Monday, December 27, 2010
Sunday, December 12, 2010
Saturday, June 26, 2010
Miiling Cutter RPM Table
You can download it here
1. Choose a Material to be converted to DIN Standart
2. Choose a cutting Speed By Material
3. Choose rpm and feedrate by Cutting Speed and Cutter were used,
a. EMC-F
b. EMC-R
c. EMC two or three Lips
d. SEMC-F
e. SEMC-R
f. Disc Cutter
Wednesday, May 26, 2010
Spherical Turning Tool
2. This is Spherical tool With Cheap Boring head
Reference by : Reed M. Streifthau
You can download tutorial here
Wednesday, April 14, 2010
Machine taper
Morse
The Morse Taper was invented by Stephen A. Morse (also the inventor of the twist drill) in the mid-1860s.[1] Since then it has evolved to encompass smaller and larger sizes and has been adopted as a standard by numerous organizations, including the International Organization for Standardization (ISO) as ISO 296 and the German Institute for Standardization (DIN) as DIN 228-1.
Sizes
Morse Tapers come in eight sizes identified by number between 0 and 7. Often this is abbreviated as MT followed by a digit, for example a Morse taper number 4 would be MT4. The MT2 taper is the size most often found in drill presses up to 1/2" capacity.
End types
Morse tapers can have three types of ends:
- tang (illustrated) to facilitate removal with a drift
- threaded to be held in place with a drawbar
- flat (no tang or threaded section)
The taper itself is roughly 5/8" per foot, but exact ratios and dimensions for the various sizes of tang type tapers are given below.
Dimensions
Morse Taper number | Taper | A | B (max) | C (max) | D (max) | E (max) | F | G | H | J | K |
---|---|---|---|---|---|---|---|---|---|---|---|
0 | 19.212:1 | 9.045 | 56.5 | 59.5 | 10.5 | 6 | 4 | 1 | 3 | 3.9 | 1° 29' 27" |
1 | 20.047:1 | 12.065 | 62 | 65.5 | 13.5 | 8.7 | 5 | 1.2 | 3.5 | 5.2 | 1° 25' 43" |
2 | 20.020:1 | 17.780 | 75 | 80 | 16 | 13.5 | 6 | 1.6 | 5 | 6.3 | 1° 25' 50" |
3 | 19.922:1 | 23.825 | 94 | 99 | 20 | 18.5 | 7 | 2 | 5 | 7.9 | 1° 26' 16" |
4 | 19.254:1 | 31.267 | 117.5 | 124 | 24 | 24.5 | 8 | 2.5 | 6.5 | 11.9 | 1° 29' 15" |
5 | 19.002:1 | 44.399 | 149.5 | 156 | 29 | 35.7 | 10 | 3 | 6.5 | 15.9 | 1° 30' 26" |
6 | 19.180:1 | 63.348 | 210 | 218 | 40 | 51 | 13 | 4 | 8 | 19 | 1° 29' 36" |
7 | 19.231:1 | 83.058 | 285.75 | 294.1 | 34.9 | - | - | 19.05 | - | 19 | 1° 29' 22" |
Brown & Sharpe
Brown & Sharpe tapers, standardized by the eponymous company, are an alternative to the more-commonly seen Morse taper. Like the Morse, these have a series of sizes, from 1 to 18, with 7, 9 and 11 being the most common. Actual taper on these is within a close range of .500" per foot.
