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02 – Vertical Milling in the Home Workshop
ماكينة التفريز الرأسية في الورش المنزلية
من سلسلة
Workshop Practices Series
Arnold Throp
C.Eng., F.I.Mech.E.
CONTENTS
Chapter One
Chapter Tw o
Chapter Three
Chapte r Four
Chapter Five
EVOLUTION OF THE VERTICAL MILLER 12
Early history of indu strial machines: milling in the
early sma ll lathes: milling attachments for lat hes
circa 19 20s: E.T, W estbury’s experimental machine
1964: the Dare-Westbury machine 1968: curre ntly
avail able sma ll machines and attachments,
MILLING FLAT SURFACES 27
Surfaces parallel to table: simple fixed-radius
f1 ycutt ers: var iab le-radius bor ing head flycutting:
multiple -tooth face mills: work holding: multip lepass mi lling: surfaces square w it h table : using side
of endmill.
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
Endmilling round ended ‘feath er’ keyways : keyways
on taper shafts: use of disc tvoe cutters for plain
sunken keyways : \Noodru ff keyways: making
Woodruff cutters in the home workshop : table of
suggested sizes of \N oodruff keys and kevvvavs fo r
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 ting: parallel flutes: taper flutes: preferred type of
cutting too l.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 IG- BORING’ 46
Using the miller as a measuring machine : drilling
holes at one setting of work and precise cent res:
engine beam: back-lash precautions: tri p gear component : mu lti-ho le boiler plates.
PROFILING 49
Curves on parts too large for lathe: loco frames :
smokebox castings : machine pad bolts: loco con
nec ting rod s and coupling rod s.
END-ROUNDING 52
Use of hardened f ilin g 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 inte rnal surfaces.
DIVIDING HEADS 54
Simple ungeared dividing heads : using change
w hee ls as index plates: examples of dividing w ork :
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 IN G 62
Limitations to strai ght spu r gears: sim ple head :
M yford worm -geared head: tooth cutting on
integral pi nion : use of home made Ilvcutters:
Brown & Sharpe disc type cutters: selectio n of
cutter to suit numb er of teet h: cutting a large
coa rse tooth gear: anti-slip back-up devices ,
Chapt er Tw elve
Chapter Thirt een
Chapter Fourt een
Chapter Fifteen
Chapter Sixteen
DIVI DING HEADS AND TOOL MAK ING 66
Fluting taps : example 5-flute Acme tap: producing
a small fine tooth milling cutter w ith ball end : use
of table stop blocks: combination of rotary tabl e
with ma in table movement: large 60 deg ree countersink fluting .
DIVIDING HEADS AND GRAD UATED
SCALES 71
Cutti ng graduation marks: use of rotary ‘engraving’
cutters : use of non-r otating plani ng type tools : use
of table stops to control line lengths: graduating
cyli ndr ical scales: gradua ting flat angular scales :
checking correct way of figuring when stamping
scales ,
CUTTER SPE EDS FOR VERTICAL MILLERS 74
Speeds affect ti me occupied on job: speeds too
high may cause excessive cutter wear and chatter:
rigidity of work, cutter and mac hine inferior as a
rule to indust rial condi tions, dry cutting instead of
lubricated: Table III gives speeds for cutters in
different kinds of tasks: machine speeds may not
alwa ys be suitable.
WORK -HOLDING WITH D IFFICULT
SHAPES 78
Comparison with full scale engi neering : use of
chucking pieces on components : thin components
and use of adhesives: advisability of making fixtures
fo r difficul t pieces : three-sided angleplates.
CHUCKS FOR MILLING CUTTERS 81
Never use taper shank tools or chucks without
drawbar: chucks for screw ed 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 withou t
locking features : ph ilosophy of ‘throw – aw ay’
cutters.
List of Illustrations
Fig.
1 Ab w ood mi llin g attac hment of the 1920s
13
2 E. T. W estb ury ‘s mill ing machine 14
3 Dore-W estbury machine 15
4 Dare-W estbury M k II machine 16
5 Rodney attachm ent 17
6 Rodney machin e 18
7 Am olco attach men t 19
8 Amol co machine 20
9 M ent or mach ine 2 1
10 M aximat attachment 23
1 1 Astra mach ine 2
12 Tw in machi ne 22
13 Senior machine 26
14 Set of three flycutt ers 2 8
15 Flycutt ing a bracket 28
16 Flycutting connecting rod ends 29
17 Flycutting tapered bar mat erial 29
18 Flycutting cy linde r soleplate 30
19 Facem ill
3
20 M illing flywheel joint face 31
21 Mi lling crosshe ad slide 32
22 M illing bear ing jaw s in bedpl ate 33
23 Slitting boss of casting 35
4 Milling feath er kevw av 3 7
25 M illing feath er keyway on tap ered shaft 38
26 Mil ling keyway with slitting saw 39
27 Set of four Woodruff keyway cutters 39
28 M ill ing W oodruff kevwav 4 1
29 Fluting locomo tive connecting rod 4 4
30 Draw ing of steam hook (lever) 4 7
3 1 Photograph of steam hook 48
32 Profiling pad bolt 50
33 Profiling coupling rods 50
34 End-rounding wi th rotary tabl e 53
35 Cutting teeth in dog clutch par t 5 5
36 Draw ing of steady stand for Myford div iding head 56
37 Steady in use on a gear cutti ng opera tic 58
38 Thro p divid ing head 58
39 Thom as versatile divid ing head 59
40 Kibbey/M .E.S. dividlnq head 60
4 1 Close-up of flycutter and pinion 63
4 2 Gearcutt ing w ith Brown & Sharpe cutter 63
4 3 Fly cutt ing 10 d.p, gearwh eel. front view 64
44 Flycutt ing 10 d.p. gearw hee l. rear view 6 5
45 Flut ing A cm e thread tap 66
46 Cutt ing teeth of ball-end cutt er 67
47 Close-up of ball-end cu tte r 68
48 Gashin g flutes in large countersinking tool 69
49 Rear view showing steady stand in use 70
50 Cylindrical machine component being grad uated 72
5 1 Close -up of prev ious operat ion 72
52 Graduating part -ci rcul ar arcua te scal e on fl at surfa ce 73
53 Tape -held workpiece being flyc ut 79
54 Hern inpwav three-sided anglep late 79
55 Tw o of the three sizes of Herninqwav angleplates 80
56 Clare milling chuck 82
57 Clarkson mi lling chuck 82
58 Osborn milling chuck k 83
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