Fig. 975Fig. 975.
Fig. 975.
Fig. 975represents a front tool for brass, which is used for carrying cuts along outside work or for facing purposes, corresponding, so far as its use is concerned, to the diamond point or front tool for iron. The top face of this tool must in no case be given rake of any kind, as that would cause it to tear rather than to cut the metal, and also to chatter. The pointashould be slightly rounded and the width atband depth atcmust be regulated to suit the depth of cut taken, the rule being that slightness in either of these directions causes the tool to chatter. When held far out from the tool post or under other conditions in which the tool cannot be rigidly held, the top face should be ground away towards the end, thus depressing the pointa, after the manner shown with reference to the cutting-off tool for brass inFig. 963. The manner in which the cuttings come off brass work when a front tool is used, depends upon the hardness of the brass and the speed at which the tool cuts.
Fig. 976Fig. 976.
Fig. 976.
In the harder kinds of brass, such as that termed gun metal, composition, or bell metal, the cuttings will fly off the tool in short angular grains, such as indicated inFig. 976, travelling a yard or two after leaving the tool if a fairly quick cutting speed is used. But if the cutting speed is too slow the cuttings will come off slowly and fly but a few inches. In the softer kinds of brass, such as yellow brass, the cuttings are longer and inclined to form short curls, which will, if cut at a high speed, fly a few inches only after leaving the tool.
Fig. 977Fig. 977.
Fig. 977.
InFig. 977is shown a right-hand side tool for brass work. It is used to carry cuts along short work, and to carry facing cuts at the same time, thus avoiding the necessity to move the position of the tool to enable it to carry a facing cut, as would be necessary if a front tool for brass were used. It is peculiarly adapted, therefore, for brass bolts, or other short work having a head or collar to be faced especially; hence, it may be traversed to its cut in either direction without requiring to be moved in the tool post. It may also be used to advantage for boring purposes. It will be found that this tool will cut smoother and will be less liable to chatter if its top face is ground slightly down towards the point and if it be not forged too slight either in depth or acrossb. Its clearance on the side is given by forging it to the diamond shape shown in the sectional view. To make the tool a left-handed one it must be bent to the right, the clearance being in any case on the inside of the curve.
Fig. 978Fig. 978.
Fig. 978.
Fig. 979Fig. 979.
Fig. 979.
The forms of single-pointed slide rest tools employed to cutV-threads in the lathe are shown inFig. 978, which represents a tool for external, andFig. 979, which represents one for an internalV-thread, the latter being a tool ground to accurate shape and secured in a holder by the set screws.
Fig. 980Fig. 980.
Fig. 980.
Fig. 981Fig. 981.
Fig. 981.
Fig. 982Fig. 982.
Fig. 982.
It is obvious that a Whitworth thread might be cut with a single-pointed tool such as shown inFig. 980, the corner atbbeing rounded to cut the rounded tops of the thread. It is more usual, however, to employ a chaser set in the tool point in the same manner as a single-pointed tool, or in a holder fixed in the tool post. When a single-pointed tool is employed to cut a thread, the angles of its sides are not the same as the angle of the thread it produces, which occurs because the tool must have clearance to enable it to cut. InFig. 981, for example, is a single-pointedtool without any clearance, and, as a result, it cannot enter the work to cut it. InFig. 982the tool is shown with clearance, and, as a result, the angle of the cutting edge is not the same angle as the sides of the tool are, because the top face is not at a right angle to the sides of the tool. It is obvious that the angle of the sides of the tool must be taken along the dotted line inFig. 982.
Fig. 983Fig. 983.
Fig. 983.
It follows then that a tool whose sides are at a given angle will cut a different angle of thread for every variation in the amount of clearance. But whatever the amount of clearance may be, the tool will produce correct results providing that the gauge to which the tool is ground is held level, as inFig. 983ata, and not at an angle as atb.
The tool, however, must be set at the correct height with relation to the work, and its top surface must point to the work axis to produce correct results.
Fig. 984Fig. 984.
Fig. 984.