Size | Lg. Dia. | Sm. Dia. | Length | Taper/Ft |
---|---|---|---|---|
1 | 0.2392 | 0.2000 | 0.94 | 0.5020 |
2 | 0.2997 | 0.2500 | 1.19 | 0.5020 |
3 | 0.3753 | 0.3125 | 1.50 | 0.5020 |
4 | 0.4207 | 0.3500 | 1.69 | 0.5024 |
5 | 0.5388 | 0.4500 | 2.13 | 0.5016 |
6 | 0.5996 | 0.5000 | 2.38 | 0.5033 |
7 | 0.7201 | 0.6000 | 2.88 | 0.5010 |
8 | 0.8987 | 0.7500 | 3.56 | 0.5010 |
9 | 1.0775 | 0.9001 | 4.25 | 0.5009 |
10 | 1.2597 | 1.0447 | 5.00 | 0.5161 |
11 | 1.4978 | 1.2500 | 5.94 | 0.5010 |
12 | 1.7968 | 1.5001 | 7.13 | 0.4997 |
13 | 2.0731 | 1.7501 | 7.75 | 0.5002 |
14 | 2.3438 | 2.0000 | 8.25 | 05000 |
15 | 2.6146 | 2.2500 | 8.75 | 0.5000 |
16 | 2.8854 | 2.5000 | 9.25 | 0.5000 |
17 | 3.1563 | 2.7500 | 9.75 | 0.5000 |
18 | 3.4271 | 3.0000 | 10.25 | 0.5000 |
R8
This taper was designed by Bridgeport Machines, Inc. for use in their milling machines. It is used with a drawbar extending up through the spindle to the top of the machine to prevent the collet from falling from the spindle when lateral forces are encountered. The collet, which is inserted into the taper, has a precision hole in one end for holding a cutting tool and is threaded for a drawbar on other end. They are also keyed (see image) to prevent rotation during insertion and removal. However, cutting torques are transferred through friction at the taper, not through the key. The drawbar thread is typically 7/16"-20tpi (UNF).
The cutting tool is placed in the collet, the collet placed into the taper, and the drawbar is tightened into the top of the collet from above the spindle. The collet has a groove to engage a key in the spindle to keep the collet from spinning inside the taper and to aid in the installation and removal of the collet. The angle of the cone is typically 16 degrees and 51 minutes (i.e. 16.85 degrees) with an OD of 1.25" (source, Bridgeport Manufacturer).
Jacobs
The Jacobs Taper (abbreviated JT) is commonly used to secure drill press chucks to an arbor.
Taper | Small End | Big End | Length | |||
---|---|---|---|---|---|---|
mm | inch | mm | inch | mm | inch | |
0 | 5.80 | 0.2284 | 6.35 | 0.2500 | 11.11 | 0.4375 |
1 | 8.47 | 0.3334 | 9.75 | 0.3840 | 16.67 | 0.6563 |
2 | 12.39 | 0.4876 | 14.20 | 0.5590 | 22.23 | 0.8750 |
2 Short | 12.39 | 0.4876 | 13.94 | 0.5488 | 19.05 | 0.7500 |
2 1/2 | 15.88 | 0.625 | 17.20 | 0.677 | 26.80 | 1.055 |
3 | 18.95 | 0.7461 | 20.60 | 0.8110 | 30.96 | 1.2188 |
4 | 26.34 | 1.0372 | 28.55 | 1.1240 | 42.07 | 1.6563 |
5 | 33.43 | 1.3161 | 35.89 | 1.4130 | 47.63 | 1.8750 |
6 | 15.85 | 0.6241 | 17.17 | 0.6760 | 25.40 | 1.0000 |
33 | 14.23 | 0.5604 | 15.85 | 0.6240 | 25.40 | 1.0000 |
Jarno
Jarno tapers range from a Number 2 to a Number 20. The diameter of the big end in inches is always the taper size divided by 8, the small end is always the taper size divided by 10 and the length is the taper size divided by 2. For example a Jarno #7 measures 0.875" (7/8) across the big end. The small end measures 0.700" (7/10) and the length is 3.5" (7/2).
The system was invented by Oscar J. Beale of Brown & Sharpe.
[NMTB Tapers
The National Machine Tool Builders Association (now called the Association for Manufacturing Technology) in the USA laid down standards for machine tool design, among other things: the taper used on CNC (Computer Numerically Controlled) milling machines.
The taper is variously referred to as NMTB, NMT or NT. Essentially this defines a taper of 3.500 inches per foot or 16.7112 degrees. All NMTB Tooling has this taper but the tooling comes in different sizes. NMTB-25, 30, 35, 40, 45, 50 and 60. With the 40 taper being the most common by far.
CAT and BT tooling use this same taper.
The goal of the taper is to allow a quick and easy change between different tools (either automatically or by hand) and still keep it tight and centered while using it. The spindle on the machine tool is built with a female taper and drawbar. Each individual tool must be fitted with a male taper and the proper adapter for the drawbar.
