ARNe-_3 THROP

VERTI
MLLING IN THE
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VERTICAL MILLING
IN THE
HOME WORKSHOP
Arnold Throp
C.Eng . F.I.Mech.E.
ARGUS BOOKS
Argus Books
Argus House
Boundary W ay
Hemel Hempstead
Hertfordshire HP2 7ST
Eng land
First publ ished 1977
Second im pression 1979
Sec ond edi ti on 1984
Rep rinted 1986, 1988, 1989, 1990, 1991. 1993
Argus Books Ltd 1977
All r ights reserved. No part of this publication may be
reproduced i n any f o rm by pri nt. photography, microfilm
or any other means wi thout written permission from t he
publisher.
ISBN 0 852 42 843 x
Phot ot ypesetti ng by Perf ormance Typesetting, Milton Key nes
Print ed and bound i n Great Br it ai n by
Biddies Ltd . Guil df ord and Kin g 's Lynn
CONTENTS
Chapter One
Chapt er Two
Chapter Three
Chapter Four
Chapter Five
EVOLUTION OF THE VERTICAL MILLER 12
Earl y history of industrial machines: mi ll ing in the
early small lathes: mi lling attachments for lat hes
ci rca 1920s: E.T, Westbury's experimental machine
1964: t he Dar e-Westbury machi ne 1968: currently
avail able sma ll machi nes and attachments,
MILLING FLAT SURFACES 27
Surf aces parallel to table: simple fixed-radi us
f1 ycutt ers: var iable-radius bor ing head flycutting:
multi ple -tooth face mi ll s: work hol ding: mult iple
pass mi ll ing: surfaces square wit h table : using side
of endmil l.
SLITTING AND CUTTING 35
Use of slitting saw for cutting through machinery
component bosses : eccentric sheaves and straps:
mar ine type big ends of connecting rods.
KEYWAY CUTTING 37
Endmill i ng round ended 'feath er' keyways : keyways
on taper shafts: use of disc tvoe cutters for plain
sunken keyways: \Noodruff keyways: making
Woodruff cutters in the home workshop : table of
suggested sizes of \Noodruff keys and kevvvavs for
model engineers,
FLUTING COMPONENTS OTHER THAN
TOOLS 43
Correct form of flutes ir loco connecting and
cou pling rods: mounting rods against angleplate for
flu ti ng: parall el flutes: taper flutes: preferred type of
cutting too l.
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 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.
ISBN 085242 843 )<
Phototypesetting by Performance Typesetting, Milton Keynes
and bound in Great Britain by
Biddies Ltd, Guildf ord and King's Lynn
CONTENTS
Chap er One
Chapter Two
Chapter Three
Chapter Four
Chapter Five
EVOLUTION OF THE VERTICAL MILLER 12
Early history f industrial machines : mill ing in the
early small lathes: milling attachments for lathes
circa 19205: E.T. Westbury's experimental machi ne
1964: the Dore-Westburv machine 1968: currently
available small machines and attachments.
MILLING FLAT SURFACES 27
Surface parallel to table: simple fixed-radius
flycutters: variable-radius bori ng head flycutting:
multiple-tooth face mills: work holding: mUltiple-
pass mill ng ' surfaces square with table: uSing side
of endmlll .
SLITTI NG AND CUTTING 3 5
Use of slit ing saw for cut ing through machinery
component bosses: eccentric sheaves and straps:
marine type big ends of connect i ng rods.
KEYWAY CUTTI NG 37
Endmilling round ended feat er' kevways: keyways
on taper shafts use of disc type cutters for pl ain
sunken keyways : Wood uff keyways ' making
Woodruff cutters in the ome workshop: table of
sugges ed sizes of Woodruff keys and keyways for
model engineers.
FLUTING COMPONENTS OTH ER THAN
TOOLS 43
Correct form of flute ir loco connecting and
coupling rods: moun ing rods against angleplate for
fluting : parallel flutes: taper flutes' preferred type of
cUlting tool.
Chapte r Six
Chapter Seven
Chapter Eight
Chapter Nine
Chapter Ten
Chapter Eleven
BORING 45
Dealing with parts too large to swing in lathe:
trepanning large holes.
'J I G- BORI NG' 46
Using the miller as a measuri ng machine: drilling
holes at one setting of work and precise cent res:
engine beam: back-lash pr ecauti ons: tri p gear com
ponent : multi-hole boi ler plates.
PROFILING 49
Curves on parts too large for lathe: loco frames :
smokebox castings: machine pad bolts: loco con
nec ting rod s and coupli ng rods.
END-ROUNDING 52
Use of hardened f iling gu ides deprecated:
mounting work on rot ary table: sta ndard size guide
plugs: anti-slip precau tio ns: direction of feed for
exte rnal and i nternal surfaces.
DIVIDING HEADS 54
Simple ungeared dividing heads : using change
wheels as index pl at es: examples of dividing wor k:
hexagons. squares. dog clutch teeth : avoiding odd
numbers: the Myford worm-geared dividing head :
avoiding back-lash erro rs : packing block for
bringing to lathe centre height : universal steady
stand for Myford head: three further dividing heads.
DIVIDING HEA DS AND GEAR- CUTT ING 62
Limitations to strai ght spur gears: simple head :
Myford worm-geared head: toot h cutt ing on
integral pi nion : use of home made I lvcut ters:
Brown & Sharpe disc type cutters: select ion of
cutter to suit number of teet h: cutting a large
coarse tooth gear: anti-slip back-up devices ,
Chapt er Twelve
Chapter Thirt een
Chapter Fourt een
Chapter Fifteen
Chapter Sixteen
DIVI DING HEADS AND TOOL MAKING 66
Fluting taps : example 5-flute Acme tap: producing
a small fine toot h mil ling cutter with ball end : use
of table stop blocks: combination of rotary tabl e
with main table movement: large 60 deg ree coun
tersink fluting.
DIVIDING HEADS AND GRAD UATED
SCALES 71
Cutti ng graduation marks: use of rotary 'engr avi ng'
cutters : use of non-r otating plani ng t ype tools : use
of table stops to control line lengt hs: graduating
cyli ndr ical scales: graduating flat angular scales :
checking correct way of figuring when stamping
scales,
CUTTER SPEEDS FOR VERTICAL MILLERS 74
Speeds affect ti me occupied on job: speeds too
high may cause excessive cutter wear and chatter :
rigi di ty of work, cutter and mac hine inferior as a
rule to i ndust rial condi t ions, dry cutting inst ead of
lubricated: Tabl e III gives speeds for cutters in
different kinds of tasks: machi ne speeds may not
alwa ys be suitable.
WORK -HOLDING WITH D IFFICULT
SHAPES 78
Comparison with full scale engi neering : use of
chucki ng pieces on components: thin components
and use of adhesives: advisability of making fixtures
for difficul t pieces : three-sided angleplates.
CHUCKS FOR MILLING CUTTERS 81
Never use taper shank tools or chucks without
drawbar: chucks for screwed shank self -tightening
collets : Clarkson chuck : Dsborn Titanic chuck:
Chucks for tee-headed locking cutters: Clare
chucks: use of small end mills and D-bits without
locking features : ph ilosophy of ' t hrow - aw ay'
cutters.
Chapter Six
Chapter Seven
Chapter Eight
Chapter Nine
Chapter Ten
Chapter Eleven
BORI NG 45
Dealing with parts too large to swing in lathe:
trepanning large holes.
'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.
PROFILING 49
Curves on parts too large for lathe: loco frames:
smokebox castings: machine pad bolts: loco con-
necting rods and coupling rods.
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.
DIVIDING HEADS 54
Simple ungeared dividi ng heads: using change
wheels a 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.
DIVIDING HEADS AND GEAR-CUTTING 62
Limitations to straight spur gears: simple head :
Myford worm-geared head: tooth cutting n
integral pinion : use of home made f'vcutters:
Brown & Sharpe disc type cut ers: selec ion 0
cutter to suit number of teeth: cutting a large
coarse tooth gear: anti-slip back-up devices.
Chapter Twelve
Chapter Thirteen
Chapter Fourteen
Chapter Fifteen
Chapter Sixteen
DIVIDING HEADS 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.
DIVI DING
SCALES
HEADS AND GRADUATED
71
Cutting graduation marks: use of rotary 'engraving
cutters: use of non-rotating planing type tools: use
of table stops to contrql line lengths: graduating
cylindrical scales: graduating flat angular scales:
checking correct way of figuring when stamping
scales
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 III gives speeds for cutters in
different kinds of tasks: machine speeds may not
always be suitable.
WORK-HOLDING
SHAPES
WITH DIFFICULT
78
Comparison with full scaie engineering : use of
chucking pieces on components: thin components
and use of adhesives: advisability of making fixtures
for difficult pieces: three- sided angleplates.
CHUCKS FOR MILLING CUTTERS 81
Never use taper shank tools or chucks without
drawbar: chucks for screwed shank self- tightening
collets : Cl arkson chuck : Osborn Titanic chuck:
Chucks for tee-headed locking cutters: Clare
chucks: use of small end mills and D-bits without
locking features : phi losophy of 'throw-away'
cutters.
List of Illustrations
Fig.
1 Ab wood mi llin g attac hment of t he 1920s
13
2 E. T. Westb ury 's mill i ng machine
14
3 Dore-West bury machi ne
15
4 Dare-Westbury Mk II machine
16
5 Rodney att achment
17
6 Rodney machine
18
7 Amolco attachmen t
19
8 Amol co machine
20
9 Ment or machine
2 1
10 Maxi mat attachment
23
11 Astr a machi ne
2
12 Twin machi ne
22
13 Senior machine
26
14 Set of three fl ycutt ers
2 8
15 Flycutt i ng a bracket
28
16 Flycutti ng connecting rod ends
29
17 Flycutti ng t apered bar mat erial
29
18 Flycutting cylinde r soleplat e
30
19 Facemil l
3
20 Mil li ng f lywheel joint face
31
21 Mi ll ing crosshead sl ide
32
22 Mill i ng bear ing jaws i n bedpl at e
33
23 Slitting boss of cast ing
35
4 Milli ng feath er kevwav
3 7
25 Milling feather keyway on tapered shaft
38
26 Mil ling keyway wi th sl itting saw
39
27 Set of four Woodruff keyway cutters
39
28 Mill ing W oodruff kevwav
4 1
29 Fluti ng locomo tive connect ing rod 44
30 Drawing of steam hook (lever) 4 7
3 1 Phot ograph of st eam hook 48
32 Profiling pad bolt 50
33 Profil i ng coupling rods 50
34 End-rounding wi th rotary tabl e 53
35 Cutti ng t eeth in dog clutch par t 55
36 Drawing of st eady stand for Myford div iding head 56
37 St eady in use on a gear cutti ng opera tic 58
38 Thro p divid ing head 58
39 Thomas versat ile divid i ng head 59
40 Kibbey/M.E.S. dividl nq head 60
4 1 Close-up of f lycut ter and pi nion 63
42 Gearcutt ing wit h Brown & Sharpe cutter 63
4 3 Flycutt ing 10 d.p, gearwh eel. front view 64
44 Flycutt ing 10 d.p. gearwheel. rear view 6 5
45 Flut i ng Acme t hread tap 66
46 Cutt i ng teeth of ball-end cutt er 67
47 Cl ose- up of ball-end cutte r 68
48 Gashin g f lutes in l arge count ersi nking tool 69
49 Rear view showing steady stand in use 70
50 Cyli ndrical machine component being grad uated 72
5 1 Close -up of prev ious operat ion 72
52 Graduati ng part -ci rcul ar arcuat e scal e on fl at surface 73
53 Tape -held workpi ece being flycut 79
54 Hern inpwav three-sided angleplate 79
55 Two of the three sizes of Herni nqwav angleplates 80
56 Clare mi ll ing chuck 82
57 Clarkson mi ll ing chuck 82
58 Osborn mill i ng chuc k 83
List of Illustrations
29 Fluting locomotive connect ing rod 44
Fig.
30 Drawing of steam hook (lever) 47
1 Abwood milling attachment of the 1920s
13 31 Photograph of stear.1 hook 48
2 E. T. Westbury's mi ll ln machine
14 32 Profiling pad bolt 50
3 Dore-Westbury machine
15 33 Profi ling coupling rods 50
4 Dore-West bury Mk 11 machine
16 34 End-rounding with rotary table 53
5 Rodneyattachment
17 35 Cutting teeth in dog clutch part 55
6 Rodney machine
18 36 Drawing of steady stand for Myford dividing head 56
7 Amolco attach ment
19 37 Steady in use on a gear cutting operation 58
8 Amolco machine
20 38 Throp dividing head 58
9 Mentor machine
21 39 Thomas versatile dividing head 59
10 Maximat attachmen t
23 40 Kibbey/M.E.S. dividing head 60
11 Astra mCtchine
21 41 Close-up of flycutter and pinion 63
12 Twin machine
22 42 Gearcutting with Brown & Sharpe cutter 63
13 Senior machi ne
26 43 Flycutting 10 d.p. gearwheel. front view 64
14 Set of three flycutters
28 44 F ycutting 10 d.p. gearwheel. rear view 65
15 Flycutting a bracket
28 45 Flut'lng Acme thread tap 66
16 Flycutt i ng connecting rod ends
29 46 Culling teeth of ball-end cutter 67
17 Flycutting tapered bar mater;al
29 47 Close-uD of ball-end c tter 68
18 Flycutting cylinder soleplate
30 48 Gashing flutes in large countersinking tool 69
19 Facemill
31 49 Rear view showing steady stand in use 70
20 Milling flywheel joint face
31 50 Cylll'\drical machine component being graduated 72
21 Milling crosshead slide
32 51 Close-up of previous operat ion 72
22 Milling bearing jaws in bedplale
33 52 Graduating part-ci rcular arcuat e scale on flat surface 73
23 Slitting boss of casting
35 53 Tape-held workpiece being flycut 79
24 Milling feather keyway
37 54 Yerringway three-sided angleplate 79
25 Milling feather keyway on tapered shaft
38 55 Two of the three sizes of angleplates 80
26 Milling keyway with sl'tting saw
39 56 Clare mi ing chuck 82
27 Set of four Woodruff keyway cutters
39 57 Clarkson mi ll ing chuck 82
28 Milling Woodruff keyway
4 1 58 Osborn rrill ing chUCK 83
Preface
In th e engineering industry the vert ical
mi ll er is very widel y used . not only for
batch product lorrbut also for tool making
and the ' one-off' jobs whi ch are so
common in general engineering. In the
home workshop. wher e most jobs are
'one-off' the versatility of th e machi ne
makes it an i mport ant comp anion to the
lathe. Thi s book des crib es many of the
infinitely wide range of oper ations wh ich
can be done. and all those described are
illustrat ed by photographs so that under
st andi ng of the methods is assured . These
cove r work on part s of model locomot ives.
stati onary engines machi nery . cutt ing
tools. gears, clutches, etc. Full informat ion
is given on the machine accessories wh ich
are requi red, suc h as var ious types of
cutters and t he chucks needed for t heir
mounting on the machi ne spindle. The use
of cheap home- made cutt ers i s shown
and encouraged. Guidance is also give n
on the work- holding dev ices such as
clamps. packings, vices. angle plates,
dividing heads. rot ary table s, and which of
these are needed for part icular kinds of
work .
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 whi ch 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
i nfinitely 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 engine machinery, cutting
tools. gears. clutches. etc. Full information
is given on the machine accessories which
are required. such as various types of
cutters and t he chucks needed for their
mounting on the machine spindle. The use
of cheap home-made cutters i s shown
and encouraged. Guidance is also given
on the work- holding devices such as
clamps. packings. vices. angl e plates.
dividing heads. rotary tables. and which of
these are needed for particular ki nds of
work.
CHAPTER 1
Evolution of the
Vertical Miller
The hori zontal mi lli ng machine evolved
natura lly fr om t he lathe i n t he fi rst or
second decade of t he nineteent h century.
Eli W hitney (U.S.A.) is said t o have had
one i n use about 18 18. and in Tools for
the Job t he lat e LTC. Rol t recount ed how
the young engi neer James Nasmyt h {later
to become famous as t he inventor of t he
stea m hammer and ot her appl iances l
fixed one up and milled t he flats on
hundreds of tiny hexagon nuts for a model
of a Maudslay marine engi ne. while
working for Henry Ma udslay . Drawi ngs of
the ear ly hori zont al mill ers show suc h a
resemb lance to t he lathes of t hat period
that al most certai nly t hey were in fact
lat hes which had been adapt ed to mil ling.
The cutters we re real ly f il es. made by t he
fi le makers of t he t imes, usi ng t he 'hand
cutt ing ' met hods (real ly a hamm er and a
special chisel) w hic h were the only
pract ice avai lable at t hat ti me.
The evolut ion of the verti cal miller
came nat ural ly after t he hori zont al
machi ne. I have not found any reli able
refe rence to a date by which the vert ical
mi ller had appeared i n i ndust ry, t houg h
this must have been we l l before 1900 .
When model engineering sta rted to
beco me an establ ished hobby at the t urn
of the cent ury quite a variety of small
12
lathes we re provided by di fferent makers.
and t he great ver sat ili ty of the lathe
created in it self a tendency to make the
lat he do every operation that arose. This
wa s enhan ced by the fact that many
modellers were working men with very
litt l e cash to spend on their hobby. Many
we re the inge nious attachment s devised
to enable the lat he to carry out work it had
never been intended to do. Such makers
as Drummond Brothers modified their
lathes wit h tee-slott ed boring tables to
help in this work. and even brought out
t he famous ro und- bed lat he. wh ich
although i nt ended for a cut -price market.
also had built into it the abi lity to do a lot
more than just simple turning. But as the
years wen t by it became ever more
appa rent somet hing better was needed
f or mi lling operat ions . None of the small
millers produced by the mac hine tool
indust ry we re oriented towards the home
workshop,
Then in the 1920s the Abwcod Tool
and Engi neeri ng Co. produced an excel
lent vertical mi lling at tachmen t for
mounting on smal l lathes. especially the
popula r 3t in. flat bed Drummond. though
adjustable features made it applicable to
other lat hes too . It had a No. 1 Morse
taper arbor which fitted into the lathe
[},'\
j:ig. t Abv/ood milling attachment of the
19205
13
CHAPTER 1
Evolution of the
Vertical Miller
The horizontal mi ll i ng machine evolved
nat urall y from t he lathe i n the first or
second decade of t he nineteenth century.
El i Whitney (U.SA) is said to have had
one in use about 1818, and in Tools for
the Job the late L.T.C. Rolt recounted how
the young engi neer James Nasmyth (later
to become famous as the inventor of the
steam hammer and other appl iances)
fixed one up and milled the flats on
hundreds of tiny hexagon nuts for a model
of a Maudslay marine engine. while
working for Henry Maudslay. Drawings of
the early horizontal mi ll ers show such a
resemblance to t he lathes of that period
that al most certainly they were in fact
lat hes which had been adapted to mill ing.
The cutters were really fil es. made by the
f il e makers of the times, usi ng the 'hand-
cutting' methods (real ly a hammer and a
speci al chi sel) which wer the onl y
practice avai lable at that time.
The evolution of the vertical miller
came naturally after t he horizontal
machine. I have not found any rel iable
reference to a date by which the vertical
mi ller had appeared in industry, though
this must have been well before 1900.
When model engineering started to
become an established hobby at the turn
of the century quite a vari ety of small
12
lathes were provided by different makers.
and t he great versat il ity of the lathe
created in itself a tendency to make the
lathe do every operation that arose. This
was enhanced by the fact that many
modellers were working en wilh very
little cash to spend on their hobby. M any
were the ingenious at achments devised
to enable the lathe to carry out work it had
never been intended to do. Such makers
as Drummond Brothers modified their
lathes with tee-slotted boring tables to
help in this work. and even brought out
t he famous r und- bed lat he. wh ich
although i ntended for a cut-price market .
also had built into it the ability to do a lot
more than just simple turning. But as the
years went by it became ever more
apparent something better was needed
for milling operations. None of the small
millers produced by the machine tool
industry were oriented towards the home
workshop.
Then in the 1920s the Abwood Tool
and Engineering Co. produced a'n excel-
lent vertical mi l ling attachment for
mounting on small lathes. he
popular 3t in. flat bed Drummond though
adjustable features made it applicable 0
other lathes lOO. It had a No. 1 Morse
taper arbor which fi ted into the lathe
Fig. r Abll'lood milling attachment of the
1920s
13
spindl e. and bevel gear s with keywa yed
shafts took t he drive up to t he vert ical
cutt er spindle. whic h had a No. 1 Morse
internal taper. All t he gears were equa l
rat io mit re beve ls. so t he cutter rot at ed at
t he same speed as th e lat he spi ndle . and
all t he six speeds of t he lat he were usable.
The wor k wa s mounted on t he lat he
boring table. and power feedi ng i n one
direction came from the lat he screwcut
t ing gear. A phot ograph of this uni t set up
on a Myford Super 7 is shown in Fig. 1. It
wa s unfort una tely a low -vol ume. labou r
int ensive uni t wit h vee slides needing
hand scrapi ng. but was sell i ng i n 1930 for
7 guineas. about a quar ter of t he cost of
the Drummond lat he. Alt hough out of
producti on for many year s now. it was in
i ts time a courage ous effo rt . but belonged
to the age when most home l at hes were
driven by flat bel t fro m a treadle or cou n
tarshaft. and the cost of elect ric mot ors
made th e independent motor drive
uneconomic i n home hobby appli cati ons.
But th e need for a handy vertical
mil li ng machine had been recognised. and
in the ear ly 1960s t hat very good fri end of
model engineers. Edgar T. West bury.
compl ete d an exper i menta l machi ne.
wh ich he desc ribed wit h drawings and
pho t og raphs i n t he Model Engi neer
during 1964. That too wa s a very labour
Fig. 2 E.T. Westbury's
milling machine
ig, 3 Dore- West bury machine
intensive machi ne wi t h vee slides, and the
main cast ings were much t oo big to be
machi ned i n th e average home workshop.
At that ti me he was una ble to find any
engi neering fir m wi lli ng to take it over and
manufacture it. or even to do the machin
ing on a contract basis at such a price as it
was thought model engi neers would be
wl lli nq to pay.
Three years l ater I found myself with
the opportunity to take a fresh look at thi s
design, whi ch he had di scussed with me
during t he experi ment al period. I evolved
a new set of drawi ngs for a simil ar
machi ne, but using flat sl ideways more
economically const ructed. a reducti on
gear f or lower bottom speeds, holl ow
spi ndl e for a drawbar. and other changes
i nt ended to make economies or i mprove
the performance. This new design was
discussed with Edgar. who agreed to the
use of the name 'Dore-Westburv' , the
machi ne to be sold as a ki t of semi
fi ni shed components by my existing fir m
Dore Engi neeri ng, I was abl e to place the
machi ning of the components with a
number of firms al ready known to me. and
the fi rst sets of mat erial s began to go out
to custo mers early in 1968. Si nce that
t ime many hundreds of sets have been
distributed. all over t he wo rld . and are still
being made i n ever grea ter quant iti es by
Mo d el Eng i neer i ng Serv i ces. o f
Chest erf ield. who took i t over from me in
197 1, when I wa nted, on acco unt of age,
to reduce my commit men ts,
Castings to t he origi nal design are,
however, st ill available from Waking Pre
cision Models of 16 Dovecot Park.
Aberdour. Fife. Scot land KY3 OTA. and a
machine fro m t hese is shown in Fig. 2.
The Dare-Westbu ry mac hi ne is depicted
in Fig. 3 and t he similarity be tween them
wi ll be at once appa rent. Duri ng it s
ent ire lif e the Dar e-West bury has been
undergoi ng small i mprovement s. and the
present suppliers have now dec ided that
t he mod i f i c at i o ns are su ff icie n t ly
st abi lised for t he present version t o be
ti t led t he Mark II model. From now on all
machines supplied will be of t his form.
though st ill subj ect to certain optional
vari ations which customers wi ll be able to
select as t hey wi sh.
The more important changes incl ude an
increase in t he quill travel f rom 2i i n. to
4-1- in. Ext ra pull ey steps wit h a new type
of belt extend the speed rang e sligh t ly
from 32 to 1880 r.p.m. with more i nt er
mediat es. providing for boring head fl y
cutting on large radi i ri ght through t o
keyway cutt ing with 1/ 16 in. cutters. The
reduct ion gear system now fi tt ed has
hel i cal gears which run i n an oi l-bath.
14
15
spindle, and bevel gears with keywayed
shafts took the dri ve up to the vertical
cu tter spindle, which had a No. 1 Morse
internal taper, All the gears were equal
ratio mitre bevels. so the cutter rotated at
the same speed as the lathe spindle, and
all the six speeds of the lathe were usable.
The work was mounted on the lathe
boring table, and power feeding i n one
direction came from the lathe screwcut-
tl ng gear. A photograph of this unit set up
on a Myfor Super 7 is shown in Fig. 1. It
was unfortunately a low-volume, labour
intensive uni t with vee slides needing
hand scraping, but was sell ing i n 1930 for
7 guineas, about a quarter of the cost of
14
the Drummond lat he. Although out of
production for many years n w, it was in
i ts time a courageous effort , but belonged
to the age when most home lathes were
driven by flat belt from a treadle or coun-
tershaft, and the cost of electric motors
made the independent motor drive
uneconomic in home hobby applications.
But the need for a handy vertical
mi lli ng machi ne had been recognised, and
in the early 1 960s t hat very good friend of
model engineers, Edgar T, Westbury,
completed an experi mental machine,
which he described wit h drawings and
photographs in the Model Engineer
dunng 1964. That too was a very labour
Fig. 2 E, T. Westbury's
milling machine
Fig. 3 Dore-Westbury machine
intensive machi ne with vee slides, and the
main castings were much too big to be
machi ned in the average home workshop.
At that time he was unable to find any
engi neering firm willing to take it over and
manuf cture it. or even to do the machin-
ing on a contract basis at such a price as it
was thought model engineers would be
willing to pay.
Three years later I found myself with
the opportunity to take a fresh look at this
design. which he had discussed with me
during the experimental period. I evolved
a new set of drawings for a similar
machine, but using flat slideways more
economically constructed. a reduction
gear for lower bottom speeds. hollow
spindl e for a drawbar, and other changes
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
Dare Engineering. I was able to place the
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, al i a er the world. and are still
being made in ever great er quantities by
Model Engineering Services, of
Chesterfield, who took it over f rom me in
1971, when I wanted. on account of age,
to reduce my commitments.
Castings to t he original design are.
however, still available from Wokin Pre-
cision Models of 16 Dovecot Park,
Aberdour. Fife, Scotland KY3 OTA. and
machine from these is shown in Fig. 2.
The Dore-Westbury machine is depi ct e
in Fig. 3 and he similarity between them
will be at once apparent. During its
entire life the 0 re-Westbury has been
undergoing small i mprovements, and the
present suppliers have now decided that
t he modificat io ns are suffi c i ent ly
stabili sed for the present version to be
t itled the Mark 11 model. From now on all
machines supplied will be of this form.
t hough still subject to certain optional
variations which customers will be able to
select as they wish.
