Summary of Contents for K. O. LEE B360
- Page 1 A HANDBOOK FOR USE WITH K.O. LEE UNIVERSAL GRINDERS TOOL AND CUTTER GRINDERS 200 South Harrison Aberdeen, SD 57402-1416...
- Page 2 Instruction Manual A HANDBOOK FOR USE WITH K. O. LEE UNIVERSAL GRINDERS AND TOOL AND CUTTER GRINDERS Price $6.00 K. O. LEE COMPANY, ABERDEEN, S. D. 57401...
- Page 3 Acknowledgements The K. O. Lee Company wishes to thank the Norton Company of Worcester, Massachusetts for the privilege of using material from their handbook Tool Room Grinding. We also wish to thank the following individuals for their special contributions of...
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Page 4: Preface And Contents
SCOPE AND PURPOSE This handbook provides information for operating and maintaining the following model series of K. O. Lee Universal Grinders and Tool and Cutter Grinders: B360, BA960. BA962, B2060. B2062. B6060. B6062 Universal Grinders; B300, BA900. B2000, Tool and Cutter Grinders. -
Page 5: Table Of Contents
Section Instruction Manual Table of Contents SECTION ONE Preface and Contents Scope and Purpose III. Table of Contents . SECTION TWO INSTALLATION INSTRUCTIONS Uncrating I I . Completing Assembly of Grinder Components I I I . Foundation and Leveling the Grinder SECTION THREE LUBRICATION Initial... -
Page 6: Table Of Contents
Instruction Manual Section Table of Contents SECTION FIVE CUTTER GRINDING AND OTHER TOOL GRINDER OPERATIONS CHAPTER I, Introduction to Sharpening High Speed and Other Cast Alloy Multi-Tooth Cutters CHAPTER 2 . Cutter Nomenclature and Measurement Cutter Nomenclature I I . Cutter Runout Tolerances I I I . - Page 7 Machine Standard Equipment Universal Tool and Cutter Grinders Tool and Cutter Grinders III. Tooling and Fixtures and Accessories Workheads for Model Series B300, B360, BA900, BA960, BA962, B2000. B2060, B2062 Workheads for Model Series B6060 and B6062 Coolant Systems Column Extension E.
- Page 8 06183 LIGHT FIXTURE TILTING HEAD MOTOR DRIVEN DOVETAIL SLIDE WORKHEAD SWIVEL TABLE RIGHT TAILSTOCK TABLE POINTER TABLE INDEX PLATE ADJUSTMENT SCREWS TABLE STOPS STOP BLOCK ELEVATION THUMB NUT HANDWHEEL CROSSFEED TABLE TRAVERSE HANDWHEEL HANDWHEEL ELECTRICAL CONTROL BOX STORAGE COMPARTMENT HEAVY CAST DOOR IRON BASE MODEL B6062B WITH OPTIONAL...
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Page 9: Uncrating
Instruction Manual Section Two INSTALLATION INSTRUCTIONS UNCRATING After the top and sides of the crate have been removed from the skid leaving the machine standing free, remove all wrapping materials and read unskidding and lifting instructions attached to machine. Remove bolts holding machine to the skid by holding the bottom of bolt-heads (under skid) with a wrench and turning off the nuts from the inside of the base of the machine. -
Page 10: Completing Assembly Of Grinder Components
Instruction Manual Section HAND POWERED TABLE TRAVEL GRINDERS W I T H BALL TRACK: As soon as you have received your machine, move the table to the extreme right side of the machine, and check the level of way lube in the channel area surround ing the hardened ways in the saddle. -
Page 11: Initial
Instruction Manual Section Three PHOTO 2 LUBRICATION INITIAL K. 0. Lee grinders are made with a variety of lubrication systems, but the standard design features a self-lubrication principal of spool rollers working in lube reservoirs (photo 2). Ways are kept wet and clean by movement action of the saddle and table. - Page 12 Section Three Instruction Manual from the hydraulic system. Valve No. 18 pictured on the Hydraulic Pump and Tank Assembly, shown in Photo 5, is used to regulate the flow of oil and has been pro perly set at the factory for the correct grade of oil at normal operating temperature. BALL-TRACK TABLE/SADDLE END VIEW PHOTO OF TOP OF BALL-TRACK SADDLE III.