Suppose, for example, that inFig. 984ais a piece of work, its horizontal centre being represented by the dotted linec, and its centre of revolution being atc. Now supposedis a screw-cutting tool cutting a depth of thread denoted bye.gis another lathe tool having teeth of the same form and angle asd, but lifted above the horizontal centre of the work. The depth of thread cut bygis denoted byf, which is shallower, though it will be seen that the point ofghas entered the work to the same depth or distance (of the tool point) asdhas. It is obvious, however, that for any fixed height, a tool suitable to cut any required depth or angle can be made, but it would be difficult to gauge when the tool stood at its proper height.
Fig. 985Fig. 985.
Fig. 985.
To facilitate setting the height of the tool, a gauge such as shown inFig. 985may be used, the height of the lineafrom the base equalling the height or distance between the top surface of the cross slides and the axial line of the lathe centres. If the lathe, however, have an elevating slide rest, the rest must be set level before applying the gauge. Or in place of using the gauge, the tool stool or tool holder, as the case may be, may be made of such height that when level in the tool post its top face points to the axis of the lathe centre, the tool being sharpened on the angles and not ground on the top face.
But in the case of a tool holder, or of a chaser holder, the tool may be ground on the top face, and adjusted for height by any suitable means, the top of the holder serving as a guide to set the tool by.
Fig. 986Fig. 986.
Fig. 986.
Fig. 987Fig. 987.
Fig. 987.
The line of the cutting edge of the tool must, to obtain correct results, be presented to the work in the same manner as it was presented to the gauge to which its angles were ground, so that if the tool were in position in the tool post, and the gauge were applied, it would point to the axis of the lathe centre, for if this is not the case the thread cut will not be of correct angle or depth. Thus, inFigs. 986and987the tooltwould cut threads too shallow, although placed at the correct height, because the cutting edges are at an angle to the radial linesc c.
It becomes obvious, then, that it is improper to set the height of a screw-cutting tool by means of any tool elevating or setting-device that throws it out of the horizontal position. To enable the correct setting of threading tools, and to avoid having to grind the angles correct to gauge every time the tool requiressharpening, various kinds of tool holders have been designed by means of which the tool may be ground on the top face, and set at correct height and in the proper plane.
Fig. 988Fig. 988.
Fig. 988.
Fig. 989Fig. 989.
Fig. 989.
Fig. 990Fig. 990.
Fig. 990.
To facilitate grinding the tools to a correct angle, the gauge shown inFig. 988is employed, the various notches being for the pitches of thread for which they are respectively marked, but, the edge of the gauge being circular, does not afford much guide to the eye in grinding the angles equal from the sides of the body of the tool; hence the form of gauge shown inFig. 989is preferable, because the tool can be so ground that the edge of the gauge stands parallel with the side of the tool steel, so that the tool will, when in correct position, point straight to the work axis. To insure correctness in setting the tool, it may then be set with a squaresinFig. 990, held firmly with its back against the side of the tool, which may be adjusted in the tool post until the bladebcomes fair with the work.
Fig. 991Fig. 991.
Fig. 991.
Fig. 992Fig. 992.
Fig. 992.
Another method of setting the tool is with a gauge as inFig. 991, which sets it true with the angle independent of whether the angle is true with the side of the tool or not. InFig. 992is a form of gauge that will serve to grind the tool by to correct angle, and also to set it in the lathe by the angles, independent of the side of the tool.
Fig. 993Fig. 993.
Fig. 993.
The same gauge may be used for setting internal threading tools by first facing the work quite true and then applying the gauge as inFig. 993.
Fig. 994Fig. 994.
Fig. 994.
By reason of the comparatively sharp points of thread-cutting tools, they are more readily dulled than the rounder pointed ordinary lathe tool, and by reason of their cutting edges extending along a greater length of the work, and therefore causing it to spring or bend more from the strain of the cut, they cannot be employed to take such heavy cuts as ordinary tools. Hence, in all thread cutting, it is necessary to turn the work down to the finished diameter before using the threading tool, so that the thread will be finished when it is cut to the proper depth. To test that depth on a piece of work having a United States standard, or a sharpV-thread, a gauge such as shown inFig. 994may be used, consisting of a piece of sheet steel about1⁄50inch thick, having a single tooth formed correct for the space of the thread, so that the edge of the gauge will meet the tops of the thread when the space is cut to admit the tooth on the gauge; the most accurate method of producing such a gauge having been described in the remarks upon screw threads.