The more important changes include an
increase in the quill travel from 2f in. to
4-} in. Extra pulley steps with a new type
of belt extend the speed range slightly
from 32 to 1880 r.p.m. with more inter-
mediates, providing for boring head fly-
cutting on large radii right through to
keyway cutting with 1/16 in. cutters. The
reduction gear system now fitted has
helical gears which run In an oi l-bath,
15
Opposite, Fig. 4 The Oore- Westbury Mkll
Fig. 5 Rodney Attachment
16 17
Fig. 6 Rodney ma chine
sealed against leakage even when incli ned
away from the vertical, and is Quieter th an
former ly. A larger table, 20 i n. by 6 i n., can
be had as an optional al ternative to the
normal 16 in. by 5t in. The column and
cros s tube are steel. as always, but now t
i n. thick and enormously st iff . 2t in.
diameter micromet er dials are now
standard. The down-feed worm has for
conveni ence been transferred to t he right
hand side of the head, a coarser pitch rack
is now used. and ther e are a number of
oth er minor i mprovements.
Opposite, Fig. 7 Amolco attachment
18 19
sealed against leakage even when incli ned
away from the vertical, and is Quieter than
formerly. A larger table, 20 in. by 6 i n., can
be had as an optional alternative to the
normal 16 in. by 5t in. The column and
cross tube are steel. as always, but now t
in. thick and enormously stiff. 2t in.
diameter micrometer dials are now
18
Fig. 6 Rodney machine
standard. The down-feed worm has for
conveni ence been transferred to the right
han side of the head, a coarser pitch rack
is now used, and there are a number of
other minor improvements.
Opposite, Fig. 7 Amolco 8tt8chment
19
Although colleges and commercial
workshops wil l probably wish to use the
all -over belt guard, it may be debatable i f
th e cost of this is j usti fied for the solit ary
mat ure model ler alo ne i n hi s home
workshop. An alternative belt gua rd wh ich
covers t he spi ndle pulley only and does
not impede belt changing so mu ch is
ava ilable and is shown on the Mark II
machine in Fig. 4 .
No do ubt the most important i mprove
ment is the (optional) provision of pow er
feed for the long movement of the table. A
small mot or wit h a 4-step pul ley and
enc lose d worm reduction gear provides
feed rates of .5 . .62 . .85 and 1.1 inches
per mi nute.
A number of attachments similar in
general concept , though much different in
detail. to t he old Abwood . have come on
Fig. 8 A mateo machine
<,
Fig . 9 Menror machine, now superseded by th e
FB2 and Maximal attachment
the rn ark et in recent year s . Tew
Machlnerv produce t he .Rodney' to suit
the Mvford ML7 and Super 7 l at hes. and
:hi s i s marketed by Myfords. It is shown in
Fig. 5 and t he complete vertica l mi ll er
based on t his attachment is that shown i n
Fig. 6.
Anot her attachment, t he 'Amolco is
supplied by N. Mol e & Co. Ltd . and
appears in Fig. 7 This has it s own motor
and attaches to t he top of t he lath e bed
also. It i s made as a compl ete ma chi ne.
snown in Fig. 8.
Fig. , t A stra machine
2 1
20
Although coll eges and commercial
workshops wil l probably wish to use the
all -over belt guard, it may be debatable if
the cost of this is justified for the sol i tary
mat ure modell er alone in his home
workshop. An alternative belt guard which
covers the spindle pulley only and does
not impede belt changing so much is
avail able and is shown on the Mark II
machine in Fig. 4.
20
No doubt the most important i mprove-
ment is the (optionall provision of power
feed for the long movement of the table. A
small motor with a 4- step pulley and
enclosed worm reduction gear provides
feed rates of .5, .62, .85 and 1. 1 inches
per minute.
A number of attachments si milar in
general concept , though much different in
detail. to the old Abwood. ha\'e come on
Fig. 8 A molco machine
.Fig. 9 Menror machine, now superseded by the
F82 and Maximat attachment
t he marke: in recent years . Tew
Machinery produce the ' Rodney' to suit
the Myford V1 L7 and Super 7 lathes. and
:his s marketed by Myfords. It is shown in
Fig. 5 and the complete verti cal miller
based on this attachment is that shown i n
Fig 6.
Another attachment, t he 'Amolco' is
supplied by N. Mol e & Co Ltd. and
appears in Fig. 7 his has its own motor
and attaches 0 the top of the lathe bed
also. II is made as a complete machine,
snown In Fig. 8.
Fig. 1 r Ascra machine
2 1
Fig. 12 Twin machi ne
Elliot machi ne Equi pment suppli ed a
continental mac hi ne, th e ' Mentor' wh ich
was available bot h in bench and fl oor
mounted forms. The bench machine is
shown in Fig. 9. They also have the
' Maximal' attachment to suit the lat he of
t he same name, whi ch f it s on t he back of
the lath e bed and has independen t motor
drive (Fig, 10). This is also avai lable as a
floor machi ne, t he FB2.
Ot her complete machin es include the
'Ast ra' suppli ed by Scot Urquhart, which
is really a horizont al mil ler wit h an ext ra
ver tical spindle with it s own motor . Made
in several sizes, the smal l one is shown in
Fig. 11.
Twi n Engin eering Co. i nt roduced a
bench machine il lustrated in Fig. 12 and
also a floor mounted machi ne of simi lar
size but slig htly di ff erent desi gn.
Finally the old established firm of Tom
Senior Ltd. now produce t heir type E
mach ine which is f loor mounted and
shown in Fig, 13.
So it will be seen that there are now
many machines and attachme nt s which
are of suit able dimensions for inclusion in
t he l i m it ed spac e o f mo st home
workshops. It would be useless to give
any detai ls of prices in a book of this kind,
as such informat ion would probably be
incorrect by t he ti me t he boo k was
printed, and readers are therefor e recom
mended t o enquire of the various adve r
t isers.
A summary of t he leading particulars of
all t hese machines etc. is given in Table 1
but agai n specifi cat ions are amended by
makers as t ime goes by, and it can be no
more tha n a general guide .
A bri ef word must be said about foreign
mac hines. part icularly those coming from
Far Eastern countries. I t wo uld appear
there are several facto ries producing
mac hi ne tool s and accessories. Some
appear to be quite good, but others are
definitely not good, and I do have personal
experience of some of these. I have not
had the chance to see one of the mill ing
machi nes working, but t hose I have
inspect ed i n exhibi t ions have some che ap
and nasty feat ur es, although t he mai n
items suc h as spindles, bear ings , and
slideways may be excell ent. Some of t he
machines are more suitable for com
merci al f act orie s th an home workshops
but there ar e others of modest dimen
sions. To anyone contemplat i ng buying
one of these one can on ly suggest that a
close i nspect ion should be made by a
knowl edgeabl e engineer , and that a
working demonstr at ion should be
requested, of th e actual machine which is
to be bought.
Fig. 10 Maximar ettscbrnent
22 23
Fig. 12 Twin machine
Elliot machine Equi pment suppl ied a
continental machine, the ' Mentor' which
was available bot h in bench and floor
mounted forms. The bench machine is
shown in Fig. 9. They also have the
' Maximal' attachment to suit the lathe of
the same name, which fits on t he back of
the lathe bed and has independent motor
drive (Fig. 10). Thi s is also available as a
floor machine, the FB2.
Ot her compl ete machines include the
'Astra' supplied by Scat Urquhart, which
Is really horizontal mill er wit h an extra
vertical spindle with its own motor. Made
in several sizes. the small one is shown in
Fig. 11 .
Twin Engineering Co. i ntroduced a
bench machine ill ustrated in Fig. 12 and
also a floor mounted machine of similar
size but lightly different design.
Finally the old established firm of Tom
Senior Ltd. now produce their type E
22
machine which is floor mounted and
shown in Fig. 13.
So it will be seen that there are now
many machines and attachment which
are of suitable dimensions for inclusion in
the limi ted space of most home
workshops. It would 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-
t isers.
A summary of the leading particular of
all these machines etc. is given in Table 1
but again specifications re amended by
makers as ti me goes by, and it can be n
more than a general guide.
A brief word must be sai about foreign
machines, parti cularly those coming from
Far Eastern countries. It would appear
there are several factories producing
machine tools and accessories. Some
appear to be quite good. but others are
definitel y not good. and I do have personal
experience of some of these. I have not
had the chance to see one of the milling
machi nes working. but those I have
inspected in exhi bitions have some cheap
and nasty f eatures. although the mai n
items such as spindles, bearings. and
slideways may be excell ent. Some of the
machines ar more sui table for com-
mercial factories than home workshops
but there are others of modest dimen-
si ons. To anyone contemplating buying
one of these one can only suggest that a
close inspect ion should be made by a
knowledgeable engineer. and that a
working demonstration should be
requested. of the actual machine which is
to be bought.
Fig. 10 Maximat attachment
23
TABLE 1
Machine or
Make or supplier attachment Tab le si ze Sp indle speeds Spindle nose Comments
Woking Preci sion W estbury' 14 x 6 6 50. 11 20. 18 50. Un- machined castings
Mon els Co. Lt d. bench machine 31 50 Myforn thread only supplied
16 Doveco t Park kit of parts. Head sw ivels.
Ab srdour. Fifp..
Scot land
M odel !'ngineering ' Dora 16 x 5 188 2 Ml pl us Now superseded
S ervices . bench mach i ne 304. 790 . 16 50 Myford thread by Mk. 11
6. Kennet Vale, kit uf parts
Brockwel l. Do re W est bury 16 x 5t 32- 1880 2 MT plus Complete ki t of parts.
Ches lJou1ielrt. Mk.l l (20 x 6 Myford thread All machi ning do ne
bench machi ne opt ion] that woul d be difficult
kit of parts. in home workshop.
Head sw ive ls.
Tew M aChinery ltd. 'Rodney' For My/ord Dri ven from 2 MT plus Rigid head.
M anor W orks a tta chm ent . M L7 anrt lathe spindl e Myford thread
Church SI. 577 lat hes.
Coggcnh oc, ' Rodney plus' 15 x 4 32 0, 450, 61 0 , Rigid head.
Northampton. floor rnachinc. 8 50.1040,1 490, Myf ord th read
2 190. 2 750
N. Mul e & Cu. Lt d. 'Amolco For Myfurd Mutur drive. 2 MT pl us Rigid head.
5. Tulpi l s I line. i:t1l8 <:l lII Ulfl l. & Aoxfor d 4 speeds, 325 Myfurd thread
WHl t",d. HHrtS. tat hes. to 1600
Oench miller. 15 x 6 325-1 600 2 MTpi ll s Rigid head.
Myf or d t hread
I ABI F 1 (continued)
MaklllH supplter
M ll chin e or
attach m ent
Table si zt! Sp indle spe eds
Spindle nose
Comments
Cllio lt M nc:hlne
' Ment or 20t x{
3 50 ,640 . 7 80.
2MT
Swivell ing head.
F.'1,Jipment.
rtlHchi l1p.
14 50
U.LC. HnllHH,
B.1nch and
ViClu , i HHrl ,
London . NW 10 6NY
f loor.
FS2 M axim at
attach me nt nr
24t x 6
120-2000
(six)
2 MT
Swivelli ng haad
floor machine
Scot Urquhart Ltd..
3 17. Earl sfield Rn..
' Astr a'
bench anrt
13 x 62 0.900 .
12 00 . 18 50
2MT
Motori sed head.
Earl sfie ld.
floor
l ondon SW18 300
Il1sch in()l';
Hor. with vert .
head.
Twi ll en!'!. Co.
eelxton Way.
'Twin'
bench machine
20 x 6 52 0 . seo.
1650.2880
2 MT plus
Myf or d thread
Rigid head.
Ho lywell i nd. Est .
W atf or u. Harts.
and floor
machine.
20 x 6 380, 640.
1 100 . 1900 .
2MT plus
Myford thread
Swivel head .
31 00
Tom Senior. Ltd .,
A tl as W or ks.
' Seni or type E'
lIoor machine.
25 x 4t 480. 9 50 .
1640, 2760
2MT
Swivel head
Hig hto wn Heights.
Liversedg e.
W est Yor ks.
t>..l
.,.
N
(J1
Make or supplier
Woking Prncision
Models Co. Ltd.
16 Dovecot Park
Ahernollr, Fife.
Scotl!fI1d
Model Fngineering
Stlrvicel;,
6. Kennel Vale,
Brockwcll ,
ChestertiFl ld.
Tew Machinery I td
Manor Works
Church SI.
Coggcmhoc,
Nonh;Jmrton.
N. Mole & Co. Ltd.
5. Tolpits I alltl .
WilI!md HHrlS.
1 ABI F. 1 (continued)
Milk!! or lIupplier
Cllioll MAchine
Equipment.
U.l.C HOtlHH,
Vic\orlfl Rd,
LOI1lJoll , NW 1 0 6NY
Scnl Urquhilrt Ltd.,
317. 3 / 3iJ Earlsfitlltl Rd.,
Earlsfitlld.
Lonnon SW18 3 DO
Twill 1:r19. Co.
Ci!)(lOnWay,
Holywclllnd Est .
Watford, Herts.
Tom S(lnior , Ltd ,
Atlas Works
Hightown Heights,
Liversedge,
West Yorks
Machine or
attachment
Westbury'
bench machine
kit of parts.
' Dare Westbury'
bench machine
kit of parts
Dore Westbury
Mk.11
bench machine
kit of parts.
'Rodney'
attachment.
' Rodney pl us'
floor machine.
'Amolco'
c<lIachml:!lll.
Oench miller.
Mllchine or
attachment
' Mentor'
mtl chinp.
Bench and
floor.
F02 Maximat
attachrntlrH
floor machine
'Astra'
bench ann
floor
machines
Hor. with ven.
ht!8d.
Twin'
bench machine
and floor
machine.
'Senior type E'
floor machine.
TABLE 1
Table size Spindle speeds Spindle nose
Comments
14 x 6 650, 1120, 1850, 2MT plus
Un-machined castings
3150
Myford thread
onl y supplied
Head swivels.
16 x 188 2MTplus
Now superseded
304, 790. 1650
Myford thread by Mk.11
16 x 5t 32 1880
2MTnlus
Complete kit 01 pans.
(20 x 6
Myford thread
All machining done
option)
that would be difficult
in home workshop.
Head swivels.
For Myford Driven from
2MTplus
Rigid head.
Ml7 and
lathe spindle
Myford thread
S77 lathes.
15 x 4-!- 320, 450, 61O, 2 MTplus
Rigid head.
850, 1040, 1490, Myford lhread
2190, 2750
For Myloru Motor drive.
2MT plus
Rigid head.
& Hoxlor d 4 speeds, 325
Myloru thread
lilthes. to 1600
15 x 6 325 1600 2MT plus
Rigid head.
Myford thread
Table size Spindle speed8 Spindle n08e Comments
20t xi
350, 640, 780, 2MT Swivelling head.
1450
24t x 6 120-2000 2MT Swivelling head
(six)
13 x 620.900. 2MT Motori sed head.
1200, 1850
20 x 6 520,960. 2MT plus Rigid head.
1650. 2880 Myford thread
20 x 6 380,640, 2MTplus Swivel head.
1100, 1900. Myford thread
3100
25 x 4t 480,950, 2MT Swivel head
1640,2760
Fig. 13 Senior machine
CHAPTER 2
Milling Flat Surfaces
Of all met al-w orking operations the
production of true flat surf aces is perhaps
one of t he most di fficult if rel iance has to
be placed on hand t oo ls and hand
methods. for it depends just about com
pl et ely on the persona l ski ll of the
workman. But a poi nt offse t from the
spi nd le cent re of a vert ica l mill ing
machine must when rotated describe a
flat plane in space i f there is no axial
movement. Therefore. provided the
spind le is truly square to the table. an
offset cutting t ool must generate a flat
surface on a work- piece att ached to the
tabl e. Model engineering, just the same as
f ull size engineeri ng. demands the produc
tion of a great many flat surfaces. so the
ability of the machine to perform this task
in a simple way, without expensive
tooling, is extremely important to the
home worker.
FlYC UTTERS
The cheapest tool for t he purpose is the
flycutter. usualtv consist ing of a small
toolbit set i n some kind of holder. There
are commercially made holders avai lable.
but i t is quite easy to make satisfactory
holders at home. and they serve jus t as
well Three home- made flycutters are
shown in Fig. 14. Each is jus t a Morse
tape r arbor wi th an enl arged head having
a slanti ng hole dr illed in i t to take a cutt er
bit (t in. in these samples) wit h a screw to
lock i t in pl ace. The head diameters are 1t
i n.. q. in. and 2t i n. so th e face s that can
be mac hined at one pass are roughl y tin.
to 1- in. wider i n each case. They were
made by boring through short pieces of
st eel of these sizes to suit t he parallel
parts of Mor se taper arbor s. It is not
perhaps widely enough known t hat tool
merchants can. if th ey will , supply Morse
taper arbors of this ki nd. whi ch are a st ock
pr oduct of t he large dri ll makers. This
met hod of fabricat i ng flycutt ers by using a
ready made arbor wi t h a head Loct ited on
saves a good deal of time and some heavy
st eel. The effectiveness of to ols made in
t his way is beyond question. Fig. 15
shows a bracket cl amped agai nst a large
anglepl ate and being milled with one.
Fig. 16 shows one working on a steel
connecti ng rod which has to be reduced
from a circular section at each end. The
rod is about 9 in. long. so it is held i n two
vices at the same time. and each end is
taken down t o fin ished size before it is
tumed over. Packi ngs are used . different
at each end to ensure the finished-surface
i s above the vice jaws, to avoid cutting
27
26
Fig. 13 Senior m8chine
26
CHAPTER 2
Milling Flat Surfaces
Of all metal-working operations the
production of true flat urfaces is perhaps
one of the most difficult If reliance has to
be placed on hand tools and hand
methods. for it depend Just about com-
pl ete ly on the persona l ski ll of the
workman. But a poi nt offset from the
spi ndle centre of a vertica l milling
machine must when rotated describe a
flat plane i space if there is no axial
movement. Therefore. provided the
spindle is truly square t the table. an
offset cutting tool must generate a flat
surface on a work- piece attached to the
table. Model engineering, iust the same as
full size engineering. demands the produc-
tion of a great many flat surfaces. so th
ability of the machine to perform this task
in a simple way, without expensive
tooling, is extremely important to the
home worker.
FlYCUTTEAS
The c eapest tool for t he purpose is the
flycutter. usual'" consisting of a small
oolbit set i n some kind of holder. There
are commercially made holders avai l able.
but ' t is quite easy to make satisfactory
holders at home. and they serve just a
well Three home-made flycutters are
shown in Fig. 14. Each is Just a Morse
taper arbor wit h an enlarged hea having
a slanting hole drilled in it to take a cutter
bit (t in. in these samples) with a screw to
lock it in place. The head diameters are 1-k
i n .. 1} in. and 2t in. so the faces that can
be machined at one pass are roughly tin.
to t in. wider in each case. They were
made by boring through short pieces of
steel of these sizes to suit the parallel
parts of Morse taper arbors. It is not
perhaps widely enough known that tool
merchant s can, if they will . supply Morse
t aper arbors of this kind, which are a stock
product of t he large drill makers. Thi s
method of f abricating fl ycutters by usin a
ready made arbor wi th a head Loct ited on
saves a good deal of time and ome heavy
st eel. The effectiveness of tool s made i n
this way is beyond question. Fig. 1 5
shows a bracket lamped against a large
angleplate and being milled wit h one.
Fig. 16 shows one working on a steel
connecti ng rod which has to be reduced
from a circular section at each end. The
rod is about 9 in. long. so it is hel d i n two
vices at the same time, and each end is
taken down to finished size before it is
turned over. Packings are used, different
at each end to ensure the finished surface
is above the vice jaws. to avoid cutting
27
Fig. ' 4 Set of three flycutters
i nt o them, and the se pack ings en sure the Owning two vi ces ali ke may at fi rst
rod is at t he ri ght att i tude fo r keeping t he t ho ught see m somet hi ng of a luxury, bu t
mi l led surf aces paral lel to the ax is, as soon as lon g art icles have to be deal t
Fig. '5 Fly cutt ing a bracket
Fig. 16 Flycutting connecting rod ends
with the benefit s ar e at once apparent. reduced t o a t apered sec tio n t o cu t up i nto
Anot her flycutt ing operat ion is shown wedge blocks for connec t ing rods or the
in Fig. 17 where a steel bar is being type in th e pr evious picture. These wedge
Fi g. 17 Flycutting tapered bar material
29
28
Fig. ' 4 Set of three flycullers
into t hem, and these packings ensure the
rod is at the right attitude for keeping t he
mil l ed surfaces parallel to the axis.
Owning two vices alike may at f irst
thought seem something of a luxury, but
as soon as long articles have to be dealt
Fig. 15 Flycu((ing a bracket
28
Fig. 16 Flycutting connecting rod ends
with the benefits are at once apparent.
Another flycutting operation is shown
in Fig. 17 where a steel bar is bei ng
reduced t o a tapered section to cut up into
wedge blocks for connecting rods of the
type in the previous picture. These wedge
Fig. 17 Flycutting tapered bar material
29
Fig. 18 Fl ycu tt i ng cyli nder soleplate
blocks are needed for adjust ing the
beari ngs in the rod ends. The rectangular
sect ion bar is held in a vice on a tilti n
angle-plate whi ch has been set at 6
degrees to the table of th e mil ler wit h a
St ar rett combin at io n pro t rac to r. The
tapered form wil l be seen on th e end of
t he compl et ed piece l yin g on th e
angleplat e. This is an easy way of getti ng
a speci al sect ion which cannot be bought,
and wh ich woul d, to say the least . be
tedious to make by fi li ng.
These flycutt er hol ders do not allo w
much adjust ment of t he radi us of the
cutte r bi t , but wit h some makes of boring
head there is quite a lot of adj ust ment . For
example the Dare boring head permi ts of
usi ng a cutt er in a fi n, dia m. bar at any
radius up to 2t in., and by sett i ng the
saddle in or out on the slide body the
radius can be adjusted by fi ne amo unts to
suit any job wit hin the range. Fig. 18
shows an old type, pre-war bori ng head
being used to face a cyli nder sole-p late for
a slide valve engine model of 2t in. stroke.
FACE MILLS
Of course, mult i-cutt i ng-edge face mi lls
permi t mac hi ning a surface quicke r tha n a
si ngl e point t ool can do, and with less
snat ch and j erki ng, but commercially
made they are very expensive, and i n the
home workshop the greate r product ivity is
not usuall y of much consequence. Never
thel ess, for anybod y will ing to spend the
time needed they can be made in the
home workshop , with several cutte r bi ts
mounted in one mi ld steel body . Fig. 19
shows a face mil l of t his kind , which was
made originall y to screw on t he spindle of
a Myf ord lat he to do some repeti tive
mi l ling of a fairly heavy nature, now no
longer required, but it is sti ll a good
general purpose tool. It has 12 tool bits :l
in. di am. set into flat bottomed holes, all
Fig. 19 Facemill
st ationary engi ne. The cast i ng is suppor
sharpened to a diameter of approx. 2t i n.
ted by a special angle plate typ e of fi xt ure,
In Fig. 20 it is shown mill ing the face of
ground off to th e same projection. and
the pattern for which was made in an
hour. Wi thout t his f ixt ure the operat ion
a half -flywheel iron cast ing for a model
31
30
Fig. 18 Flycucting cylinder soleplate
blocks are needed for adjus ing the
beari ngs in the rod ends. The rect angular
section bar is held In a vice on a tilting
angle-plate which has been set t 6
degrees t o the t able of the mil ler wit h a
Starrett combi nati on protractor. The
tapered form wil l be seen on the end of
the completed piece l yi ng on th e
angl eplate. This is an easy way of getting
a special section which cannot be bought,
and whi ch woul , to say th least. be
tedious to make by filing.
These flycutter holders do not allow
much adjust ment of the radius f the
cutter bit. but with some makes of boring
head there is qui te a lot of adjustment. For
example the Dare boring head permits of
usi ng a cutt er in a i in. diam. bar at any
radius up to 2t In .. and by setting the
saddle in or out on the slide body t he
radius can be adjusted by fine amounts to
suit any job within the range. Fig. 18
shows an old type. pre-war boring head
30
being used to face a cylinder sole- plate for
a slide valve engine model of 2 ~ in. stroke.
FACE MILLS
Of course, multi-cul ting-edge face mills
permit machi ning a surface quicker than a
single point t ool can do. and with less
snatch and j erki ng. but commercially
made they are very expensive. and in the
home workshop the greater productivity is
not usuall y of much consequence. Never-
t heless, f or anybody will ing to spend the
ti me needed t hey can be made in the
home workshop. wi th several cutter bits
mounted in one mild steel body. Fig. 19
shows a face mill of t hi kind. which was
made originally to screw on the spindle of
a Myford lat he to do some repetitive
mi ll ing of a fa irl y heavy nature. now no
longer required. but it is still a good
general purpose to I. It has 12 tool bits t
in. di am. set into flat bottomed holes, all
Fig. 19 Facemill
ground off to the same project ion. and
sharpened to a diameter of approx. 2* i n.
In Fi g. 20 it is shown milling t he face of
a half-flywheel iron cast ing for a model
stat ionary engi ne. The cast ing is suppor-
ted by a special angle plate type of fi xt ure.
the patt ern for which was made in an
hour. Without this f ixture the operati on
Fig. 20 Milling flywheel joint face
31
Fig. 2 ' Milling crosshead slide
would be some wha t diff ic ul t. If th
casting was held in a vice on t he t able t he
point of cutti ng would be a long way from
the holding poi nt . and mo vement of the
cast ing under the pressure of cutti ng
would be not easy to prevent. Vibratio n
and chat ter would be more likely. It very
often happens that the only wa y to get a
satisfactory job is to make some equip
ment speciall y for it. This is not usuall y
wastef ul. especiall y jf a duplicate compo
nent is ever requi red. but t he equipment is
usually found adaptable for some ot her
job later. Doing met al cutti ng by 'knife
and-fork' methods can Soon lead to
disaster. The ot her half of t he wheel
cast ing. wit h the cast- in teeth for the
barring ' rack' , can be seen in t he bott om
half of the picture. The wheel is 9f in.
diameter and has 96 teet h.
Broad f lat surfaces can be. and some
ti mes have to be, produced by Success ive
par allel passes wit h an endmi ll much
narrower th an t he face requ ired . Apar t
from taki ng mor e ti me than a too l wit h a
wide sweep. minut e ridges tend to be left
where the passes overlap. and t hese may
have to be removed lat er by fil ing or
scrapin g. So whil e t his method is feasible
the f lyc utter or boring head is better
where t here is room to use it, and the
cutter bits are cheape r than endmill s and
easily sharpened li ke any l at he tool.
However. an example of work wh ere a
small Cutter and successive passes mus t
be used is shown i n Fig. 2 1 where a flat
bedpl at e sli de for the crosshead on a
model stat ionary engi ne is being milled.