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Page 13: Lubrication Chart
Section Three Instruction Manual become visible. The level of lubrication should be maintained at the top of the overflow, cut-out section of the saddle extension casting. With hydraulic ma chines, the level of way lube is approximately ⅜" deep from the bottom. If the level appears to be low, adjust oil flow valve for the ways, (Part No, BA931W, Index No. - Page 14 Instruction Manual Section Three PHOTO 3 -- 4 --...
- Page 15 Instruction. Manual Section Three LUBRICATION INSTRUCTIONS AND SPECIFICATIONS Station When Procedure Lubricant Parts Machine Model To Oil Numbers Lubricated Specification None Factory grease-packed Motor and spindle bearing Models for life of bearings dead center for workheads. and all workheads with ball bearings Crossfeed and elevating shaft(s)
- Page 16 Instruction Manual Section Four MODEL B6062H WITH B10043M MOTORIZED WORKHEAD PHOTO 4 Switch on Machine with Toggle Switches Table Index Plate Table Adjustment Screws Belt Guard Adjustable Stop Tilting Degree Dial Table Stop Cartridge Spindle Lacking Screw Crossfeed Handwheel Wet Wheel Guard Thumb Nut B923CL Motor Shaft Guard Elevation Handwheel...
- Page 17 Section Four Instruction Manual MODEL B2060H PHOTO 5 17. Tailstock Center Clamp Bar Socket Screws 1. On-Off Valve Control Oil Flow Valve for Ways Index Plate Speed Central remove cover for adj. 11. Pointer Directional Control Arm Swivel Table Friction Socket Screws Dwell Control 21.
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Page 18: Safety Precautions
Section Four Instruction Manual GENERAL OPERATION INSTRUCTIONS SAFETY PRECAUTIONS ALWAYS WEAR SAFETY CLASSES or an eye shield when operating a grind ing machine. ALWAYS USE A WHEEL GUARD AND BELT GUARD. Machines are pro vided with wheel guards of the correct size and necessary mounting brackets. Consult Part III of this section and general set-up photos in this manual on how to attach these to the machines. -
Page 19: Motorized Workheads
Section Four Instruction Manual housing, is a "Forward-Off-Reversing" type with the " O f f position in the cen ter. Spindle motors should be completely stopped in one direction prior to reversing. Check the rotation of the spindle for "Forward" switch designa tion, Rotation should be down at the point of grinding as one faces the wheel periphery, with the spindle parallel to the grinder table. - Page 20 Section Four Instruction Manual B855Y Special Nut 2. 5/16 x 3/4 NF Hex Socket Cap Screw B860CN Special Nut Belt Adjustment Handwheel V-Belt Eccentric Shaft Hand Nut Column Lock Lever B955C Lock Screw Assembly PHOTO 7 (b) All Other Models: The transmission is shipped with gears in neutral position.
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Page 21: Manual
Section Four Instruction Manual handwheel until the key in the transmission drops into the low ratio slot. To shift from the low ratio, push in the knurled knob while oscillating the handwheel. Not over ¼ turn of the handwheel is necessary to shift into either of the two ratios. -
Page 22: Column Elevation
Normal backlash in the nut is about .005 inch. Column Elevation: 1. All B300, B360, BA900, BA960, BA962, B2000, B2060, and B2062 series grinders: The elevation handwheel, located at (23) Photo 5 and on some machines also at the center of the machine base just below the column, has an index disc calibrated in thousandths —... - Page 23 Instruction Manual Section Four tightening screw and handwheel (4) Photo 6 is used to move the motor relative to the spindle for installing and tightening the belt Always leave enough slack in the belt tension so that the belt can be depressed to a depth of ⅜...
- Page 24 Section Four Instruction Manual PHOTO 9 —14—...
- Page 25 Section Four Instruction Manual Other arbors shown in Photo 8 are the standard internal grind ing arbors (B780J, B780K, and B780C) which are held in the left end of the spindle by an inner taper lock and threaded end. Tighten these arbors in place by using an open-end wrench while holding the spindle shaft with a wrench at the right end.
- Page 26 Section Four Instruction Manual 4, 6, or 8 inch dry guard the B955BT vertical T-slot bracket is used The bracket is mounted to the spindle housing horizontal surface (SEE INSET). The wheel guard is mounted with the use of the accompanying wheel guard bracket (SEE INSET).
