
metal is concerned, but the length of the automatically. Coupling rods usually have
flutes is usually greater, and the length of flutes that are parallel sided, and so do
the pieces demands some well arranged some types of Canadian and American
holding methods. One occasionally sees connecting rods. In these cases a single
rods which have been fluted with an pass with a cutter the right width will
endmill by the same method as shown in complete the job. Most British
Fig. 24, giving rounded end flutes like a locomotives, on the other hand, had
feather keyway. This is entirely wrong, no tapered connecting rods with parallel
full size rods were fluted this way. They flanges, i.e. tapered flutes. For these two
have flutes with rounded internal corners passes are needed, and this can be
in the bottom, and with swept out ter- achieved in a very simple way.
minations at the ends, which is done to In Fig. 29 the rod of a Canadian engine
avoid the notch fatigue cracks which can is seen fixed on the angleplate. In each
propagate from sharp corners. Fortunately end is a screw with a head turned to the
it is quite easy to produce flutes which are size of the hole in the rod end. This is a 12
in accordance with full size practice, and in. long angleplate with no slots, as holes
not even necessary to have a fancy milling are drilled and tapped just wherever they
cutter. A simple tool bit, ground rather like are needed for each job. İt will be many
a parting tool, with the corners rounded years before it is so perforated as to be no
off, is put into a transverse hole in a cutter further use. The tvvo holes for the locating
bar, and mounted in a chuck on the miller. screws are the same distance from the
The rod to be dealt with is fixed edgeways table, and they only provide the location,
up, as it goes in the loco, preferably the rod being secured against the cutting
against a long angleplate, and the rotating forces by tvvo small clamps as shovvn. For
cutter is fed in like a Woodruff cutter this rod and for coupling rods the set-up is
would be. When in to proper depth, exactly as shown. But for British type
usually quite shallow, the table movement rods, the screvv in the big end is made
is started and the flute is then made smaller than the hole in the rod by the

43
 Fig. 29 Fluting locomotive connecting rod

amount of the taper (at the hole centres) square bar can be dropped into it. That
and for the first operation the rod can be enables fixtures to be instantly lined up
allowed to drop down on the screw while with the table movement, including
the first cut is taken. Then for the second dividing heads as well as angleplates. The
cut the rod is lifted up as far as the screw thrust of the cutter in this example tends
will let it go, and re-clamped, and a to move the angleplate away from the bar,
second cut taken. The rod will now finish but it is secured with two qood bolts in
with a taper flute and two parallel flanges. the table slots, not visible in the
This fluting is a very simple operation. photograph. It should not be forgotten
The angleplate is extremely rigid. The that locomotive rods which are fluted at
machine in the picture is happily provided all must be done on both sides, but with a
with a 3 in. wide keyway along the centre set-up like this the job is so simple it
of the table, only + in. deep, but a + in. would be a pity not to have it right.

14
CHAPTER 6

Boring

It is not uncommon to have bore holes in hole) on the miller table and using a cutter
components which are much too larqe to in a boring head. With the worm-actuated
swing around in the lathes that are found down feed, and the bottom speed of the
in most home workshops. But there is no Dore-Westbury machine, 34} rpm, an
need in many cases to resort to hand excellent hole was obtained four inches
tools, even for holes where great accuracy diameter. Without these facilities the work
is not needed. The vertical miller can be would have been sent out to some
used for boring (with a trepanning tool ina engineering firm. The ampler space on the
boring head) such things as fire-hole tables of milling machines, compared with
doors in boiler plates, bosses on castings what one can get on a lathe saddle with
such as long levers, and many other an angleplate, makes the miller invaluable
objects. In order to motorise a shaper | for work of this kind and of course by
had to bore a hole through 2 in. of cast doing external turning with a boring head
iron to mount a worm reduction gearbox, one can deal with male registers as well
and this had to be a true round hole. It as holes. This is a simple operation too:
was done by fixing the casting (15 in. long one just turns the cutting tool inward
in one direction from the centre of the instead of outward.
CHAPTER 7

Jig-Boring
The term ‘jig-boring’ is likely to be the parallel motion, pump rods, etc. The
unfamiliar to many readers of this book, casting can be clamped to the table quite
and they may think that whatever it firmly, resting on packaging of reasonable
means it must be a long way removed thickness so that a penetrating drill does
from model engineering. This is not so, for not dip into the table. At this stage all
in model making plenty of operations arise bosses can be faced with an end mill,
that can be done by ‘jig-boring’ to advan- even if they are at different levels. The
tage. Basically it only means fixing a com- centre line of the casting should have
ponent to the machine table and then been set parallel with the line of the table
using the table screws as measuring movement. Put the drill chuck in the
devices to position the spindle over any spindle, with a fine pointed dummy drill
part of the component that is desired similar to a centre punch, and bring this
before drilling or boring a hole. In many over the first boss centre. Then wind on
ways this method is better than marking the table the amount to the next hole and
out, measuring with a rule, then centre- check if the point comes in the right place
punching followed by drilling on a drilling over that boss. Wind on again to the next
machine. For one thing the workpiece is and so on checking at each boss. If all
firmly held, the table screws are come central, all is well. If one or more
reasonably good measuring devices, and don’t, then an allowance will have to be
many holes can be made, of any diameter made as a compromise. Make a note of
needed, without losing the attitude of the what it is, re-start at the beginning, and do
piece to the table, or one hole to another. another run till you are satisfied you have
Let's take a fairly common component, got the right starting point for the best
the beam casting of a model beam engine. results. If you happen to turn the table
This will have several holes to be drilled, screw a bit too far at one of the stopping
usually along one straight line, and rather points, dont worry, but dont turn it back a
important, all these should be parallel with bit as a correction, because that vvay you
one another if the finished engine is to run could introduce an error through backlash
smoothly. There will be one hole at each (lost motion due to slackness) in the
end, and a main trunnion hole at the screw and nut. Go back to the very start
middle, plus one or more for the links of and come at it again. It's a good thing

46
 3 HOLES “6 lo

Fig. 30 Drawing of steam hook (lever)

when doing an exercise of this kind to position by using the table cross-screw to
have a paper and pencil handy and write provide the amount off the main line.
down the micrometer dial readings which When all the holes are finished the beam
are the stopping points. This reduces the can be turned over and the bosses milled
chances of accidental error. It is a method on the other side.
used by men in industry who are engaged The beam engine casting is just one
on delicate work where a momentary example of how this sort of task can be
interruption can be disastrous. | have handled. Fig. 30 is a drawing of a compo-
myself used it for many years. At this nent of the trip gear of a model steam
stage drilling can now start. Each hole engine, and the holes which have to be
should be centred with a D-bit ground to drilled are in positions which would not be
about 118 degrees, followed by the easily attained by the common marking-
appropriate drill, though the larger holes out and centre punching process. Fig. 31
may need a pilot drill putting through first. shows one of the finished pieces with one
As each hole is finished, with reaming if only part-made, to show the method
needed, move on to the next hole by the adopted. One inch diameter bar was used,
table wind, and go through the procedure as that gives the outside profile needed.
with that, too. By this method all the holes Set true in the four-jaw chuck it was
will be the right distance apart, and will all bored 9/16 in., then set out of true by
be parallel to one another in two planes. It .047 in. and the hole re-bored to the same
will be clear that if any holes are wanted setting. Next it was set well off centre to
which are not on the main centre line, it is drill the No. 38 drill hole. The correct
a simple matter to drill these in an off-set setting was established by measurements