Fig. 995Fig. 995.
Fig. 995.
If the tool is known to be ground to the correct angle and is set properly, the gauge for depth may be dispensed with by turning the body of the work to correct diameter, and also turning a smallpart, as a inFig. 995, down to the correct diameter for the bottom of the thread, so that when the tool point meetsathe thread will be cut to correct depth.
Fig. 996Fig. 996.
Fig. 996.
Fig. 997Fig. 997.
Fig. 997.
Figs. 996and997represent a method of cutting a round top and bottom, or any other form of thread, by means of a single-pointed circular cutting tool, which is mounted on a holder. On the circumference of the cutter is cut a single thread, and a piece is cut out ateto form a cutting edge. To cut a right-hand thread on the work, a left-hand one must be cut on the cutter, so as to make its thread slant in the proper direction. The tool is sharpened by grinding the top face, and moved on the holding pin to set it to the proper height or in position to enable it to cut. A top view of the tool and holder is shown infigure 997.
It is obvious that two gaps may be cut in the wheel or cutter so as to provide two cutting edges, one of which may be used for roughing, and the other for finishing cuts.
Fig. 998Fig. 998.
Fig. 998.
In roughing out coarse threads, a single-pointed tool, formed as inFig. 998, and set considerably above the centre as shown, may be used to great advantage. It will carry a heavy cut and throw off a cutting but very little curved; hence but little power is absorbed in bending the cutting. To preserve the cutting edge, the point of the tool should be slightly rounded. Such a tool, however, requires to be rigidly held, and requires experience to use it to the best advantage.
Fig. 999Fig. 999.
Fig. 999.
An English tool holder for a single-pointed tool for cutting coarse pitch threads, such as square threads, is shown inFig. 999. The stem of the holder is cylindrical, and is held between two clamping pieces, while the short piece of steel used as a tool (which is thinnest at the bottom, so as to provide for the clearance without grinding it) is clamped in a swiveled post, so that it may be set at the angle sideways required for the particular pitch of thread to be cut, as is shown in the end view.
Fig. 1000Fig. 1000.
Fig. 1000.
Fig. 1001Fig. 1001.
Fig. 1001.
The difficulty of adjusting the height of threading tools that are ground on their top faces to sharpen them is obviated in a very satisfactory manner by the tool holder patented by the Pratt and Whitney Company, and represented inFigs. 1000and1001.ais the body of the holder,cis the tool clamp, andbthe set screw forc;dis a pin fast inaand projecting intocto adjust it square upona. The threading toolghas a grooveh, into which the projectionefits, so that the tool is held accurately in position.fis the screw which adjusts the height of the tool, being threaded intoaand partly intog, as is shown ati. The holder once being set in correct position, the threading tool may be removed for grinding, and reset with accuracy. The facekof the holder is made at 30° to the front or leading face of the holder, so that the stem or body of the holder will be at an angle and out of the way of the work driver.
Fig. 1002Fig. 1002.
Fig. 1002.
If a chaser instead of a single-pointed tool be used to cut a thread, the thread requires to be gauged for its full diameter only, because both the angles of the thread sides and the thread depth are determined by the chaser itself. Chasers are also preferable to a single-pointed tool when the work does not require to be cut to an exact diameter, nor to have a fully developed thread clear up to a shoulder; but when such is the case a single-pointed tool is preferable, because if the leading tooth should happen to run against the shoulder the whole of the teeth dig into the work, and more damage is done to it than with a single-pointed tool. When the thread does not run up to a shoulder, or in cases where the thread may be permitted to run gradually out, and, again, where the thread is upon a part of enlarged diameter, a chaser may have its efficiency increased in two ways, the first of which is shown inFig. 1002. When the chaser is set and formed as atain the figure, the leading tooth takes all the cut, and the following tooth will only cut as it is permitted to do so from the wear of the leading bolt. This causes the tooth to wear, but the teeth may be caused to each take a proportion of the cut by chamfering them as atbin the figure, which will relieve the front tooth of a great part of its duty and let the following teeth perform duty, and thus preserve the sharpness of the cutting edges. We are limited in the degree of chamfer that may be given to the teeth, first, because as the cutting edge is broader and the strain of the cut is greater it causes the tool to spring or bend more under the cut pressure; and secondly, because if the tool be given many teeth in order to lengthen the chamfer, then the pitch is altered to a greater extent by reason of the expansion which accompanies the hardening of the chaser.