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Page 27: Swivel Table Adjustments For Taper And Clearance
Instruction Manual Section Four Spindles, Pulleys, and Wheel Mounting: High-Speed for standard Universal Grinders with B6055 Head: The B6Q55A spindle (Photo 8) has normal speed range of 3,450 to 17,250 R.P.M. The B6055F pulley and wheel arbor has the same function as the one described in D-2(d), with the excep tion that it uses a face lock rather than a taper lock principle, I.D, arbors B6055JS, B6055JL, and B6055C have the same func... -
Page 28: Tailstocks And Workheads
Instruction Manual Section Four clamp bar socket screws (9) located at the right end of the table. the swivel table adjustment screws (8) to align it with the sub-table. When the pointer (11) mark aligns with the 0 line on the index plate (10), the two tables are aligned If greater accuracy than a sight scale is needed, use a test arbor between tailstocks in conjunction with a dial indicator to... -
Page 29: Toothrests And Height Gauges
Instruction Manual Section Four Lower the Wheelhead so that the spindle shaft center is slightly above the diamond point. Slant the axis of the nib at an angle of about 15 degrees from per pendicular to the wheel to be dressed. Using the Crossfeed to advance the diamond to the wheel, traverse the diamond across the face of the wheel, using the table handwheel, with transmission in low ratio. - Page 30 Instruction Manual Section Four B827 Plain Micrometer Toothrest B6027 Plain Micrometer Toothrest straight arbor, shown in the inset. They may also be used to index cutter teeth directly. They have a micrometer extendable barrel assembly to hold various blades. Height gauges B939 and B6039 are used to set the wheel spindle axis at the same height as the centers of tailstocks or workheads.
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Page 31: Cutter Grinding And Other Tool Grinder Operations
Silicon Carbide wheels may be successfully used where wheel wear is not a large factor in holding size. Example of this type of wheel is the K. O. Lee RV6NH100 recessed straight wheel used with the B945 Tilting Table Attachment. - Page 32 Instruction Manual Section Five for best results. The main factors to be considered are the material being ground, size of work, amount of stock to be removed, and the finish desired. The harder the material, the softer the wheel required. The larger the work diameter, the coarser and softer the wheel.
- Page 33 Instruction Manual Section Five III. RELIEF ANGLE (CLEARANCE) Relief Angle: Relief may be defined as the amount of stock removed from the teeth behind the cutting edge to permit the teeth to cut freely and to clear the material after the cutting edge has done its work. It is important that the relief angle be correct.
- Page 34 Instruction Manual Section Five The relief on the end teeth of end mills should be about 3 degrees to 5 degrees. On formed milling cutters or involute gear cutters, relief does not have to be considered in resharpening because the teeth are so formed that when they are ground radially on the face, the relief remains the same.
- Page 35 Section Five Instruction Manual Figure 16—Developing the relief angle Figure 15—Developing the relief angle when using a cup wheel. when using a straight wheel. Setting the Toothrest, Using a Straight Wheel (SEE TABLE I. PAGE 104, FOR CLEARANCE ANGLE SETTING.) Figure 15 illustrates a milling cutter being ground with a straight wheel The distance C between the center lines of the wheel and cutter varies with the relief angle.
- Page 36 Instruction Manual Section Five NOTE: If the cutter grinder is equipped with a tilting Wheelhead, this is simply set to the desired relief angle, as read on the machine scale, but the toothrest blade end and the center of the cutter are left on the same plane.
- Page 37 Instruction Manual Section Five STAGGERED TOOTH MILLING CUTTERS (SEE PACE 41 FOR ILLUSTRA TION AND DESCRIPTION OF A TYPICAL SET-UP.) Staggered tooth milling cutters, having alternately right and left-hand spiral teeth may be sharpened at one setup by using a toothrest with the top of the blade either rounded or shaped with a double angle (INVERTED V).
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Page 38: Chapter 7. Angular Cutters
Instruction Manual Section Five The same relief angles are used for the face edges which, for rough milling, should have a land about ⅜ inch wide, with the remaining portion of the edge ground off at an angle of about 3 degrees toward the center of the cutter, Finish milling is a thin shearing operation, and for best results, the face of the cutter should be ground off at an angle of 1 degree to 2 de... - Page 39 instruction Manual Section Five advantageously be increased to about 7 degrees while on larger saws, around 10 inches in diameter, for example, it should be reduced to about 3 degrees. To minimize the effect of wheel wear, a light finishing cut should be taken completely around the saw.