47
taken off the outside surface of the 1 in. complete control and exactly as specified
bright bar. With the piece still held, the on the dravving.
chuck was removed from the lathe and There are many other articles in model
bolted on the milling machine table. A engineering vvhich lend themselves very
number 38 drill, running in a true chuck, well to the jig-boring technique. Locomo-
then ‘picked up’ the existing hole and the tive boiler tube plates vvith a large number
dial readings on both screws of the table of holes can be done this vvay, and
were noted (and written down). The drill because some of the holes may be ? in. or
was changed for a very short stiff 1/16 in. even more in diameter it is vital to have
drill, the table screws were rotated, to the metal clamped dovvn to avoid
bring the first 1/16 in. hole position under personal injury, as copper is not one of the
it and that hole then drilled. Further kindest of materials for machining. But if
rotation of the screws brought in turn clamped on packings on the miller, any
each of the other holes into position and large holes for vvhich drills are not avail-
the drilling was quickly completed. The able can still be dealt vvith by using a
chuck was then returned to the lathe. The boring head. İf a large drill is available, and
first boss around the No. 38 hole was the machine has a low enough speed to
turned and the piece parted off, care being avoid chatter, there will be no ‘three-
taken to leave the shallow boss on the cornered’ holes made to cause embarrass-
parting side. Then the second boss was ment when fitting flue tubes and silver-
turned, another parting off, and the two soldering them at a later stage. It will be
components were through that part of the found that as familiarity with the vertical
process. It remained only to cut the miller develops, other examples will arise
desired piece out of the ring and file up in which this high-sounding but really
the two ends to the rounded profile. By quite simple technique can be borrowed
these methods a component of a rather from industrial practice, with great
complicated shape was produced under benefits.

Fig. 31 Photograph of steam hook

“əti
”.—.
as. Pie

ahsm.
p 48. A
< 2. . `

48
CHAPTER 8

Profiling

lt is not unusual for large components to for locking tvvo machine parts together.
have portions which are circular arcs. The tvvo parts of the pad bolt vvhich are
Locomotive frames are common being profiled to suit a round column vvere
examples, with cut-aways to clear bogie made from one piece of steel, and cut
wheels. Such pieces are much too large to apart after the profiling. A groove can be
swing in the lathe, and while the bandsaw seen vvhere the separating cut vvas to be
if available can do a lot to relieve the taken. The cutter in the boring bar vvas set
tedium of drilling, hacksawing and filing, to the finished radius. Only the cross-feed
the miller can do a lot more. Using a of the table vvas used (to put the cut on
trepanning cutter in a boring head it can bit by bit) the other slide being locked. The
take away the unwanted metal in a single tool vvas traversed by the dovvn feed. İt is
operation to finished size on any arc. not possible to take the full amount of
Alternatively with a boring type tool it can metal removal in a single pass in a job like
follow the bandsaw and just avoid the this, but vvith successive cuts a perfect iob
filing. is assured. Similarly the holes for such pad
Smokebox castings for locomotives bolts are ‘part holes’ and could not be
and traction engines, however, often have drilled in the second stage to full size
circular arcs to fit the boiler shell, and the without guide bushes for the drill. But
bandsaw can be nohelp with these. But if drilling undersize and then opening out
they are set up on the miller, the radius with a boring head gets there just the
can be determined by the setting of a same, a bit less quickly.
boring head cutter, and traverse across Profiling locomotive connecting rods
the vvork provided by the dovvnfeed of the and coupling rods can be a somewhat
spindle, even though this is usually tiring operation if one has to do it by
manual. That feed length may not be sawing and filing. Trying to do this work
enough to cover the face vvidth, but after on the boring table of the lathe with
going as far as the spindle will move, a vertical slide or angleplate is not very
second cut can be taken by resetting the happy either. Usually the cross-slide travel
head of the machine. is much too short to complete the length
İn machinery details the same in one pass, so that re-setting is
problems arise. Fig. 32 shovvs a pad bolt necessary, and the lathe does not have

49
 Fig. 32 Profiling pad bolt

Fig. 33 Profiling coupling rods

50
the in-feed facilities needed. Generally set-up shown in Fig. 33, where a pair of
with a vertical slide the point at which coupling rods, with ‘chucking pieces’ of
cutting is being done at the ends of a long extra metal at each end, are clamped on
rod is a very long way from the place packings in a safe and rigid set-up.
where the slide is secured, so that apart Generally the diameter of end mill used
from ‘spring of the piece there is danger can be arranged to give the right radius
of slipping taking place with disastrous where the body of the rod joins the
results. Compare such attempts with the bosses.

51
CHAPTER 9

End-Rounding

In model work, as in full sized machinery, another table which | have possesses a
many components such as crank webs, No. 2 Morse taper central hole and arbors
connecting and coupling rods, machine can be put in this for location. It is, in fact,
links, etc. have to have rounded ends. a Model Engineering Services Type RT3
These can be produced by filing, and the which does not have a tee-slotted table,
use of hardenerd steel collars and rollers but has a spindle screwed like the Myford
for quides has often been recommended lathes and will accept any chucks or
in Model Engineer to help the not-so-good faceplates from the lathes. This makes it
filer to achieve a good appearance. Even feasible to turn, say, a cylinder cover and
with these, this kind of filing demands a transfer it to a rotary table for drilling the
skill which many modellers just do not bolt holes without losing the accuracy of
have (and will never acquire, for want of setting. But that is not a feature of impor-
practice, if nothing else) so for that reason tance for round ending operations. | have
alone it is not a good method. But it is used it for a number of engine cranks in
also rather severe on files, which are now the manner shown in Fig. 34. Each crank
quite expensive tools, and unlikely ever to was located on the arbor but also clamped
get cheaper. with a slot plate resting on Picador
So where there is a vertical miller avail- stepped packings, a pair of these being
able, why not do the job the right way, as also under the crank itself. The cutter is a
it would be done in commercial engineer- + in. end mill cutting on its side.
ing? It means investing in a rotary table, In all rotary milling of this kind where
but these can be bought in kit form as well the cutter is working on the outside of the
as complete ready for use, and if component it is vitally necessary to feed
machined and assembled by the home the table clockwise seen from above. All
worker himself, are not terribly expensive. normal milling cutters rotate the same
Presuming that the component has a way as a twist drill, so whichever side of
round hole at one end, a plug is needed in the work the cutter is touching, the work
the table so as to locate by that hole. | must meet the cutter, and that means
have a small rotary table with a 2 Whit. clockwise rotation is essential. Otherwise
hole in the centre and have a number of if the cutter is going the same way at the
plugs of standard sizes to fit that. But surface as the work it is certain to grab