The surface being cut is in a recess tin.
deep and t he Corners cannot be deal t wit h
by a tool cutt i ng the full Width. as the
radius left would be too great. Not e the
stop bar bolted to the table. Accurately
squared with the tabl e it provides not only
correct locat ion for the casti ng (wh ich was
follo wed by others) but also insurance
agai nst sl ipping .
In the full sized engi nes t hese slides
were always planed, and every engi ne
build ing shop had planers for thi s ki nd of
work. In the one wh ere I work ed t here
were several of diHere nt sizes. and t he
arqest , built by Joshua Buckt on of Leeds.
auld plane any cast i ng up to 20 ft. long.
12 ft. wide and 12 ft. high. It was said at
that time to be t he largest in Yorksh ire.
and certainly it often did cast ings for ot her
fi rms. Cutti ng coul d be done in bot h direc
tions of the tab le travel at equal speeds. or
in one di rection with a qui ck return the
other wa y. Each of t he four too lheads had
power operat ion independent of table
movement, so that cross-planing cou ld
be done through bearing recesses . etc.
One of the pictures shows this operati on
on a model bei ng done by mill i ng. Each
head could also be swivelled so t hat
angular faces could be planed also.
After the planing of crosshead slides
t hey we re tackled by t he fi llers and
scraped to a portable surf ace plate. Thi s
was coated sparing ly wit h a mixture of
lamp black and oil. slid to and fro on t he
slide . li ft ed off. and then all the bl ack
marks scraped away. The surfa ce plat e
was then put on again and a fresh lot of
marks mad e. which i n turn were scraped
away. This work went on for many hours,
indeed on a big slide two men cou ld
spend two or three days. For such work
t he surface plat e wo uld be so large th at
two men cou ld not lift it wit hou t t he use
of the shop crane. Event uall y af ter a long
t ime t he fi ni sh obtained woul d be
regarded as acceptable. It then consisted
of a very large number of extremely
shal low depressions bet ween t he marks.
and each of these proved to be an oi l
Fig. 22 Milling bearing j aws in bedp late
33
32
Fig. 21 Millmg crosshead slide
wou.ld be somewhat difficult . If th
was held in a vice on the table the
pOint of cutti ng would be a long way from
the holding point, and movement of the
casting under the pressure of utting
would be not easy to prevent . Vibration
and chatter would be more l ikely. It very
oftr:m happens that t he only way to get a
job is to make some equip-
ment specially for it. This is not usu lI y
especially if a duplicat e compo-
nent IS ever require , but the equipment is
usually found adaptable for some other
job later: DOing metal cutting by 'knife-
methods can soon lea to
disaster. The other half of t he h I . .
w ee
the cast-i n teeth for the
barnng rack , can be seen i n the bottom
of the picture. The wheel is 9
1
i n
diameter and has 96 teeth. 4'
t
. Broad flat surfaces can be, and some-
Imes have to be d
,pro uced by successive
32
parallel passes with an end mi ll much
narrower than t he face requi red. Apart
taking more ime than a tool with a
Wide sweep, minute ridges tend to be left
where the passes overlap, and these may
have. to be removed later by fil ing or
scraping. So while this met hod is feasible
the flycutter or boring head is better
wher is room to use it, and the
bi ts are cheaper than endmills and
easily sharpened like any lathe tool.
However. an example of work where a
small cutter and successive passes must
be used is shown in Fig. 21 where a flat
bedplate slide for the cross head on a
model stationary engine is being milled.
The surface being cut is in a recess i- in.
deep and the corners cannot be dealt with
by .a tool cutt ing the full width, as the
radiUS left would be too great. Note the
stop bar to the table. Accurately
squared wi th the table it provides not only
correct location for the casting (which was
fol lowed by others) but also insurance
agai nst slipping,
In the full sized engines these slides
were always planed, and every engine-
buil ding shop had planers for this kind of
work. In the one where I worked there
were several of different sizes. and the
largest. built by Joshua Bucklon of Leeds,
could plane any casting up to 20 ft. long,
12 ft. wide and 12 ft . high. It was said at
that time to be the largest in Yorkshire,
and certainly it often did castings for other
irms. Cutting could be done in both direc-
tions of the table travel at equal speeds, or
in one direction with a qui ck return the
other way. Each of the four tool heads ha
power operation independent of table
movement , so that cross-pl anin could
bE' done through bearing recesses, etc.
One of the pictures haws this operation
on a model being done by milling Each
head could also be swivelled so that
angular faces could be planed also.
After the planing of crosshead slides
they were tackled by the fitter and
scraped to a portable surface plate. This
was coated sparingly with a mixture of
lamp bl ack and oil . slid to and fro on the
slide, lifted off, and then all the black
marks scraped away. The surface plate
was then put on again and a fresh lot of
marks made, which in turn were scraped
away. This work went on for many hours,
indeed on a big slide two men could
spend two or three ays. For such work
the surface plate would be so large that
twO men could not lift it without the use
of the shop crane. Eventually after a long
time the fini sh obtai ned would be
regarded as acceptable. It then consisted
of a very large n Im er of extremely
shallow depressions between t he marks,
and each of these proved to e an oil
Fig. 22 Milling bearing jaws in bedplate
33
pocket. When the engine was eventually
put to work, with the cross-head having
had similar treatment. the result was that
the cross- head ran to and fro on a film of
lubr ican t which reduced wea r to a very
small amount. Engines in textile mil ls
would run 60 years and at the end you
would find the scraper marks still there .
The oil was continuously renewed by
brass combs attached to the crosshead
which picked up oil from a well at each
end of the slide. An engine runni ng night
and day. as many of them did . with a
speed of about 80 r.p.m. would make
approx. 3600 million cross-head strokes
in t hat time! Not a bad performance?
When flat surfaces have to be produced
at right angles to the table it is necessary
to use the side of an endmill . This may be
quite unavoidable on some components,
such as t he model engine bedplate shown
in Fig. 22. There is not much choice about
milling out the jaws for the crankshaft
bearings. This is an operation wh ich t he
big planer used to do with the power drive
on the heads of t he cross -rail.
CHAPTER 3
Slitting and Cutting
It is common practice to design mac hinery
components wit h spli t bosses which can
be cont racted with a screw for tightening
purposes. The slitting can be done with a
hacksaw. bu t if done in unskilful fashion
will not look good when completed .
Slitting saws and many other disc type
cutters can be readi ly used on the vertical
miller by mounting t hem on a Mo rse taper
arbor having a parallel portion for the
cutter, and a nut to secure it . Its a good
t hing to put a pair of flats on the arbo r to
hold it by when turning the nut. Fig. 23
shows a slitting saw in use cutti ng
through one side of the boss of one of the
parts of the Quorn grinder. On t hat
machine there are several components
w ith this feature, so time will be saved if
they are all col lected and cut through
while the saw and vice are i n position.
Fig. 23 Slitting boss of casting
35
34
pocket. When the engine was eventually
put to work, with the cross-head having
had similar treatment, the result was that
the cross- head ran to and fro on a film of
lubricant which reduced wear to a very
small amount. Engines in textile mills
would run 60 years and at the end you
would find the scraper marks still there.
The oil was continuously renewed by
brass combs attached to the crosshead
which picked up oil from a well at each
end of the slide. An engine running night
and day, as many of them did. with a
34
speed of about 80 r.p.m. would make
approx. 3600 million cross-head strokes
in that time! Not a bad performance?
When flat surfaces have to be produced
at right angles to the table it is necessary
to use the side of an endmill. This may be
quite unavoidable on some components.
such as the model engine bedplate shown
in Fig. 22. There is not much choice about
milling out the jaws for the crankshaft
bearings. This is an operation which the
big planer used to do with the power drive
on the heads of the cross-rail.
CHAPTER 3
Sitting and Cutting
It is common practice to design machinery
components with spli t bosses v-:hich can
be contracted with a screw for tightening
purposes. The slitting can be ?one w i t ~ a
hacksaw. but if done in unskilful fashion
will not look good when completed.
Slitting saws and many other disc t ~ p e
cutters can be readily used on the vertical
miller by mounting them on a Morse taper
arbor having a parallel portion for the
cutter. and a nut to secure it. Its a good
thing to put a pair of flats on the arbor to
hold it by when turning the nut. Fig. 23
shows a slitting saw in use cutting
through one side of the boss of one of the
parts of the Quorn grinder. On that
machine there are several components
with this feature, so time will be saved if
they are all collected and cut through
while the saw and vice are in position.
Fig. 23 Slitting boss of casting
35
Many other jobs of si mila r nat ure wil l
come to mind, such as engi ne eccent ri c
sheaves, and especiall y eccent ric straps .
wh ich can be cast in one pi ece and then
cut thr oug h, leavi ng two surfaces t hat
need only a touch with a fi le to rem ov e
burrs to enabl e them at once to be bolted
toget her. Not only are castings involved
but also parts made from bar material.
Ma rine type connect ing rod ends are an
example. and this method can also be
used for producing bearings in hal ves.
CHAPTER 4
Keyway Cutting
Keys and keyways are a very commo n
feat ure of machi nery and naturally of
models too. The common round-e nded
keyway. for a ' feather' key . is easily
produced on a parallel shaft by hol di ng the
shaft i n the vice and using a small endmill ,
or two -f lute 'slot -drill' . Fig. 24 shows the
set up for t his ope ration.
Various parts of car and motor cycl e
engi nes. gearboxes, and other machi nery
components in t he past have had wheels
mount ed on tapered shafts wi th the
keyways foll owing the slope of the taper.
Modellin g one of these would i nvolve
followi ng the same proce du re. One way in
wh ich this can be done is shown i n Fig.
25. The vice hol di ng the shaft is set on a
tilting angleplate so th at the top of the
Fig. 24 Milling I eet her keywa y
37
36
Many other jobs of similar nature will
come to mind, such as engine eccentric
s h ~ a v e s , and especially eccentric straps,
which can be cast in one piece and then
cut through, leaving two surfaces that
need only a touch with a file to remove
36
burrs to enable them at once to be bolted
together. Not only are castings involved
but also parts made from bar material.
Manne type connecting rod ends are an
example, and this method can also be
used for producing bearings in halves,
CHAPTER 4
Keyway Cutting
Keys and keyways are a very common
feature of machinery and naturally of
models too. The common round-ended
kfl yway. for a 'feather' key, is easily
produced on a parallel shaft by holding the
shaft in the vice and using a small endmi ll ,
or two-flute 'slot -drill' . Fig. 24 shows the
set up for this operation.
Various parts of car and motor cycle
engines, gearboxes, and other machinery
components in t he past have had wheels
mounted on tapered shafts with the
keyways following the slope of the taper.
Modelling one of these would i nvolve
following the same procedure. One way in
which this can be done is shown in Fig.
25. The vice holding the shaft is set on a
tilting angleplate so that the top of the
Fig. 24 Milling feather keyway
37
Fig. 25 Milling feat her ke yway on t ap er ed shal t
tapered part comes parallel wit h the
machine t able. The shaft shown in t he
picture is a simple one and quit e short .
and could have been j ust t ilted in t he vice
i n a set-up like t hat of Fig. 24. But a long
shaft might wel l fo ul the t able at it s lower
end so t he elevation which t he anglepl at e
gi ves could in such a case prove essent ial.
Small endmill s are rather f rail tools at
best and li able to easy breakage. The di sc
type cutt er is more rob ust and a coll ecti on
of these acquired either as the need fo r
one crops up, or bought cheaply seco nd
hand, is wort h while. Of course the disc
cutte r cannot always go close to a
shou lder on t he shaft , and copying a
pro totype may i n some cases rule it out .
For the work do ne in t he home workshop
t here is no need to insist on the rel ativel y
expe nsive side - and-face cutt ers, (t hose
wit h teet h on t he f aces as well as the peri
phery ) because the sli tting saw, with teeth
only on t he periphery, wil l do qu ite wel l.
These are made i n a very great variety of
t hicknesses , and are always comi ng on
t he surp lus market at low prices. One of
t hese is shown in Fig. 2 6 mi lli ng an
ord inary sunken keyway, the shaf t bei ng
held in a vice wi th enough overhang t o
avoid t he cutt er t ouchi ng t he vice.
WOODRUFF KEYS
The Woodruff key is one w idely used in
ind ust ry. This is in effect a slic e off a round
bar, cut i n half and set into t he shaf t i n a
recess made by a sma l l diameter slitti ng
saw. Th is is rath er an oversi mplif ied
descr iption, but it wi ll serve we ll enough
as an int roduct ion to the Woodruff key for
those in home w o rks hop s w i t hou t
i ndust rial ex perience. Seriously. th e
Wood ruff key. which I t hi nk was of
American or igi n, has some very real
advant ages for th e mass pr oducti on
i ndust ry, and some of t hes e are of j ust as
gr eat import ance i n t he home workshop
and t he fi eld of light engineering.
Fig. 26 M illing keyway wi th sli tt ing saw
For a sta rt the key itsel f can be part ed ac curacy f rom t he bri ght ba r. The
off from a piece of round mi ld st eel or thi ckness needs caref ul cont rol, but if it
silver st eel. So it s diameter is sett led wit h com es off a bit t oo t hick i t can be rubbed
Fig. 27 Set 01four Woodruff keyway cutters
38
3 9
Fig. 25 Milling feather keyway on tapered shaft
tapered part comes parallel wit h the
machi ne table. The shaft shown in the
picture is a simple one and quite short .
and could have been j ust til ted in the vice
i n a set-up like that of Fi g. 24. But a long
shaft might well foul the t able at its lower
end so the elevation which t he angleplate
gives could i n such a case prove essent ial.
Small endmill s are rather frai l tool at
best and liabl e to easy breakage. The disc
type cutter is more robust and a collec ion
of these acquired either as the need for
one crops up, or bought cheaply second-
hand, is worth while. Of course the disc
cutter cannot always go close to a
shoulder on t he shaft, and copying a
prototype may in some cases rule it out.
For the work done in the home workshop
there is no need to insist on the relatively
expensive side- and-face cutters, (those
wit h teet h on t he f aces a well as the peri-
phery) because the slitting saw, with teeth
only on the periphery, will do quite wel l.
These are made in a very great variety of
38
thicknesses, and are always coming on
t he surplus market at low prices. On of
t hese is shown in Fig. 26 milling an
ordinary sunken keyway, the shaft bei ng
held in a vice with enough overhang t o
avoid t he cutter touching t he vice.
WOODRUFF KEYS
The Woodruff key is one widely used in
industry. This is in effect a slice off a round
bar, cut i n half and set into t he shaft in a
recess made by a small diameter slitting
saw. This is rather an oversimplified
description, but it will serve well enough
as an introduction to the Woodruff key for
those in home workshops w it hout
i ndustrial experience. Ser iously, the
Woodruff key, which I thi nk was of
American origi n, has some very real
advant ages for the mass production
i ndustry, and some of these are of just as
great importance in t he home workshop
and the field of light engineering.
Fig. 26 Milling ic.eyway with slitting saw
For a start t he key itself can be part ed
off from a piece of round mil d steel r
sil ver steel. So it s di ameter is sett led with
accuracy f rom the bright ba r. The
thi kness needs carefu l control , but if it
comes off a bi t t oo thick i t can be rubbed
Fig. 27 Set of four Woodruff keyway cutters
39
teet h can be cu t in two ope rations using
an ordinary end mi ll ; the re is no need for
angu lar cu tters. as t he diagra m on the
opposit e page indicates. The num ber of
teeth is no t importa nt, but six is a co n
venient numb er for small cutters. It is
possible to file t he teet h if you do not have
access to a div iding head. as the spacing
is not at all critical , but it's a little more
difficult . Fig. 27 shows a batch of cutters
made to the sizes i n Table II and Fig. 28
shows a keyway bei ng cut . There seems
to be no place where sizes of Woodruff
keys and cutters are disp layed for model
engi neers . Machinery's Handbook giv es
sizes wh ich are used in i ndustry. but the
sheer range of sizes is i tself conf using, and
of cou rse t he tables are libe rally sprin kl ed
wit h to lerances that model lers cou ld
neither follow no r wa nt . I have t herefore
picked ou t a few sizes wh ich I t hi nk wi l l
serve ou r pu rpo se. and as we don ' t have
to provide interchangeability i n our
products, if anybody w ant s t o depa rt a bit
41
Fig. 28 Milling Woodruff keyway
the diametra l li ne of t he shaft. the n th e
cutt er is fed in by a predetermined
amount.
The resulti ng keyw ay is deep enough to
give the key a good ho ld, so that i t cannot
roll over, and yet the shaft is no t unduly
wea kened. Norm all y th e t op of t he key is
just clear of the keyway i n the wheel or
lever wh ich is bei ng secu red , it s purpose
bei ng to provi de eit her tor qu e or angular
locat ion, and some mea ns such as a grub
screw may have to be used to preve nt
endwise movement.
W oodruff cutters are not very cheap,
but they can easi ly be made in t he home
workshop, f rom sil ver steel. The process is
reall y qu ite si mple. A blank can be t urned,
mak i ng a shank to sui t some sta nda rd
col let. t hen with t he shank held in the
colle t the working part of the cutter can be
turned to it s diameter, and th ickness. The
sides sho ul d be very sligh tly undercut by
setting a kni fetool a little off square. Using
a sim ple un-geared dividi ng head the
key is ma de, with an int egral shank of pre
ferably some sta nda rd di ame t er w hich can
be run true in a collet on t he mi ller. So the
shape of the keyw ay pro fi le - and its
w idt h - is settled by t he cutter form. The
cutti ng par t of the cutter is set in line w ith
2
TABLE II
3 F
~ x20 B.S.F. FOR
CLARKSON Be. OSBORN CHUCKS.
WOODRUFF
KEY S & KE.YWAYS CUTTERS
A B C D E F
G
~
I
'10 9
'030
44 -(6
'073 '037 '10 0
~ 6
.%
140 '/ 0 4 '03 7 '/04 '037
.6
3-'8
%2 '172 '/23 '053 -/ 29 '045
~
~ 2 -203 '155 '053 -1 87 '060
2
G ~
down on a flat file . It needs t o be cu t in
two on a line w hich is nearly a dia me ter,
but the cut edge can readily be filed to
br ing it to f ina l shape . The keyw ay is made
by a simple cutter like a slitti ng saw, of the
same diameter as the bar from wh ich the
40
down on a flat file. It needs to be cut in
two on a line which is nearly a diameter.
but the cut edge can readily be filed to
bring it to fina l shape. The keyway is made
by a simple cutter like a slitting saw, of the
same diameter as the bar from which the
key is made, with an integral shank of pre-
ferably some standard diameter which can
be run true in a collet on the miller. So the
shape of the keyway profile - and its
width - is settled by the cutter form. The
cutting part of the cutter is set in line with
TABLE 11
3", "ZO B,S.F. FOR
CLARKSON &, OSeORN CHUCKS.
WOODRUFF
KEYS & K E.YWAYS CUTTERS
A B C 0 E F
G
~
I
-109 ~ -(,
'073 '037 '100 -030
~ 6
.%
16 140 '104 '037 '104 '037
~
%a "112 '123 '053 '129 -045
~
2 %2 '203 "155 '053 -187 -060
40
the diametral line of the shaft, then the
cutter is fed in by a predetermined
amount.
The resulting keyway is deep enough to
give the key a good hold, so that i t cannot
roll over, and yet the shah is not unduly
weakened. Normally the top of the key is
just clear of the keyway in the wheel or
lever which is being secured, its purpose
being to provide either torque or angular
location, and some means such as a grub
screw may have to be used to prevent
end wise movement.
Woodruff cutters are not very cheap,
but they can easily be made in the home
workshop, from silver steel. The process is
really quite simple. A blank can be turned,
making a shank to suit some standard
collet , then with the shank held in the
collet the working part of the cutter can be
turned to its diameter, and thickness. The
sides should be very slightly undercut by
setting a knife tool a little off square. Using
a simple un-geared dividing head the
teeth can be cut in two operations using
an ordinary end mill ; there is no need for
angular cutters, as the diagram on the
opposite page indicates. The number of
teeth Is not important. but six is a con-
venient number for small cutters. It is
possible to file the teeth if you do not have
access to a dividing head, as the spacing
is not at all critical. but it's a little more
difficult. Fig, 27 shows a batch of cutters
made to the sizes in Table 11 and Fig. 28
shows a keyway being cut. There seems
to be no place where sizes of Woodruff
keys and cutters are displayed for model
engineers. Machinery's Handbook gives
sizes which are used in industry, but the
sheer range of sizes is itself confusing. and
of course the tables are liberally sprinkled
with tolerances that modellers could
neither follow nor want. I have therefore
picked out a few sizes which I think will
serve our purpose, and as we don't have
to provide interchangeability in our
products, if anybody wants to depart a bit
Fig. 28 Milling Woodruff keyway
41
from t hese di mensions he can certai nly do
so. Up to date of writing I have not seen
any spec ifica tion of Woodruff keys i n
met ric sizes.
The cutters shown in Table II have
screwed shanks to suit Clarkson and
Osborn chucks, which have collets that
close on t he cutter shank through end
thrust exerted by t he cutter agai nst t he
inside of the chuck. If you are maki ng
cutters for use in a Clare chuck or just to
use i n a 3-j aw. these thr eads are not
needed. It may be noticed that the cutters
shown in Fig. 27 are stamped with t hei r
size detai ls. It is a goo d plan to have a set
of small stamps. say 1/1 6 in. character s.
so that appropriate identity can be mar ked
on all home made tools. j igs. etc as we ll as
model compo nents. The hol es dr il led i n
these cutte rs were provided for the con
venien ce of the har dener . They were
harde ned for me by a f irm where liquid
salt bath s are used for heat ing and
quenching tools. A small hole enables the
tool to be hung on a wire i n t he bat hs
without damage to cutt ing edges.
CHAPTER 5
Fluting Components
other than Tools
Fluti ng of locomot ive connecti ng rods and
coupli ng rods is an operation very similar
t o keyway cutting so far as the removal of
metal is concerned. but t he lengt h of t he
flutes is usually greater, and the lengt h of
the pieces deman ds some well arrange
holding met hods. One occasionall y sees
rods which have been f luted wit h an
endmi ll by t he same metho d as shown in
Fig. 24. giving rounded end flutes l ike a
feather keyway. Thi s is ent irely wrong. no
full size rods were fluted thi s way. They
have flutes wi th rounded i nt ernal corne rs
in the bot tom. and wi t h swept out t er
minatio ns at the ends, whi ch is done to
avoid t he notch fatigue cracks which can
propagate fr om sharp corners. Fort unately
it is qui te easy to produce fl utes which are
i n accordance wit h full size pract ice. and
not even necessary to have a fancy mill ing
cutl er. A si mp le tool bit , gro und rat her like
a partin g too l. wi th the corners rounded
off. is put into a t ransverse hole in a cu tler
bar , and mounted in a chuck on the mil ler.
The rod to be dealt wit h is fixed edgeways
up, as it goes in t he loco. preferably
against a long angleplate. and the rotat ing
cutler is fed in like a Wood ruff cutl er
would be. Wh en i n to proper depth.
usually quite shallow, t he table movement
is started and the f lute is then made
progressive ly along th e rod, l eavi ng
behi nd t he swe pt end. Where the cut
fini shes there i s also a swept end,
automaticall y. Coup li ng rods usuall y have
flutes that are parallel sided, and so do
some t ypes of Canadi an and American
con nect ing rods. In t hese cases a single
pass wit h a cutler the right widt h wi ll
c omplete t he job. Most Bri t i sh
locomot ives. on the ot her hand, had
tape red connec ting rods wi th parall el
f langes. l.e. tapered fl utes. For these two
passes are needed. and this can be
achieved in a very si mpl e way.
In Fig. 29 the rod of a Canadi an engi ne
is seen fixed on the angleplate. In each
end is a screw with a head tu rned to the
size of the hole in the rod end. Thi s is a 12
i n. long angl eplate wi th no slots. as hol es
are dri ll ed and tapped just wherever they
are needed for each job. It will be many
years bef ore i t is so perforated as to be no
fur ther use. The two holes for the locating
screws are the same distance f rom the
table. and t hey only provide the locati on.
t he rod bei ng secured against t he cu tting
forc es by two small clamps as shown. For
this rod and for coupling rods t he set -up is
exactly as shown. But for Bri tish type
rods . the screw in the big end is made
smaller t han the hole in the rod by the
42
43
from t hese dimensions he can certainly do
so. Up to date of writing I have not seen
any specification of Woodruff keys in
metric sizes.
The cutters shown in Table II have
screwed shanks to suit Clarkson and
Osborn chucks, which have collets that
close on the cutter shank through end
thrust exerted by the cutter against the
inside of the chuck. If you are making
cutters for use in a Clare chuck or just to
use i n a 3-jaw, these threads are not
needed. It may be noticed that the cutters
42
shown in Fig. 27 are stamped wi th their
size detai ls. It is a good plan to have a set
of small stamps, say 1;16 in. characters,
so that appropriate identity can be marked
on all home made tools, jigs, etc as wel l as
model components. The holes drilled in
these cutters were provided for the con-
venience of the hardener. They were
hardened for me by a f irm where liquid-
sal t baths are used for heat ing and
quenching tools. A small hole enables the
tool to be hung on a wire in the baths
without damage to cutt ing edges.
CHAPTER 5
Fluting Components
other than Tools
Fluti ng of locomotive connecti ng rods and
coupli ng rods is an operation very similar
to keyway cutting so f ar as t he removal of
metal is concerned, but t he lengt h of t he
flutes is usually greater, and the length of
the pieces demands some well arrange
hol di ng methods. One occasionall y sees
rods which have been f luted wit h an
endmil l by t he same method as shown in
Fig. 24, giving rounded end f lutes like a
feather keyway. Thi s is ent irely wrong, no
full size rods were f luted t his way. They
have fl utes with rounded internal corners
in t he bottom, and with swept out ter-
mi nations at t he ends, whi ch is done to
avoid the notch f atigue cracks whi ch can
propagate from sharp corners. Fort unately
it is quite easy t o produce f l utes which are
in accordance wi th full size pract ice, and
not even necessary to have a fancy mi ll ing
cutter. A simple tool bit. ground rather like
a p rting tool, with t he corners rounded
off, is put into a t ransverse hole in a cutt er
bar, and mounted in a chuck on t he miller.
The rod to be dealt with is fixed edgeways
up, as it goes in the loco, preferably
against a long anglepl at e, and the rotati ng
cutter is fed in like a Woodruff cutter
would be. When in to proper depth,
usually Quite shallow, the tabl e movement
is started and the f lute is then made
progressively along t he rod, l eaving
behin t he swept end. Where the cut
finishes t here is al so a swept end,
automatically. Coupling rods usuall y have
flutes that are parall el sided, and so do
some types of Canadian and American
connect ing rods. In these cases a single
pass wit h a cutter the right width wi ll
comp l ete t he job. Most Br itish
locomotives, on the other hand, had
tapered connecting rods wi th parall el
flanges. i.e. tapered flutes, For these two
passes are needed, and t his can be
achieved in a very si mple way.
