Machining a Block Square
Initially you must make a non-parallel block by…
1. On the horizontal band saw cut out a block of material (CRS or Cold Rolled Steel) approximately 1” thick 1 ½” wide and 3” long
2. Return excess material to rack
3. In a mill, vise the block on the 1” face without parallels on a slight angle
4. Mount a fly cutter into the machine spindle. (See instructor if you have not done this before) Set the machine for the proper speed for the size of cutter and the material being machined. CSX4/D Alum = 400 CRS = 100 Remember that D is the diameter of the cutter.
5. Start the machine and raise the table until the cutter just touches near the high end of the work piece
6. Mill the block until the face is cleaned up
7. Remove block and de-burr, this can be with a file or the grinder
8. Using a cylinder for clamping (See step #3 below) on the newly machined face mill the 1 ½” face on a slight angle
9. De-burr
10. The ends of the block should be non-parallel as they are saw cut
11. Bring the non-parallel block to instructor for confirmation
12. Stamp the block with your initials on a machined face
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Machining Side 1
1. Clean the vise and parallels thoroughly, and remove all burrs from the work-piece.
2. Set the work-piece in the vise centre with the largest surface (the 1 ½” face) facing up.
3. Use a round bar between the work-piece and the moveable jaw to help force irregular shaped work-pieces squarely against the solid jaw and tighten the vise securely
4. Tap the work piece down with a rubber mallet, then check the parallels for movement to ensure the work piece is fully down. There is sometimes one parallel that will move when the bottom of work piece is not yet finished.
5. Start the machine and raise the table until the cutter just touches near the high end of the work piece
6. Move the work clear of the cutter
7. Raise the table about .030” and machine side 1 using a steady feed
8. STOP the revolving cutter, and take the work-piece out of the vise and remove all burrs from the edges with a file
Machining Side 2
9. Thoroughly clean the vise, work and parallel
10. Place the work on parallels, if necessary, with side 1 against the solid jaw and side 2 upward
11. Place a round bar between side 4 and the movable jaw approximately in the center of the work-piece
12. Tighten the vise securely and tap the work down until the parallels are tight
13. Follow steps 4 to 8 and machine side 2 marking each machined side with a marker identifying number of the side machined
Machining Side 3
13. Clean the vise, work and parallels thoroughly
14. Place side 1 against the solid vise jaw, with side 2 resting on parallels if necessary
15. Position the parallel to the left so the work-piece extends just beyond the parallel about .25”
16. Place a round bar between side 4 and the movable jaw, making sure the that the round bar is in the center of the amount of work held inside the vise
17. Tighten the vise securely
18. Start the machine and raise the table until the cutter just touches near the right-hand end of side 3
19. Move the work clear of the cutter and raise the table about .010”
20. Raise the table the required amount and machine side 3 to the correct width
21. STOP the revolving cutter and remove the work and file off all burrs
Machining Side 4
22. Clean the vise, work, and parallels thoroughly
23. Place side 1 down on the parallels with side 4 up and tighten the vise securely
24. Tighten the vise securely. Tap the work down until the parallels are tight
25. Machine side 4
Machining Side 5
26. Set the work in the center of the vise with one of the ends (side 5 or 6) up and tighten the vise lightly
27. Hold a square down firmly on the accurate surface of the vise and bring the blade of the square into light contact with the side of the work
28. Tap the work until its edge is aligned with the blade of the square ensuring an accurate right angle cut
29. Tighten the vise securely and recheck the square-ness of the side
30. Take a cut machining the end square
31. Remove the burrs from the end of the machined surface
Machining Side 6
32. Clean the vise and set the machined end down
33. Tighten the vise securely and tap the work down until the parallels are tight
34. Take a trial cut from the end until the surface cleans up
35. Measure the size of the work-piece
36. Raise the table the required amount and machine the work to size. You may need to take a roughing cut leaving a finish cut of about .010”
37. Raise the table the required amount and machine the work to finish size
38. Follow proper clean up procedures