52
 š ? , alı
Fig. 34 End-rounding vvith rotary table

hold and that means at least spoiled work, drill the chuck boss vvell avvay from this,
probably a broken cutter, and a lot of grief. so that you have tvvo positively separated
But if one is working on an internal profile, dimples, each for its ovvn accessory.
such as trimming the inside of the rim of a | have used a 5/16 in. BSF socket grub
flywheel, then the forces are reversed and screw for this purpose, with a point
the work needs rotating anti-clockwise. modified (in the lathe) to a longer cone.
Now the threads of the RT3 spindle are But | found the ordinary hexagon key was
like the Myford lathes, right hand, so not really long enough to be convenient
when one is doing inside work a chuck or with a standard 7 ins. Myford faceplate.
faceplate is tightened by the thrust of the So | cut off the short bent end of the key
cutter. But when doing the, perhaps, more and fitted the long part to an extension
normal milling on the outside of a piece, made of + in. bright mild steel. This was
the cutter thrust tends to undo the drilled in the lathe 3/16 in. deep with a
faceplate, and unless the work is very light No. 16 drill which is about the across-
cutting, this is what will certainly happen. corners size of the hexagon, then 7/16 in.
The only satisfactory answer to this further with a No. 22 drill which is about
problem is to drill and tap a hole through the across-flats size. The two pieces were
the boss of the faceplate, make a coned then pressed together in a big vice, the
dimple in the table spindle at the same squared-off end of the hexagon cutting its
spot, and insert a screvv vvith a cone point way down the hole in the mild steel. A
that fits the dimple. Not a difficult matter 5/32 in. cross pin was fitted, Loctited in,
at all. But if you are going to use a chuck and now | have a Tee wrench long enough
on the same table for the same kind of to reach the screw in the boss without any
vvork, then make a pencil mark to shovv difficulty. İt took only five minutes to make
where the dimple is for the faceplate, and and is a convenience there for ever.

53
CHAPTER 10

Dividing Heads

For many products the use of a dividing teeth of the change wheel may be badly
head is an absolute necessity. Many home damaged. In fact when doing this sort of
workers, especially those without any fixing | always disengage the plunger,
engineering experience, regard them as then if the screwpad does not hold, no
most mysterious devices, almost border- damage is done.
ing on the occult, and say without really By selecting a suitable change wheel it
thinking, ‘Oh. | could never use one of is possible to get quite a lot of divisions
those!’. Well, a dividing head is really no very easily. For example a 60 tooth wheel
more than a headstock with a spindle on will give 2, 3, 4, 5, 6, 10, 12, 15, 20 or 30
which the work is mounted, with some divisions. İt vvill not give 8, but a 40 tooth
means of turning it through positive vvheel vvill do so. VVhen doing dividing
angular amounts, and holding it there vvith this kind of device it is a good thing
when each movement has been made. to have a bit of chalk handy and mark the
Naturally there are many types of dividing appropriate tooth gaps vvhere the plunger
head and over the years many designs is going to have to drop in, before starting
have appeared in Mode/ Engineer for cutting, to avoid incorrect settings vvhich
heads which can be made in the home vvould spoil the vvork. Many examples of
workshop. A great deal of quite machinery parts to vvhich a simple head of
satisfactory work can be done with a this kind can be usefully applied could be
simple head of the type shown in Fig. 35. given. Such items as crankcase drain or
On the spindle, provision is made for filler plugs vvhich need hexagons, square
mounting a lathe change wheel. A spring- ends on shafts, tools like taps, reamers,
loaded plunger with a conical point drops parallel flats for spanners on round
into the gap between two teeth of the articles, all these can be formed so very
wheel, and then the spindle is locked by a easily vvith an end mill, vvith less physical
screw bearing on a pad inside the main effort than filing, and vvith an accuracy
bearing. It is advisable not to rely on the which enhances the appearance of the
plunger holding the spindle against article even if dimensional accuracy as
rotation when screwing on chucks of such is not important.
when fixing a component on an arbor by But there are examples vvhere accuracy
means of a nut. If the spindle turns, the is fairly important, and one vvhich could

54
hardly be done at all with hand tools is strength was needed to transmit a lot of
shown in Fig. 35. This is one half member power this might have to be done, but it is
of a dog clutch. The 12 teeth are being cut a good deal more difficult and would
with a slitting saw which passes across rarely be worth the trouble. Unless you are
the work right on the centre line. After using a well-established design for which
each cut, the locking screw was eased, drawings are available, it is advisable to
the plunger lifted out, the wheel turned lay out the tooth design on the drawing
five teeth, and the plunger dropped in board, preferably at an enlarged scale, to
again. The spindle was then locked and verify the thickness of cutters which will
the next tooth gap cut. Really a very produce the desired result. They may be
simple procedure. Now on the other half the same thickness for both halves, but
member of the clutch the teeth have to maybe not, it depends on the thickness of
have parallel sides, and the gaps them- tooth selected. It is also a good thing to
selves are taper sided. This just involves avoid an odd number of teeth, because
setting the cutter with its bottom edge the curve of the cutter when going
above the centre line by half the thickness through one side may be chewing into the
of the teeth left upstanding in the first metal which has to be left intact on the
half. The same procedure of cutting right opposite side to make the tooth. If your
across is followed, and after six passes the design can arrange for an even number of
job is complete. It is feasible, if you are teeth this risk will be eliminated. Another
willing to take the trouble, to make a point is to check that the desired number
clutch with all tooth sides tapered, so that of teeth can really be secured with the
the two halves are identical. If maximum dividing head you intend to use.