In Fig. 29 the rod of a Canadi an engi ne
is seen fixed on the angleplate. In each
end is a screw with a head turned to t he
size of the hole i n the rod end. This is a 12
in. long anglepl ate with no slots, as holes
are drilled and tapped just wherever they
are needed for each job, It will be many
years before i t is so perforated as to be no
further use. The two holes for the locating
screws are t he same distance from the
table. and they only provide the location,
t he rod being secured against the cutting
forces by two small clamps as shown. For
this rod and for coupling rods the set -up is
exact ly as shown. But for British type
rods, the screw in the big end is made
smalier than the hole in the rod by the
43
Fig. 29 Fluting locomotive conn ec ting rod
amount of the taper (at the hol e cent res)
and for t he f irst operat ion the rod can be
allowed to dro p down on t he screw whi le
the fi rst cut is t aken. Then for the second
cut the rod is lift ed up as far as the screw
will let i t go. and re-ctarnped. and a
second cut taken, The rod wi ll now fi nish
wit h a taper flute and two paral lel flanges.
This f luti ng is a very simple operat ion .
The angleplate is extremely rigid. The
machine i n t he pi cture is happily provided
wi th a t in. wide keyway along the cent re
of the table. only t in. deep . but a i- i n.
square bar can be dr opped int o it. That
enabl es fixtures to be instantly lined up
wi t h th e t abl e movemen t . incl udi ng
divi ding heads as we ll as angleplates. The
t hrust of t he cutte r in t his example tends
to move the anglepl ate awa y from the bar .
but it is secured wit h two good bolts in
t he t abl e sl ot s. not visi ble i n t he
photograph. It should not be forgott en
t hat locomotive rods which are fluted at
all must be done on bot h sides. but wi th a
set- up li ke t his the j ob is so si mp le it
would be a pity not to have it right.
CHAPTER 6
Boring
It is not uncommon t o have bor e holes in
components which are much too large to
swing around in t he lathes t hat are found
in most home workshops. But there is no
need in many cases t o resort to hand
too ls. even for holes where great accuracy
is not needed. The vert ical mil ler can be
used for bori ng (wit h a trepanning tool in a
bori ng head) such things as fi re- hole
door s i n boiler plates. bosses on casti ngs
such as long levers. and many ot her
objects. I n or der t o rnot ori se a shaper I
had to bore a hole through t in. of cast
iron t o mount a worm reduct ion gearbox.
and t his had to be a t rue round hol e. It
was done by fixi ng t he cast ing (15 i n. long
i n one direct ion f rom t he cent re of the
hole) on the mil ler tabl e and usi ng a cutt er
in a boring head. Wit h t he worm- act uat ed
down feed. and t he bot tom speed of the
Dare-Westbury machine. 34t rpm. an
excellen t hole wa s obtai ned four i nches
diameter. Wi t hout these facil i t ies t he work
would have been sent out to some
engineeri ng fi rm. The ampler space on t he
tables of mil li ng machines. compared with
what one can get on a lat he saddl e wit h
an angleplate. makes the mi ll er invaluable
for work of thi s ki nd and of cour se by
doing external turnin g wit h a boring head
one can deal wit h male regist ers as we ll
as hol es. This is a simp le operat ion too;
one j ust turns the cutt i ng tool inward
instead of outward.
44
45
Fig. 29 Fluting locomotive connecting rod
amount of the taper (at the hole cen tr s)
and for the f irst operation the ro can be
allowed to drop down on t h screw while
the first cut is t aken. Then for the second
cut the rod is lifted up as far as the screw
wil l let it go. and re-clamped. and a
second cut taken. The rod wil l now fi nish
with a taper flute an two parall I flanges.
Thi s fluting is a very simple operat ion.
The angleplate is extremely rigid. The
machine i n t he pict ure is happily provided
with a t in. wide keyway along the centre
of the table. onl y t in. deep. but a t in.
44
square bar can be dropped into it. That
enables fixtures to be instantly lined up
with the tabi e movemen t . i ncl uding
dividing hea s as well as angleplates. The
t hrust of the cutter in this example tends
to move the an leplate away from the bar,
but it is secured with two good bolts in
t he t able slots. not visible i n the
photograph. It should not be forgotten
that locomotive rods which are fluted at
all must be done on both sides. but wi t h a
set-up li ke this th j ob is so si mple it
wou ld be a pi ty not to have it righ t.
CHAPTER 6
Boring
It is not uncommon to have bore holes in
components which are much too large t o
swing around in t he lat he t hat are found
in most home workshops. But there is no
need in many cases t o resort to hand
tool s. even for holes where great accuracy
IS not needed. The verti cal mil ler can be
used for boring (with a trepanning tool in a
bori ng head) such things as fi re-hol e
doors in boiler plates. bosses on cast ings
such as long levers, and many other
objects. I n order to motorise a shaper I
had to ore a hole through t in. of cast
i ron to mount a worm reduction gearbox,
and this had to be a true round hole. It
was done by fixi ng he cast i ng (15 i n. long
in one direction f rom the centre of the
hole) on the mi ller table and usi ng a cutter
in a boring head. With the worm-act uated
down feed. and the bottom speed of the
Dore-Westbury machine, 34t rpm. an
excell ent hole was obtained four i nch s
diameter. Withou t hese faci liti es the work
w uld have been sent out to some
engineeri ng firm. The ampler space on the
tables of mil ling machi nes. compared with
what one can get on a lathe saddl e wi t h
an angleplate. makes the mi ll er i nvaluable
for work of this ki nd and of course by
doing external turning wit h a boring head
one can deal with male registers as well
as holes. This is a simple operat ion too;
one j ust turns the cutting tool inward
instead of outward.
45
47
.J.
/6
-+--II-- -005
.l
+
a
6+
,..,38
posit ion by usi ng t he table cross-screw to
provide the amount off th e main line.
W hen all t he ho les are finished t he beam
can be tu rned over and the bosses mill ed
on the other side .
Th e beam engine cast i ng is just one
example of how t his sort of t ask can be
handled. Fig. 30 is a draw ing of a compo
nent of th e t rip gea r of a model steam
engine. and t he holes w hich have to be
dri ll ed are in posi t ion s w hich w ou ld not be
easil y att ained by the co m mon marki ng
out and centr e punching proces s. Fig. 31
shows one of th e fi nishe d pi eces w it h one
only part-ma de, to show the me thod
adopted. One i nch diamet er bar wa s used .
as t hat gives th e outside prof il e needed.
Set true in th e fo ur- j aw chuck it was
bore d 9/ 16 i n., the n set out of true by
.047 in. and the ho le re-bored to t he same
sett ing. Next it was set well off centre to
dril l t he No. 38 drill hole. Th e correct
setting was established by measurements
Fig. 3 0 Drawing of stea m hook (l ever)
r - I
. ~ - - "
=::--
...,."
t - I
\ I ~ ~ :
~
~ : 7
w hen do ing an exercise of t his kind to
have a paper and pencil handy and w rit e
dow n the micromet er dial readings w hich
are th e st opp ing poi nts. This reduces t he
chances of acciden t al error. It is a method
used by men i n i ndust ry w ho are engaged
on delicat e w ork w here a momentary
in t erru pti on ca n be disast rou s. I have
my self used it for many year s. A t th is
stag e dri llin g can now sta rt . Each hol e
should be centred w it h a D-bi l groun d to
about 1 18 degrees, foll ow ed by the
app ropriat e dri ll. thoug h th e l arger holes
may need a pil ot dr ill put t i ng t hrough first .
As each hole is fi ni shed. w ith reami ng if
needed, move on to the next hole by the
table wi nd. and go th rough the procedu re
with th at . too. By this meth od all the holes
w il l be the right distance apar t , and w i ll al l
be paralle l to one another i n tw o plane s. It
w ill be clear th at if any holes are wanted
which are not on t he mai n centre l ine, it is
a si mp le mat t er t o drill these in an off-set
t he parall el motion, pump rods, etc. The
casti ng can be cl amped t o t he tabl e qu i te
firmly, rest ing on packaging of reason able
thic kness so t hat a penetrati ng drill do es
not dip in to the t able. A t th is stage all
bosses can be faced w it h an end mill ,
even if t hey are at differen t levels. The
centre lin e of t he cast i ng should have
been set paralle l w ith t he line of t he t able
movement . Put t he drill chuck in the
spind le. w ith a f ine poi nt ed du mmy dri ll
sim ilar to a ce ntre punch. and br ing t his
over t he fi rst boss cen tre . Then wi nd on
th e table t he amou nt t o t he next hole and
check if t he poi nt com es in t he ri ght place
over t hat boss. W ind on again to th e next
and so on checking at each boss. If all
come cen tra l. all is wel l. If one or mo re
don' t. then an allow ance w il l have to be
made as a co mprom ise. Ma ke a not e of
wha t i t is. re-start at the beginning, and do
another run t ill you are satisf ied you have
got t he rig ht starti ng point for t he best
results. If you happen to tu rn the ta ble
screw a bi t t oo far at one of the stopping
points, do n't worry, but do n' t turn it back a
bit as a correct ion , because th at way you
cou ld i ntroduce an error thro ug h back lash
(lost mot ion due to slackness) i n the
screw and nut. Go back to the very start
and come at it again. It's a good thing
CHAPTER 7
Jig-Boring
The ter m 'j ig-boring' is likely t o be
unfa mili ar to many readers of t his boo k,
and they may thi nk t hat w hateve r it
mean s it must be a long way removed
from model engineering. This is no t so, for
in model making pl enty of operations arise
th at can be don e by 'jig-bori ng' to adva n
t age. Basicall y it only means fixi ng a com
ponen t to t he machine tab le and th en
using the tab le screw s as measuring
devices to posit ion the spindl e over any
part of th e com ponen t that is desired
before dr i lli ng or boring a hole. I n many
ways t hi s meth od is better than marking
out, measu ri ng wi t h a rule, then centre
pu nch ing fo ll owed by dri ll ing on a drilli ng
machine. For one t hi ng th e wo rkp iece is
f i r m ly held , t he t ab l e screws are
reasonably goo d measuri ng devices, and
man y ho les can be made, of any diameter
needed. without losing the att i tude of t he
piece to t he tabl e, or one hole to another.
Let's take a fairly com mon componen t,
the beam cast i ng of a model beam eng ine .
This will have severa l holes to be dri lled ,
usual ly along one straight line. and rat her
importan t. all t hese shou ld be parallel wi th
one another if the finished engi ne is to run
smoothly. There will be one ho le at each
end, and a main trunnion ho le at the
middle, plus one or more for the links of
46
CHAPTER 7
Jig-Boring
The term 'j ig-boring' is likely to be
unfamiliar to many readers of t his book,
and they may thi nk that what ever it
means it must be a long way removed
from model engineeri ng. This is not so, for
in model making plenty of operations ari se
that can be done by 'jig-boring' to advan-
tage. Basically it only means fixi ng a com-
ponent t o t he machine table and then
using the table screws as measuring
devices to posit ion t he spindle over any
part of the component that is desired
before drilli ng or boring a hole. I n many
ways this method is better than marking
out, measuring wit h a rule, then centre-
punching followed by dri lling on a drilli ng
machine. For one thing the workpiece is
firml y held, the tab l e screws are
reasonably good measuring devices. and
many holes can be made, of any diameter
needed, without losing the atti tude of t he
piece to the table, or one hole to another.
Let's take a fairly common component,
the beam casting of a model beam engi ne.
This will have several holes to be dri lled
usually along one straight line, and rathe;
import ant, al l these should be paral lel with
one another if the finished engine is to run
smoothly. There will be one hole at each
end, and a main trunnion hole at the
middle, plus one or more for the links of
46
the parallel mot ion, pump rods, etc. The
casting can be clamped to the table quite
fir ml y, resting on packaging of reasonable
thickness so that a penetrati ng drill does
not di p into the t able. At this stage all
bosses can be faced with an end mill,
even if t hey are at different levels. The
cent re line of t he cast ing should have
been set parall el wi t h the line of the table
movement. Put t he drill chuck in the
s ~ i ~ d l e , with a f ine point ed dummy dri ll
Simi lar to a centre punch, and brin t his
over t he fi rst boss cent re. Then wind on
the table t he amount to the next hole and
check if the point comes in the right place
over that boss. Wind on again to the next
and so on checking at each boss. If all
come central , all is well . If one or more
don't, then an allowance will have to be
made as a compromise. Make a note of
what it is, re-start at the beginni ng, and do
another run till you are satisfi ed you have
got the right starting point for t he best
results. If you happen to turn the table
screw a bit t oo f ar at one of the stopping
points, don't worry, but don't turn it back a
bit as a correction, because that way you
could introduce an error through backlash
(lost mot ion due to slackness) in the
screw and nut. Go back to the very start
and come at it again. It's a good thing
,..38
.L
+
-+-...... -'005
.l..
16
Fig. 30 Drawing of steam hook (lever)
when doi ng an exercise of t his kind to
have a paper and pencil handy and write
down the micrometer dial readings which
are the stopping points. This reduces t he
chances of accident al error. It is a method
used by men i n indust ry who are ngaged
on deli cat e work where a momentary
interrupti on can be disastrous. I have
myself used it for many years. At this
stage dri ll ing can now start . Each hol e
should be centred with a D-bi t ground to
about 118 degrees, followed by the
appropri ate dri ll , though the larger hol es
may need a pilot drill putting t hrough first.
As each hole is finished, with reaming if
needed, move on to the next hole by the
table wi nd, and go through the procedure
with that. too. By this method all the oles
wi ll be the right distance apart, and will all
be parallel to one another in two planes. It
will be clear that if any holes are wanted
which are not on the main centre line, it is
a si mple matter to drill these i n an off-set
position by usi ng t he table cross-screw to
provide the amount off the main line.
When all t he holes are finished t he beam
can be turned over and the bosses milled
on the other side.
The beam engine casting is just one
example of how this ort of t ask can be
handl ed. Fig. 30 is a drawing of a compo-
nent of the trip gear of a model steam
engine, and t he holes which have to be
drilled are in posi ti ons which would not be
easily attained by the common marking-
out and centre punching process. Fig. 31
shows one of the finished pieces with one
only part-made, to show the met hod
adopted. One i nch diameter bar was used,
as t hat gives the outside profile needed.
Set true in the four- j aw chuck it was
bored 9/ 16 in., then set out of true by
.047 in. and the hole re-bored to the same
setting. Next it was set well off centre to
drill the No. 38 dri ll hole. The correct
setting was established by measurements
47
taken off the outside surface of t he 1 i n.
bri ght bar. Wit h t he pi ece st il l held. t he
chuck was removed from t he lath e and
bolt ed on t he mil ling machine tabl e. A
number 38 dr ill . runni ng i n a true chuck.
t hen ' picked up' the exist ing hol e and the
di al readin gs on both screws of the table
were noted {and wri tten down !' The drill
was chan ged for a very short st iff 1/ 16 in.
drill . t he t able screws were rot ated . to
bri ng t he fi rst 1/16 in. hol e posit ion under
it and t hat hole t hen dr i lled. Furt her
rotation of th e screws brought i n turn
each of the ot her holes into posit ion and
the drill ing wa s quickly completed. The
chuck was t hen returned to t he lat he. The
fi rst boss around the No. 38 hole was
t urned and t he piece parted off. care bei ng
taken to leave t he shall ow boss on t he
part ing side. Then t he second boss was
turned. anot her part i ng off . and the two
component s were th rough t hat part of t he
process. It remained only to cut the
desi red piece out of the ring and file up
the two ends t o t he rounded profil e. By
t hese met hods a component of a rather
compli cated shape was produced und er
complet e cont rol and exactly as specifi ed
on the drawi ng.
There are many ot her art icles in model
engi neering wh ich lend themselves very
well to the j ig-boring technique. Locomo
t ive boi ler t ube plates wit h a large number
of holes can be done t his way. and
because some of t he hol es may be t in. or
even mo re in di ameter it is vital to have
th e met al clamped do w n t o avoi d
personal inj ury. as copper is not one of the
kindest of mat eri als for machi ni ng. But if
cl ampe d on packi ngs on the mill er. any
large holes for which dr ills are not avai l
able can st ill be dealt wit h by using a
bori ng head. If a large dri ll is available. and
th e machi ne has a low enough speed t o
avoid chatter. t here will be no 't hree
cornered' hol es made to cause embarrass
ment when f itting fl ue tubes and sil ver
soldering them at a later st age. It wil l be
found t hat as fami liari ty wit h the vert ical
mi ll er develops. ot her exampl es wi ll arise
in which t his high- soun di ng but really
qui te si mple technique can
fr om i ndust ri al pract ice.
benefit s.
be bo rrowed
wi t h great
Fig. 3 1 Photograph of st eam hook

CHAPTER 8
Profiling
It is not unusual for large component s to
have porti ons which are ci rcular arcs,
Loco mot i ve f r ames ar e co m mon
examples. wit h cut -aways t o cl ear bogie
wheels. Such pi eces are much too large to
swing in the lat he. and wh ile t he bandsaw
if available can do a lot t o reli eve t he
tedi um of drilli ng. hacksawing and f ili ng.
the mill er can do a lot mor e. Usi ng a
t repanni ng cutt er i n a boring head it can
take away the unwant ed metal i n a single
operat ion to finished size on any arc.
Alternatively wit h a bor ing typ e tool it can
follow the bandsaw and j ust avoid th e
fi li ng.
Smokebox cast ings for locomotives
and tract ion engines. however, oft en have
circular arcs t o fit t he boiler shell. and t he
bandsaw can be nohelp wit h t hese. But if
they are set up on th e mi ller. the radi us
can be deter mined by the sett ing of a
boring head cutt er. and t raverse across
the wo rk provided by the downfeed of t he
spi ndl e. eve n t hough th i s i s usuall y
manual. That feed lengt h may not be
enough to cover t he f ace widt h, but aft er
going as f ar as the spindle wil l move. a
second cut can be taken by resetting th e
head of the mach ine.
I n mach i ner y de t ai l s t h e same
probl ems arise. Fig. 32 shows a pad bol t
for locki ng two machine parts together.
The two part s of the pad bolt which are
being pro fil ed t o suit a round col umn we re
made fro m one pi ece of steel. and cut
apart afte r th e profiling. A groove can be
seen wher e t he separating cut wa s to be
taken. The cutt er i n the bor ing bar was set
to t he fini shed radius. Only t he cross-feed
of the t able was used (to put t he cut on
bi t by bit) th e ot her slide being locked. The
tool was t raversed by t he down f eed. It is
not possible to tak e the full amount of
metal removal i n a singl e pass i n a job li ke
t his, but wit h successive cuts a perf ect j ob
is assured. Si milarly t he hol es for such pad
bol t s are ' part holes' and coul d not be
dril led i n the second st age to full size
without gui de bus hes for t he dril l. But
drill i ng under size and then open ing out
wit h a bori ng head get s t here j ust t he
same, a bit less quickly.
Prof i ling locomoti ve connect i ng rods
and coupli ng rods can be a somewhat
t i ri ng operat ion if one has t o do it by
sawi ng and filing. Trying to do this wor k
on the bori ng table of the lathe wi t h
vert ical sl ide or angleplate is not very
happy eith er. Usual ly the cross- sli de travel
i s much too short to comp lete the lengt h
i n one pass. so t hat re - sett i ng is
necessary. and the lathe does not have
48
49
taken off the outside surface of t he 1 in.
bright bar. With th piece sti ll held, t he
chuck was removed from the lathe nd
bolted on the milling machine table. A
number 38 drill , running in a true chuck.
then 'picked up' the existing hole and the
dial readings on both screws of the table
were noted (and written down!. The drill
was changed for a very shor t stiff 1/ 16 in.
drill , the tabl e screws were rotated, to
bring the first 1/ 16 in. hole position under
it and that hole then drill ed. Further
rotation of the screws brought in turn
each of t he other holes into position and
the drilling was quickly completed. The
huck was then returned to the lathe. The
fi rst boss around the No. 38 hole was
t urned and t he piece parted off, care bei ng
t ken to leave the shallow boss on the
parting side. Then the second boss was
turned, another parti ng off, and the two
component s were through t hat part of the
process. It rem ined only to cut the
desired piece out of the ring and fi le up
the two ends to the round d profil e. By
these methods a component of a rather
complicated shape was produced under
complete cont rol and exactly as specified
on the drawing.
There are many other articles in model
engineering which lend themselves ery
w 11 to the j ig-boring technique. Locomo-
tive boiler tube plates with a large n mber
of holes can be done this way. and
because some of t he holes may be J in. or
even more in diameter it is vital to hav
the meta l clamped down t o avoid
personal injury, as copper is not one of the
kindest of materials for machining. But i f
clamped on packings on the miller, any
large holes for which drills are not avai l-
able can sti ll be dealt with by usi ng a
boring head. If a large drill is avail able, and
the machine has a low enough speed t o
avoid chatter, th re wi ll be no 'three-
cornered' holes made to cause emb rrass-
ment when fitting fl ue tubes and si lver-
soldering them at a later st age. It will be
found that as fa miliarity with the vert ical
mi ll er develops, other examples wi ll arise
in whi ch this high-sounding but r ally
qui t e simple technique can be borrowed
from in ustri I pract ice, with grea t
benefits.
Fig. 31 Photograph of steam hook
48
CHAPTER 8
Profiling
It is not unusual for large component to
have portions which are circular arcs.
Locomot i ve fr ames ar e commo n
examples, with cut-a ways t o clear bogie
wheels. Such pieces are much too large to
swing in the lathe, and whil e the bandsaw
if available can do a lot to reli eve the
tedium of drilling, hacksawing and f ili ng.
the mill er can do a lot more. Usi ng a
trepanning cutt er in a boring head it can
take away the unwanted metal in a si n le
operation to finished size on any arc.
Al ternatively with a boring type tool it can
foll ow the bandsaw and just avoid the
filing.
Smokebox castings for locomotive
and traction engines, however, often have
circular arcs to fit the boiler shell , and the
bandsaw can be no'help wit h t hese. But if
they are set up on the miller, the radius
can e determined by the setting of a
bori ng head cutter. and traverse across
the work provided by the downfeed of t he
spi ndle, even though th is 's usually
manual. That feed length may not be
enough to cover t he face width, but aher
going as far as the spindle wi ll move. a
second cut can be taken by resett ing the
head of the machine.
In mach i ne r y de ta i ls th e same
problems anse. Fig. 32 shows a pad bol
for locking two machine parts together.
The two parts of the pad bolt which are
bei ng profiled to suit a round column were
made from one piece of steel, and cut
apar aher the profiling. A groove can be
seen where the separa ti ng cut was to be
taken. The cutter i n t he boring bar was set
to t he finished radi us. Only the cross-feed
of the t abl e was used (to put the cut on
bi t by bit) the other sl ide being locked. The
tool was t raversed by the down f eed. It is
not possible to take the full amount of
metal removal in si ngle pass i n a job like
this, but with successive cuts a perfect job
is assured. Si mil arly t he holes for such pad
bolts are 'part holes' and could not be
dri lled in the second stage to full si ze
without gui de bushes for the drill. But
drilling undersize and then opening out
with a boring head gets there j ust the
same, a bit less quickly.
Profi ling locomo ive connecting rods
and coupling rods can be a somewhat
tiring operation if one has to do it by
sawing and fil ing. Trying to do thi s work
on the boring table of the lathe with
vertical slide or angleplate is not very
happy either. Usually the cross-slide travel
is much too short to complete the length
in one pa ss, so t hat re -setting is
necessary, and the lathe does not have
49
the in-feed faci lities needed. Generall y
with a vertical sl ide t he poi nt at which
cutt ing is being done at t he ends of a long
rod is a very long way f rom the place
where the sli de is secured, so t hat apart
from 'spring' of the pi ece t here is danger
of slipping t aki ng place wit h dis astr ous
result s. Compare such attempts w ith the
Fig. 32 Profiling pad bolt
Fig. 33 Profiling coupling rods
set- up shown in Fig. 33. wher e a pair of
coupling rods . with 'chucki ng pieces' of
ext ra metal at each end , are clamp ed on
packings in a safe and rigid set-up.
Generally the di amet er of end mil l used
can be arranged to give the right radi us
where t he body of t he rod joins t he
boss es.
50
51
Fig. 32 Profiling pad bolt
Fig. 33 Profiling coupling rods
50
the in-feed facilities needed. General ly
with a vertical slide the point at which
cutting is being done at the ends of a long
rod is a very long way from the place
where the slide is secured, so that apart
from 'spring' of the piece there is danger
of sli pping taking place with disastrous
results. Compare such attempts with the
set- up shown in Fig. 33, where a pair of
coupling rods, with 'chucking pieces' of
extra metal at each end, are cl amped on
packings in a safe and rigid set-up.
Generally the diameter of end mill used
can be arrang d t o give the right radius
where the body of the rod joins the
bosses.
51
CHAPTER 9
End- Rounding
In model work, as in ful l sized machi nery,
many components such as crank webs,
connect ing and coupling rods , machi ne
li nks, etc. have to have rounded ends.
These can be produced by fili ng, and the
use of hardenerd steel coll ars and roller s
for guides has oft en been recommended
i n Model Engineer t o help the not-sa-good
f iler to achieve a good appearance. Even
wi th these, t his kind of filing demands a
skill wh ich many modellers jus t do not
have (and wi ll never acquire, for wa nt of
pract ice, if not hing else) so for that reason
alone it is not a good met hod. But it is
also rathe r severe on fi les, which are now
qui t e expensive too ls, and unli kely ever t o
get cheaper.
So where t here is a vert ical mill er avail
able, why not do t he job th e right way. as
it would be done in commercial engi neer
i ng? It means invest ing i n a rotary tabl e.
but these can be bought i n kit form as we ll
as comp let e ready for use. and if
machined and assembled by the home
worker hi mself. are not terribly expensive.
Presumi ng that the component has a
round hole at one end. a plug is needed in
t he table so as to locat e by that hol e. I
have a small rotary table with a t Whit.
hole in the cent re and have a number of
plugs of standard sizes to fi t that. But
anot her t able wh ich I have poss esses a
No. 2 Morse taper central hole and arbor s
can be put in t his for locat ion. It is. in fact ,
a Model Engineeri ng Services Type RT3
wh ich does not have a t ee-slott ed table,
but has a spi ndle screwed lik e the Myf ord
lat hes and will accept any chucks or
faceplates from the lat hes. This makes it
feasible to t urn, say, a cyl inder cover and
t ransfer it to a rotary table for dri l li ng t he
bolt hol es wi t hout losi ng t he accur acy of
setti ng, But that is not a feature of impor
tance for round endi ng operat ions. I have
used it for a number of engi ne cranks i n
the manner shown in Fig. 34. Each crank
was located on t he arbor but also clamped
with a slot plate resti ng on Picador
stepped packings, a pair of these being
also under the crank itself. The cutter is a
t in. end mill cutt ing on it s side.
In all rotary mil li ng of t his kind where
t he cutter is working on t he outside of the
component it is vit ally necessary to feed
the table cl ockwise seen from above. All
normal milling cutt ers rot at e the same
w ay as a twist dfl l l, so whichever side of
the work t he cutte r is touching, the work
must meet the cut ter. and t hat means
clockwise rotation is essenti al. Oth erwi se
if the cutt er is goi ng the same way at the
surface as the work i t is certa in to grab
hold and tha t means at least spoiled work.
probably a broken cutt er. and a lot of grief.