From http://wikipedia.com/
Tuesday, April 13, 2010
Tap and Dies / Tap dan Sney
Tap
- Bottoming tap or plug tap:The tap illustrated in the top of the image has a continuous cutting edge with almost no taper — between 1 and 1.5 threads of taper is typical.This feature enables a bottoming tap to cut threads to the bottom of a blind hole. A bottoming tap is usually used to cut threads in a hole that has already been partially threaded using one of the more tapered types of tap; the tapered end ("tap chamfer") of a bottoming tap is too short to successfully start into an unthreaded hole. In the US they are commonly known as bottoming taps, but in Australia and Britain they are also known as plug taps.
- Intermediate tap, second tap, or plug tap: The tap illustrated in the middle of the image has tapered cutting edges, which assist in aligning and starting the tap into an untapped hole. The number of tapered threads typically ranges from 3 to 5. Plug taps are the most commonly used type of tap. In the US they are commonly known as plug taps, whereas in Australia and Britain they are commonly known as second taps.
- Taper tap: The small tap illustrated at the bottom of the image is similar to a plug tap but has a more pronounced taper to the cutting edges. This feature gives the taper tap a very gradual cutting action that is less aggressive than that of the plug tap. The number of tapered threads typically ranges from 8 to 10. A taper tap is most often used when the material to be tapped is difficult to work (e.g., alloy steel) or the tap is of a very small diameter and thus prone to breakage.
The most common type of power driven tap is the "spiral point" plug tap (also referred to as a "gun tap"), whose cutting edges are angularly displaced relative to the tap centerline. This feature causes the tap to continuously break the chip and eject it into the flutes, preventing crowding. Another version of the spiral point plug tap is the spiral flute tap, whose flutes resemble those of a twist drill. Spiral flute taps are widely used in high speed, automatic tapping operations due to their ability to work well in blind holes.
Whether manual or automatic, the processing of tapping begins with forming and slightly countersinking a hole (usually by drilling) with a diameter slightly smaller than the tap's major diameter. The correct hole diameter may be determined by consulting a drill and tap size chart, a standard reference item found in many machine shops. If the hole is to be drilled, the proper diameter is called the tap drill size.
In lieu of a tap drill chart, it is possible with inch sized taps to compute the correct tap drill diameter as follows:
where TD is the tap drill size, MD is the major diameter of the tap (e.g., ⅜ inch for a ⅜"-16 tap), and N is the number of threads per inch (16 in the case of a ⅜"-16 tap). For a ⅜"-16 tap, the above formula would produce 5⁄16 as a result, which is the correct tap drill diameter for a ⅜"-16 tap. The result produces a tap drill size that results in an approximate 75 percent thread (recommended for most applications).
With soft or average hardness materials, such as plastic, aluminum or carbon steel, the common practice is to use a plug tap to cut the threads. If the threads are to extend to the bottom of a blind hole, the plug tap will be used to cut threads until the point of the tap reaches bottom, after which a bottoming tap will be used to finish the hole. Frequent ejection of the chips must be made in such an operation to avoid jamming and possibly breaking the tap.
With hard materials, the machinist may start with a taper tap, whose less severe diameter transition reduces the amount of torque required to cut the threads. If threads are to be cut to the bottom of a blind hole, the taper tap will be followed by an intermediate (plug) tap and then a bottoming tap to finish the operation.
In metal working, the use of a tap lubricant is essential to achieve cleanly formed threads and to minimize friction. Failure to use the correct lubricant may result in ragged threads, as well as a substantial increase in the amount of torque required to turn the tap, possibly resulting in breakage.
Machine tapping
Tapping is essentially the internal threading of a hole. This may either be achieved by hand tapping by using a set of taps first tap, second tap & final (finish) tap or using a machine to do the tapping, such as a lathe, radial drilling machine, bench type drill machine, pillar type drill machine, vertical milling machines, HMCs, VMCs. Machine tapping is faster, and generally more accurate because human error is eliminated. Final tapping is achieved with single tap.Although in general machine tapping is more accurate, tappin
g operations have traditionally been very tricky to execute due to frequent tap breakage and inconsistent quality of tapping.