Fig. 35 Cutting teeth in dog clutch part

AS
 STEADY STAND For
MYFORD Div DG HEAD

56
MYFORD DIVIDING HEAD worm geared dividing head. When moving
from one position to the next, always turn
The Myford dividing head is an excel- the worm the same way, never go back. If
lent piece of equipment, with a very wide by chance you overshoot the right hole, of
range of divisions. The main spindle has a course you have to turn back, but go well
60 tooth worm wheel on it, and a single- back, way beyond the hole you want by a
start worm meshes with that. Concentric good margin, then come up to it afresh. If
with the worm there is provision for you fail to do this you will have an error in
mounting a multi-holed division plate your dividing and a scrapped work-piece.
which remains stationary and does not Our old enemy ‘back-lash’ will see to that.
rotate with the worm. On the worm But it's easy enough to avoid this kind of
spindle is fitted an arm carrying a spring- disaster. There is provided on the head a
loaded plunger which has a point of most important aid to correct counting of
parallel shape that enters holes in the the number of holes needed when turning
division plate. This arm is slotted and can the worm. Two brass blades are fitted
be set to such a radius as will bring the around the worm shaft, above the division
plunger in the right place for any of the plate, and these can be moved relative to
rows of holes that are already drilled in the one another, by loosening a screw, and
plate. Having set the arm, if one turns the set to embrace the number of holes
worm one whole turn and drops the needed. Than after locking with the
plunger back into the same hole from screwdriver, they make a mask to show
which it started, the main spindle will just where the plunger should be dropped
have rotated one sixtieth of a turn. But if in. After each movement you rotate them
one moves the worm and arm five till one blade comes against the plunger,
complete turns before dropping in, the and you are then ready (after doing the
main spindle will have turned one twelfth cutting of course) for the next move. In
of a turn. Basically, that is all there is to this part of the procedure the two blades
getting any desired number of divisions. move together as if they were one piece of
Having got the right division plate on the metal.
head one moves the arm so many turns,
plus if necessary, a certain number of
holes extra to the complete turns. A chart STEADY STAND
supplied with the head gives all the avail- | have found in using the Myford head
able combinations. In order to accomplish that it is a convenience to be able to set it
all divisions up to 100 it is necessary to at lathe centre height when fixed on the
have 4 plates, but two of these are needed boring table. If one wants to drill cylinder
only for some rather outlandish numbers covers and similar work the radius of the
with which few model engineers will ever row of holes can be readily obtained by
have to deal, so the two normal plates will the cross slide screw and the measure-
serve almost everything. There is one ment is direct. So | have a packing block
point of practical importance in using a of the right thickness which | can place
under it for this purpose.
There is one minor criticism of the
Myford head which is nevertheless impor-
Opposite, Fig. 36 Drawing of steady stand for tant from a practical point of view. The
Myford dividing head single bolt which holds it to a machine

57
 Fig. 37 Steady in use on a gear cutting operation

Fig. 38 Author's design for simple dividing head

58
table or vertical slide, etc. does on for gripping the 1 in. bar of the head. The
occasion come a long way from the point various clamps can be moved separately
where cutting is being done, and accor- and make a pretty universal fitting. The
dingly there is danger of the work being whole thing is shown in use in Fig. 37.
spoilt by the head slipping. To overcome This fitting of my design is not on the
this | have made up a steady stand from market, but it has proved so useful to me
mild steel bar material which bolts on the that | am giving a working drawing of it in
table of the miller, and clamps on the 1 in. Fig. 36 and anybody who likes can make a
overarm bar of the head. The stand has a unit for himself.
vertical š in. bar set into a flat base with a
slot for a table bolt. A two-way clamp
OTHER DIVIDING HEADS
slides on this vertical bar, and another š
in. bar passes through it horizontally. At Since the last edition of this book was
the end of this is a two-plate clamp printed three new dividing heads have
gripping the 2 in. bar, with provision also appeared on the market. The first, of my

Fig. 39 The George H. Thomas Versatile Dividing Head

59
 “
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CHAPTER11

Dividing Heads and

Gearcutting
The availability of a dividing head is again held for convenience in a boring head. It is
essential for doing gearcutting on the shown in close-up in Fig. 41. The profile
milling machine. Of course there are types was established by grinding to suit a
of gears one just cannot do, but ordinary wheel of the same pitch with slightly more
spur gears can be done perfectly well for teeth. The variation is so small as to be of
model engineering purposes, where no importance, especially as the pinion
neither high speeds, extreme silence, nor rotates at only a low speed.
high rates of power transmission are But if several gears are to be made, and
demanded. The design of qears is a especially if duplicates may be wanted
subject outside the scope of this book, later, it can be worth while to invest in one
which is intended to deal with workshop or more proper disc type gear cutters of
operations, but there are plenty of sources what is now universally known as the
of information on gear design. The simple ‘Brown & Sharpe’ type, because they
type of dividing head already illustrated were developed by the famous firm of
will serve very well if the gears to be cut Brown & Sharpe in U.S.A. many years
have such a number of teeth as the ago. They are of course now made by
indexing change wheels can deal with. British firms as well, and by others all over
But if the number required cannot be qot the world, to an accuracy of international
from existing wheels, then a more standards, far better than anything that is
complex head such as the Myford, will be needed for model engineering, and are
needed. Fig. 37 shows this in use cutting properly backed off as well as being made
the teeth of a pinion which are integral from high speed steel. No single cutter
with the shaft. The blank was turned to 3 will properly deal with all number of teeth,
in. diameter on the part to be held and this so they are made in sets, eachs cutter
was gripped in the standard Myford + in. dealing with a limited range, and each
collet, while the other end of the compo- bears an identifying number. The range
nent being centred was supported by a runs as follows:
60 degree centre in the overarm fitting. No.1 135toarack No.5 21to25
This picture shows the steady bracket No.2 55 to 134 No.6 17to20
described in the last chapter in use. The No.3 35 to 54 No.7 14to 16
cutter is a simple flycutter in a boring bar No. 4 26 to 34 No. 8 12 and 13

62
 bi

< ? ”..

kəs

Fig. 41 Close-up of flycutter and pinion

Fig. 42 Gearcutting with Brown & Sharpe cutter

63
 P

Fig. 43 Flycutting 10 d.p . gearwheel, front view

These cutters can be bought singly at teeth are 10 d.p., approx. 5/16 in. centres,
any time from regular tool merchants and so quite a lot of metal had to be removed
| doubt if any discount would be given for at each tooth. The cutting was done with
buying a complete set of 8. So there is no a flycutter, ground up by hand to match a
need to go to the expense of acquiring a silhouette of a 10 d.p. tooth in
complete set unless it is firmly known Machinery’s Handbook, using a magnifier,
there will be a use for every one! Fig. 42 this cutter being set in a boring bar of
shows one of these doing a similar job to rather excessive length in a boring head.
that depicted in Fig. 37. The smoother Two cuts were taken, but even then there
action of the multi-toothed cutter made it was a good deal of spring and noise. The
possible to dispense with the use of the shape of the blank casting was arranged
steady stand, though care was taken not to provide for mounting by 8 bolts on the
to be too rough with the feed, especially large Myford faceplate, (9 in. diameter)
at the start of each cut. and this was fixed on the miller table so as
Going now from what might be called to overhang the side. That permitted fixing
the sublime to the ridiculous, or at least a standard angleplate on the table too,
from the miniature to the outsize, the next just touching the back of the faceplate,
photograph shows the cutting of a much which reduced the springiness of that, and
larger gear, actually 9.600 in. p.c.d. This is provided a back-stop against the danger
a gunmetal gear needed as part of a metal of slipping. It would have been asking a lot
pattern from which the flywheel of Fig. 20 of the single bolt of the dividing head to
was made. It is only 3/16 in. thick but the prevent movement, under the conditions

64
 Fig. 44 Flycutting 10 d.p. gearwheel, rear view

prevailing, but using this safeguard all avoid damaqe to machines and work, as
went well. well as possible injury. Fig. 43 shows the
İt is well worth keeping in mind in the front of the gear disc, and in this view the
home workshop that this method of dividing head is not visible. But in Fig. 44
back-up is widely used in the engineering both the angleplate and the dividing head
industry, especially in the heavier are seen. The gear blank would only just
sections, on planing machines and others swing in the gap of the Myford lathe so
where there is either high thrust or high without raising blocks it represents about
impact, sometimes both, because it can the largest job that can be turned.