- Page 40 Instruction Manual Section Five cylindrically to the exact size desired, and then "back off" the teeth so as to leave practically a sharp cutting edge, the land being no more than a few thousandths of an inch wide. A few light strokes along the cutting edges (FACES) with an oilstone will remove any slight burr produced in grinding.
- Page 41 See Chapter 14, page 92, for application of this task to a K. O. Lee tool grinder.
- Page 42 Instruction Manual Section Five CHAPTER 2 Cutter Nomenclature and Measurement I. CUTTER NOMENCLATURE radial rake angle helical rake angle Figure 18A radial relief (positive (l.h. helix shown) angle shown) tooth face Figure offset fillet flute tooth face width helical teeth Solid FORM Solid HELICAL...
- Page 43 Instruction Manual Section Five FLANGE FOR MOUNTING POSITIVE AXIAL ON SPINDLE NOSE RAKE ANGLE TOOTH ANGLE RELIEF CHAMFER SECONDARY FACE OF RELIEF WORKING DIAMETER CUTTER DIRECTION OF ROTATION RELIEF BLADE PRIMARY CUTTING CLEARANCE EDGE ANGLE SECONDARY CLEARANCE ANGLE WEDGE ENLARGED VIEWS OF BLADE Figure 18E—Nomenclature of a Face Milling Cutter HAND TAPS Figure 18F—Sketch illustrating tap terms, as employed in Taps—Cut and Ground...
- Page 44 Section Five Instruction Manual REAMER NOMENCLATURE Figure 18G Chamfer ang/e Point or cutting edge S t r a i g h t f l u t e s Rake angle and shown right hand MACHINE REAMER POINT r o t a t i o n shown Radial face(0º...
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Page 45: I I I . When T O Sharpen A Cutter
Instruction Manual Section Five CUTTER RUNOUT TOLERANCES Periodically check the runout of straight arbors used to hold cutters. Do this also for workhead spindles and their workholding adapters. Use a .0001 inch dial indicator. If it shows more than .0005 inch runout at any point on the workholding device, locate the source of the trouble before mounting the cutter. -
Page 46: Plain Milling Cutters
Instruction Manual Section Five CHAPTER 3 Plain Milling Cutters SET-UP PREPARATION PHOTO 20 PHOTO 21 Mount a cup wheel on the wheel arbor attached to spindle, or directly to the motor shaft arbor. If the wheel is already mounted on a collet, mount this assembly directly to quill nose at the opposite end from drive pulley. - Page 47 Section Five Instruction Manual For tilthead grinders, adjust the quill swivel bracket to the desired primary clearance angle. Mount the toothrest assembly from below the wheel on the quill housing bracket as shown in Photo 22 so that the end of the blade is approximately at the center of the cup wheel on the left side;...
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Page 48: Shell End Mills And Other End Mills
Instruction Manual Section Five CHAPTER 4 Shell End Mill and Other End Mills SET-UP PREPARATIONS The set-up for the periphery is the same as for a Plain Milling Cutter except that the cutter is held in a workhead with an adaptor arbor or collet rather than being held between centers. - Page 49 Instruction Manual Section Five gauge. Lock the workhead spindle with the spindle in the horizontal zero degree position. PHOTO 25 PHOTO 26 Mount the toothrest assembly on top of the workhead in a position as shown in Photo 25, if the cutter edge to be sharpened is facing up. the toothrest may be set on the table, pointed upwards at the tooth edge, if the latter is to be faced downward at the point of grinding.
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Page 50: Straight Tooth Side Milling Cutters
Instruction Manual Section Five bearing from front to rear. If teeth lands show a taper, make small adjustments on the table swivel. 10. After the teeth appear sharp, loosen the workhead vertical swivel and adjust the workhead tilt to the desired secondary clearance angle, then lock. -
Page 51: Stagger Tooth Cutters
Instruction Manual Section Five CHAPTER 6 Stagger Tooth Cutter PHOTO 28 PHOTO 29 SET-UP PREPARATION FOR PERIPHERY Refer to Chapter 3-1, page 36, for the initial procedure in holding the cutter, for the wheel used, etc. Refer to Photo 28 for approximate location of the cutter on the machine and the cutter relative to the wheel. - Page 52 Instruction Manual Section Five slightly loosen the Hand-Nut on the BA940 toothrest that holds the toothrest cross arm and blade rigid, and move the cross arm and blade slightly toward the high tooth, reclamping the Hand-Nut. Grind the next two teeth and check them again.