Research has shown that the important reasons causing tap breakage are as follows:
- Tap-related problems:
- Wearing of tap cannot be easily quantified (use of worn-out taps)
- Use of tap with improper tap geometry for a particular application.
- Use of non-standard or inferior quality taps.
- Clogging with chips
- Tapping does not follow the pre-tap hole (misalignment)
- Mismatch of machine feed and tap feed may cause the tap to break in tension or compression.
- Use of improper cutting fluid or not enough fluid.
- No safety mechanism to limit torque below torque breakage value of tap.
- Improper or zero float for use with screw machines (recommended feed .1 slower to establish float for 40 tpi or higher and .15 slower for 40 tpi or finer )
- Improper spindle speed
These are usually classified as conventional tool holders and CNC tool holders. Addressed in detail in section below.
Precautions to be taken while tapping
- The tap should be made of a material that is suitable for machine tapping. The high-carbon steel used in hand tools is most likely too brittle; high speed steel (HSS) is preferable for virtually all workpiece materials.
- Proper cutting compound or coolant should be used during tapping.
- Spindle or tap is turning in the correct direction.
- Tap is lined up to the hole.
Tool holders for tapping operations
Various tool holders may be used for tapping depending on the requirements of the user:Aids for hand-tapping (simple jigs and fixtures)
The biggest problem with simple hand-tapping is accurately aligning the tap with the hole so that they are coaxial—in other words, going in straight instead of on an angle. The operator must get this alignment rather close to ideal in order to (a) produce good threads and (b) avoid tap breakage. The deeper the depth of thread, the more pronounced the effect of the angular error becomes. With a depth of 1 or 2 diameters, it matters little. With depths beyond 2 diameters, the error becomes too pronounced to ignore. Another fact about this alignment task is that the first thread or two that is cut establishes the direction that the rest of the threads will follow. In other words, you can't make corrections to the angle once you have cut the first thread or two.To help with this alignment task, several kinds of jigs and fixtures can be used to provide the correct geometry (i.e., accurate coaxiality with the hole) without having to use freehand skill to approximate it:
- Hand-tapper: A simple fixture analogous to an arbor press in its basic shape (photo here). Its spindle is thus held accurately perpendicular to the work. Standard taps are held in the spindle, and the operator turns the spindle manually via a handlebar. This fixture obviates the need for the operator to carefully and skillfully approximate perpendicularity, which even for a skilled operator can easily result in a 2°-5° error.
- Tapping guide, or "tap and reamer aligner/holder", a simple conical guide slipped over a tap when using a regular tap handle. As with a hand-tapper, the basic principle is simply that of a jig or fixture to provide the correct alignment.
Heads for machine tool spindles
- Tapping attachments: these may be normal (available in a range of tap sizes) or quick-change
- Quick-change drilling & tapping chucks (variations available for both CNC & manual-control tools)
- Rigid tapping attachments (for CNC)
- Twin chucking: tap is held both, on diameter as well as on the square thus giving it positive drive.
- Safety clutch: The built in safety mechanism, operates as soon as the set torque limit is crossed & save the tap from breakage.
- Float radial parallel: small misalignments are taken care of by this float.
- Length compensation: built in length compensation takes care of small push or pull to the spindle or feed difference.
Tapping stations
- Tapping stations are worktables with a tapping head attached to the end of a pantograph-style arm similar to that of a balanced-arm lamp. The operator guides the tapping head to each (already-drilled) hole and quickly taps it.
- Drilling and tapping centers, whose name sounds similar to that of tapping stations, are actually light-duty, affordable machining centers of 2, 2.5, or 3 axes that are designed for a life of mainly drilling and tapping with limited milling use.
Die
eates a male threaded piece which functions like a bolt. The dies shown are
- top left: an older split die, with top adjusting screw
- bottom left: a one piece die with top adjusting screw
- center: a one piece die with side adjusting screw (barely visible on the full image)
- right: two dies without adjusting screws
The adjusting screws allow the die to be compressed or expanded to accommodate slight variations in size, due to material, manufacture, or die sharpness. The two rightmost dies shown in the image have no adjusting screws. However the die holder can exert pressure and decrea
se the size if required.