65
CHAPTER 12

Dividing Heads and

Tool Making
There are many occasions in tool making rough and ready methods just will not do,
when dividing is necessary. Multiple and as in the next example the physical
edged cutting tools like taps, reamers, difficulty of getting at the metal that has
milling cutters, countersinks, etc. all really to be taken away more or less settles that
need dividing devices to produce the best mechanical dividing must be employed.
results, even though some of the simple Fig. 45 shows the fluting of a long-thread
cutters can well be made by filing or Acme tap which is held in a collet in the
freehand grinding. However, the form of spindle of a simple dividing head, using
the teeth or flutes sometimes settles that change wheels for the dividing. İn order to

Fig. 45 Fluting Acme thread tap

66
obtain the maximum swarf clearance this Another example of the use of the
tap has five flutes. The head has no dividing head, this time coupled with the
tailstock so the outboard end of the tap is use of a small rotary table, is shown in
rested on a pair of Picador blocks and the Figs. 46 and 47. The workpiece to be
clamp rests on another pair. These are produced was a fine tooth milling cutter
very useful accessories for milling opera- with a round end for routing or hand
tions. Of course each time that a flute is milling on the light alloy cylinder head of a
completed the clamp has to be released car engine. The commercially available
before the work can be rotated to the cutters for use in electric drills had such
position for the next flute. A suitable coarse teeth that once they touched the
tailstock, were it available, would obviate surface of the alloy they were uncontroll-
the need for this. The 5 flutes are obtained able and pulled sideways so violently that
by moving 12 teeth at a time on a 60 damage to the cylinder head was almost a
tooth wheel. The cutter being used is a certainty. So as fine pitch cutters
commercial tap-fluting cutter picked up appeared to be not purchasable it was
cheaply at a sale. These cutters are made decided to make one. The blank, of a
with a somewhat lop-sided rounded carbon steel similar to silver steel but
profile specifically for this duty, but if it somewhat lower in carbon, was made to
had not been available, a flycutter would hold in a collet and was given a small
have been ground up to the profile of a recess in the end for the fluting cutter to
similar tap. The profile is not desperately run into. The dividing head, with a 50
important and a small error would not tooth change wheel on its spindle, was
matter. mounted on a steel plate so that the end

Fig. 46 Cutting teeth of ball-end cutter

67
 Fig. 47 Close-up of ball-end cutter

of the work-piece was beyond the centre table traversed along bringing the cutter
of the rotary table by half its diameter. In into operation cutting along the cylindrical
other words, the centre of the ball end portion. When the table was arrested by
was over the centre of the rotary table. the temporary stop block, the rotary table
The axis of the work was on the rotation was turned by means of its worm, so the
centre. This is not apparent from the dovetail cutter continued cutting round
photograph, but was an essential feature the ball end of the work. When the cutter
of the set-up. A stop block was clamped ran into the recess, the feed was reversed
to the underside of the milling machine first with the rotary table, then with the
table with a toolmaker's clamp, visible in main table, back to the starting point,
the photoqraph, to limit the table where the cutter was clear of the work
movement positively to this position. In shank. The dividing head was then
the other direction the movement of the indexed one tooth on the wheel, and a
table brought the cutter to a part of the new cut started. Eventually all 50 cuts
tool shank smaller than the diameter at were completed as shown in Fig. 47.
the bottom of the flutes so that indexing The working diameter of this tool is š
could be done with the cutter in the clear. in. and there are 50 perfect teeth. The tool
The cutter used was a carbon steel one was hardened and tempered, and when
made originally for producing locomotive put to use in an electric drill was found to
lubricator ratchet wheels, with a 60 be entirely satisfactory. It worked com-
degree single angle. With the axis of the pletely chatter-free, with no tendency to
work parallel to the table a cut was run away, and in spite of its fine and
Started at the required full depth, and the shallow teeth, removed metal at a very

68
 Fig. 48 Gashing flutes in large countersinking tool

gratifying rate. The work on the ports in this was to use a vertical slide. There was
the alloy head was completed to the great quite a lot of metal to be taken out of the
satisfaction of the user, leaving a beautiful 25 flutes in this decidedly tough steel, and
smooth surface for the gas flow. as usual the cutting was a long way from
Another example of cutting tool making the anchorage point, so the steady stand
is shown in Figs. 48 and 49. A large 60 was brought into use at the back of the
degree countersink was needed for a head, as it proved too difficult to set it at
commercial operation on steel tubes, the the same side as the cutter. However, it
tool being about 2+ in. diameter. İt was served quite well in that position and
made with an internal form identical with there was never any suggestion of
the Myford lathe spindles from a carbon- insecurity.
manganese chrome alloy of known The main gashes for the flutes were
identity, so that subsequent hardening taken out first, with two cuts down each
could be done without risk of failure in a flute. Then the head was tilted to a new
commercial establishment with angle and another series of cuts taken to
knowledge of this steel. İn the picture it is accomplish the relief. Because of the
shown mounted on the Myford dividing conical shape of the work the vertical slide
head having the flutes cut with a special had to have its base set at an angle to the
angle form disc type cutter. Because of miller table. All these apparently com-
the peculiar angles which are involved it plicated settings had to be established
was necessary to be able to set the head experimentally (though possibly with a lot
with its axis at an inclination to the table, of effort they might have been calculated)
and it proved that the simplest way to do to give the desired form of the cutting

69
 Fig. 49 Rear view showing steady stand in use

edges of the countersink and the rake if it had had to be made in a commercial
angles desired in two directions. The small factory.
division plate in use is one which had It is hoped that these examples of
been made some time previously for doing tool making will encourage all who need
125 division micrometer dials, for which non-standard tools, and who know of no
unfortunately the standard Myford plates firm that would take them on, or are
do not provide, or did not at that time. deterred by the high cost of labour-
However, with this set-up and not too intensive specials. Who knows, somebody
many hours work it proved possible with in a home workshop might take on the job
home workshop equipment to produce a of helping out some tool factory that
very suitable special countersink which would not want to be diverted from its
would inevitably have cost a small fortune normal work by jobs of this kind?