But if one is worki ng on an i nt ernal profile,
such as trimming t he inside of the rim of a
flywh eel. then the forces are reversed and
the work needs rotat ing ant i-clockwise.
Now the t hreads of th e RT3 spi ndle are
like the Myf ord lat hes. right hand, so
wh en one is doing inside work a chuck or
facepl ate is t ight ened by t he t hrust of th e
cutter. But when doing t he. perhaps, more
normal mill ing on t he outside of a piece,
t he cutt er thrust tends to undo the
f aceplate. and unless the work is very light
cutti ng. this is what will cert ai nly happen.
The only sat isfactory answer to thi s
problem is to drill and tap a hol e t hrough
the boss of the f aceplat e. make a coned
di mp le i n th e t able spindle at the same
spot, and insert a screw with a cone poi nt
that fit s the dimple. Not a diffi cult mat ter
at al l. But if you are going to use a chuck
on the same table for the same kind of
work, then make a penci l mark to show
wh ere the dimple is for the faceplat e, and
Fig. 34 End-roundinq with rotary table
dri ll t he chuck boss well away fr om this,
so that you have two posit ively separated
dimp les, each for i ts own accessory .
I have used a 5/ 16 in. BSF sock et grub
screw for t his purpo se. wit h a point
modified (in t he lat he) to a longer cone.
But I found the or dinary hexagon key was
not really long enough to be conveni ent
wit h a standard 7 ins. Myford faceplate.
So I cut off th e shor t bent end of the key
and fi tt ed t he long part to an extension
made of 1 i n. bright mi ld steel. This was
dril led i n the lat he 3/ 16 in. deep wit h a
No. 16 drill wh ich is about t he across
corners size of th e hexagon, then 7/ 16 in.
further wit h a No. 22 drill wh ich is about
t he across-f lats size. The two pieces were
then pressed together in a big vice, t he
squared-off end of t he hexagon cutt ing i ts
way down t he hole i n t he mild steel. A
5/32 in. cross pi n was fitted. Loct it ed i n,
and now I have a Tee wrenc h long enou gh
to reach the screw in the boss without any
diffi culty. It took only five mi nutes to make
and is a convenience there for ever.
52
53
CHAPTER 9
End-Rounding
In model work, as in full sized machi nery,
many components such as crank webs,
connect ing and coupl ing rods. machine
links, etc. have to have rounded ends.
These can be produced by fili ng, nd the
use of hardenerd steel coll ars and roll ers
for guides has often been recommended
in Model Engineer t o help the not- sa-good
fil r to achi eve a g od appearance. Even
with these, t his kind of fi li ng demands a
ski ll which ma ny modell rs just do not
have (and wi ll never acquire, for want of
practice, if nothing else) so for that reason
al one it is not a good met hod. But it is
also rather severe on fi les, whi ch are now
quite expensive tools, and unli kely ever to
get cheaper.
So where there is a vertical miller avail-
able, why not do the job the right way, as
it would be done in commercial engineer-
ing? It means investing in a rotary table.
but these can be bought in kit form as well
as complete ready for u e. and if
machined and assembled by the home
worker himself. are not terribly expensive.
Presumi ng tha t the component has a
round hole at one end. a plug is needed in
the table so as to locate by that hole. I
have a small rotary table with a i Whit.
hole in the centre and have a number of
plugs of standard sizes to fit that. But
52
anot her t able which I have possesses a
No. 2 Morse taper cent ral hol e and rbors
can be put in t his for locat ion. It is, in fact.
a Model Engineering Services Type RT3
whi ch oes not have a tee-slotted table,
but has a spindle screwed like the Myford
lathes and will accept any chucks or
facepla tes from the lathes. This makes it
feasible to t urn. say. a cyli nder cover and
transfer it to a rotary table for ril li ng the
bolt hol es wi t hout losing t he accuracy of
setti ng. But that is not a feature of impor
tance for round ending operations. I have
used it for a number of engine cranks in
the manner shown in Fig. 34. Each crank
was located on the arbor but also clamped
with a slot plate rest ing on Picador
stepped packing , a pair of t hese being
also under the crank itself. The cutter is a
t in. end mill cutting on its side.
In all rotary mill ing of t his kind where
the cutter is working on the outside of the
component it is vitally necessary to feed
the table clockwise seen from above. All
normal milling cutters rotate the same
way as a twist dri ll . so whichever ide of
the work the cutter is touching. the work
must meet the cutter. and that means
clockwise rotation is essential. Otherwise
if the cutter is going the same way at th
surface as the work it is certain to grab
Fig. 34 with rotary table
hold and that means at least spoil ed work.
probably a broken cutter. and a I t of grief.
But if one is working on an int ernal profil e.
such as trimming the inside of the rim of a
flywheel . th n the forces are reverse and
the work needs rotating anti-clockwise.
Now the threads of the RT3 spindle are
like the Myford lathes. right han , so
when one is doing inside work a chuck or
faceplate is tighten d by the t hrust of he
cutter. But when dOing the. perhaps. more
normal mil ling on t he outside of a piece.
the cutter t hrust tends to undo the
faceplate. and unless the work is very light
cu t ing. thi s is what will cer ainly happen.
The only satisfactory answer to thi s
problem is to drill and tap a hole through
the boss of the faceplate. make a coned
dimple i n the t able spindle at t he same
spot. and insert a screw with a cone point
that fit s the dimple. Not a diffi cul t matter
at all. But if you are going to use a chuck
on the same table for the same ki n of
work. then make a penci l mark to show
where t he dimple is for th faceplate. and
dri ll the chuck boss well away f rom this.
so that you have two positively separate
dimples. each for its own accessory.
I have used a 5/ 16 in. BSF ocket grub
screw for this purpose. with a point
modified (in the lathe) t o a longer con .
But I found the ordi nary hexagon key was
not reall y long enough to be convenient
with a st andard 7 ins. Myford faceplate.
So I cu t off the short bent en of the key
and fi tted t he Ion part to an extension
made of } in. bright mi ld steel. Thi was
dri ll ed i n the lathe 3/16 in. deep with a
No. 16 ri ll which is about the across-
corners size of the hexagon. then 7/ 1 6 in.
further with a No. 22 drill which is about
th across-fl ats size. The two pieces were
t hen pressed together in a big vice. t he
squared- off en of the hexagon cutt ing its
way down the hole in the mild steel. A
5/32 in. cross pin was fitted. Locti ted i n.
and now I have a Tee wrench long enough
to reach the screw in the boss without any
difficulty. It took only five minutes to make
and is a conveni ence there for ever.
53
CHAPTER 10
Dividing Heads
For many products the use of a divid i ng
head is an absolut e necessity. Many home
workers, especially t hose wit hout any
engineering experience, regard them as
mos t myst eriou s devic es. al most border
ing on t he occ ult , and say wi t hout reall y
thinki ng, ' Oh. I could never use one of
those!' . We ll , a dividing head is real ly no
more than a headstock wit h a spindle on
which t he wo rk is mount ed, with some
means of turn i ng it t hrough positive
angular amou nts, and holding it t here
wh en each movement has been made.
Nat urall y th ere are many types of div idi ng
head and over t he years many designs
have appeared in M odel Engineer for
heads which can be made i n t he home
w o rksho p. A g r eat dea l o f qu i t e
sat isfactory work can be done wit h a
simple head of the type shown in Fig. 35.
On the spi ndle, provision is made for
mount ing a lat he change wheel. A spri ng
loaded plunger wit h a conical poi nt drops
into th e gap between two teeth of t he
wheel , and t hen t he spindle is locked by a
screw bearing on a pad i nside t he mai n
bearing. I t is advisable not to rely on t he
plu nger hol di ng the spi ndl e agai nst
rot at ion when screwing on chucks of
when fixi ng a component on an arbor by
means of a nut. If t he spindle t urns, t he
teet h of t he change wheel may be badly
damaged. I n fact when doing this sort of
f ixing I always disengage the plunger,
then if t he screwpad does not hol d. no
damage is done .
By selec ti ng a suit able change wheel it
is possible to get quit e a lot of divisions
very easi ly. For example a 60 toot h wheel
wil l gi ve 2. 3, 4. 5. 6. 10. 12. 15. 20 or 30
divisions. It will not gi ve 8. but a 40 toot h
wheel will do so. When doing dividing
with thi s kind of device it is a good t hing
t o have a bi t of chalk handy and mark the
appropriat e toot h gaps where t he plunge r
is going to have to drop in, before start ing
cutti ng, to avoi d i ncorrect sett ings which
would spoi l the wor k. Ma ny examp les of
machi nery parts to which a simple head of
this ki nd can be usefull y appli ed could be
given. Such it ems as cr ankc ase dr ain or
fill er plugs wh ich need hexagons. square
ends on shafts, tools like taps, reamers.
pa rallel fl at s f or spanners on round
art icles, all th ese can be formed so very
easily with an end mil l, w ith less phy sical
effort than fil ing, and wit h an accu racy
which enhances the appearance of the
arti cl e even if dimensional accuracy as
such is not i mport ant.
But t here are examp les where accuracy
is fai rly i mportant, and one which cou ld
hardly be don e at all wit h hand tools is
shown i n Fig. 35. This is one half member
of a dog clutch. The 12 teet h are bei ng cut
wit h a slitting saw which passes across
the work right on t he centre line. Aft er
each cut . the locki ng screw was eased .
t he plung er li fted out, th e wheel turned
five teeth . and t he plunger dropped in
agai n. The spi ndle was t hen locked and
the next too th gap cut. Really a very
si mple procedure. Now on the other half
member of t he cl utc h the teet h have to
have parall el sides, and t he gaps t hem
selves are t aper sided. This just involves
sett ing the cutt er wit h its bott om edge
above t he cent re line by half the thi ckn ess
of t he teet h left upstanding i n the fi rst
half. The same procedure of cutti ng right
acr oss is foll owed. and afte r six passes the
j ob is complete. It is feasible. if you are
wi l li ng to t ake the t rouble. to make a
clutch wi t h al l toot h sides t apered. so that
the two halves are ident ical. If maximum
strengt h was needed to transmi t a lot of
power thi s mig ht have to be done. but it is
a good deal mo re difficult and would
rarely be worth the t rouble. Unless you are
usi ng a we ll-established desi gn for wh ich
drawings are available. it is advisabl e to
layout t he toot h design on t he draw ing
boa rd, preferably at an enlarged scale. to
verify t he t hickness of cutters which wil l
produce the desired result . They may be
t he same thickness for bot h halves. but
maybe not . it depe nds on the t hickness of
toot h selected. It is also a goo d t hing to
avoid an odd number of teet h. because
the curve of the cutt er when going
through one side may be chewi ng int o t he
met al whi ch has to be left int act on the
opposite side to mak e the toot h. If your
design can arrange for an even number of
teet h this risk will be eli mi nated. Anot her
poi nt is to chec k t hat th e desi red number
of t eeth can reall y be s ecured wi t h t he
dividi ng head you int end to use.
Fig. 35 Cutt ing teet h in dog clutch part
55
54
CHAPTER 10
Dividing Heads
For many products the use of a dividi ng
head is an absolute necessity. Many home
workers, especially those wit hout any
engineering experience, regard them as
most mysterious devices, almost border-
ing on the 0 cult, and say without really
thinking, 'Oh. I could never use one of
t hose I'. Wel l, a dividi ng head is really no
more t han a headstock with a spindle on
whi ch the work is mounted, wi th some
m ans of t urni ng it through positive
angular amounts, and holding it there
when each movement has been made.
Naturally there are many types of dividi ng
head and over t he years many designs
have appear d in Model Engineer for
heads which can be made in the home
workshop. A g r ea t deal of quite
satisfactory work can be done wit h a
simple head of the type shown in Fig. 35.
On the spindl , provision is made for
mounting a lathe change wheel. A pring-
loaded plun er with a conical point drops
into the gap between two teeth of the
wheel. and t hen the spindle is locked by a
screw bearing on a pad inside the main
bearing. It is advisable not to rely on the
plunger holding the spindle against
rotation when screwing on chucks of
when fixi ng a component on an arbor by
means of a nut. If the spindle turns, the
54
teeth of t he change wheel may be ba Iy
damaged. I n fact when doing this sort of
fixing I always di sengage the plunger.
then if t he screwpad does not hol d, no
damage is done.
By selecting a suit abl e change wheel it
is possi ble to get quit e a lot of divisions
very easily. For example a 60 tooth wh el
wi ll give 2, 3, 4, 5, 6, 10, 12, 15, 20 or 30
divisi ons. It will not give 8, but a 40 tooth
whe I will do so. When doing divi ding
with this kind of device it is a good thing
to have a bit of chalk handy and mark t he
appropriate t ooth gaps where the plunger
is going 0 have to drop in, before starting
cutt ing, to avoid incorrect settings which
woul spoi l t he work. Many examples of
machinery parts to which a simple h ad of
this ki nd can be usefully applied coul d be
given. Such items as crankcase drain or
fill er plugs which need hexagons, square
ends on shafts, tools like taps, reamers,
parall el flats fo r spanners on round
articles, all these can be formed so very
easily with an end mill, with less physical
effort than filing, and with an accuracy
which enhances the appearance of the
article even if dimensional accuracy as
such is not i mportant.
But there are examples where accuracy
is fairly important, and one which could
hardly be done at all with hand tools is
shown i n Fig. 35. This is one half member
of a dog clutch. The 12 teeth are being cut
with a slitting saw which passes across
the work right on the centre line. After
each cut , the locking scr w was eased,
the plunger lifted out. the wheel turned
five teeth, and t he plunger dropped in
agai n. The spi ndle was t hen locked and
the next tooth gap cu. Really a very
si mple procedure. Now on the other half
member of t he cl utch the teeth have to
have parallel sides, and the gaps them-
selves are t aper sided. This just involves
sett ing the cutter wit h its bott om edge
above t he centre line by half the thickness
of t he teeth left upstanding in t he first
half. The same procedure of cutti ng right
across is followed, and after six passes the
job is complete. It is feasi ble. if you are
wil ling to t ake the trouble, to make a
cl utch with all tooth sides tapered, so that
the two halves are identical. If maximum
strength was needed to transmit a lot of
ower this might have to be done, but it is
a good deal more difficult and would
rarely be worth the trouble. Unless you are
using a well -established design for which
drawings are available. it is advisable to
lay ou the tooth design on the drawing
board, preferably at an enlarged scale. to
verify the thickness of cutter which will
produce the desired result. They may be
the same thickness for both halves. but
maybe not, it depend on the thickness of
toot h selected. It is also a good thing to
avoid an od number of teeth. because
the curve of the cutter when going
through one side may be chewi ng into t he
metal which has to be left intact on the
oppo ite side to make th toot h. If your
design can arrange for an even number of
teeth this risk will be eliminated. An ther
point is to check that the desi red number
of teeth can really be s ecured wit h the
dividing head you int end to use.
Fig. 35 Cutting teeth in dog clutch part
55
I PIN %x4 I
STEADY STAND
I have found in using the Myford head
that it is a convenience to be able to set it
at lath e centre heigh t when fixed on the
boring table. If one wants to drill cylinde r
covers and simi lar work the radius of th e
row of holes can be readily obt ained by
the cross slide screw and the measure
men t is direct. So I have a packing block
of the right thi ckness whi ch I can place
under it for th is purpose.
There is one minor cr it icism of th e
Myford head which is never t heless impor
tant from a pra ctical point of view. The
single bolt wh ich holds it to a machine
57
w orm gea red di vidi ng head . When moving
from one position to t he next. always turn
the worm the same wa y, never go bac k. If
by chance you overshoot t he rig ht hole . of
course you have to t urn back. but go we ll
bac k. way beyo nd the hole you want by a
good margin. the n come up to it afr esh. If
you fai l to do t his you wi ll have an erro r i n
your dividi ng and a scrapped work-piece.
Our old enem y ' back- lash' wi ll see to t hat.
But it' s easy enough to avoid th is ki nd of
disaster. Th ere is provided on the head a
most impo rtant aid to correct counti ng of
t he number of holes needed w hen t urning
the worm. Two brass blades are fitted
around t he worm shaft . above t he divis ion
plate, and t hese can be moved relat ive to
one anot her, by looseni ng a screw, and
set to em brace th e num ber of holes
needed. Than afte r lockin g w it h the
screwdriver, they make a mask to show
just where the plu nger should be dropped
in. After each movement you rotate t hem
ti ll one blade comes agai nst the plunge r,
and yo u are t hen ready (afte r doi ng t he
cutting of cou rse) fo r the next move. In
t his part of t he procedure t he two blades
move together as if t hey were one piece of
met al.
Opposite, Fig. 36 Drawing of st eady st and for
M yford dividing head
The Myford dividing head is an exce l
lent piece of equ ipment, w ith a very w ide
range of divisions. The main spi ndle has a
60 tooth worm wheel on it. and a si ngle
start worm meshes with that. Concent ri c
with the worm there is provis ion for
mounting a mult i- holed division plate
which remains stationary and does not
rotate w it h t he wo rm . On the worm
spindle is f itted an arm carrying a spring
loaded pl unger wh ich has a po int of
paral lel shape t hat ente rs holes in t he
divi sion plat e. Thi s arm is slotted and can
be set to such a radius as w ill br ing the
plunge r in t he right place for any of the
row s of ho les t hat are already dri lled in the
plate. Having set t he arm. if one tu rns the
worm one w hole t urn and drops t he
pl unger bac k int o the same hole from
w hich it star ted , t he main spi ndle w i ll
have rot at ed one sixt ieth of a t urn. But if
one moves t he w orm and arm f ive
complet e tu rns befo re dropping i n, the
ma i n spindle will have turned one twelft h
of a tu rn. Basically. t hat is all there is to
getti ng any desi red number of divisions.
Hav ing got the right divisi on plate on t he
head one moves t he arm so many turns,
plus if necessary, a certa in number of
holes extra to the comp lete turns. A chart
supplied wit h the head giv es all t he avail
able combi nat ions. I n order to accomplish
all divisions up to 100 it is necessary to
have 4 plates . but two of these are needed
on ly for some rather out landish numbers
with whi ch few model engineers w ill ever
have to deal , so the two normal plat es w il l
serve. almost everyt hing. There is on e
point of practi cal imp ortance in using a
M YFO RD DIVIDING HEAD
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I
9
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3 2.
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STE A DY STAND fO R
MYFOR 0 Dlv'O'G HEAD
i
1
1. )( 3
4 4
1.
16


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,
;5'
56
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56
3'
J.
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-
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9
, 16
n
iO
STE.ADY STAND fOR
MYFOR 0 DIV'O'G HEAD
MYFORD DIVIDING HEAD
The Myford dividing head is an excel
lent piece of equipment, with a very wide
range of divisions. The main spindle has a
60 tooth worm wheel on it, and a single-
start worm meshes with that. Concentric
with the worm there is provision for
mounting a multi-holed division plate
which remains stationary and does not
rotate with the worm. On the worm
spindle is fi tted an arm carrying a spring-
loaded plunger which has a point of
paral lel shape that enters holes in the
division plate. This arm is slotted and can
be set to such a radius as will bring the
plunger in t he right place for any of the
rows of holes that are already drill ed in the
plate. Having set the arm, if one turns the
worm one whole turn and drops t he
plunger back into the same hol e from
which it started, the main spi ndle wil l
have rotated one sixt ieth of a turn. But if
one moves the worm and arm five
complete turns before dropping i n. the
mai n spindle will have turned one twelfth
of a turn. Basically. t hat is al l there is to
gettin any desired number of divisions.
Having got the right division plate on the
head one moves t he arm s many turns.
plus if necessary. a certain number of
holes extra to the complete turns. A chart
supplied with the head gives all the avail-
able combinations. In order to accomplish
all divisions up to 100 it is necessary to
have 4 plates. but two of these are needed
only for some rather outlandish numbers
with which few model engineers will ever
have to deal . so the two normal plates will
se. ve . almost everything There is one
point of practical importance in using a
Opposite, Fig. 36 Drawing of steady stand for
Myford dividing head
worm geared dividing head. When moving
from one position to the next . always turn
the worm the same way, never go back. If
by chance you overshoot the right hole. of
course you have to turn back. but go well
back. way beyond the hole you want by a
good margin, then come up to it afresh. If
you fail to do this you will have an error in
your dividing and a scrapped work-piece.
Our old enemy 'back-Iash' will see to that.
But it' s easy enough to avoid this kind of
disaster. There is provided on the head a
most important aid to correct counting of
the number of holes needed when t urning
the worm. Two brass blades are fitted
aroun t he worm shaft. above the division
pi te, an t hese can be moved relative to
one another, by looseni ng a screw, and
set to embrace the number of holes
needed. Than after locking with the
screwdriver. they make a mask to show
just where the plunger should be dropped
in. After each movement you rotate them
till one blade comes against the plunger,
and you are then ready (after doi ng the
cutt ing of course) for the next move. In
thi s part of the procedure the two blades
move together as if they were one piece of
metal.
STEADY STAND
I have found in using the Myford head
that it is a convenience to be able to set it
at lathe centre height when fixed on the
boring table. If one wants to drill cylinder
covers and similar work the radius of the
row of holes can be readily obtained by
the cross slide screw and the measure
ment is direct . So I have a packing block
of the right thickness which I can place
under it for this purpose.
There is one minor criticism of the
Myford head which is nevertheless impor
tant from a practical point of view. The
single bolt which holds it to a machine
57
Fig. 37 Steady in use on a gear cutt i ng operation
Fig. 38 Author 's design for simple dividing head
tab le or vert ical slide , etc . does on
occasion come a long way from the poi nt
where cutt ing is being done . and accor
di ngly t here is danger of t he work being
spoilt by t he head sli ppi ng. To overcome
this I have made up a st eady stand from
mi ld stee l bar material wh ich bol ts on t h
table of the mill er, and clamps on the 1 in.
overarm bar of the head. The st and has a
vertic al t in. bar set i nto a fl at base with
slot for a table bolt . A two-way clamp
sli des on thi s vert ical bar, and anot her t
in. bar passes t hrough it horizont all y. At
the end of t his is a two- plate clamp
ri pping the t in. bar, wit h provision also
for gripping the 1 in. bar of the head. The
various clamp s can be moved separately
and make a pretty universal fi tt ing. The
wh ole t hi ng is shown in use in Fig. 37.
This f itting of my design is not on the
market , but it has proved so useful to me
that I am giv i ng a working drawi ng of it in
Fig. 36 and anybody who likes can make a
unit for hi msel f.
OTHER DIVIDI NG HEADS
Since t he last editi on of this book was
pri nted thr ee new divi din g heads have
appeared on the market. The fi rst. of my
Fig. 39 The George H. Thomas Versatil e Di vi di ng Head
\\
59
58
Fig. 37 Steady in use on a gear cutting operation
Fig. 38 Author s design for simple dividing head
58
table or vert ical sli de, etc. does on
occasion come a long way from the point
where cutting is bei ng done, and accor-
di ngly t here is danger of t he work being
spoilt by t he head slipping. To overcome
this I have made up a steady stand from
mil d steel bar material which bol ts on t he
table of the miller, and clamps on the 1 in.
overarm bar of the head. The stand has a
vertical t in. bar set into a flat base wit h
slot for a table bolt. A two-way clamp
slides on thi s vert ical bar, and another t
in. bar passes t hrough it horiz ntally. At
the end of t his is a two-plate clamp
ripping the t in. bar. with provision also
for gripping the 1 in. bar of the head. The
various clamps can be moved separately
and make a pretty universal fitt ing. The
whole t hi ng Is shown in use in Fig. 37.
This fitting of my design is not on the
market. but it has proved so useful to me
that I am givi ng a working drawing of it in
Fig. 36 and anybody who li kes can make a
unit for himself.
OTHER DIVIDING HEADS
Since t he last editi on of this book was
printed three new ividing heads have
appeared on the market. The first, of my
Fig. 39 The George H. Thomas Versat ile Dividing Head
59
own desi gn, replaces that shown in Fig.
35, long out of production after the maker
died sever al years ago. It is essenti ally
similar wi t h detail i mprovements. It has a
tailstoc k for support ing long slender
piece s, and a pai r of raising blocks which
bring t he cent re height up to j ust ove r 3t
in. and t hereby all ow fo r rotat ing work up
to t he size of the 7" diameter Myford
facepl ate. It is shown in Fig. 38.
The second type is a much more
elabo ra t e and v er sati le appliance
desi gned by Mr Geo . Thomas, and
suppl ied, li ke t he f i rst one, by N.S. & A.
Hem ingway, 30 Links View, Hal f Acre,
Rochdal e. I n this head a 24-hole division
plate prov ides for si mple dividi ng wit h
those factor s associat ed wit h 24. A 40
tooth worm w heel and wor m can also be
engaged, w i t h a si x- row dri l l ed- hal
division plat e, givi ng much finer di visions.
This plate can be rotated by a subsidi ary
worm, t hereby permi tting very high
Opposite, Fig. 40 The Kibbey dividing head
numbers of divisions to be obtained. Most
peop le will need some help to make t he
f ull est use of t hi s device and the book by
Geo . Thomas himself on its construct ion
and use, (Dividing and Graduat ing , Ar gus
Books Ltd.) will be fou nd t he best source
of i nfor mat ion. Th is head is also availabl e
wit h tai lstock and rai sing blocks, but in
normal for m is shown in Fig. 39.
The third head is supplied also in kit
form by Model Engi neering Serv ices. and
was designed by Mr Ron Kibbey. It uses
sta ndard Myford cha ng e wheels as
division plates, but has a fork ed locki ng
plu nger whi ch can span over a tooth as
we ll as drop between t wo t eet h. Thus the
number of di vi sions increases to twice the
number of teet h i n any w heel. I n addition
it has a mount ing for a wheel- pai r to mesh
wi th t he spindle w heel. giving a gear ratio
to add to the basic divisions. It is not at
present provided with a tailstock or raising
bl ocks. The head, w ith ext ra gear pair i n
pos ition, is shown in Fig. 40.
6 1
own design, replaces that shown in Fig.
35, long out of production after the maker
died several years ago. It is essentially
similar with detail improvements. It ha a
tailstock for supporting long slender
pieces, and a pai r of raising blocks which
bring the centre height up to j ust over 3
in. and thereby allow for rotating work up
to the size of the 7" diameter Myford
faceplate. It is shown in Fig. 38.
The second type is a much more
elabo r at e and versa t i l e appliance
designed by Mr Geo. Thomas, and
supplied, like the first one, by N.S. & A.
Hemingway, 30 Li nks View. Hal f Acre.
Rochdale. In this head a 24-hole division
plate provides for simple divi di ng wit h
those factors associated with 24. A 40-
tooth worm wheel and worm can Iso be
engaged. wi th a six- row drill ed- hol
division plate. giving much fi ner divisions.
This plate can be rotated by a subsidiary
worm. thereby permitting very high
Opposite, Fig. 40 The Kibbey dividing head
numbers of divisions to be obtained. Most
people will need some help to make the
fullest use of this device and the book by
Geo. Thomas himself on its construction
and use, (Dividing and Graduating. Argus
Books Ltd.) will be found t he best source
of information. This head is also available
with tai lstock and raising blocks. but in
normal form is shown in Fig. 39.
