Machinery Repairman

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Engage the power feed and the coolant flow.
When the cut is finished, stop the spindle and
return the work to the starting point.
Loosen the index head spindle lock.
Rotate the work one-half revolution
index crank.
Tighten the index head spindle lock.
Take another cut on the work.
with the
When this cut is finished, stop the cutter and
return the work to the starting point.
Measure the distance across the flats to
determine whether the cutter is removing the
same amount of metal from both sides of the
work. If not, check your calculations and the
setup for a possible mistake.
If the work measures as it should, loosen the
index head spindle lock and rotate the work
one-quarter revolution, tighten the lock, and
take another cut.
Return the work to the starting point again.
Loosen the spindle lock.
Rotate the work one-half revolution.
Take the fourth cut.
Return the work again to the starting point
and set the machine for finishing speed and
feed.
22. Now, finish machine opposite sides (1 and 3),
using the same procedures already
mentioned.
23. Check the distance across these sides. If it is
correct, finish machine the two remaining
sides.
24. Deburr the work and check it for accuracy.
NOTE: You can also machine a square or
hexagon with the index head spindle in the horizontal
position, as shown in figures 7-62 and 7-63. If you
use the horizontal setup, you must feed the work
vertically.
Square or Hexagon Work Mounted Between
Centers
Machining a square or hexagon on work mounted
between centers is done in much the same manner as
when the work is held in a chuck.
7-38
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Mount the index head the same way, only
with the spindle in a horizontal position. The
feed will be in a vertical direction.
Insert a center into the spindle and align it
with the footstock center.
Select and mount the desired end mill,
preferably one whose diameter is slightly
greater than the length of the flat you are to
cut, as shown in figure 7-63.
Mount the work between centers. Make sure
that the drive dog is holding the work
securely.
Set the machine for roughing speed and feed.
Pick up the side of the work and set the
graduated cross-feed dial at ZERO.
Lower the work until the cutter clears the
footstock.
Move the work until the end of the work is
clear of the cutter.
Align the cutter with the end of the work.
Use a square head and rule, as shown in
figure 7-66.
NOTE: Turn the machine off before you align
the cutter by this method.
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Move the table a distance equal to the length
of the flat desired.
Move the saddle the distance required for the
roughing depth of cut.
While feeding the work vertically, machine
side 1. Lower the work to below the cutter
when you have completed the cut.
Loosen the index head spindle lock and index
the work one-half revolution to machine the
flat opposite side 1.
Tighten the lock.
Engage the power feed. After completing the
cut, again lower the work to below the cutter
and stop the cutter.
Measure the distance across the two flats to
check the accuracy of the cuts. If it is
correct, index the work one-quarter
revolution to machine another side. When
you complete that side, lower the work, index
one-half revolution, and machine the last