Modern Machine-Shop Practice Part 154

[Ill.u.s.tration: Fig. 2282.]

The first thing to do is to mark off the keyway by scribing lines on the surface of the shaft, indicating the location for the feather seat; and for this purpose nothing is better than the key seat rule shown in Fig.

2279, in which W is the key seat rule, and S the shaft. After the lines are drawn they should be defined by centre-punch dots, as in Fig. 2280, and then the metal should be cut out on the sides first, using a cape chisel, and cutting close to the side lines, as in Fig. 2281, in which A is a cape chisel cut taken along one side, D a second cape chisel cut, being carried along the other side, C the cape chisel, C' the cut taken by the chisel, and B a piece of metal to be cut out after the cape chisel has done its work. Suppose, now, the ma.s.s of the metal is removed, then the dovetailing is performed as follows: Next the _setting_ or _upsetting_ is proceeded with as shown in Fig. 2282, which is a side sectional view. S is a set chisel driven by hammer blows against the walls of the feather seat (as against the end _e_), causing it to bulge up, as shown at _f_. This setting will enlarge the feather seat or recess, so that the wide part of the dovetail on the feather will just pa.s.s in (the dotted lines shown in Fig. 2281 having, of course, been marked to the size of the feather, where it will, when fixed, meet the surface of the shaft). The feather is then placed in its seat and bedded properly by red marking applied to its bottom surface to show the high spots on the seat of the recess, and when properly bedded it is fastened, as in Fig. 2283, in which S is a set chisel, which, by being struck with hammer blows, closes the bulged metal back again on the dovetail of the feather, and firmly locks it in the shaft. And all that remains is to file the shaft surface around the feather level with the surrounding surface, there being usually a little surplus metal from the upsetting.

[Ill.u.s.tration: Fig. 2283.]

[Ill.u.s.tration: Fig. 2284.]

[Ill.u.s.tration: Fig. 2285.]

[Ill.u.s.tration: Fig. 2286.]

[Ill.u.s.tration: Fig. 2287.]

As an example of chipping and filing let it be required to chip and file to shape and to fit a knuckle joint (or a double and single eye, as it may more properly be termed), such as in Fig. 2284. The eye being marked out by lines, the first operation will be to remove the surplus metal around the edges by chipping, which should be done (with the pin in place, so that it may support the eye) before the joint faces are filed at all, and should be carried in a direction around the eye, as shown in Fig. 2285, in which _v_ is the vice jaw, E a lead clamp, C the cut, and D the chisel. By chipping in this direction two ends are served: first, the force of the chipping blows is less likely to bend the eye if it is a light one, and, secondly, the chipping will not break out the metal at the edge of the eye, which it would be apt to do if the chipping was carried across. This is shown in Fig. 2286, where a chisel cut is supposed to have been carried across from A to B and a piece has broken out at B. If the width of the eye is too broad for one chisel cut, a cape chisel should be run around it, as in Fig. 2287, A D showing the cutting, the flat chisel cuts B, C being taken separately afterwards.

In order to ill.u.s.trate the filing clearly, it will be necessary to show more metal to be filed off than would be the case in practice, unless the eye were very small, in which case it would not pay to chip.

[Ill.u.s.tration: Fig. 2288.]

Put the eyes together with the pin in and let the two lowest places on the edges coincide. Then file a flat place clear across them, as shown in Fig. 2288 at F, making it parallel to the pin, and, say, down to within 1/100 of the finished depth. To test the parallelism of the flat place, take out the pin and apply to the flat place a square, rested against the radial face of the double eye, or measure its distance from the hole of the eye on each side of the double eye, that is at each end of the hole.

[Ill.u.s.tration: Fig. 2289.]

When it is true and down to the required size, put the eyes together and let their relative positions be such that the flat places do not coincide, and that on the double eye will serve as a guide to carry the filing around the single eye, while that on the single eye will serve as a guide to carry the filing around the double eye, as will be seen on reference to Fig. 2289, in which the flat places A, B on the double eye serve as a guide to file C down to, while the flat place on the single eye at D is a guide to file the metal at E, F down to, and it is obvious that by moving the eyes to different positions the eye may on that side be filed true and to circle.

When the filing has thus been carried around as far as the movement of the eyes permits on that side, turn the single eye over in the double eye, and they will appear as shown in the end view, Fig. 2290, A being the filed side of the single and E D that of the double eye; hence the metal at C, B must be filed down level with A, and that at F down level with E, D.

[Ill.u.s.tration: Fig. 2290.]

We have a.s.sumed that the edges only required finis.h.i.+ng irrespective of the joint faces; but let it be a.s.sumed that the whole of the eye has been dressed up by machine tools, and that it requires fitting and finis.h.i.+ng by the file both on its joint faces and on its edges.