The third head i supplied also in kit
form by Model Engi neering Services. and
was designed by Mr Ron Kibbey. It uses
standard Myford change wheels as
division plates, but has a forked locking
plunger which can span over a tooth as
well as drop between two teeth. Thus the
number of divi si ons increases to twice t he
number of teet h in any wheel. I n addition
it has a mounting for a wheel-pai r to mesh
with the spindle wheel. giving a gear ratio
to add to the basic divisions. It is not at
present provided with a tailstock or raising
blocks. The head. with extra gear pair in
position, is shown in Fig. 40.
61
CHAPTER 11
Dividing Heads and,
Gearcutting
The availabi lity of a di viding h e a ~ is again
essent ial for doing gearcutti ng on t he
mill ing machine. Of cou rse there are types
of gears one j ust cannot do, but ordinary
spur gears can be done perfectly wel l for
mod el engi neeri ng purposes. wh ere
nei the r high speeds. extre me si lence, nor
hi gh rates of power tr ansmission are
demanded. The desi gn of gear s is a
subj ect outside t he scope of t his book,
which i s i ntended to deal with workshop
operat ions. but there are plenty of sources
of inf ormat ion on gear design. The si mple
type of dividi ng head al ready illu st rated
wil l serve very well if the gears to be cut
have such a number of teet h as t he
i ndexi ng change wheels can deal wi t h.
But if the number required cannot be got
f rom exi st ing wheels, t hen a more
complex head such as t he Myfo rd. will be
needed. Fig. 37 shows this in use cutti ng
the teeth of a pinion which are i ntegr al
wit h the shaft. The blank was t urne d to t
in. dia met er on the part t o be held and this
was gripped in the sta ndard Myford t i n.
coll et. whi le the other end of th e compo
nent bei ng centred was support ed by a
60 degree centre in t he overarm f itt i ng.
This picture shows the st eady bracket
descr ibed i n the last chapter in use. The
cutt er is a si mple flycutt er in a boring bar
held for conven ience in a boring head. It is
shown i n cl ose- up in Fig. 41 . The prof i le
was establi shed by gri ndi ng to suit a
wheel of the same pitch wi th slight ly mo re
teet h. The vari at ion is so small as to be of
no import ance. especial ly as the pi nion
rot at es at only a low speed.
But if several gears are to be made. and
especia lly if duplicat es may be want ed
lat er, it can be worth whil e to invest in one
or more prope r disc type gear cutt ers of
what is now universally known as the
' Brown & Sharpe' type, because they
we re deve lop ed by the famous fir m of
Brown & Sharpe in U.S.A. many years
ago. They are of course now made by
Britis h firms as well. and by others all over
the world. to an accu racy of internat ional
st andards. f ar better than anyt hing that is
needed for model engineering, and are
properly back ed off as well as bei ng made
f rom hi gh speed steel. No single cutt er
will properl y deal wit h al l number of teet h,
so t hey are made in set s. e a c ~ cutter
dealing wi t h a li mit ed range. and each
bears an ident ifying number. The range
runs as fo ll ows:
No.1 135 to a rack No.5 21 to 25
No. 2 55 to 134 No. 6 17 to 20
No.335 t05 No.7 14 to 16
No. 4 26 to 34 No.8 12 and 13
I
III
Fig. 4 1 Close-up of fl ycut t er and pinion
Fig. 42 Gearcutting with Brown & Sharpe cut t er
63
62
CHAPTER 11
Dividing Heads and,
Gearcutting
The availability of a dividing head is again
essent ial for doing gearcutting on the
mi lli ng machine. Of course there are types
of gears one just cannot do, but ordi nary
spur gears can be done perfectly well for
model engi neering purposes, where
neither high speeds, ext reme silence, nor
high rates of power transmi ssion are
emanded. The design of gears is a
subject outside the scope of t hi s book,
which is intended to deal with workshop
operations, but there are plenty of sources
of information on gear design. The si mple
type of ividi ng head already illustrated
will serve very well if the gears to be cut
have such a number of teeth as the
indexing change wheels can deal with.
But if the number required cannot b got
from existing wheels, t hen a more
complex head such as t he Myford, will be
needed. Fig. 37 shows this i n use cutting
the teeth of a pinion whi ch are integral
with the shaft. The blank was t urne to t
in. diameter on the part to be held and this
was gripped in the standard Myford t in.
collet, while the other end of the compo-
nent being centred was supported by a
60 degree centre in t he overarm fitting.
This pict ure shows the steady bracket
described in the last chapter in use. The
cutter is a simple f lycutter in a boring bar
62
held for convenience in a boring head. I t is
shown i n close-up in Fig. 41 . The profi le
was establi shed by grinding to suit a
wheel of the same pitch with sl ightly more
teet h. The variati on is so small as to be of
no importance, especi all y as the pi ni on
rot ates at only a low speed.
But if several gears are to be made, and
especiall y if duplicates may be wanted
later, it can be worth whil e to invest i n one
or more proper disc type gear cutters of
what is now universally known as the
' Brown & Sharpe' type, because they
were developed by the f amous fir m of
Brown & Sharpe in U.S.A. many years
ago. They are of course now made by
British firms as well, an by others all over
the world. to an accuracy of int erna ional
standards. far better than anything that i
needed for model engineering. and are
properly backe off as well as being made
from hi gh speed steel. No single cu tter
will properly deal with all number of teet h.
so they are made in sets. e a c ~ cutter
dealing with a li mited range. and each
bears an identifying number. The range
runs as foll ows:
No. 1 135 to a rack
No.2 55 to 134
No. 3 35 to 54
No. 4 26 to 34
No. 5
NO.6
No. 7
No. 8
21 to 25
17 to 20
14 to 16
12 and 13
Fig. 41 Close-up of flycutter and pinion
Fig. 42 Gearcutting with Brown & Sharpe cutter
63
Fig. 43 Flycutting 10 d.p
These cutt ers can be bought singly at
any time from regular tool merchants and
I doubt if any discount would be giv en for
buyi ng a complete set of 8. So there is no
need to go to t he expense of acquiri ng a
compl ete set unless it is fir mly known
there wil l be a use for every one ! Fig. 42
shows one of these doi ng a si milar job to
t hat depicted in Fig. 37. The smoother
acti on of t he mul t i-tooth ed cu tter made it
possible to dispense wit h the use of the
steady stand. though care was taken not
to be too rough wi t h the feed. especiall y
at th e st art of each cut.
Going now from what might be called
the subli me t o t he ridiculous. or at least
f rom th e mi niature to t he outsize. t he next
photograph shows the cutting of a much
larger gear. act ually 9.600 i n. p.c.d. This is
a gunmetal gear needed as par t of a metal
pattern from which the fl ywheel of Fig. 20
was made. It is only 3/1 6 in. t hick but t he
. gearwheel, fron t view
t eet h are 10 d.p.. approx. 5/ 16 in. cent res.
so quite a lot of met al had to be removed
at each too t h. The cutting was done wi t h
a flvcut ter. ground up by hand to match a
si l ho ue tte of a 10 d . p . t oo t h i n
M achinery's Handbook. using a magnifi er,
this cutter bein g set in a boring bar of
rather excessive length in a boring head.
Two cuts were taken, but even t hen there
was a good deal of spring and noise. The
shape of t he bla nk casting wa s arranged
to provide for mo untin g by 8 bolt s on t he
large Myford faceplat e. (9 i n. diameter!
and this wa s fi xed on t he mi ll er t able so as
to overhang the side. That permittgd fixi ng
a standard angleplat e on t he table too.
just to uchi ng the back of t he facepl at e,
which reduced t he spri ngi ness of that. and
provided a back -stop against t he danger
of sl ippi ng. It would have been asking a lot
of t he single bolt of the divi di ng head to
prevent movement, under the condit ions
Fig. 44 Fl ycutt i ng 10 d.p. gearwheel, rear view
prevai li ng. but using t his safeguard all
w ent w ell.
It is well worth keepi ng i n mind in th e
home wor kshop that this method of
back-up is wi dely used in t he engi neeri ng
in dustry. espe ci al ly i n t he heav ie r
sect ions, on plani ng machi nes and ot hers
where t here is eit her high thrust or high
impact,' sometimes both, because it can
avoid damage to machi nes and work. as
well as possible i nj ury. Fig. 43 shows t he
front of the gear disc. and i n this view t he
di viding head is not visibl e. But i n Fig. 44
both th e angleplat e and t he dividing head
are seen. The gear blank would only j ust
swing in t he gap of t he Myf ord lath e so
without rai si ng block s it repres ents about
t he largest job t hat can be t urned .
65
64
Fig. 43 Flycutting 10 d.p . gear wheel. front view
These cutters can be bought singl at
any t ime from regular t ool merchants and
I doubt if any discount would be given for
buying a complet e set of 8. So there is no
need to go 0 the expense of acqui ri ng a
complete s t unl ss it is f irmly known
there will be a use for every one! Fig. 42
shows one of these doing a similar j ob to
that depicted in Fig. 37. The smoother
action of the mul t i- toothed cutter made it
possible to di pense with the use of the
steady stand, though care was taken not
to be too rough with the feed, especially
at the start of each cut.
Going now from what might be called
the sublime to the ridiculous. or at least
from the miniature to the outsize. t he next
photograph shows the cutting of a much
larger gear. actually 9.600 in. p.c.d. This is
a gun metal gear needed as part of a metal
pattern from which the ffywh el of Fig. 20
was made. It is only 3/ 16 in. thick but the
64
teeth are 10 .p. , approx. 5/ 16 in. centres,
so quite a lot of metal had to be removed
at each tooth. The cutt ing was done with
a flycutter, ground up by hand to match a
si l houette of a 10 d .p. t oo t h i n
Machinery's Handbook, usi ng a magni fier ,
thi s cutter being set in a bori ng bar of
rather excessive length in a boring head.
Two cuts were taken, but even then there
was a good deal of spring and noise. The
shape of the blank casting was arranged
to provide for mounting by 8 bolts on t he
large Myford faceplate, (9 in. diameter)
and this was fixed on the mill er tabl e so as
to overhang the side. That fixi ng
a standard angl eplate on the table too,
just touching the back of the faceplate,
which reduced the springiness of that , and
provided a back-stop against the danger
of slipping. It would have been aski ng a lot
of the single bolt of t he dividi ng head to
prevent movement under the condit ions
Fig. 44 Flycutting 10 d. p. gearwheel, rear view
prevailing, but using this safeguard all
went well.
It is well worth keeping in mind in the
home workshop that this method of
back-up is widely used i n t he engi neering
industry. especi ally in t he heavie r
sect ions, on planing machi nes and ot her
where there is either high thrust or high
impact.' sometimes both, because it can
avoid damage to machines and work, as
well as possible injury. Fig. 43 shows the
front of the gear disc. and i n this view the
dividing head is not visibl e. But in Fig. 44
both the angleplat e and the divi ding head
are seen. The gear bl ank would only just
swing in the gap of the Myford lathe so
without raising blocks it represents about
the largest job t hat can be turned.
65
CHAPTER 12
Dividing Heads and
Tool Making
There are many occasions i n tool making rough and ready methods j ust will not do.
when divi di ng is necessary. Multiple and as i n t he next example t he physical
edged cutt ing too ls like taps. reamers, di fficulty of getti ng at the metal t hat has
milli ng cutters, countersi nks. et c. all really to be taken away mo re or less sett les t hat
need divi di ng devi ces to produce t he best mechanical divi di ng must be employed.
results, even though some of the simple Fig. 4 5 shows t he fl uti ng of a long-thread
cutters can we ll be made by f iling or Acme t ap whi ch is held in a col let in t he
free hand gr indi ng. However, the f orm of spi ndle of a si mple dividi ng head, using
the teet h or flut es somet imes sett les that change wheels for t he dividing. I n order to
Fig. 45 Fluti ng Acme thread tap
obtain t he maximum swa rf clea rance this
Anot her example of the use of the
tap has five fl utes. The head has no
dividing head, this t ime cou pled with the
tailstock so the outboard end of t he tap is
use of a small rotary table, is shown i n
rested on a pai r of Picador blocks and the
Figs. 46 and 47 . The wo rkpiece to be
clamp rests on anoth er pai r. These are
produced was a fi ne tooth mill ing cutter
very usefu l accessories for mi lli ng opera
wit h a roun d end for routing or hand
tions. Of course each time t hat a flute is
milli ng on t he li ght al loy cylinder head of a
completed the clamp has to be released
car engine. The commercial ly avai lable
bef ore the work can be rot at ed to the
cutters for use in elect ric drills had such
posi ti on for the next fl ut e. A sui table
coarse teet h t hat once they touched the
tailstcck. were it available, woul d obv iate
surf ace of t he alloy t hey we re uncontroll
the need for this. The 5 flu tes are obt ai ned
able and pulled sideways so violent ly that
by mo vi ng 12 teet h at a ti me on a 60
damage to the cyli nder head was al most a
tooth wh eel. The cutte r being used is a
cert ain ty. So as fine pi tch cut t ers
commerci al t ap-f lut ing cutte r picked up
appea red to be not purchasable it was
cheaply at a sale. These cutters are made
decided to make one. The blank, of a
wit h a somewhat lop- sided rounded
carbon st eel si mil ar to si lver st eel but
prof i le speci ficall y for t his duty, but if it
somewhat lower in carbon, wa s made to
had not been avai lable, a flycutt er woul d
hold in a collet and was give n a small
have been gro und up to the profil e of a
recess in t he end for t he flut ing cutte r to
si mil ar tap. The prof ile is not desperat ely
run into. The div idi ng head , with a 50
impor t ant and a small error would not
to ot h change wheel an its spi ndle . was
mount ed on a stee l plat e so that t he end
matt er.
Fig. 46 Cut ti ng teeth of ball -end cut ter
66 67
CHAPTER 12
Dividing Heads and
Tool Making
There are many occasions in tool maki ng
when divi di ng is necessary. Multipl e
edged cu t ing tools l ike t aps, reamers,
mill ing cutters, countersi nks, etc. all reall y
need di vidi ng devices to produce the best
results, even though some of the simple
cutters can well be made by f il ing or
freehand grindi ng. However. the form of
the teeth or flutes someti mes settl es that
rough and ready methods j ust will not do,
and as in t he next exampl the physical
difficulty of getti ng at t he metal that has
to be taken away more or less set t les t hat
mechanical dividing must be employed.
Fi g. 4 5 shows t he fl ut ing of a long-thread
Acme tap whi ch is held in a coll et in t he
spi ndle of a si mpl e dividi ng head, using
change wheels for the divi ding. In order to
Fig. 45 Fluting Acme thread tap
66
obtain the maximum swarf clearance this
tap has five flutes. The head has no
t ailstock so t he outboard end of the tap is
rested on a pair of Picador blocks and the
clamp rests on another pai r. These are
very useful accessories for milli ng opera-
tions. Of course each time t hat a fl ute is
compl eted the clamp has to be rei ased
before the work can b rotated to the
posit ion for the next fl ute. A suitable
tailstock, were i t avail abl e, would obviat e
the need for thi s. The 5 flutes are obtained
by moving 12 teeth at a ti me on a 60
tooth wheel. The cutter being used is a
commerci al t ap-fl uti ng cutter pi cked up
cheaply at a sale. These cut ter are made
with a somewhat lop-si ded rounded
profil specificall y for thi s duty, but if i
had not been avail abl e, a fl ycutter woul d
have been ground up t o the profile of a
si mil ar tap. The prof il e is not desperat el y
i mportant and a small error would not
matter.
Another example of the use of the
dividing head, this t i me coupled with the
use of a small rotary table, is shown i n
Figs. 46 and 47. The workpiece to be
produced was a fi ne tooth mill ing cutter
wit h a round end for routing or hand
mill ing on t he li ght alloy cylinder head of a
car engine. The commerci ally avai lable
cutters for use in elect ric dri lls had uch
coarse eet h that once they touched the
surface of t he all oy t hey were uncontroll -
able and pulled sideways so violently that
damage to the cyli nder head was al most a
cert ai nty. So as fine pitch utters
appeared to be not purchasabl e it was
decided to make one. The blank, of a
arbon st eel si mil ar to si lver steel but
somewhat lower i n carbon, was made to
hold i n a coll et and was given a small
recess in t he end for t he fluti ng cutter to
run into. The dividi ng head, with a 50
toot h change wheel on its spi ndle, was
mounted on a steel plate so that t he end
Fig. 46 Cutting teeth of ball-end cutter
67
Fig. 4 7 Cl ose-up of ball-end cutter
of the wo rk- piece was beyond the centre
table t raversed along br ingi ng the cutter
of t he rotary t able by half its diamet er. In
int o operation cutting along th e cylindrical
other words, t he centre of t he ball end
port ion. When the tabl e was arrested by
was over t he centre of the rot ary table.
the te mporary stop block, t he rotary table
The axis of t he work was on the rot atio n
wa s t urned by means of it s wor m, so t he
cent re. This is not apparent fro m th e
dovet ail cutt er cont inued cutting round
pho tog raph, but was an essent ial feat ure
t he ball end of the work. When the culler
of the set- up. A stop block wa s clamped
ran i nto t he recess, the feed was reversed
to the underside of the mi lling machine
fi rst wi th t he rot ary table, then wit h t he
table with a tool maker 's clamp, visi ble in
main t abl e, back to the st art ing poi nt ,
t he pho to graph , to l i mi t t he ta bl e
wher e the cutt er was cl ear of the work
movement positive ly to this posit ion. In
sha nk , The di vi di ng head was t hen
t he ot her direct ion the movement of the
indexed one toot h on t he wheel. and a
table brought the cutt er to a part of the
new cut st arte d, Eventuall y all 50 cuts
too l shank smaller than the diameter at
we re comp leted as shown in Fig. 4 7.
the bottom of t he flutes so that indexing
The working' diameter of this tool is f
could be done wit h th e cutter in the clear.
in. and tlgere are 50 perfect teet h. The too l
The cutter used was a carbon steel one
was hardened and tempered, and when
made origi nall y for produci ng locomot ive
put to use in an electric dri ll was found to
lubricator ratchet wheels, wit h a 60
be ent irely sat isfactory, It worked com
degree singl e angle. W ith t he axis of t he
pletel y chatt er-free, wi t h no tendency to
work parall el to t he tabl e a cut was
run away, and in spite of its fine and
started at t he requ ired full depth, and the
shallo w t eeth, removed metal at a very
Fig. 48 Gashing fl ut es in large countersinki ng tool
gr ati fyin g rat e. The work on the ports in this was to use a vertical sli de. There was
the alloy head wa s comp let ed t o the great quite a lot of metal to be t aken out of the
sati sfaction of the user, leaving a beaut if ul 25 f lutes in this deci dedly tough steel , and
smoot h surfa ce for t he gas flo w. as usual the cutt ing wa s a long wa y f rom
Anot her example of cutti ng tool making t he anchorage poi nt, so t he st eady stand
is shown i n Figs. 48 and 49. A large 60 was brought i nt o use at the back of t he
degree count ersi nk was needed for a head, as it proved too diff icul t t o set it at
com mercial operati on on steel tubes, the the same side as t he cutt er. Howe ver, it
tool being about 2 -!- in. diamete r. It wa s served quite well in that posit ion and
made with an internal form ident ical wit h t her e w as never any suggest ion of
the Myford lat he spi ndles from a carb on insecuri ty.
ma nga nese ch rome all oy of known The main gashes for the flut es were
identity, so that subsequent hardening taken out first, wit h two cut s down each
coul d be done without risk of fai lure i n a flu t e. Then t he head wa s t il ted to a new
co mmercia l est ab li shmen t wit h angl e and anot her series of cuts take n to
knowledge of this st eel. I n t he pictu re it is accomplish t he rel ief. Because of the
shown moun ted on t he Myford dividing coni cal shap e of the work the vert ical slide
head having th e f lut es cut wi th a specia l had to have it s base set at an angle to the
angle form di sc type cutt er. Because of mill er table. All these appa rently com
th e peculiar angl es which are invol ved it plicated setti ngs had to be established
was necessary to be able to set the head experi ment ally (t hough possibly with a lot
with it s axi s at an i ncli nat ion to t he table, of effort they mig ht have been calcul at ed)
and it proved that the si mp lest way to do to give the desired for m of t he cutt ing
69
68
Fig. 47 Close- up of ball-end cutter
of the work-piece was eyond the centre
of the rotary table by half its diameter. In
other words. the centre of the ball end
was over the centre of the rotary table.
The axis of the work was on the rotation
centre. This is not apparent from the
photograph, but was an essent ial feature
of the set-up. A stop block was clamped
to the underside of the mi ll ing machine
table with a tool maker' s clamp, visible in
th e phot ograph, to l imit the t abl e
movement positively to thi s position. In
the other direction t he movement of the
table brought the cutter to a part of the
tool shank smaller than the diameter at
the bottom of the flute so that indexing
could be done with the cutter in the clear.
The cutter used was a carbon steel one
made originally for producing locomot ive
lubricator ratchet wheels, with a 60
degree single angle. With the axis of the
work parallel to t he table a cut was
started at the required full depth. and the
68
table traversed along bringi ng the cutter
int o operation cutting al ong the cyli ndrical
portion. When the table was arreste by
the temporary stop block, the rotary table
was t urned by means of its worm, so the
dovetail cutter cont i nued cutting round
the ball end of the work. When t he cutter
ran into the recess, the feed was reversed
fi rst with t he rotary table, then with the
mai n table, back to the starting point,
where the cutter was clear of the work
shank. The dividing head was then
indexed one toot h on the wheel , and a
new cut started. Eventually all 50 cuts
were completed as shown in Fig. 47.
The working' diameter of this tool is f
in. and tillere are 50 perfect teet h. The tool
was hardened and tempered, and when
put to use in an electric drill was found to
be entirely satisfactory. It worked com-
pletely chatter-free, with no tendency to
run away, and in spite of its fine and
shall ow teeth, removed metal at a very
Fig. 48 Gashing flutes in large countersinking tool
gratifying rate. The work on the ports in
the alloy head was compl eted to t he great
satisfaction of the user, leaving a beaut iful
smoot h surface for the gas flow.
Another example of cutt ing tool making
is shown in Figs. 48 and 49. A large 60
degree countersink was needed for a
commerci al operation on steel t ubes, the
tool being about 2t in. diameter. It was
made with an internal form identical wit h
the Myford lathe spi ndles from a carbon-
manganese chrome alloy of known
identity, so that subsequent hardening
could be done without ri sk of failure i n a
commercial establishment with
knowledge of this steel. I n the picture it is
shown mounted on t he Myford dividing
head having t he ffutes cut with a special
angle form disc type cutter. Because of
the peculiar angles which are involved it
was necessary to be able to set the head
with its axis at an incli nation to t he table.
and it proved that the simplest way t o do
this was to use a vertical slide. There was
quit e a lot of metal to be taken out of the
25 flutes in thi s decidedly tough steel , an
as usual the cutting was a long way from
the anchorage point. so the steady stand
was brought into use at the back of t he
head, as it proved too difficult to set it at
t he same si de as the cutt er. However, it
served qui te well in that positi on and
t here was never any suggestion of
insecurity.
The main gashes for the fl utes were
taken out first, with two cuts down each
flute. Then the head was tilted to a new
angle and another series of cuts taken to
accompli sh the reli ef. Because of the
conical shape of the work the vert ical slide
had to have its base set at an angle to the
mill er table. All these apparently com-
plicated setti ngs had to be established
experiment all y (though possibly with a lot
of effort they might have been calculated)
to give the desired form of the cutting
69
Fig. 49 Rear view showing s teady stand in use
edges of the count ersi nk and the rake
angles desired in two direct ions. The small
division plate in use is one wh ich had
been made some ti me pr eviously for doing
12 5 division micrometer dial s. for which
unfo rt unatel y t he st andard Myford plates
do not provide, or did not at t hat t i me.
However, with this set -up and not too
many hours wor k it proved possible wit h
home workshop equipment to produce a
very suitable specia l countersink which
would inev itably have cost a small fortune
if it had had to be made in a commercial
factory.
It is hoped that these exampl es of
too l maki ng wi ll encourage al l who need
non- standard t ools, and wh o know of no
firm th at would take t hem on, or are
det erred by the high cost of labour
int ensive specials. Who knows, somebody
in a home workshop might t ake on the j ob
of hel ping out some tool fact ory t hat
would not wa nt to be diverted from its
normal wor k by job s of t his kind?
CHAPTER 13
Divi ding Heads and
Graduated Scales
In the construction of smal l machi ne tools
and access ories it is ofte n desirable to
have gradua ted sca les for t he co n
venience of precise measurements, and
the cyli ndr ical micrometer dia l is undoub
tedly t he commo nest type . Dependi ng on
the number of graduations required the
engraving or cutt ing of t he li nes can be
done wit h eit her a simp le head or the
worm geared type. There is a choice
between using a non-rot ati ng cutte r of t he
plani ng or slott ing type, and using a
rot at ing cutt er like t hose employed on
pantograph engraving machi nes. In each
case the work is mounted on the dividi ng
head and t he table screw is used t o move
the work against the too l. It is advisable to
clamp stops to t he table . if the mac hi ne
does not have st op devices bui lt in. so as
to positively li mit the t abl e movement an
keep the li nes the correct l ength. Where
there are li nes of mor e t han one lengt h on
t he same di al, one or more slips of sheet
metal can be i nserted i n front of the stop
to obtai n t he short lines . The cu tting tool
can be gro und to an i ncluded angle of
about 50 degrees, Few modellers have
access to an engraving cutter gr i nder.
which is the ideal machi ne for grindi ng the
D-bit type cutters with conical end which
are neede d. but t hey can i n fact be ground
on t he Quorn gri nder. whic h is becomi ng
more and more popul ar wi t h model
engi neers. Those who do not possess one
of these versatile mac hi nes may have
some friend who can hel p out by grindi ng
an occasiona l cutter. For my par t I pr efer
t he rotating cutter but t hen I do have the
machine to grind them. Wi thout thi s a
slotting tool can easily be ground and if
ri gidly held wi ll also do a good job,
Fig. 50 shows a cylindrical scale being
engraved on the mill er with a rot at ing
tool. This is not a loose collar, the scale is
on the co mponent itself. act ually par t of a
Quorn gri nder, but a separate collar would
just be mount ed on an arbor and treat ed
in t he same way. Fig. 51 is a close- up of
this operation,
Some art icles need the scale on a flat
surface but sti ll in a curve, One of t hese is
needed on t he Ouorn gri nder, and Fig, 52
shows t his set on a rotary table on t he
mill er and being dealt with by a rot at ing
cutte r as the last example. The M. E.S.
table in the pict ure has a 90 tooth worm
wheel. so one revolut ion of the worm
gives 4 degrees movement and each
division on its 16- line micrometer collar
gives one quarter of one degree, The scale
being eng raved i s one specified i n
degrees, as it is an angle-setting scale.