- Page 53 Instruction Manual Section Five must be swiveled the angle equivalent to that between the cutting edges and the axis of the cutter. See Chapter 3, I and II. If the angular cutter is to be shank mounted in a workhead, the set-up is identical to that of a shell end mill, except that the table or workhead must be swiveled in the horizontal plane to the angle of the cutter.
- Page 54 Section Five Instruction Manual grees toward the cutter center; with a chamfer of 60 degrees from parallel with the axis of cutter, with simulated peripheral cutting edges; all cutting edges having only one relief angle of 5 degrees ( for chamfer and face). Instructions are for non-tilthead grinders unless otherwise noted.
- Page 55 Instruction Manual Section Five Toothrest and Clearance Angle Settings: Non-tilthead grinders: Prior to setting the toothrest, adjust the workhead upward to the necessary primary clearance angle. The base of the uni versal toothrest may be clamped on top of the workhead or on the top of the swivel table, depending on the size of the cutter and the position of its blades.
- Page 56 Instruction Manual Section Five Install the wheel guard in a position that will not contact the mill when traversed for grinding and that allows visual observation. When the toothrest is fixed on the column as in part B-3 above, traverse the table in the same manner as in C-1.
- Page 57 Instruction Manual Section Five Tilthead grinders: Instead of tilting the workhead, place the workhead axis level with the table, and adjust it for the necessary chamfer angle. Take chamfer clearance directly from the tilt of the Wheelhead by the visual method, or from the corner clearance table on page 108. Grinding Procedure: 1.
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Page 58: Form Relieved Cutters
Section Five Instruction Manual the steps in set-up procedure given in parts I, I I , and III for primary clearance. Match the secondary clearance angles on the cutter or use the suggested clearance from table V, on page 107. The toothrest may have to be adjusted, the workhead tilted one way or the other farther (IN THE VERTICAL PLANE), or, when the machines have a tilting wheel-... - Page 59 Section Five Instruction Manual Grinding wheel Radial line on which Grinding wheel tooth correctly face ground Radial rake Tooth rest. angle Base circle Figure 37B—Form-relieved cutters are face-sharpened only. grinding the teeth backs is one of the important factors in producing uniform tooth height which insures the successful operation of these cutters.
- Page 60 Instruction Manual Section Five Mount the universal toothrest on the grinder table, as shown in Photo 37 and using the micrometer with the spring loaded blade, place it near the back of the tooth to be ground and lock the hand-nut temporarily. Now reposition the machine Crossfeed in to a point where the original 0 point was reached.
- Page 61 If the cutter is not stamped with the amount of horizontal off-set from •NOTE: on B360, BA960. B2060 Series, it is easier to mount toothrest if B955PC Dovetail Clamp is used. - 5 1 -...
- Page 62 Section Five Instruction Manual the center of the cutter, continue with step C by moving the Crossfeed until it is possible to mount the cutter with its arbor between centers. Visually align the face of a tooth with that of the wheel until they are in the same vertical plane.
- Page 63 .001", making it possible to roll cutter without moving machine Crossfeed. Unit has a height setting collar for fast swing away from work. Adapts to all K. O. Lee grinders (except B300) produced after 1960, without drilling, with standard B670T T-slot block.
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Page 64: Grinding Cutters With Spherical Ends Or Corner Radii
(LETTER DESIGNATIONS REFER TO PHOTOS 43, 44, and 45; NUMBERS ARE FROM FIGURE 45A.) The K. O. Lee Radial Grinding Fixture is a precision bearing instrument for gen erating convex or concave radii on cutting tools. By means of its own Crossfeed... - Page 65 Instruction Manual Section Five RADIAL GRINDING FIXTURES PHOTO 43 PHOTO 44 BA986 STANDARD EQUIPMENT LISTED BELOW BA985 RADIAL GRINDING FIXTURE STANDARD EQUIPMENT A280 Friction Collar. A281 Friction Collar, A290A Table Adjusting Screw, A657, A660 T-Slot Bolts. B620D Back Plate B620G Swivel Stud, B684N Nut, B684S Diamond Screw, B685B1 V," Cutter Bushing, B685B2 1"...
- Page 66 Instruction Manual Section Five BA985 AND BA986 RADIAL GRINDING FIXTURES Figure 45A Min. ⅛ 2¾ Max. Figure 45C —56-...