70
CHAPTER 13

Dividing Heads and

Graduated Scales
In the construction of small machine tools on the Quorn grinder, which is becoming
and accessories it is often desirable to more and more popular with model
have graduated scales for the con- engineers. Those who do not possess one
venience of precise measurements, and of these versatile machines may have
the cylindrical micrometer dial is undoub- some friend who can help out by grinding
tedly the commonest type. Depending on an occasional cutter. For my part | prefer
the number of graduations required the the rotating cutter but then | do have the
engraving or cutting of the lines can be machine to grind them. Without this a
done with either a simple head or the slotting tool can easily be ground and if
worm geared type. There is a choice rigidly held will also do a good job.
between using a non-rotating cutter of the Fig. 50 shows a cylindrical scale being
planing or slotting type, and using a engraved on the miller with a rotating
rotating cutter like those employed on tool. This is not a loose collar, the scale is
pantograph engraving machines. In each on the component itself, actually part of a
case the work is mounted on the dividing Quorn grinder, but a separate collar would
head and the table screw is used to move just be mounted on an arbor and treated
the work against the tool. It is advisable to in the same way. Fig. 51 is a close-up of
clamp stops to the table, if the machine this operation.
does not have stop devices built in, so as Some articles need the scale on a flat
to positively limit the table movement and surface but still in a curve. One of these is
keep the lines the correct length. Where needed on the Quorn grinder, and Fig. 52
there are lines of more than one length on shows this set on a rotary table on the
the same dial, one or more slips of sheet miller and being dealt with by a rotating
metal can be inserted in front of the stop cutter as the last example. The M.E.S.
to obtain the short lines. The cutting tool table in the picture has a 90 tooth worm
can be ground to an included angle of wheel, so one revolution of the worm
about 50 degrees. Few modellers have gives 4 degrees movement and each
access to an engraving cutter grinder, division on its 16-line micrometer collar
which is the ideal machine for grinding the gives one quarter of one degree. The scale
D-bit type cutters with conical end which being engraved is one specified in
are needed, but they can in fact be ground degrees, as it is an angle-setting scale.

71
 Fig. 50 Cylindrical machine component being graduated

Fig. 51 Close-up of previous operation

mu... əyə

L I

72
 Fig. 52 Graduating part-circular arcuate scaleon flat surface

Conical microrneter collars are sometimes that the figures are the right way up as
required, but they are more difficult to seen in using the scale. The figures may
produce and should be avoided in the need to have rising value ... 10, 20, 30
designing if at all possible. For graduating ... to the right hand from the zero mark,
one of these the dividing head would need but quite possibly, depending on circum-
to be tilted after the fashion of that in Fig. stances they may need to be the opposite
48, but possibly in the other direction, way. It is as well to get this thoroughly
depending on the actual design of the sorted out before starting to use marking
collar. punches to put the figures in, because it
One point in making scales of any kind. can be very difficult to retrieve the situa-
The figuring should always be done so tion if the start was made the wrong way.

73
CHAPTER 14

Cutter Speeds for

Vertical Milling
In general | am afraid model engineers do As an example, turning back to Fig. 20 will
not have very clear ideas about how fast show how elevated the surface of the
they should run their lathes, drills or work is from the table slides, and in this
milling machines. To run too slowly example low speeds were essential to
extends the working time unnecessarily, obtain a reasonably good finish.
but to run too fast will soon blunt a cutter The rates of feed and depth of cut
and may also cause poor work finish which are commonplace on industrial
through chatter. The wear on milling machines are quite out of order in the
cutters (apart from flycutters) is quite home workshop. Not only are industrial
important because of the trouble of machines heavy and rigid, so are the work
sharpening them, and broken cutters can holding devices, and the work itself is
be quite an expense. The principles which much more robust and rigid. Also, and this
govern the speeds of cutting metal in applies particularly when cutting steel,
other machines such as the lathe and drill these machines can usually flood the
can be taken as a useful guide, in the cutter with coolant, taking away the heat
sense that any speed which an a particular generated in the cutting operation, and
material will blunt a lathe tool or drill will that is not normally possible on machines
likewise blunt a milling cutter. But on the in the home workshop. So Table Ill has
vertical miller there are other problems been compiled to give some guidance in
too. Generally the point of cutting is much the kind of operations which have been
further from the support than that of the described in the book. İt is based on using
lathe tool. It will also be a long way com- speeds which will conserve the sharpness
paratively from the spindle bearings. The of the cutters likely to be used. For flycut-
work may be much further from the ters, commercially made endmills, and
slideways than it would be from the bed of Brown and Sharpe gear cutters, the tools
the lathe. The cutting tool is normally themselves will be properly hardened high
unsupported at its cutting end, and its speed steel. For the Woodruff cutters it is
own elasticity is added to that of the based on these being home made cutters
chuck, spindle, work, etc. So speeds produced from carbon steel or ‘silver’ steel
which might be feasible on the lathe may (which is a carbon steel with about 1.2%
well be found much too high on the miller. carbon and no alloy). More than one

74
article in Model Engineer in years past has miller is a matter of great importance.
described methods for making gear Reference has already been made to tools
cutters of the Brown and Sharpe type, and | which screw directly on the spindle nose,
have some of these myself, made from and another chapter in this book will give
plain carbon steel of about 1% carbon. descriptions of the milling chucks which
Such cutters must be run more slowly are currently available.
than the high speed steel cutters of com- It will be found that some of the millers
mercial make, but it is possible that a at present on offer have speed ranges
wider variety of tools will in future be which do not go low enough to match the
made in the home workshops, as a better bottom end of the recommended speeds
understanding of tool making and the con- on Table Ill. This is unfortunate, but it is a
tribution which the vertical miller can fact of life, and one must do the best one
provide comes to be recognised. The can with it, even it it means occasionally
cutting speeds to be used with such tools borrowing the use of a friend's machine.
will need to be arranged to suit the tool Naturally it will tend to influence the
materials and the work they are doing. decision when thinking of purchasing a
The proper mounting of tools in the machine.
FLY
CUTTING.
Flat surfaces aşinFig 16. 11.5.5. cutters. sayiy sharpened.
Depth
ofcut:
Mad tee! nn
am Min
ght toy wn
new

Das of
onneg: 1 Li n 3 ” . bad
See tpn:
Mad Steet 180 100 78 (60 9 45 3 x
bi 130 150 006 90 75 65 587 s
Ug tor 670 390 285 250 190 165 145 us
Speeds may well bebewited bythe extent that revert theswn afmout the workshop con be
cepted
EROMALUING
Sr Mite MSS etree Depth
of cot
te 2/16 1. wenu Ot un Widths ofshew being cut
(ates!
Cuna amam — 1⁄6 302 1⁄4 06 104 39 127 5⁄4 3⁄4

Mod west 1800 1900 1200 800 050 450 360

J 2500 2000 1600 1190 850 690 450
Ugo 3500 3000 2500 1700 1400 1200 900
KEYVVAY CUTTING. 11.5.5. spwal uted çoxdan orwot drs fig.24
Via
ofheyvəy 1/16 2327 18 3⁄4 14 3 t

epi ofowt (maaa ofanverect

MAD Sheet wo * 25 20 4 To io
Lx n 1) 2) 40 @ 1000 140
Ugh söy W 06 x 46 6 10 1%

Speeds
pm.
arusa 1800 4500 1200 #00 “€“”o, “o xo
_ 2900 2000 1600 1180 850 600 480
ght səv 340 3000 2900 1700 1400
 TABLE
Hi (conmnwed)
REYWAY CUTTING. wn w S $.dee ou Fig. 26 ovsiting
Fig 23.
"rev
5.4 2 3 3 s
Sow rem.
Mae sheet “° s “ s
Breve 16 “ "” “
pn Alev 9 . us no *
asc
GEARCUTTING. Comes M S S Brown & Sharpe cutters 2 | im ameter Fig 42
Sosada gm
.—.... “as
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Light Atey "0