Each tool is used independently, but are usually sold in paired sets of both types, one die and three taps. Some sets may provide a lesser number of taps. The common sets shown are designed for hand operation, but different types such as helical or spiral may be used in production tools such as CNC machining tools, which employ die heads to make large volumes of threaded parts.
Tap drill bit size table
Pipe
Threaded pipe is often used in plumbing and pneumatic applications. Because pipe joints must form a seal, the threaded portion is slightly conical rather than cylindrical. As a result, threaded pipe requires specialized taps and dies. Conventional pipe threads must be assembled with a jointing compound or use PTFE tape in order to achieve a leak proof seal.A modified form of the basic pipe thread shape is the Dry-Seal thread. The Dry-Seal thread is formed so that during assembly, the tips of the male threads are slightly crushed into the roots of the female threads, effecting, in theory, a liquid-tight fit. In practice, a small amount of pipe dope is usually necessary to assure a pressure-tight seal, and to prevent galling of the mating parts.
BSP (British Standard Pipe) parallel threads are available in sizes 1/8, 1/4, 3/8, 1/2, 5/8, 3/4, 1 inch and over. Above 6 inch welding is usually done. They are also available in Tapered thread-form and called BSPT (British Standard Pipe Tapered) for British pipe sizes. Currently UK BSP male threads are tapered and the female is parallel.
North American equivalents to BSPT are called NPT (National Pipe Tapered), and range from 1/16 inch through large integral sizes. Although BSPT and NPT are functionally identical, they are not mechanically interchangeable.
Thread classes and callouts
The Unified and American National Threads callout for a thread is usually shown as follows: 4-40UNF-2A or 1/4"-20UNC-2BWhere (A) - (B) (C) - (D) (E) mean the following:
A: major diameter of the thread in inches (or No. size)
B: threads per inch
C: Unified Nation Coarse(UNC) or Unified Nation Fine(UNF)
D: class of fit. 1 for loose tolerance. 2 for general purpose. 3 for tight tolerance
E: external or internal threads - A for external - B for internal
Metric threads are usually called out as follows: M5X0.8-6g
Where M (A) X (B) - (C) (D) mean the following:
M: ISO metric thread
A: nominal major diameter in millimeters
B: thread pitch in millimeters (distance from crest to crest on thread)
C: tolerance from 3 to 9. 3 being fine. 9 being coarse.
D: thread class as E,G or H. E being large allowance. G being tight allowance. H being no allowance. External threads are shown as lower-case e,g,or h. Internal threads are shown as upper-case E,G,or H.
Lubricants
The use of a suitable lubricant is essential with most tapping and reaming operations. Recommended lubricants for some common materials are as follows:- Carbon steel
- Petroleum-based or synthetic cutting oil.
- Alloy steel
- Petroleum-based cutting oil mixed with a small amount (approximately 10%) of kerosene or mineral spirits. This mixture is also suitable for use with stainless steel.
- Cast iron
- No lubricant. An air blast should be used to clear chips.
- Aluminum
- Kerosene or mineral spirits mixed with a small amount (15-25%) of petroleum-based cutting oil. WD-40 and 3-In-One Oil are acceptable substitutes in some cases.
- Brass
- Kerosene or mineral spirits.
- Bronze
- Kerosene or mineral spirits mixed with a small amount (10-15%) of petroleum-based cutting oil.
Wednesday, March 24, 2010
History Of Lathe
History Of The Lathe
In its simplest form - a form which is still employed by the natives of India - the lathe consists of two upright posts, each carrying a fixed pin or dead centre, between which the stock to be turned is made to revolve by an assistant, who pulls alternately the two ends of a cord passed around it. A cutting tool is held firmly in a bar which forms a "rest"; this attacks in succession the projecting parts, and in this way the entire surface is brought to an equal distance from the central axis. In other words, the cross section becomes somewhat circular.
In its rudest form this sort of a lathe consists only of two stakes driven into the ground, through which sharpened nails are driven to support the work. The stock is revolved, as in the first case, by means of a cord in the hands of an assistant.
The first illustration of anything in the shape of a turning lathe was published in a German work in 1568, the picture showing a man at work turning a sphere. The lathe shown is of the most primitive kind, yet the picture shows a number of turned articles, such as tops, vases, balusters, spin-dles, etc., giving evidence of the practical results obtained by its use.