- Page 67 Instruction Manual Section Five 1¼ (B985JG) if the cutter has no corner radii, or install the optional 'V Gauge (B985J) if it already has corner radii. The Crossfeed of the machine should be out far enough from the wheel so that the Gauge stands in front of the cup wheel or straight wheel.
- Page 68 Section Five Instruction Manual VERTICAL GRINDING RADIUS VIEW WHEEL ON WHEEL HAS TO BE LESS THAN CONCAVE RADIUS R - RADIUS OF TOOTH CENTERED ON WHEEL [CONVEX). R = RADIUS OF TOOTH CENTERED ON WHEEL (CONCAVE) additional amount for the periphery by checking the amount to rotate the cutter about its Stud mount from Tables 1 and 2 on pages 11 and 12.
- Page 69 Instruction Manual Section Five PHOTO 47 PHOTO 48 After the correct radius is established, use the slides of the fixture to blend the radius to the cutter. Usually the upper slide handwheel " A " will be used to feed the cutter into the wheel for stock removal. The Crossfeed of the grinder must not be moved, as this will change the radius.
- Page 70 Instruction Manual Section Five If the cutter helix is not too steep or the radius too large, mount the Universal Toothrest on the fixture in the manner described in l-D, except that the base of the BA940 toothrest will be placed on top of the B985H Housing and Spindle Assembly or on the Table of the fixture similar to the set-up in Photo 46.
- Page 71 Section Five Instruction Manual sary to use a dial indicator on the mounted cutter or on a test arbor mounted in the B985H in order to determine parallelism with the table travel Locate the toothrest on the right edge of the cup wheel (OPPOSITE TO THE POSITION AS SHOWN IN PHOTO 47) and attach to the Wheelhead.
- Page 72 Instruction Manual Section Five wheel periphery, lightly advance the machine Crossfeed while holding the cutter against the toothrest with the handwheel (C). When the first sparks appear, stop the machine Crossfeed and slowly rotate the fixture and the Spindle Assembly to follow one spiral flute through its arc swing to the left until the fixture stop is contacted.
- Page 73 Instruction Manual. Section Five Begin to form the wheel with the diamond by advancing the machine Crossfeed while swinging the fixture through a predetermined arc. It will often be possible to measure the amount of total infeed of the nib into the wheel by means of the machine Crossfeed dial.
- Page 74 Instruction Manual Section Five CHAPTER 11 Reamers A reamer is a cutting tool combining economy and accuracy for enlarging holes to a required diameter. Reamers cut their way into holes with their leading edges and produce a smooth finish while cutting to size. REAMER TYPES Most reamers fall into the following general categories: hand reamers, straight shanked...
- Page 75 Instruction Manual Section Five and approximately 50 percent lower tor stainless steel and Monel Metals. They may also recommend considerably narrower margins for soft metals such as bronze, brass, aluminum, magnesium, etc., on the order of .002 inch maximum. apprentice or student is advised to duplicate the margin and clearance angle known to exist on the reamer when new.
- Page 76 Instruction Manual Section Five only a cup wheel, check the portion of the teeth back of the chamfer or lead taper for any built-in back taper. This may be done with a hand micrometer, since "feel" will reveal tapers of .001 inch per inch or less. Set the reamer in place between the centers and locate a toothrest on the machine Wheelhead (from above or below the wheel) and the blade on center with the center of the reamer.
- Page 77 Section Five Instruction Manual I I . GRINDING A HAND REAMER USED WITH CAST IRON, STAINLESS STEEL, AND MONEL METALS Generally there will be a few exceptions to the above procedure for hand reamers for steel. The major difference will be final margin width left (primary relief) on the reamer front leading taper and the remainder of the blades back from this taper.
- Page 78 Instruction Manual Section Five taper. This may be done by micrometer O.D. measurement or actual use of the reamer in a hole, by checking the hole reamed with a plug gauge. When grinding a helical flute taper reamer, it is necessary to mount the uni versal toothrest on the Wheelhead, as in Photo 51 or 52.
- Page 79 PHOTO 56 INTRODUCTION TO THE FIXTURE The K. O. Lee B947 Tap Grinding Fixture is designed to accommodate taps from No. 0 size to 254 inches in diameter, two to six flutes, with available components. It is adaptable to any make of tool grinder and can be mounted on a surface grind...