71
70
Fig. 49 Rear view showing teady stand in use
edges of the countersink and the rake
angles desired in two directions. The small
division plate in use is one whi ch had
been made some time previously for doing
125 division micrometer dial s. for which
unfortunately the standard Myford plates
do not provide. or did not at t ha t ime.
However, wi th thi s set-up and not too
many hours work i proved possible wit h
home workshop quipm nt to produce a
very suitable special countersink which
would inevitably have cost a small fortune
70
if it had had to be made in a commercial
factory.
It is hoped that these exampl es of
tool maki ng will encourage all who need
non- standard t ools, and who know of no
firm that would take t hem on, or are
det rred by the high cost of labour-
intensi ve specials. Who knows. somebody
in a home workshop might take on the job
of hel ping out some tool fact ory t hat
would not want to be diverted from its
normal work by jobs of t hi s kind?
CHAPTER 13
Dividing Heads and
Graduated Scales
In the construction of small machin tools
and accessori es it is often desi rable to
have graduat ed scales for the con-
venience of precise measurements. and
the cyl indrical micrometer dial is undoub-
tedly t he commonest type. Dependin on
t he number of graduat ion required the
engravi ng or cutt ing of t he li nes can be
done with either a simple head or the
worm geared type. There is a choice
between using a non-rotating cutter of the
planing or slotting type. and using a
rotating cutter like those employed on
pantograph engraving machines. In each
ca se the work is mounted on the dividing
head and the table screw is used to move
the work gainst the tool. It is advisable to
clamp stops to the table. if the machi ne
does not have stop devices buil t in. so as
to positively li mit the table movement an
keep the lines the correct lengt h. Where
there are li nes of more than one length on
the same di al . one or more slips of sheet
metal can be inserted in front of the stop
to obtain t he short lines. The cutting tool
can be ground to an included angle of
about 50 degrees. Few modellers have
access to an engraving cutter gri nder.
which is the ideal machine for grinding the
D-bit type cutters with conical end which
are needed. but they can in fact be ground
on the Quorn gri nder. which is becoming
more and more popular with model
engineers. Those who do not possess one
of these versatile machi nes may have
some friend who can help out by grindi ng
an occasi onal cutter. For my part I prefer
the rotating cutter but then I do have the
machine to grind them. Without t his a
slott ing tool can easily be ground an if
rigidly held will Iso do a good job.
Fig. 50 shows a cylindrical scale being
engraved on the miller with rotating
tool. This is n t a loose collar. the scale is
on the component itself. actuall y part of a
Quorn grinder. but a separate collar would
j ust be mounted on an arbor and treated
in the same way. Fig. 51 is a close- up of
this operation.
Some articles need the scale on a flat
surface but s i ll in a curve. One of these is
needed on t he Quorn gri nder. and Fig. 52
shows this set on a rotary table n the
miller and being dealt with by a rotat i ng
cutter as the last example. The M.E.S.
table in the picture has a 90 tooth worm
wheel. so one revolution of the worm
gives 4 degrees movement and each
ivision on its 16-line micrometer collar
gives one quarter of one degree. The scale
being engraved is one specified i n
degrees. as it is an angle- setting scale.
71
Fig. 50 Cyl indrical machi ne component being graduate d
Fig. 5 T Close-up of previous operation
Fig. 52 Graduating part- circul ar arcuat e scale on fla t surface
Conical mi crometer collars are somet i mes
required, but t hey are more diff icult to
prod uce and should be avoided i n the
designi ng if at al l possible. For graduat ing
one of t hese the dividing head woul d need
to be t i lted aft er the fashi on of th at in Fig,
48. but possibly i n t he other di rection.
dependi ng on t he actual design of the
collar.
One point in making scales of any ki nd.
The fig uring should always be done so
that the figures are t he right way up as
seen in usi ng t he scale. The f igures may
need to have ri sing value . . . 10, 20, 30
. . . to t he right hand f rom t he zero mark,
but quite possibly, depe nding on circum
stances they may need to be the opposit e
way. It is as wel l t o get t his t horoughly
sorted out before starting to use marking
punches to put the figures i n. because it
can be very di fficult t o ret ri eve the sit ua
tion if the start was made the wrong wa y.
73 72
Fig. 50 Cylindrical machine component being graduated
Fig. 51 Close-up of previous operation
72
Fig. 52 Graduating part-circular arcuate scaleon flat surface
Coni cal micromet er coll ars are sometimes
required, but t hey are more diffi cult to
produce and should be avoided in the
designing if at all possible. For gradu<lt ing
one of t hese the divi ding head would need
to be tilte after the fashion of that in Fig.
48, but possibly in t he ot her i rection,
depending on the actual design of the
coll ar.
One point in making scales of any kind.
The figuring should always be done so
that the figures are the right way up as
seen in using the scale. The figures may
need to have rising value ... 10, 20, 30
. . . to t he ri ght hand f rom t he zero mark,
but quite possibly, depending on circum-
st ances t hey may need to be t he opposite
way. It is as well to get this th roughly
sorted out before starting to use marking
punches to put the figures in, because it
can be very difficult to r trieve the situa-
tion if the start was made the wrong way.
73
CHAPTER 14
Cutter Speeds for
Vertical Milling
In gene ral I a ~ af raid model engineers do
not have very clear ideas about how fast
they should run t heir lath es, dri l ls or
mi lling machines. To run t oo slowly
extends the wor king time unnecessarily,
but to run t oo fast will soon blunt a cutter
and may also cause poor work finish
t hrough cha tter. The wear on mil ling
cutters (apart f rom flyc uttersl is quite
important because of t he trouble of
sharpening t hem, and broken cut ters can
be quite an expense. The pri nciples which
govern the speeds of cutting metal in
othe r mac hines such as the lat he and dri ll
can be taken as a usef ul guide, in the
sense t hat any speed which an a part icular
material wi ll blunt a lat he tool or drill wil l
li kewise blunt a mill i ng cutter. But on t he
vertical mill er there are other problems
too. Generall y t he point of cutting i s much
further from the supp ort than t hat of the
lathe t ool. It wi ll also be a long wa y com
paratively from t he spind le beari ngs. The
work may be much further from the
slideways t han it would be from the bed of
the lathe. The cutt ing tool is normally
unsupport ed at it s cutting end, and it s
own elasticity is added to that of the
chuck, spindle, work, etc . So speeds
which might be feasible on the l at he may
well be fou nd much too high on t he mi ller.
As an exampl e, t urni ng back to Fig. 20 wi ll
show how elevated t he surface of the
wor k is f rom t he t able slides, and in this
example low speed s were essential t o
obtai n a reasonably goo d fi nish.
The rat es of feed and dept h of cut
which are commonp lace on i ndustrial
machines are quite out of order i n t he
home workshop. Not only are industrial
machines heavy and rigid, so are t he wo rk
holdi ng dev ices, and the work it self is
much more robust and rigid. Also, and this
applies particularly when cutting stee l ,
t hese machi nes can usuall y flood t he
cutter wit h coolant , t aki ng away the heat
generated i n t he cutt i ng ope ration, and
that is not normally possibl e on machi nes
in t he home wo rkshop. So Table III has
been compiled to give some guidance i n
the kind of opera t ions which have been
described i n the boo k. It is based on usi ng
speeds which wi ll conserve t he sharpness
of the cutters likely to be used. For f lycut
ters, commercially made endrni lls. and
Brown and Sharpe gear cutters, t he tools
t hemselves wil l be properly hardened high
speed stee l. For the Woodruff cutters it is
based on these being home made cutt ers
produced from carbon stee l or ' silver' st eel
(whi ch is a carbon stee l with about 1.2%
carbon and no alloy) . More t han one
article in Model Engi neer in years past has
descri bed met hods for maki ng gea r
cutters of t he Brown and Sharpe type. and I
have some of these mysel f , made from
plai n carbon st eel of about 1% carbon.
Such cutters must be run more slowly
t han the hi gh speed steel cutters of com
mercial make, but it is possi ble that a
wider var i ety of tools wil l in fut ure be
made i n t he home workshops, as a bett er
understa nding of too l maki ng and th e con
t ribution which t he vert ical mill er can
provid e comes t o be recognised. The
cutti ng speeds t o be used with such tools
will need to be arranged t o sui t t he tool
materi als and t he work t hey are doing.
The proper mount i ng of tools in the
miller is a matter of grea t import ance.
Ref erence has already been made to t ools
which screw di rect ly on t he spind le nose,
and anothe r chapter in this boo k w ill give
descriptions of the milling chucks w hic h
are currently available.
It will be foun d that some of t he mi llers
at present on offer have speed ranges
wh ich do not go low enough to mat ch the
bottom end of the recommended speeds
on Table II I. This is unfort unate, but it is a
fact of life, and one must do t he best one
can wit h it, even it it means occasional ly
bor rowing t he use of a friend 's machi ne.
Nat ural ly it will t end to influ ence the
decision when t hi nki ng of purchasing a
machine.
74
75
CHAPTER 14
Cutter Speeds for
Vertical Milling
In general I am afraid model engineers do
not have very clear ideas about how fast
they should run t heir lathes, drills or
milling machines. To run too slowly
extends the working time unnecessarily,
but to run too fast will soon blunt a cutter
and may also cause poor work finish
through chatter. The wear on milling
cutters (apart f rom flycutters) is quite
important because of the trouble of
sharpening t hem, and broken cutters can
be quite an expense. The principles which
govern the speeds of cutting metal in
other machines such as the lathe and dri ll
can be taken as a useful gui de, in t he
sense that any speed which an a particular
material wi ll blunt a lathe tool or drill wi ll
likewise blunt a milling cutter. But on the
vertical miller there are other problems
too. Generally the point of cutting is much
further from the support than t hat of the
lathe tool. It will also be a long way com-
paratively from the spindle bearings. The
work may be much further from the
slideways than it would be from the bed of
the lathe. The cutt ing tool is normally
unsupported at its cutting end, and its
own elasticity is added to that of the
chuck, spindle, work, etc. So speeds
which might be feasible on the lathe may
well be found much too high on the miller.
74
As an example, t urni ng back to Fig. 20 wi ll
show how elevated t he surface of the
work is from the table slides, and in this
example low speeds were essential t o
obtain a reasonably good fi nish.
The rat es of feed and dept h of cut
which are commonplace on industrial
machines are quite out of order in t he
home workshop. Not only are indust rial
machi nes heavy and rigid, so are the work
holding devices, and t he work itsel f is
much more robust and rigid. Also, and this
applies particularly when cu tt ing steel ,
t hese machi nes can usuall y flood t he
cutter with coolant , taking away the heat
generat ed in the cutting operation, and
that is not normall y possible on machines
in the home workshop. So Table II I has
been compiled to give some guidance in
the kind of operati ons which have been
described i n t he book. It is based on using
speeds which wi ll conserve t he sharpness
of the cutters likely to be used. For f lycut-
ters, commercially made endmills, and
Brown and Sharpe gear cutters, the tools
t hemselves will be properly hardened high
speed steel. For the Woodruff cutters it is
based on these being home made cutters
produced from carbon steel or 'silver" steel
(which is a carbon steel with about 1.2%
carbon and no alloy). More than one
article in Model Engineer in years past has
described methods for making gear
cutters of t he Brown and Sharpe type, and I
have some of these myself, made from
plain carbon steel of about 1 % carbon.
Such cutters must be run more slowly
than the high speed steel cutters of com-
mercial make, but it is possible that a
wider variety of tool s will in future be
made in the home workshops, as a better
understanding of tool maki ng and the con-
tribution whi ch t he verti cal mill er can
provide comes to be recognised. The
cutting speeds to be used wit h such tools
will need to be arranged to suit t he t ool
materials and t he work they are doi ng.
The proper mounti ng of t ools i n t he
miller is a matter of great importance.
Reference has already been made to tools
which screw directly on the spindle nose,
and another chapter in this book will give
descriptions of the milling chucks which
are currently avail able.
It will be found that some of t he mi ll ers
at present on offer have speed ranges
which do not go low enough to match the
bottom end of the recommended speeds
on Tabl e Ill. This is unfort unate, but it is a
f act of life, and one must do the best one
can wit h it , even it it means occasionally
borrowing t he use of a friend's machi ne.
Naturall y it will tend t o infl uence the
decision when t hinking of purchasing a
machine.
75
TABLE III
FLYCUTIING. Flat surfa ces as in Fig. 16, H.S.S. cutters, easil y sharpened.
Dep th of cut :
Mild steel .030 i n.
Brass .04 5 i n.
Light Alloy .060 i n.
(inches)
Diameter of
cu tt ing : 1 I t 2 2
l
2
3 31 4 4 t 5
Speeds r.p.rn.:
Mi ld Stee l 150 100 75 60 50 45 38 34 30
Brass 230 150 115 90 75 65 57 50 46
Light alloy 57 0 380 28 5 230 190 165 14 5 125 115
Speeds may well be l imit ed by the extent t hat swarf thrown about the workshop can be
accepted.
ENDMILLING . Spiral fl ute H.S.S. endmill s. Dept h of cut up to ~ of cutter diame ter up
to 3/ 16 in., then up to -i- of diameter. Width of step being cut up to } of diameter.
(inches)
Cutt er diamet er 1/1 6 3/32 1/8 3/16 1/ 14 3/8 1/ 2 5/8 3/ 4
Speeds r.p.m.:
Mild steel 18 00 1500 1200 800 65 0 450 3 50 2 50 180
Brass 2500 2000 1600 11 50 850 650 450 350 250
Light al loy 3500 3000 2500 1700 1400 1200 900 800 700
KEYWAY CUTIING. H.S.S. spi ral fluted endmill s or slot dr ills. Fig. 24.
(inches)
W idth of keyway 1/ 16 3/ 32 1/ 8 3/ 16 1/4 3/8 1/ 2 5/8 3/4
Depth of cut: (thousandt hs of an i nch)
Mi ld steel 10 15 25 30 4 5 70 100 200 250
Brass 12 17 27 40 60 100 140 250 300
Light all oy 15 18 30 45 65 110 135 300 3 50
Speeds r.p.rn.:
M ild steel 1800 1500 1200 800 65 0 450 350 250 180
Brass 2500 2000 1600 11 50 850 650 450 350 250
Light alloy 3500 3000 2500 1700 1400 1200 900 800 700
TABLE III (continued)
KEYWAY CUTIING. With H.S.S. disc cutter Fig. 26, or slitt ing Fig. 23.
(inc hes)
Cutter diameter. 2 2t 3 3
' 2
4
Speeds r.p.m.
Mild stee l 65 55 45 38 33
Bras s 115 9 5 75 65 55
Light Al loy 190 155 125 110 95
GEARCUTIING. Commercial H.S.S. Brown & Sharpe cutters 2 ~ in. di ameter. Fig. 42.
Speed s r.p.rn.
Mil d steel 48
Brass 80
Light Alloy 110
' Home-made' cutters produced from 'sil ver steel' ,
(inches)
Cut ter diameter, 1t
1
2
t
2 2}
Speeds r.p.m.:
Mild st eel 60 50 38 30
Brass 120 100 75 60
Light Alloy 180 150 110 90
WOODRUFF KEYWAYS. Usi ng 'home- made' silver steel cu tters, Speeds may be
increased by one thi rd for commercial H,S.S. cutters.
(inc hes)
Cutter diameter. 1/4 5/ 16 3/8 1/2
Speeds r.p.rn.:
Mi ld steel 380 300 250 200
Brass 700 580 450 350
Light All oy 1000 900 800 650
Cast ir on, unless exceptiona lly hard, may be cu t at the same revs. as mi ld steel, but for
work on carbon stee l ('sil ver steel'). alloy steels, and free CU ll ing stainless reduce revs.
by one third. For non - magnetic stainless reduce by half.
77
76
TABLE III
FLYCUTTING. Flat surfaces as in Fig. 16, H .S.S. cutters, easily sharpened.
Depth of cut:
Mild steel .030 in.
Brass .045 in.
Li ght Alloy . 060 in.
(inches)
Diameter of
cutting:
11
2 21
2
3 31 4 4t 5
Speeds r.p.m :
Mild Steel 150 100 75 60 50 45 38 34 30
Brass 230 150 115 90 75 65 57 50 46
Li ght all oy 570 380 285 230 190 165 145 125 115
Speeds may well be limited by t he extent t hat swarf thrown abou t the workshop can be
accepted.
ENDMILLlNG. Spi ral flute H.S. S. endmill s. Depth of cut up to ~ of cutter diameter up
to 3/1 6 in., then up to -i- of diameter. Width of step being cu up to t of diameter.
(inches)
Cutter diameter 1/ 163/32 1/8 3/ 161/14 3/ 8 1/2 5/8 3/4
Speeds r.p.m.:
Mild steel
Bra s
Light alloy
1800 1500 1200 800 650 450 350 250 180
2500 2000 1600 1150 850 650 450 350 250
3500 3000 2500 1700 1400 1200 900 800 700
KEYWAY CUTTING. H.S.S. spi ral fluted endmills or slot dri ll . Fig. 24.
(inche )
Width of keyway 1/ 16 3/32 1/8 3/16 1/4 3/8 1/ 2 5/8 3/4
Depth of cut : (thousandths of an inch)
Mild steel 10 15 25 30 45 70 100 200 250
Brass 12 17 27 40 60 100 140 250 300
Light alloy 15 18 30 45 65 110 135 300 350
Speeds r.p.m.:
Mil d steel 1800 1500 1200 800 650 450 350 250 180
Brass 2500 2000 1600 1150 850 650 45 350 250
Light alloy 3500 3000 2500 1700 1400 1200 900 800 700
76
TABLE III (continued)
KEYWAY CUTTING. With H.S.S. dis cutter Fig. 26, or slittillg Fig. 23.
(inches)
Cutter diameter . 2 2t
3 31
4
Speeds r.p.m.
Mild steel 65 55 45 38 33
Brass 115 95 75 65 55
Light Alloy 190 155 125 110 95
GEARCUTTING. Commercial H.S. S. Brown & Sharpe cutters 2 i i n. diameter Fig. 42.
Speeds r.p.m.
Mild steel
Brass
Light Alloy
48
80
110
' Home made' cutters produced from 'silver steel '.
Cutter diameter.
Speeds r.p.m. :
Mild teel
Brass
Light All y
1.t
60
120
180
- made'
(inches)
q
50
100
150
silver steel WOODRUFF KEYWAYS, Using 'hom
incr ased by one third f r commercial H. .S. cutters.
Cutter diameter.
Speeds r.p.m.:
Mild steel
Brass
Light Alloy
1/4
380
700
1000
(inches)
5/ 16
300
580
900
2 2t
38 30
75 60
110 90
I:ulters. Speeds may be
3/ 8 1/ 2
250 200
450 350
800 650
Cast iron, unless exceptionally har . may be cu t at the same 'INS. as mild steel, but for
work on carbon steel ('silver steel'). alloy steels. and free CUlling stainless reduce revs.
by one third. For non-magnetic st ai nless reduce by half.
77
CHAPTER 15
Work-holding with
Difficult Shapes
Problems do arise f rom time to time
regarding t he meth ods of holding work i n
the milling machi ne. In ful l scale engi neer
ing these problems are not nearly so acut e
as components are mor e solid and clamps
can be app lied without crus hi ng the
pieces. Oft en wi t h model parts it is
di ff icu lt to get a hold sufficient ly fi rmly
wit hout more or less mutil at ing t he piece.
One method I often use bot h for cast ings
and bar material is to arrange for an
accurate chuc ki ng piece to be left on t he
co mpone nt unti l all operati ons are
co mplete and th en t o remove th is.
Gener all y this piece is made to suit one of '
the Myf ord coll et s, from t i n. diamet er
downwards, since the collets do hold the
part w it h great accuracy, and after turn ing
operations it can be tra nsferred to t he
miller wit h t he coll et pl aced in a di viding
head; even if no indexing has to be done ,
t he head act s as a very effec tive vice.
Some times t hi n components prese nt
problems i n holdi ng on t he mill i ng
machine. If one side is al ready fl at one can
use double- side d sticky tape, available
from drawing off ice supply shops and
some stat ioners. If two or three strips can
be used , an astonishing ly fi rm grip can be
obtained, w hich w ill stand up t o shear
forces induced by milling. I have also i n an
i ndust rial plant stu ck down met al which
had to be tooled all th e way across the
piece, on a fal se base wit h woodwork er' s
gl ue and a sheet of newspaper. Afte r t he
operati ons are complet ed a f ine chisel is
knocked in between t he part s and t he
paper t ears wi thin its t hick ness, so the
pieces come apart wit h some paper
st icking to each. This can then be washed
off wit h hot wat er. There is not hing very
origi nal abo ut t his, of course, it is an age
old pat ter nrnakers' meth od of produci ng a
patt ern wh ich has eventua lly to be i n
hal ves , but it is a sound met hod not nearly
so wel l known as it sho uld be. Fig. 53
shows a light alloy cast i ng being faced
right across w it h a fl ycutter, the casting
bei ng stuck to t he t able wi th sticky tape
and nothi ng else.
However, t he var ious exampl es given
t hroughout the book shou ld serve to show
how to undert ake a really wide range of
jobs . At the ri sk of seemi ng repe ti tive I
would agai n st ress th at it is often wort h
while to make a ji g fo r hol ding or locat ing
th e work, j ust to make sure i t can be held
fi rmly enough without damage i n the rig ht
attitude. The ki nd of ji gs and f ixt ures
needed in modelling seldo m involve mo r
t han a few mi nutes or perhaps an hour to
make, and if this safeguards the compo-
Fig. 53 Tape- held workpiece bei ng fly cut
Fig. 54 Three-f ace anglepl at e used to align vee-blocks
79
78
CHAPTER 15
Work-holding with
Difficult Shapes
Problems do arise from time to time
regarding the met hods of holding work in
the milling machine. I n fu ll scale engineer-
ing these problems are not nearly s acut e
as components are more solid and cl amps
can be applied without crushing the
pieces. Often with model parts it is
di ffi cul t to get a hold sufficiently fi rmly
without more or less muti lati ng t h piece.
One method I often use both for ca t i ngs
and bar material is to arrange for an
accurate chucki ng piece to be left on the
component unti l all operations are
compl ete and th en to re move th is.
Generally this piece is made to suit one of
the Myford collets. from t in. diameter
downwards. since the collets do hold the
part with great accuracy. and after turning
operations it can be transferred to t he
miller with the collet placed in a divi ing
head; even if no indexing has to be done.
t he head acts as a very effect ive vice.
Sometimes thin components present
probl ems in holding on t he milli ng
machine. If one side is already flat one can
use double-sided sticky tape. available
from drawing office supply shops and
some stationers. If two or three strips can
be used. an astonishi ngly firm ri p can be
obtained. which will stan up t shear
forces induced by milling. I have also in an
78
industrial plant stuck down metal which
had to be tooled all the way across the
piece. on a false base wi h woodworker' s
glue and a sheet of new paper. After t he
operations are completed a fine chisel is
knocked in between the parts and t he
paper tears within its t hickness. 0 the
pieces come apart with some paper
sticking to each. This can then be washed
off with hot water. There is nothing very
origi nal abou this. of course. it is an age-
old pattern makers' method of producing
pattern which has eventuall y to be i n
halves. but it is a sound method no nearly
so wel l known as it should be. Fig. 53
shows a light alloy casting b ing faced
right across w ith a flycutter. the casting
bei ng stuck to the t able with sticky tape
and nothing else.
However. the arious exampl es given
throughout the book should serve to show
how t o undertake a really wide range of
jobs. At the risk of seeming repet i tive I
woul d again stress that it is often worth
while to make a jig for holding or locating
the work. j ust to make sure i t can be held
firmly enough without damage in the right
atti tude. The kind of ji gs and fixtures
needed in modell ing seldom involve more
than a few minutes or perhaps an hour to
make. and if this safeguards the compo
Fig. 53 Tape-hel d workpiece being flycut
Fig. 54 Three-face angleplate used to align vee-blocks
79
Fig. 55 Three-face angleplat es used as mai n packi ng
nent , as wel l as t he tool s and machine. it an g l epl at es, wh i ch ar e sent out
is ti me we ll spent. If a dupl icate compo unmachined in lig ht all oy, are in t hree
nent is ever needed t hat wi ll be produced sizes very convenient for use i n home
expedit iously wit hout risk t oo. workshops and can easily be f aced up on
the Myford lat he boring t able or faceplat e.
Angl eplates Fig. 54 shows one of them set across a
A new type of anglepl at e has been mil ler tabl e t o locat e the two vee-block s in
int roduced by Hemingway. This has three which th e work is rest ing. Fig. 55 shows
faces machi ned at 90 degrees to one anot her pai r used as main packings wit h
anothe r. I have found over many years Picador st epped blocks on t op t o give the
that cast - in slot s i n angleplates never last bi t of hei ght adj ust ment for t he cl amp
seem to be in the ri ght place for any j ob, pl at es. So many sizes are availab le by
and it seems bet t er to just dri ll a hole selecting di ffer ent atti tudes of the se blocks
wh ere i t happens to be needed. These tha t they are very usef ul indeed.
CHAPTER 16
Milling Chucks for
Safe Cutter Holding
The newcomer to vert ical milli ng may
wo nder why there shoul d be any need for
special chucks for milli ng cutters, and
especially when he sees t hat these are
fairly expensive accessories. may be
tempted t o make do without one. But first
of all it i s nece ssary to realise th at t he
forces acti ng upon mil li ng cutters in use
are generall y quit e di ff erent from those
act ing on dr il ls i n a dri ll i ng machine or
lat he. The dri ll is usuall y subj ect ed, except
at t he mo ment of compl et e penet ration, to
axial forces only, whi ch press it mo re and
more fi rmly int o t he Morse t aper hole i n
t he spi ndle. Even if it is held in a drill
chuck and has a parall el shank, t he same
t hi ng applies.
But th e mil ling cutt er is subject ed to
t ransverse for ces, across th e axis, and
unless it is screwed on the spi ndle, t hese
forces have a component which i s
pressing against t he i nsi de of t he Morse
tap er hol e, and thereby try ing to cause the
cutter to slide out of the spindle . Each
ti me t he spindle rota tes the pres sure is
transferred to t he opposite side of t he
hol e. and this waggl es t he tool out of t he
spi ndle. So fi rst of all , any tool mounted
by a t aper shank, whet her it is a chuck or a
solid endmill with taper shank, MUST be
provided with a drawbar t hrough the
spindle to stop this ten dency to work out.
For cutt i ng tools which i n operat ion
produce no end forces that precaution is
suff icient. But all the spiral fl uted endmill s
and slot dr i lls do generate end forc es,
tending to screw t hem out of the holding
device. (St rict ly speaki ng t his applies to
cutt ers with ri ght hand rot at ion, li ke a drill,
and ri ght hand f luti ng, also like a drill. But
as it woul d be remarkable for any ot hers,
tho ugh manuf act ured, t o be fou nd in a
home wo rkshop, the ot hers can we ll be
disregar ded.) So spiral flut ed cutt ers will
t ry t o work out of a chuck, if parallel
shanked, and must be forci bly prevented.