“Vora nate cutters protecms

tram ‘sven ime!
Lal
5. "“ " 2
Sereda pm
Müxt sisel: “° bed x
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CHAPTER 15

Work-holding with
Difficult Shapes
Problems do arise from time to time industrial plant stuck down metal which
regarding the methods of holding work in had to be tooled all the way across the
the milling machine. In full scale enqineer- piece, on a false base with vvoodvvorker”s
ing these problems are not nearly so acute glue and a sheet of newspaper. After the
as components are more solid and clamps operations are completed a fine chisel is
can be applied without crushing the knocked in between the parts and the
pieces. Often with model parts it is paper tears within its thickness, so the
difficult to get a hold sufficiently firmly pieces come apart with some paper
without more or less mutilating the piece. sticking to each. This can then be washed
One method | often use both for castings off with hot water. There is nothing very
and bar material is to arrange for an original about this, of course, it is an age-
accurate chucking piece to be left on the old patternmakers’ method of producing a
component until all operations are pattern which has eventually to be in
complete and then to remove this. halves, but it is a sound method not nearly
Generally this piece is made to suit one of so well known as it should be. Fig. 53
the Myford collets, from $ in. diameter shows a light alloy casting being faced
downwards, since the collets do hold the right across with a flycutter, the casting
part with great accuracy, and after turning being stuck to the table with sticky tape
operations it can be transferred to the and nothing else.
miller with the collet placed in a dividing However, the various examples given
head; even if no indexing has to be done, throughout the book should serve to show
the head acts as a very effective vice. how to undertake a really wide range of
Sometimes thin components present jobs. At the risk of seeming repetitive |
problems in holding on the milling would again stress that it is often worth
machine. If one side is already flat one can while to make a jig for holding or locating
use double-sided sticky tape, available the work, just to make sure it can be held
from drawing office supply shops and firmly enough without damage in the right
some stationers. If two or three strips can attitude. The kind of jigs and fixtures
be used, an astonishingly firm grip can be needed in modelling seldom involve more
obtained, which will stand up to shear than a few minutes or perhaps an hour to
forces induced by milling. | have also in an make, and if this safeguards the compo-

78
 ”
P
Fig. 53 Tape-held workpiece being flycut

Fig. 54 Three-face angleplate used to align vee-blocks

79
 Fig. 55 Three-face angleplates used as main packing

nent, as well as the tools and machine, it angleplates, which are sent out
is time well spent. İf a duplicate compo- unmachined in light alloy, are in three
nent is ever needed that will be produced sizes very convenient for use in home
expeditiously without risk too. workshops and can easily be faced up on
the Myford lathe boring table or faceplate.
Angleplates Fig. 54 shows one of them set across a
A new type of angleplate has been miller table to locate the two vee-blocks in
introduced by Hemingway. This has three which the work is resting. Fig. 55 shows
faces machined at 90 degrees to one another pair used as main packings with
another. | have found over many years Picador stepped blocks on top to give the
that cast-in slots in angleplates never last bit of height adjustment for the clamp
seem to be in the right place for any job, plates. So many sizes are available by
and it seems better to just drill a hole selecting different attitudes of these blocks
where it happens to be needed. These that they are very useful indeed.

80
CHAPTER 16

Milling Chucks for

Safe Cutter Holding
The newcomer to vertical milling may provided with a drawbar through the
wonder why there should be any need for spindle to stop this tendency to work out.
special chucks for milling cutters, and For cutting tools which in operation
especially when he sees that these are produce no end forces that precaution is
fairly expensive accessories, may be sufficient. But all the spiral fluted endmills
tempted to make do without one. But first and slot drills do generate end forces,
of all it is necessary to realise that the tending to screw them out of the holding
forces acting upon milling cutters in use device. (Strictly speaking this applies to
are generally quite different from those cutters with right hand rotation, like a drill,
acting on drills in a drilling machine or and right hand fluting, also like a drill. But
lathe. The drill is usually subjected, except as it would be remarkable for any others,
at the moment of complete penetration, to though manufactured, to be found in a
axial forces only, which press it more and home workshop, the others can well be
more firmly into the Morse taper hole in disregarded.) So spiral fluted cutters will
the spindle. Even if it is held in a drill try to work out of a chuck, if parallel
chuck and has a parallel shank, the same shanked, and must be forcibly prevented.
thing applies. İt is not good enough to hold them in a
But the milling cutter is subjected to three-jaw lathe chuck, especially since
transverse forces, across the axis, and most of these exert more pressure at the
unless it is screwed on the spindle, these inner end than the outer, through wear
forces have a component which is existing in the jaw slides, in effect giving
pressing against the inside of the Morse them a slight taper.
taper hole, and thereby trying to cause the This is where the specially designed
cutter to slide out of the spindle. Each milling chuck comes into its own. There
time the spindle rotates the pressure is are two basic types, but each is arranged
transferred to the opposite side of the to grip the cutter firmly on its parallel
hole, and this waggles the tool out of the shank by a split collet closed by a screw
spindle. So first of all, any tool mounted thread forcing the collet into a conical part
by a taper shank, whether it is a chuck or a of the chuck. In addition one type uses
solid endmill with taper shank, MUST be cutters formed with a special shaped end,

81
 Fig. 56 Clare milling chuck

and the other type uses cutters with a collet is not only retained in the chuck
short screw thread at the end of the body by an internally screwed cap which
shank. The first of these, the Clare, has a fits on the body, but is also closed on the
rectangular end for the cutter, and this shank by it. The collet screws into another
end is undercut by milling. After passing it thread in the cap, which ensures that it
through a rectangular slot in the collet, the loosens when required, a small spanner
cutter is turned through a smail angle, so being provided by the makers for this
the part not undercut overhangs the end purpose. This type of chuck will in fact
of the collet, and cannot slide out. The hold cutters which do not have the ‘tee’

Fig. 57 Clarkson milling chuck

82
 Fig. 58 Osborn milling chuck

end, and have just a plain round shank, hand without the use of a spanner. There
though of course the security feature is is provision with each of these for using
then non-existent. But for small cutters ‘throw-away cutters, which are made
and light duty it will serve very well. cheaply in sizes up to + in. These have a
The other type of chuck, made both by plain shank, unscrewed, of + in. diameter
Clarkson and Osborn, uses only a screwed whatever the size of the cutting portion,
shank type of cutter and cannot be used which has a small flat in one place. They
except with this. The screw thread on the are set in an adaptor with a small screw at
shank, when subjected to the torque the side, which bears on the flat, and this
necessary to drive the cutter, provides the is sufficient to prevent their working out of
force to close the collet and thereby grip the chuck. The idea of these cutters is that
the tool shank. A centre device inside the they are made so cheaply that in a com-
body engages with the centre dimple in mercial engineering shop it will cost more
the end of the cutter to reduce friction to re-sharpen one than to replace it by a
forces that would hamper rotation of the new one. Whether or not that is really true
cutter. The Clarkson chuck needs a will depend on the particular establish-
spanner, provided with the tool, to release ment in which they are being used, but in
the collet for changing cutters. The the home workshop, if there is a Quorn
Osborne uses a finer thread on the grinder, it will be feasible to re-sharpen
securing sleeve, together with some lost them at a worthwhile cost in time and
motion provisions, and can be released by trouble, for a while, until a certain amount