Fig. 1003Fig. 1003.
Fig. 1003.
A chaser thus chamfered may be set square in the tool post by placing a scale against the work as atsinFig. 1003, and setting the bottoms of the chaser teeth fair with the outer edge of the scale as in the figure.
Fig. 1004Fig. 1004.
Fig. 1004.
The second method of increasing the efficiency of a chaser is to grind the top face at an angle as fromatobinFig. 1004, and set it so that the last toothbis at or a little above the work axisd. This causes the last toothbto stand sufficiently nearer the work axis than the other teeth to enable it to take a light scraping cut, producing a smooth cut, because the duty on the last tooth being light it preserves its cutting edge, and therefore its form.
Chasers are often in shops, doing general work, formed in one piece in the same way as an ordinary tool, but it is preferable to use short chasers and secure them in holders.
Fig. 1005Fig. 1005.
Fig. 1005.
Fig. 1006Fig. 1006.
Fig. 1006.
Figs. 1005and1006show a convenient form of holder, the chaserabeing accurately fitted into a recess in the holderd, so that it may be set square in the holder without requiring to be adjusted to come fair with the thread grooves after having been ground to resharpen it. The short chasers are held by the clampb, which has atca projection fitting into a recess in the holder to cause the clamp to adjust itself fairly.
Fig. 1007Fig. 1007.
Fig. 1007.
Fig. 1008Fig. 1008.
Fig. 1008.
In setting a chaser to correct position in a tool post the points of the teeth may be set to the surface of the work as inFig. 1007, or if the thread is partly produced and the lathe has a compound slide rest, the tool may be set to the tops of the thread as inFig. 1008, and then brought into position to meet the thread grooves by operating the slide rest.
It is obvious that the height and position of a chaser require to be as accurately set as a single-pointed tool, but it is more difficult to set it because it can only be sharpened by grinding the top face, and this alters the height at each grinding.
Fig. 1009Fig. 1009.
Fig. 1009.
Thus, suppose that when new its teeth are of correct height, when the bottom facei,Fig. 1009, lies upon the restr, the facehbeing in line with the centreb bof the work, then as facehis ground the tool must be lifted to adjust its height. On account, however, of the curve of the teeth it is very difficult to find when the chaser is in the exact proper position, which in an ordinary chaser will be when it has just sufficient clearance to enable it to cut, as is explained with reference to cutting up chasers and using them by hand.
Fig. 1010Fig. 1010.
Fig. 1010.
Fig. 1011Fig. 1011.
Fig. 1011.
To obviate these difficulties, an excellent form of chaser holder is shown inFigs. 1010and1011. Its top facecbeing made of such a height that when the holder rests on the surface of the slide rest and is in the tool box,cwill stand horizontally level with the horizontal centre of the work, as denoted by the horizontal lined e; then the tool proper may have long teeth as denoted bya, and the surface of the teeth may always be brought up level with the top surface of the tool holder as tested with a straight-edge. This is a ready and accurate mode of adjustment. A top view of the tool holder is shown inFig. 1011, in whichais the tool holder,bthe threading tool, with a clamp to holdb, and a screw to tighten the clamp.
Fig. 1012Fig. 1012.
Fig. 1012.
It may now be pointed out that a common sharpV-chaser may be used to cut a United States standard thread by simply grinding off the necessary flats at the points of the teeth, because when the chaser has entered the work to the proper depth it will leave the necessary flat places at the top of the thread, as is shown inFig. 1012.
In cutting internal, inside, or female threads (these terms being synonymous) the diameter of the bore or hole requires to be made of the diameter of the male threadat the root.
Since, however, it is impracticable to measure male threads at the root, it becomes a problem as to the proper size of hole to bore for any given diameter and pitch of thread. This, however, may be done by the followingrules:—
To find the diameter at the roots or bottom of the thread of United States standard threads:
Rule.—Diameter - (1.299 ÷ pitch) = diameter at root.
Example.—What is the diameter at the root of a United States standard thread measuring an inch in diameter at the top of the thread and having an 8 pitch?