If the eye has been bored and faced in the lathe the faces will be about true with the hole, but if it has had its faces trued in a machine, as a planer or slotter, and the hole bored subsequently in a slotting machine, the hole may not be true to the faces. This may occur from want of truth in the chucking devices, from these devices having been held to a table or carriage moving on slides, and having lost motion or play, in which case from the leverage of the pressure of the boring tool-reamer or bit, this table may have lifted to the extent of such play, in which case the hole will not be at a right angle to the face or faces.

[Ill.u.s.tration: Fig. 2291.]

First, then, these faces must be tested for truth and smoothed by filing. The best testing device is a pin and washer, the pin neatly fitting the hole in the eye and the washer neatly fitting the pin. The radial face of the pin head and of the washer should then be given a light coat of marking, and be inserted in the eye, as shown in Fig.

2291, in which _a_ is the pin head and B the washer. If each be then rotated under pressure against the eye, they will mark the high spots, which may be filed and draw-filed until an even contact all around is shown.

The single eye should be similarly faced and fitted, a somewhat tight fit, into the double eye. In a job of this kind, where accuracy of fit is essential, it is usual to bore the hole about 1/100 inch smaller than its finished diameter, and after fitting the two eyes, to ream out the eyes while bolted together.

For the reaming the two eyes should be clamped together. The single eye is left somewhat too tight a fit to the double eye to permit of the finis.h.i.+ng being done after the holes are reamed, because the reaming may slightly alter the axial line of the hole. The two bolts holding the clamping plates should be brought just home on the plates, and then tightened up gradually and alternately, so that the eyes may be gripped fair, and not liable to move during the reaming. The bores of the eyes should be set as true as possible one with the other before the plates are tightened upon the eyes, for if it is attempted to set the eyes true by hammer blows afterwards, the pressure of the plates would cause the arm or hub of the double eye which received the hammer blow to move more than the other, or, in other words, to spring out of its normal position, and the eye will be distorted. But when released from the pressure of the clamping plate the double eye will resume its normal shape, and the holes will not be axially true in the two eyes.

After the holes are reamed the temporary pin and washer used for the facing will be too loose, and the proper pin should be used for all future operations. The eyes should be put together with a light coat of marking on both faces of the single eye, and, with the pin in place, one eye should be moved back and forth, when they may be taken apart again and filed on the high spots. When by repet.i.tion of this process they fit properly the outside edges may be filed up, as already described.

It is obvious, however, that the pin and washer shown in the figure may be hardened and used to file the edges up before the reaming, in which case, their diameters being equal, and equal to that of the required finished diameter of the eye, it is easy to file the eye edges true and to size; but even in this case the eyes should be finished by reversing and moving as before described. There is, however, the objection to filing the edges--first, that the joint will show plainer, because in filing the side faces to fit the single into the double eye, that part of each face near the edge is apt to be filed away slightly too much, causing the joint to show; but if the circ.u.mferential edges of the eye be filed last, the part so filed away is removed and the joint may be made almost invisible.

The best plan of all is to first fit the eyes, then ream them out and then provide a hardened pin and washer to fit the reamed hole, then file down the circ.u.mferential edges nearly level with the pin and washer and finish by reversing and moving the eyes as before described.

In the absence of any pin and washer, such as shown in Fig. 2291, the inside faces of the jaws of the double eye must be filed parallel to the outside radial faces of the single eye, the outside surfaces being trued when the hole is bored. If none of the surfaces have been trued with the hole, the outer ones should first be trued, using a [T]-square (if there is no pin) to test the truth of the face with the hole, and the inside jaw faces must be trued with the outside, measuring each jaw with outside calipers, and the width between the jaws with inside calipers.

[Ill.u.s.tration: Fig. 2292.]

Let us now suppose that it were attempted to first fit the single to the double eye a tight fit, then to ream the hole and then to make the joint an easy working fit. In this case the finished hole in one eye may become out of true with that in the other, that is, it may not be parallel with that in the other, and for the following reasons:--The holes of the two eyes will rarely come quite true with each other, even though the radial faces of the eyes be turned in the lathe or faced in a machine when the holes are bored, and it is the duty of the reamer to true as well as smooth them in whatever direction they may be out of true or face one with the other until they are put together. Now, if they be put together a tight fit, the outside jaws are sprung open to some extent. Again, they may be sprung slightly atwist, and if the hole be reamed true and this twist taken out afterwards the hole will come atwist or out of fair in proportion as the jaws lose their twist from being fitted.

Again, reaming the hole slightly alters its axial line, and the radial faces, if at a right angle to the hole before reaming, will not be so after reaming, and it is not practicable to discover in just what direction and to what degree reaming the hole will alter its axial direction; hence, the single eye must be fitted as near as may be before the holes are reamed, and finished afterwards as described.

Let it be required to reduce by filing, the diameter of a round pin or to file it to fit a taper hole, and the diameter of the pin being small it may be held by one end in the vice jaws or by means of the clamps, shown in Fig. 2091 or those in Fig. 2092. But the filing can be more truly and easily finished as in Fig. 2292, in which there is shown fastened in the vice a filing block having [V]-grooves (of varying width to suit varying diameters of work), in which the pin to be filed may be rested.