83
of shortening has taken place. these chucks can be fully recommended
All the cutters with screwed ends to as being good precision tools which
suit the Clarkson and Osborn chucks have provide complete security against cutters
Whitworth form threads 20 per inch working out in use. If an accident of that
irrespective of diameter. On + in. shanks kind happens due to not having a security
this conforms to B.S.W. and on ğ in. chuck, a spoiled component is certain, a
shanks to B.S.F. for both of which dies can broken cutter is possible, and | have seen
be readily obtained. But for other this happen on a number of occasions. So
diameters, if one needs to make a special do be warned, and don't think the cost of
cutter in the home workshop, screwing a a proper chuck is too high to face.
shank 20 threads per inch is not a difficult Photographs of the three chucks
task. Making the special ends for the Clare mentioned are shown in Figs. 56, 57 and
cutters is not quite so easy in my view, but 58. The Clarkson Autolock chuck shown
the Clare chuck has the advantages of a here, as well as in pictures in the text, is
short overhang and a smaller diameter of fitted with a damping ring. After the
body. This is particularly useful when chuck is fixed in the Morse taper, this ring
holding work in a 3 or 4-jaw chuck on a can be screwed up to contact the end of
dividing head, when sometimes it is the machine spindle, giving extra support
difficult to clear the chuck jaws. But all against vibration.

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ARNOLD THROP was an apprentice then
an Outside Erector with the famous
engineers Cole, Marchent & Morley,
Bradford, Yorks. Products: compound
engines to 2500 hp, Uniflows to 1500 hp,
Diesel oil engines, condensers for largest
power stations. Later he held technical-
administrative posts in high-tension
switchgear, mining machinery, stainless
fabrication, machine tools, and marking
devices, At his retirement he was the
Director of Engineering, Edward Pryor &
Son, Sheffield.
He has been an l.Mech.E. in mounting
seniority over 50 years, serving on several
committees and one of B.S.I. He has read
papers to l.Mech.E. and the Newcomen
Society of vvhich he is a member. He has
vvorked for half a dozen years as demon-
strator on the VVorkshop Stand of S.M.E.E.
at Model Engineer Exhibitions, con-
tributed articles to Model Engineer from
1932, and having been in Sheffield
S.M.E.E. from 1937 has been its Presi-
dent for. some years.
Founding Dore Engineering in 1963, he
redesigned Edgar VVestbury”s vertical
miller and sold it as the Dore-VVestbury
until transfer to Model Engineering
Services in 1971.
His present interests are stationary
engines, vvorkshop equipment, gardening
and photography.
The author

87
 Index

Abwood milling attachment

Amolco milling attachment and
machine
Angleplates
Angleplate used as backstop 27,
Arbors for slitting saws and disc cutters
Astra milling machine

Boring operations
Boring heads

Chucks, Clare, Clarkson, Osborn

Clutch teeth
Connecting rods
Crosshead slides, engine bedplate

Dividing heads, description and

principle
Plain type, change wheel
indexing
Myford worm-geared type
Use of division plates
Use of locating blades
Packing block for centre height
Steady stand for extra rigidity
Dividing heads and gear-cutting
Plain type
Pinion cutting
Large gear cutting

88
Dividing heads and graduated scales
Planing/slotting and rotating tools
Table stops and line length control
Cutting/engraving cylindrical scale
Cutting/engraving flat arcuate scale
Conical micrometer dials
Marking figures of scales right way
Dividing heads and tool-making
Fluting screwing tap
Cutting fine tooth milling cutter
Cutting large countersink
Special division plate, 25 hole
D-bit for hole centring to start drills
Dore-Westbury milling machine

End-rounding:
Filing collars and rollers
Using rotary table
Fittings for rotary table
Rounding engine cranks
Direction of table rotation
Locking precautions for external
work
Engine bedplate bearing jaws
Engine cylinder soleplate
Evolution of vertical miller

Fluting operations, locomotive rods,

correct flute form
Rods for British engines
Rods for Canadian and American
engines

89
 Flywheel (in halves) joint face 31

Gear cutting 62
Grinder for engraving cutters and D-
bits 71

Identification of cutters etc. by marking

when made 42

Jig-boring:
Measuring by table screws
Written record of measurements
Example of beam for model engine
Trip gear lever of model engine
Boiler tube plates
Avoidance of back-lash errors
Jigs for milling operations —”

Keyways for plain sunk keys:

Endmilling feather keyways on plain
shafts
Keyways on taper shafts with tilting
angleplate
Disc cutter milling of keyways

Loctiting for permanent assembly

Long components, holding problems 38,

Machine specifications, table of 24

Maximat milling attachment 22

90
Mentor milling machine 22
Milling cutters, multi-tooth:
Early (19th century) ‘file-cut’ cutters 12
Facemills 30
Endmills 38
Slitting saws 35
Disc cutters . 40
Woodruff cutters 40
Brown & Sharpe cutters 62
Tap fluting cutters 67
Angle cutters 69
Milling cutters, single tooth:
Flycutters 27
Connecting rod fluting cutter 43
Profiled gear tooth cutters 62
Engraving cutters 71
Milling operations:
Flat surfaces parallel
to table 32
Flat surfaces square
to table 34
Slitting and cutting 35
Component fluting 43
Tool fluting 67
End rounding 52
Gear-cutting 62
Keywaying 39
Woodruff keys and
keyways 38
Boring 45
Jig-boring 46

91
 Profiling 49
Engraving at
Myford-Rodney milling attachment and
machine 21
Myford collets 62
Myford dividing head 57

Profiling:
Circular arcs 49
Locomotive frames 49
Smokebox and cylinder saddles 49
Pad-bolts 49
Small arcs derived from curve of
endmills 51

Quorn grinder for tool sharpening 83

Quorn grinder, parts of 35, 71

Rotary tables 52
Rotary table, M.E.S. 52

Senior milling machine 22

Security of milling cutters:
Forces acting upon drills and cutters 81
Use of dravvbars in machine spindles 81
Positive locking of screvved cutters in
chucks 82
Positive locking of Tee cutters in
chucks 82
Slitting and cutting operations 35
Speeds of milling cutters 74

92
Tapered sections
"Throvv-avvay” cutters
Twin milling machine

Vices, use of two together

Westbury, Edgar T.
Westbury milling machine
Woodruff keys and keyways
Work holding for difficult shapes:
Use of chucking pieces later
discarded
Sticky tape for thin articles
Glue and paper for thin articles
Specially made jigs for difficult
shapes

93
 en the pressure’s on
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