For the sharpV-thread the following rule is employed:
Rule.—Diameter-(1.73205 ÷ pitch) = diameter at root.
Example.—What is the diameter at the root of a sharpV-thread of 8 pitch, and measuring 1 inch diameter at the top of the thread?
Fig. 1013Fig. 1013.
Fig. 1013.
For cutting square threads the class of tool shown inFig. 1013is employed, being made wider at the cutting pointcthan atbor atd, so that the cutting may be done by the edgec, and the sidesamay clear, which is necessary to reduce the length of cutting edge and prevent an undue pressure of cut from springing the work.
Fig. 1014Fig. 1014.
Fig. 1014.
Fig. 1015Fig. 1015.
Fig. 1015.
The sides of the tool fromatobmust be inclined to the body of the tool steel, as shown inFig. 1014, the degree of the inclination depending upon the pitch of thread to be cut. It may be determined, however, by the means shown inFig. 1015.
Draw the linea, and at a right angle to it lineb, whose length must equal the circumference of the thread to be cut and measured at its root. On the lineaset off frombthe pitch of thread to be cut as atc, then draw the diagonald, which will represent the angle of the bottom of the thread to the work axis, and the angle of the tool sides must be sufficiently greater to give the necessary clearance. The width of the pointcof the tool should be made sufficiently less than the width of the thread groove to permit of the sides of the thread being pinched (after the thread is cut to depth) with a tool such as was shown inFig. 968.
Fig. 1016Fig. 1016.
Fig. 1016.
For coarser pitches the thread is cut as shown inFig. 1016.The tool is made one-half the width of the thread groove, and a groove,a,a,a, is cut on the work. The tool is then moved laterally and a second cut as atb bis taken, this second cut being shown in the engraving to have progressed as far asconly for clearness of illustration. When the thread has in this manner been cut to its proper depth, the side tools are introduced to finish the sides of the thread. If the thread is a shallow one each side may be finished at one cut by a side tool ground and set very true; but in the case of a deep one the tool may be made to cut at and wear its end only, and after taking a cut, the tool fed in and another cut taken, and so on until, having begun at the top of the thread, the tool operated or fed, after each traverse, by the cross feed, finally reaches the bottom of the thread. If a very fine or small amount of cut is taken, both sides of the thread may in this way be finished together, the tool being made to the exact proper width.
When used on wrought iron the tool is sometimes given top rake, which greatly facilitates the operation, as the tool will then take a heavier as well as a cleaner cut.
After the first thread cut is taken along the work, it is usual to remove it from the lathe and drill, at the point where it is desired that the thread shall terminate, a hole equal in diameter to the width of the thread groove, and in depth to the depth of the thread. This affords relief to the cutting tool at the end of the cut, enables the thread to end abruptly, and leaves a neat finish.
On account of the broad cutting edge on a screw-cutting tool, the lathe is always run at a slower speed than it would be on the same diameter of work using an ordinary turning tool. After the tool is set to just clear the diameter of the work it is moved (for a right-hand thread) past the end of the work at the dead centre, and a cut is put on by operating the cross-feed screw. The feed nut is then engaged with the feed screw and the tool takes its cut as far along the work as the thread is to be, when the tool is rapidly withdrawn from the work and the lathe carriage traversed back again, ready to take another cut. If, however, the thread to be cut runs close up to a shoulder, head, or collar, the lathe may be run slower as the tool approaches that shoulder by operating the belt shipper and moving the overhead belt partly off the tight pulley and on to the loose one, or the lathe may be stopped when the tool is near the shoulder and the belt pulled by hand.
Fig. 1017Fig. 1017.
Fig. 1017.
Fig. 1018Fig. 1018.
Fig. 1018.
An excellent method of finishing square threads after having cut them in the lathe to very nearly the finished dimensions is with an adjustable die in a suitable stock, such as inFigs. 1017and1018, in whichsis a stock having handleh, and containing a died, secured by a capc, pivoted atp. To adjust the size of the die, two screws,aandb, are used,apassing through the top half of the die and threading into the half below the split, whilebthreads into the lower half and abuts against the face of the split in the die, so that, by adjusting these two screws, the wear may be taken up and the size maintained standard. This device is used to take a very light finishing cut only, and is found to answer very well, because it obviates the necessity of fine measurement in finishing the thread. The diedis seated in a recess at the top and at the bottom so as to prevent it moving sideways and coming out.