It i s not good enough to hold th em i n a
thre e-jaw lat he chuck, especiall y since
most of th ese exert more pr essure at t he
inner end than th e out er, through wear
exi st i ng in t he jaw sli des, in eff ect givi ng
t hem a slight t aper.
This is where the speci all y designed
mill ing chuck comes i nt o its own. There
are two basi c types, but each is arranged
to grip t he cutter fi rmly on it s paral lel
shank by a split coll et clo sed by a screw
thread forcin g t he collet i nto a conical part
of t he chuck. I n addition one typ e uses
cutt ers formed wit h a special shaped end ,
81
80
Fig. 55 Three-face angleplates used as main packing
nent, as well as the tools and machine. it
is time well spent. If a duplicate compo-
nent is ever needed tha t wi ll be produced
expedi t iously without risk t oo.
Angleplatas
A new type of anglepl ate has been
introduced by Hemingway. This has three
faces machined at 90 degrees to one
another. I have found over many years
that cas -in slots i n angleplates never
seem to be In the right place for any job,
and it seems better to just drill a hole
where it happens to be needed. These
80
an gl eplates, whic h are sent out
unmachined in light all oy. are in t hree
sizes very conveni ent for use in home
workshops and can easily be faced up on
the Myford lathe boring table or faceplat e.
Fig. 54 shows one of them set across a
mi ll er tabl e t o locate the two vee-blocks in
which the work is resti ng. Fig. 55 shows
another pai r u ed as mai n packings wit h
Picador stepped blocks on top to give the
last bi t of height adj ust ment for t he clamp
plates. So many sizes are available by
sel ecting different attitudes of these blocks
that they are very useful indeed.
CHAPTER 16
Milling Chucks for
Safe Cutter Holding
The newcom r to verti cal milling may
wonder why there should be any need for
speci al chucks for milling cutt ers, and
especial ly when he sees t hat these are
fairly expensive accessories. may be
tempted to make do without one. But first
of all it i s necessary to realise that the
forces acti ng upon mi ll ing cutters in use
are generall y quite different from those
acting on dri ll s in a dril li ng machine or
lathe. The drill is usually subjected, except
at the moment of complete penet rat ion. to
axi al forces only, which press it more and
more firmly int o t he Morse t aper hole in
t he spindle. Even if it is held in a drill
chuck and has a parallel shank, t he same
t hing applies.
But the mi lling cutter is subjected to
transverse forces, across the axis, and
unl ess it is screwed on the spindle. t hese
forces have a component which is
pressing against the insi de of the Morse
taper hole, and thereby trying to cause the
cutter to slide out of the spindle. Each
time t he spindle rotates the pressure is
t ransferred to the opposite side of the
hol e, nd this waggles the tool out of the
spindle. So first of all, any tool mounted
by a taper shank. whether it is a chuck or a
solid endmill with taper shank, MUST be
provided wit h a drawbar through t he
spi ndle to stop t his ten ency to work out.
For cutting tools which i n operati on
produce no end forces t hat precau ti on is
suffici ent . But all the spi ral fl uted endmills
and slot drills do generate end forces.
tending to screw t hem out of the holding
device. (St ri ctly speaking t his applies to
cutters with ri ght hand rotat ion. l ike a dri ll,
and ri ght hand f luting, also l ike a drill . But
as it woul d be remarkabl e for any ot hers,
though manuf actured, to be fou nd in a
home workshop. the ot hers can well be
disregarded. ) So spi ral fl ut ed cutters will
try to work out of a chuck, if parall el
shanked, and must be forci bly prevented.
It is not good enough to hold them in a
three-jaw lathe chuck, especially since
most of these exert more pressure at t he
inner end than the outer, through wear
existing in the jaw slides, in effect giving
t hem a slight taper.
This is where the specially designed
milling chuck comes i nto its own. Ther
are two basic types, but each is arranged
to grip the cutter firmly on its parall el
shank by a split collet closed by a screw
thread forcing the collet i nto a conical part
of the chuck. In addition one type uses
cutters formed with a special shaped end,
81
Fig. 56 Clare milling chuck
and t he ot her type uses cutt ers wit h a
collet is not only retai ned in the chuck
short screw thread at t he end of t he
body by all int ernal ly screwed cap which
shank. The first of t hese, the Clare, has a
fit s on t he body , but is al so closed on t he
rect angular end for t he cutt er, and this
shank by it. The col let screws i nt o anot her
end is undercut by mil ling. After passi ng it
th read in t he cap, which ensures t hat it
t hrough a rect angular slot in the coll et , t he
loosens when requi red, a small spanner
cutter is t urned t hrough a smai l angle, so
being provided by the makers for t hi s
the part not und ercut overhangs t he end
pur pose. This type of chu ck w ill in fact
of the coll et , and cannot slide out. The
hold cutters whi ch do not have the 'tee'
Fig. 5 7 Clar kson milling chuck Fig. 58 Osborn mill ing chuck
end, and have jus t a plai n rou nd shank, hand wit hout the use of a spanner. There
t hough of cou rse t he security feature is is provision wi t h each of t hese for usi ng
t hen non-exist ent . But f or small cutt ers 't hrow - away' cutters, w hich are made
and light duty it w ill serve very we ll. cheapl y in sizes up to :l- i n. These have a
The ot her type of chuck, made both by plai n shank. unsc rewed, of t in. di ameter
Clarkson and Osborn, uses only a screwed w hate ver the size of the cutt ing portion.
shan k typ e of cutt er and cannot be used
which has a sma ll f lat in one place . They
except wit h t his. Th e screw th read on the
are set in an adaptor w ith a smal l screw at
shank, w hen subjected to the torque
the side, whic h bears on the fl at , and t his
necessary to dr ive the cutter, provides t he
is sufficient to prevent t heir working out of
force t o clos e the collet and thereby gr ip
t he chuck. The idea of these cutt ers is tha t
the t ool shank. A cent re device i nside t he
t hey are made so cheaply t hat in a com
body engag es wit h t he centre dimple i n
mercial engineeri ng shop it wi ll cost more
the end of t he cutt er to reduce fr iction
t o re-sharpen one than to replace it by a
forces that would hamper rot at ion of the
new one. Whet her or not t hat is really t rue
cutter. The Clarkson chuck needs a
will depend on t he par t icular establ ish
spanner, provided wit h th e tool. to release
ment in which t hey are being used, but i n
t he co l let for changi ng cutt ers. The
the home workshop, if the re is a Quam
Osborn e uses a finer t hread on t he
grinder. it will be feasible t o re-sharpen
secur i ng sleeve . t oget her wi t h some lost
them at a wort hwhi le cost in ti me and
mot ion provisions. and can be released by
t roubl e, for a whi le, unti l a cert ai n amount
82 83
Fig. 56 Clare milling chuck
and the other type uses cutters with a
short screw thread at t he end of t he
shank. The first of t hese, the Clare, has a
rectangular end for the cutter, and this
end is undercut by mill ing. Aher passing it
through a rect angular slot in the coll et, the
cutter is t urned t hrough a smal l angle, so
the part not undercut overhangs t he end
of the collet, and cannot sli de out. The
collet is not only retained in the chuck
body by an internal ly screwed cap which
fi ts on t he body. but is also closed on the
shank by it. The coll et screws int o another
thread in the cap, whi ch ensures that it
loosens when required, a small spanner
being provided by the makers for thi s
purpose. This type of chuck will in fact
hol d 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,
t hough of course the security feat ure is
then non-existent . But for small cutters
and light duty it will serve very well.
The other type of chuck, made bot h by
Clarkson and Osborn, uses only a screwed
shank type of cutter and cannot be used
except with thi s. The screw thread on t he
shank, when subjected to the orque
necessary to drive the cutter, provides t he
force to close the collet and thereby grip
the tool shank. A centre device inside the
body engages with t he centre dimple in
the end of t he cutter to reduce frict ion
forces that would hamper rotat ion of the
cutter. The Clarkson chuck needs a
spanner, provided with the tool , to release
the col let for changing cutters. The
Osborne uses a finer thread on t he
securing sleeve. t ogether with some lost
motion provisions, and can be released by
hand withou the use of a spanner. There
is provision with each of these for using
'throw- away' cutters, which are made
cheaply in sizes up to t in. These have a
plain shank, unscrewed, of t in. diameter
whatever the size of the cutting portion,
which has a small flat in one place. They
are set in an adaptor with a small screw at
the si de, which bears on the flat, and this
is sufficient to prevent their working out of
the chuck. The idea of these cutters is that
they are made so cheaply that in a com-
mercial engineering shop it wi ll cost more
to re-sharpen one than to replace it by a
new one. Whet her or not that is reall y true
will depend on t he part i ular establish-
ment in which they are being used, but in
the home workshop. if there is a Quorn
grinder, i t will be feasible to re-sharpen
them at a worthwhi le cost in time and
trouble. for a whil e, until a certain amount
83
of shortening has taken place.
All the cutters with screwed ends to
suit the Clarkson and Osborn chucks have
Whitworth form threads 20 per inch
irrespective of diameter. On t in. shanks
this conforms to B.S.W. and on t in.
shanks to B.S.F. for both of which dies can
be readil y obtained . But fo r other
diameters, if one needs to make a special
cutter in the home workshop. screwing a
shank 20 t hreads per inc h is not a difficult
task. Making the specia l ends for the Clare
cutlers is not quite so easy in my view. but
the Clare chuck has t he advantages of a
short overhang and a small er diamet er of
body, This is part icularly useful when
holding wo rk in a 3 or 4- jaw chuck on a
divi di ng head, when somet imes i t is
difficult to clear the chuck jaws. But al l
these chucks can be fully recommended
as being good precision tools which
provide complete security against cutters
worki ng out in use. If an accident of tha t
kind happens due to not having a security
chuck. a spoi led component is certain, a
broken Culler is possible. and I have seen
t his happen on a numbe r of occasions, So
do be warned, and don' t think the cost of
a proper chuck is too high to face.
Phot ographs of the t hree chucks
mentioned are shown in Figs. 56 , 57 and
58. The Clarkson Autolock chuck shown
here, as we ll as in pict ures in the text , is
f itt ed wit h a damping ring . After t he
chuck is f ixed in t he Morse taper, t his ri ng
can be scr ewed up to cont act t he end of
the machi ne spindle, giving extra support
agai nst vibrati on.
84
of shortening has taken place.
All the cutters with screwed ends to
suit the Clarkson and Osborn chucks have
Whitworth form threads 20 per inch
irrespective of diameter. On t in. shanks
this conforms to B.S.W. and on t in.
shanks to B.S.F. for both of which dies can
be readi ly obtained. But for other
diameters. if one needs to make a special
cutter in the home workshop. screwing a
shank 20 threads per inch is not a difficult
task. Making the special ends for the Clare
cutters is not quite so easy in my view. but
the Clare chuck has the advantages of a
short overhang and a smaller iamet er of
body. This is particularly useful when
holding work i n a 3 or 4-jaw chuck on a
dividing head. when sometimes it is
difficult to cl ear the ch uck Jaws. But all
84
these chucks can be fully recommended
as bei ng good pr cision tools which
provide complete security against cutters
working out in use. If an accident of that
kind happens due to not having a security
chuck. a spoil ed component is certain. a
broken cutter is possible, and I hay seen
t his happen on a number of occasions, So
do be warned, and don' t think the cost of
a proper chuck is too high to face.
Photographs of the three chucks
mentioned are shown in Figs. 56, 57 and
58. The Clarkson Autolock chuck shown
here, as well as in pictures in the text, is
fitted wi th a damping ring, After the
chuck is f ixed in the Morse taper, t hi s ri ng
can be screwed up to cont act the end of
the machine spi ndle, giving extra upport
against vibration.
ARNOLD THROP wa s an apprentice then
an Outside Erector wit h t he famous
engineer s Cole. Marchent & Morley.
Bradford. Yorks. Produc t s: compound
engines to 250 0 hp, Uniflows t o 1500 hp.
Di esel oi l engi nes, condensers for largest
power stations. Lat er he held t echnical
admi nist rat ive po st s i n high- t ensio n
swi tchqear. mi ni ng machin ery. st ainless
fabricat ion. mac hi ne tools, and marking
devices. At hi s ret ireme nt he was th e
Dir ector of Engineering, Edward Pryor &
Son. Sheffield.
He has been an I.Mech.E. in mo unting
seniori ty over 50 years, serving on several
committ ees and one of B.S.1. He has read
papers t o I.Mech.E. and t he Newcomen
Society of whi ch he is a member. He has
worked for half a dozen years as demon
st rator on the Workshop Stand of S.M. E.E.
at Mod el Engi neer Exhi bi t io ns, con
tributed art icles to Model Engineer f rom
1932, and having been i n Sheff ield
S.M.E.E. f rom 1937 has been it s Presi
dent for. some year s.
Founding Dore Engineeri ng i n 19 63 . he
redesigned Edgar Westbury 's vertic al
miller and sold i t as the Dore-West bury
unti l tra nsfer t o Model Engineering
Services in 19 71.
His present interests are stationary
engi nes. wo rkshop equ ipment , gardening
and phot ography.
The author
86
87
86
ARNOLD THROP was an apprentice then
an Outsid Erector with the famous
engi neers Cole, Marchent & Morley,
Bradfo rd, Yorks. Product s: compound
engines to 2500 hp, Uniflows to 1500 hp,
Di sel oil engi nes, condensers for largest
power stations. Later he held technical-
admin istrati ve posts in high-tension
swit hgear, mining machinery, stainless
fabrication, machi ne tools, and marki ng
devices. At his retirement he was the
Director of Engi neering, Edward Pryor &
Son, Sheffield.
He has been an I.Mech.E. in mounting
seniority over 50 years, serving on several
committees and one of B.S.I. He has read
papers 0 I.Mech.E. and the Newcomen
Soci ety of which he is a member. He has
worked for half a dozen years as demon-
strator on the Workshop Stand of S.M.E.E.
at Model Engi neer Exhibi t ions, con-
tributed articl s to Model Engineer from
1932. and having been i n Sheff ield
S.M.E.E. f rom 1937 has been its Presi-
dent for. some years.
Founding Dore Engineering in 1963, he
redesigned Edgar Westbury' s vert ical
mill er and sold it as the Dore-Westbury
unt il transfer to Model Engineering
Services in 1971.
His present interests are stationary
engines, workshop equipment. gardening
and photography.
The author
87
Index
Abwood mil ling attachment
12
Amo lco mi ll i ng atta ch men t and
machi ne
21
A ngleplat es
80
Angleplate used as backst op
27, 29
Arbors for sli tt ing saws and disc cutters
35
As tra milli ng machine
22
Boring operations
45
Bori ng heads
30
Chucks, Clare, Clarkson, Osborn
82
Clutch teeth
55
Connecti ng rods
43
Crosshead slides , engine bedp late
30
Divid ing heads. descr iption an d
principle
54
Plai n typ e. change wheel
indexing
55
Myford worm-geared type
57
Use of division plat es
57
Use of locating blades
57
Packing block for centre height
57
Steady stand for extra rigidity
56
Di viding heads and gear-cutting
62
Plain type
62
Pinion cutt ing
62
Large gear cutti ng
64
Divi ding heads and graduated scale s 71
Plani ng/ slotti ng and rotating too ls 71
Tabl e stop s and li ne length co ntrol 7 1
Cutti ng/engraving cyli ndrical scale 72
Cutt ing/ engraving flat arcuate scale 73
Conical micromet er di als 73
Markin g fig ures of scales right way 73
Dividi ng heads and tool-m aki ng 66
Fluti ng screwing t ap 66
Cutt ing f ine tooth mil li ng cutter 6 7
Cutting large counter sink 69
Specia l di vision pla te. 2 5 hole 70
D-b it fo r hol e cen tri ng to start dri lls 47
Dor e-W est bury mill ing machin e 14
End-roundi ng :
Fil ing coll ars and roll ers 52
Using rotary tab le 52
Fittings for rot ary tabl e 52
Rounding engi ne cranks 52
Direc tion of table rotation 52
Lock ing pre cauti on s f o r ex te rna l
work 53
Engine bedpl ate bearing j aw s 33
Engi ne cyli nder solepla te 30
Evolut ion of ver t ical mi ll er 12
Flut i ng operat ion s. l ocom ot ive rods,
cor rec t f lut e form 4 4
Rods for Briti sh engines 43
Rods for Canadian and Am erican
engines 43
89
88 88
Index
Abwood mi ll ing attachment
Amolco milling attachmen t and
12
machine
Angleplates
Angleplate used as backstop
Arbors for slitting saws and disc cu tters
Astra mil ling machine
Boring operations
Bori ng heads
Chucks. Clare. Cl arkson. Osborn
Clutch teeth
Connecting rods
Crosshead slides. engine bedplate
Dividing heads. descr i ption 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
21
80
27.29
35
22
45
30
82
55
43
30
54
55
57
57
57
57
56
62
62
62
64
Dividing heads and graduated scales
Planing/slotting and rotating tool
Table stops and line length control
Cutti ng/engraving cylindrical scale
Cutti ng/engraving flat arcuate scale
Conical micrometer di als
Marking figures of scales right way
Dividi ng heads and tool - maki ng
Fluti ng screwing tap
Cutting f ine tooth milli ng cutt er
Cutting large countersi nk
Special division plate. 2 5 hole
D- bit for hole centring to start drills
Dore-Westbury mil ling machine
End-rounding:
71
71
71
72
73
73
73
66
66
67
69
70
47
14
Filing collars and rollers 52
Using rot ary table 52
Fittings for rotary table 52
Rounding engine cranks 52
Direction of table rotation 52
Locking precautions for external
work 53
Engine bedplate bearing jaws 33
Engine cylinder soleplate 30
E olution of vertical miller 12
Fluting operations. locomot ive rods.
correct flute form 44
Rods for British engines 43
Rods for Canadian and American
engines 43
89
Flywheel (in hal ves) j oi nt face 3 1
Gear cutt ing 62
Grinder f or engraving cutlers and o
bits 7 1
Identi fication of cutters etc. by mark ing
when made 42
Jig-boring:
Meas uring by t able screws 46
Wri tten recor d of measurem ent s 47
Example of beam for model engine 47
Trip gear lever of model engine
Boiler t ube plates
Avoi dance of back-l ash erro rs
Jigs for milli ng operat ions
Keyways for plain sunk keys:
Endmilling feather keyways on
shahs
Keyways on taper shafts wi th
angleplate
Disc cutter milling of keyways
Locti t ing for permanent assembly
Long components, holding problems
Machi ne specificat ions. table of
Maximat milling attachment
48
48
46
78
plain
37
t ilti ng
38
41
27
38. 49
24
22
Me ntor mi lli ng machine
22
Mill ing cutters. mu lti -toot h:
Early (19t h century) 'fil e-cut' cutters 12
Facemills
30
Endm ills
38
Sli tti ng saws
Disc cutters
3 5
40
Woodruff cutt ers
40
Brown & Sharpe cutters
62
Tap flut i ng cutters
67
Angle cutt ers
69
Milling cutters, single toot h:
Flycutters
Connecti ng rod fl ut i ng cutt er
27
43
Profi led gear tooth cutters
62
Engraving cutters
71
Mill i ng operat ions:
Flat surf aces parallel
to table
32
Flat surfaces square
to table
34
Slitting and cut ti ng
35
Com ponent f l ut ing
43
Tool fluting
End rounding
Gear- cutti ng
67
52
62
Keywaying
39
W oodruff keys and
keyw ays
Bor ing
Jig-boring
38
45
46
9 1
90 90
Flywheel (i n halves) joint face 31
Gear cutting 62
Grinder for engravi ng cutters and D-
bits 7 1
Identi fi cat ion of cutters etc. by marking
when made 42
Jig-boring :
Measuri ng by table screws 46
Written record of measurements 47
Example of beam for model engine 47
Trip gear leverot model engine 48
Boiler tube plates 48
Avoidance of back-lash errors 46
Jigs for milling operati ons 78
Keyways for plain sunk keys :
Endmilling feather keyways on plain
shafts 37
Keyways on taper shafts wi h ti lting
angleplate 38
Disc cutter milling of keyways 41
Loctiting for permanent assembly
Long component s, holding problems
Machi ne specifications, table of
Maximat milling attachment
27
38, 49
24
22
Mentor mi ll i ng machine
Milling cutters, multi -tooth :
Early (19t h century) 'file-cut' cutters
Facemills
Endmills
Slitting saws
Disc cutters
Woodruff cutters
Brown & Sharpe cutters
Tap flut ing cutters
Angle cutters
Milling cutters, singl e tooth:
Flycutters
Connecting rod fluti ng cut ter
Profiled gear tooth cutters
Engraving cutters
Milling operations:
Flat surfaces parallel
to table
Flat surfaces square
to table
Slitting and cutting
Component fluting
Tool fluting
End rounding
Gear-cutting
Keywaying
Woodruff keys and
keyways
Boring
J ig-boring
22
12
30
38
35
40
40
62
67
69
27
43
62
71
32
34
35
43
67
52
62
39
38
45
46
91
Profili ng 49
Engraving 71
Myford-Rodney milli ng attachment and
mach ine 21
Myford collets 62
Myford dividing head 57
Profiling :
Circular arcs 49
Locomot ive frames 49
Smokebox and cyli nder saddl es 49
Pad-bolts 49
Sma l l ar cs der i ved f rom curve of
endmills 51
Quorn grinder for t ool sharpe ning 83
Quorn gri nder , parts of 35 ,71
Rotary tab les 52
Rotary tabl e. M.E.S. 52
Senior milli ng machine 22
Security of mill i ng cutters:
Forces act ing upon drills and cutters 81
Use of drawbars i n machine spindles 81
Positive lock ing of screwed cutters in
chucks 82
Posit ive locking of Tee cutters in
chucks 82
Slitting and cutti ng operations 35
Speeds of mi lling cutters 74
Tapered sections 29
Throw-away' cutte rs 83
Twi n mil li ng machine 22
Vic es. use of two tog ethe r 27
Westbury, Edgar T. 14
Westbury mi ll i ng machi ne 14
Woodruff keys and keyways 38
Work holdi ng for difficult shapes:
Use of chucking pieces lat er
discarded 78
Sticky tape for t hi n art icles 78
Glue and paper for t hin articles 78
Specia lly made jigs for di ff icult
shapes 78
92
93 92
Profiling 49
Engravi ng 71
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 deri ved from curve of
endmills 51
Quorn grinder for tool sharpening
Quorn grinder. parts of
83
35.71
Rotary tables
Rotary table. M.E.S.
Senior milling machine
Security of milling cutters:
Forces acting upon drills and cutters
Use of drawbars i n machine spindles
Positive locking of screwed cutters in
chucks
Positive locking of Tee cutters i n
chucks
Slitting and cutting operations
Speeds of mill ing cutters
52
52
22
81
81
82
82
35
74
Tapered sections
Throw-away' 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 t hin articles
Glue and paper for thin articles
Specially made jigs for difficul t
shapes
29
83
22
27
14
14
38
78
78
78
78
93
",on't let
e" thepressure's on
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WOR HO PRACTICESERIES
3 9525 00 117696 6
1. Hardening. Tempering and 8. heet Meta! Work 15. Workholding in the i.athe
Heat Treatment R.E. Wakeford Tubal Cain
Tubal din
2. vertical Milling in the Homo
9. Soldering and Brazing
Tubal Cain
16 . Electric Motor"
V.1. Cox
Workshop
Arnold Throp
J . Screwcutting in the Lathe
Milflin Cleeve
4. Foundrywork tor the Amateur
B.T. Aspin
5. Milling Operations in the Lathe
Tubal Cai n
6. Measu ring and Ma rking
10. Saws ami SawlI1g
Ian Bradley
1I . Electroplating
I. Poyner
12. onn is ,md Dies
Tubdl Cain
I J . Workshop Drawing
Tubal Cain
17. Gears and Gear Cutting
I. Law
18. B""ic Benchwork
Les Oldridge
19. Spring De'ign and 1\t.mutocture
Tubal ain
20. Mt' t,l/work and Machining
Hint and Tip
Ian Bradley
Ivan LdW
14 . Mak ing mall Workshop
21. Adhes ives and Sea lants
7. The Art of Welding Tools
David Lamm as
W.A. Vause S. Bray
2. Vertical Milling in the Hom Worksho
The increasing appearance of vertic, I mil ling machines in model
engi neers' and other smal l workshops has brought the versati lit y of thi s
type of machine to the notice of a large and growing group of pot ntial
users, but until the fi rst edition of the book was publi shed i n 197 7 there
was little easily avai lable guidance for the average amateur or smal l user.
This third, revi sed edition incl udes descriptions of many of the very wide
range of operations possibl e, wi th photographed examples, plus i nfor
mat ion on machines, acce sories, cutters, chucks, r quirement s and
methods of work-holdi ng.
Arnold Throp enjoyed a long and successful engi ne ring care r
start i ng with very larg steam and oil engi nes and including high tension
switchgear, mining machinery and machine tool s. He has a hi eved over
55 years' membership of the Institute of Mechanical Engineers.
ISBN 0-8 5242-843-X
I I
IIII II1 I
6.50 net UK
9 78 085 2 428 436
WORKSHOP PRACTICE SERIES
11111111
1. I fardenmg, Tempermg and
Heat Treatment
Tubal am
2 Vertical Milling In the Home
Workshop
Arnold Throp
3 rewcutting m the Lathe
Martin Cleeve
4. lor the Amateur
B.T. A pin
5 Milling Operation, In th Ldthe
Tubal Cain
6. dnd Marking Metals
Ivan Law
7 The Art of Welding
W.A Vause
8. heet felal Work
R.E Wakcford
9. Soldering and BraZing
Tubal Cain
1 O. and Sawmg
lan Bradl y
1 I Electroplatmg
J Poyner
12. Drill , T,lP; and Die}
Tubal Cam
1 J . Work hop Drawlnl{
Tubal Cain
14 . Making mall Work,hop
Tool,
S. Bray
3 9525 001 17696 6
15. Workholding In the Ldthe
Tuboll Cam
16 flectric MOlOrs
V.1. Cox
1 7 Gears and Gear Cutting
I. Law
18 BiHI< Bench work
Le .. Oldridge
19 prmg De"sn dnd \1dnutacture
Tubal aln
20. Metalwork and Machlnmg
Hmt dnd TIp;
lan Bradley
21 . Adhesive and Sealants
Davld Lammas
2. Verti cal Milling in the Horn Workshop
The increasing appearanc of vertic I mil ling machines in model
engineers' and other small work hops ha brought the ver atil ity of this
type of machine to the notice of large and growing group of p t ntial
users, but until the first edition of the book wa published i n 1977 there
wa little easily available guidanc for the average amat ur or small user.
This third, revis d edition incl udes description of many of the v ry wide
range of operation possible, wi th photographed examples, piu infor-
mation on machines, acc ori ,cutter, hucks, r quirem nts and
methods of work-holding.
Arnold Throp enjoyed a long and successful ngine ring care r
starting with very large steam and oil engines and including high ten ion
swit hgear, mining machinery and machine tools. He has a hieved over
55 years' member hip of the Institute of Me hanical Engineer.
ISBN 0-85242-843-X
6.50 net UK