The pin is held by the hand vice shown, and is rotated towards the operator during the forward file stroke (one hand holding the hand vice and the other the file), and in the opposite direction during the back stroke. After every few file strokes the hand vice is partly rotated in the hand so that the whole of the pin surface may be subjected to the file. The hand vice enables the pin to be forced into its hole and rotated, to show by the contact or bearing marks where it requires filing to adjust the fit.

[Ill.u.s.tration: Fig. 2293.]

Fig. 2293 represents an excellent form of hand vice for holding pins, &c., the jaws being pivoted to a cross piece and opened by a cone, the handle threading to the stem of the cross piece, and being hollow so that the work may pa.s.s through it. The work is thus very firmly gripped and not liable to move in the jaws as it is when the hand vice is fastened upon the work by a thumb nut.

Very thin pieces of metal cannot be well held in the vice jaws, and as an example of this kind of work holding, let it be required to file up a caliper leg, which being curved cannot well be held in any of the vice fixtures heretofore shown.

[Ill.u.s.tration: Fig. 2294.]

In Fig. 2294 there is a block of wood having an extension at A that may be gripped in the vice jaws. Upon the surface of the block the caliper leg is held by brads or nails driven around its edge, as shown, or it is obvious screws may be used.

[Ill.u.s.tration: Fig. 2295.]

An excellent example of filing is to file up a hexagon nut or a bolt head. This is apparently a simple piece of work, but it is in fact a job that requires a good deal of care and precision to properly accomplish.

The requirements are that the nut shall measure alike across the flats, that each flat shall be parallel to the axial line of the bolt, and at a proper and equal angle to both of its neighbors, and that the nut shall be of equal thickness all round. The method of accomplis.h.i.+ng this result is as follows: Let Fig. 2295 represent a bolt head, after it has been turned in the lathe. It will be observed that the end face of the bolt head is rounded. Now a bolt head of this form gives a very neat appearance, but it presents difficulties in the filing up, as we shall see presently.

[Ill.u.s.tration: Fig. 2296.]

[Ill.u.s.tration: Fig. 2297.]

[Ill.u.s.tration: Fig. 2298.]

[Ill.u.s.tration: Fig. 2299.]

Suppose that one flat (which we will call flat A) of a nut, is nearest to the bore, then to make the nut of equal thickness all around, the other flats must be so filed down as to approach the bore as nearly as A does, and it is a.s.sumed that there is metal enough to permit this. The flat A will then be the first one to be filed up, taking off just sufficient to make it true when tested by the nut gauge, applied as in Fig. 2296, in which N is the nut, and G the gauge. The flat must also be filed true when tested by the gauge, as in Figs. 2297 and 2298, the gauge G being tried rested on A and applied to B, and then rested on A and applied to C. A should be filed so that, if possible, it will be at the proper angle to both B and C, but if, from errors in the angles of B and C, this is impossible, the error should be divided between the two, as shown, for example, in Figs. 2299 and 2300, where the gauge is shown in the two positions necessary to test each respective flat, B and C; the amount of error being equal at H and I.

The next flat to file will be E, Fig. 2299. Now, in a small nut, the chamfer of the nut edge will be sufficient guide to the eye in filing E to an equal thickness (that is, equal for distance from the bore to A).

In order that the finished nut shall be so true that the nut gauge shall show that the flats or angles are true one with the other all around the nut, it is necessary that the flat E shall stand parallel to A; hence it should be made so by measurement with calipers, irrespective of its angle to either D or F. After E is filed it will serve as a base from which D and F may be filed to angle, while A will serve as a base from which the flats D and C may be filed to angle; but, while testing the angle with the gauge, C and D should be tried for parallelism, and F and B for parallelism, while the diameters across these flats should be equal on all sides.

[Ill.u.s.tration: Fig. 2300.]

If it were attempted to go all around the nut, filing to the gauge, as, for example, filing C, Fig. 2300, from A, F from C, E from F, D from E, and B from D, all the error in the angle of the gauge, or errors of workmans.h.i.+p, will (supposing the latter to be always in the same direction) be multiplied upon, or rather added to B when tested with A, and these two will not be of correct angle. Again, any error made upon one flat will be copied upon the one filed to gauge angle from it; whereas, filing E parallel to A insures the correctness of these two, and testing the parallelism of the others, as B, F, serves to discover and correct any error of angle that may exist. It is obvious that in filing each flat the gauge must be applied as in Fig. 2296, as well as in Fig. 2298.

In filing the opposite flats to diameter to fit the wrench or gauge, if one be used, it is best to leave them a tight fit until all are nearly finished, so that any error that may be discovered may be corrected while finis.h.i.+ng them.

[Ill.u.s.tration: Fig. 2301.]

[Ill.u.s.tration: Fig. 2302.]