Lathe Tool Holders for Outside Tools.—When a lathe cutting tool is made from a rectangular bar of steel it requires to be forged to bring it to the required shape at the cutting end, and to avoid this labor, and at the same time attain some other advantages which will be referred to presently, various forms of tool holders are employed.
These holders fasten in the tool post, or tool clamp, and carry short tools, which, from their shapes and the manner in which they are presented to the work, require no forging, and maintain their shapes while requiring a minimum of grinding.
Fig. 1019Fig. 1019.
Fig. 1019.
Fig. 1020Fig. 1020.
Fig. 1020.
Fig. 1021Fig. 1021.
Fig. 1021.
Fig. 1019represents a side view of Woodbridge’s tool holder at work in the lathe, andFig. 1020is a view of the same set at an angle to the tool rest.Fig. 1021is an end view of the tool and holder removed from the lathe.
The tool seatais at an angle of about 4 degrees to the base of holder (a greater degree being shown in the cut for clearness of illustration), so that the sidejof the tool will stand at an angle and have clearance without requiring such clearance to be produced by grinding. The seatbof the capcupon the tool is curved, so that the cap will bind the middle of the tool and escapethe edges, besides binding the tool fair upon its seata. The top face is formed at the angle necessary for free and clean cutting, and the tools are, when the cutting edge is provided at one end only, hardened for half their length.
The holder, and therefore the tool, may obviously be swung at any chosen angle of the work or to suit the requirements.
Fig. 1022Fig. 1022.
Fig. 1022.
Fig. 1022shows a right and left-hand diamond-point tool in position in the holder with the cap removed, the cutting edge being atg, the angle of the top face being fromftoe. The tool, it will be observed from the dotted line, is supported close up to its cutting corner.
Fig. 1023Fig. 1023.
Fig. 1023.
Fig. 1023shows a right and left-hand side tool in position, the dotted line showing that it is supported as close to the cutting edgedas the nature of facing work will permit. When left-hand tools are used the holder is turned end for end, so as to support the tools in the same manner as for right-hand ones, and for this purpose it is that the holder is beveled off at each end.
By grinding both ends of one tool, however, to the necessary shape and angle, one tool may be made to serve for both right and left, the tool holder being simply reversed end for end in the tool post. There are, however, furnished with each holder a right and left-hand diamond point and a right and left-hand side tool, each being hardened for half its full length.
It is obvious, however, that there is no front rake to the tool, and that it therefore derives its keenness from the amount of side rake, which may be regulated to suit the conditions.
When tool holders of this class are employed, the end face only of the tool requires grinding to resharpen the cutting edges; hence the area of metal requiring to be ground is much less than that on forged tools, and therefore the grinding occupies less time; and if the workman grinds the tools, he is enabled to run more lathes and not keep them idle so long while grinding the tool. Or if the tools are kept ground in stock (about 200 of the tools or cutters serving to run 24 lathes a week) the workman has but to slip in a new tool as the old one becomes dull, no adjustment for height being necessary as in the forged tool.
Fig. 1024Fig. 1024.
Fig. 1024.
When the tool requires to be set to an exact position, as in the case of screw cutting, it is desirable that the tool holder be so constructed that the tool may be removed therefrom and replaced without disturbing the position of the tool holder in the tool post or tool clamp; and means must therefore be provided for securing the tool to the holder independently of the tool post or clamp screw.Fig. 1024represents a tool holder possessing these features:his the holder provided with a clampc, secured by a screwb,trepresenting the tool, which is in this case a chaser, having teeth down the full length of its front face;kis a key or feather fast in the holderh, and fitting into a groove provided in the side of the tool. The vertical angle of this feather obviously determines the angle of clearance at which the tool shall stand to the work.
The Pratt and Whitney Company, who are the manufacturers of this holder, make this angle of clearance 15 degrees. The height of the tool in the holder is adjusted by the screws, which has journal bearing in the holder, and threads to the end edge of the tool.
Now it is obvious that the holderh, once being set to its proper position in the tool post, the tooltmay be removed from and replaced in the exact same position, both in the holder and with reference to the work.