The turner stands with his back against a rail, a custom that is practiced to this day in some parts of Austria and Hungary, where the finest of children's toys are made, equal in many respects to the famous wooden ware of Tunbridge Wells. The manner by which this lathe is driven is not very clear, but from all indications it is probably driven by a pole, as there appears to be one with one of its ends inserted in the wall at the back of the lathe. The stock to be turned was rotated by means of a cord, which was wound around the work two or three times, having one end attached to an elastic pole, and the other formed like a stirrup, into which the foot of the workman was inserted.
When the foot was forced downwards the work would be rotated in the direction of the cutting tool, and the end of the pole bent downwards toward the work. When the foot reached the floor the work would cease to revolve, and the turner was compelled to draw the cutting tool back while the foot was raised, the spring in the pole drawing the stirrup up, thus causing the work in the lathe to rotate in the opposite direction.
When the pole recovered its straight form the operation would be repeated and continued until the job was completed. By this method the stock in the lathe rotated alternately, first in one direction and then in the other, and the operator was compelled to withdraw the cutting tool at every change of motion, - something that must have severely taxed his patience and skill.
Fig. 1,
Fig. 1 shows a "dead-centre lathe" of the kind used in Europe during the eighteenth century, in which the centres are carried by " poppets," which can be adjusted to suit the length of the work, the turner giving the rotation by means of a treadle and spring lath attached to the ceiling. This lath, having immortalized itself by giving its name to the " lathe," has now almost entirely disappeared, the waste of time in its upward stroke (during which time the work revolves in the wrong direction) being a fatal objection to its use in an age in which economy in that respect is of such importance. Dead centre lathes themselves are now almost things of the past, though within their own limits, - which are of course confined to such articles as are turned on the outside only, and can be supported at the ends, - they offer a steadiness of support and a freedom of rotation which others seldom equal and never surpass. The system, however, still survives in the small lathes, or "throws," used by watch and clock makers; and for their purposes it is not likely to be superseded.
Another method of operating the early lathe was by the aid of a bow. This instrument generally had several strings to it, which were fastened to a sort of roller or pulley at their middle point. This roller had a cord attached to it which was wound several times around the material to be turned and, extending down, was fastened to a treadle under the lathe, similar to that shown in Fig. 1.
The bow was an improvement on the pole, as it equalized the force and was not so hard on the operator. The power was more uniform, enabling him to work with greater accuracy on the most delicate jobs. The bow was so constructed that it could be attached to the frame of the lathe, to the ceiling, or to the side wall, as might be most convenient.
Travellers tell us that this kind of lathe is still in use in many parts of India and China, where the itinerant mechanics carry with them their tools, including one of these lathes, and do a job of turning wherever their services may be required. It is stated that their skill in turning with the aid of this rude machine is something marvelous.
It seems to have taken a long time to develop this "treadle-lathe" into the "foot-lathe," the application to it of a fly-wheel worked by a crank and treadle having been exceptional rather than usual even in the early part of the last century, though a separate fly-wheel turned by an assistant had long previously been employed, and must have made possible the turning of heavy work which could not have been attempted without it.
The early attempts at modifying the dead-centre lathes so that articles, such as bowls, vases, and the like, could be turned without the support of what was then called the "back-centre," (corresponding to what we now call the tail-centre or dead-centre) were not very encouraging. A spin-dle or mandrel was after a time introduced, carrying a pulley for the lathe belt and having a rude form of screw thread at one end so that the work could be attached to it. This of course gave a rude sort of "head-stock" resembling Fig. 2. Unfortunately however the discarding of the dead-centre point and the substitution of a front bearing, - a step which was necessary in order to free the end of the spindle, and so enabling it to carry the work, - must have been accompanied by a loss of power and an amount of unsteadiness which quite account for the tenacity with which the simple bow-lathe and the very similar "spring-bow lathe" survived.
Fig. 2.
A careful study of the history of the lathe as given here shows us that the principal features essential to all lathes are, 1st., an axis of revolution for the material being operated on, and 2nd, some means for supporting and guiding the cutting-tool.