- Page 80 Section Five Instruction Manual B947 Tap Grinding Fixture S T A N D A R D E Q U I P M E N T B647B5/8 B u s h i n g — T a p 5 / 8 B 6 4 I C C o l l e t B 9 4 7 C 2 F l u t e 0...
- Page 81 Section Five Instruction Manual SHARPENING STANDARD TAPS UP TO 1 INCH DIAMETER Equipment and Accessories required (see Figure 53A): B947 Tap Grinding Fixture; B641C inch collet (STANDARD 5C — STAND ARD EQUIPMENT); B647B Bushings to fit taps No. 7 & 8, 9 & 10. 11 & 12. and sizes ¼...
- Page 82 Instruction Manual Section Five The Cam is now free to be removed with one's fingers. Lift it up, as it is keyed to the Spindle. Install the correct Lift Cam and push the Spindle back into the Housing position When the Spindle Assembly is being installed, guide the Spindle through the rear end of the Housing by lifting slightly the rear end of the Spindle Assembly.
- Page 83 Instruction Manual Section Five GRINDING TAPS OVER 1 INCH IN DIAMETER Equipment: The same equipment is required as is used for smaller taps, with the addition of the B641C .800 inch Collet, plus the following items: B647P Driver for the tap shank;...
- Page 84 Instruction Manual Section Five fixture lift Cam (No. 13) and reassemble the fixture Spindle Assembly as described in l-F. This procedure will allow the fixture Draw Tube, Collet, and Collet Adapter (all of the moving inner spindle parts) rotate freely together in a clockwise or counterclockwise manner. Lock Screw (No.
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Page 85: Cylindrical Grinding And Internal Grinding
Section Five Instruction Manual CHAPTER 13 Cylindrical Grinding and Internal Grinding PHOTO 58 PHOTO 57 On K. 0. Lee Universal Grinders, cylin drical grinding is accomplished either by using the standard spindle with the ma chine or by obtaining a high-speed spindle which has the capability of mounting both Internal Diameter (I.D.) wheels and the larger wheels for Outside Diameter (O.D.! - Page 86 Instruction Manual Section Five The cylindrical grinding set-up makes possible the grinding of reamers, lathe cen ters, mandrels, straight or tapered tool shanks, gauges, and many facing opera tions performed on cutters The work may be held in a universal chuck mounted in the workhead spindle, in a collet with collet fixture, or in various other adapter sleeves if no cutter for support is needed on the unheld end of the work.
- Page 87 Instruction Manual Section Five. For extreme accuracy, it will be necessary to install a test arbor in the work head or between centers to check for alignment with the table travel. enough material is to be removed, the work may be gauged as ground and the table taper adjusted.
- Page 88 The general method of producing the grinding action is similar to that of O. D. cylindrical operations. On many K. O. Lee grinders, the standard spindle on the machine is capable of holding I. D. wheel-holding arbors and can achieve the necessary high R.P.M. to...
- Page 89 Section Five Instruction Manual B780C COLLET CHUCK ASSEMBLY B780K and B780J ARBORS I D depth of hole range— ID depth of hole range — @ 1⅛" with ½" or @ 2" with ½" or ⅜" ⅜" diameter wheel diameter wheel. @ 2⅛"...
- Page 90 Section Five Instruction Manual work-mounting device into the workhead spindle. Mount the work and check its runout with an indicator. Very thin bushings may have to be held with the aid of a special bushing chuck or by end pressure to avoid distortion. Loosen the handle screws on the right side of the Wheelhead dovetail slide and move the Wheelhead forward enough so that there will be adequate cross- feed capability while aligning the wheel with the work hole.
- Page 91 Instruction Manual Section Five a cut across the work. Steady movement is essential. When finish grinding, reduce the traverse speed. Experience will tell the correct traverse for the size and type of work. The revolution of the work should not be stopped until the wheel has been backed away from the work.
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Page 92: Special Operations And Miscellaneous Tool Grinder Setups
Cylindrical grinding operations are performed with the cutter mounted in the motorized workhead in the position as shown in Figure 57, Chapter 13. Use a silicon carbide grinding wheel, such as the K. O. Lee RV6NH100, for rough grinding the periphery. - Page 93 Section Five Instruction Manual the general instructions, Section Four, Part I I I , Page 13 to 17. Mount the grinding wheel and collet assembly on the spindle of the machine. Check diamond cup wheels with a dial indicator to determine if there is any face "run-out."...
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Page 94: Miscellaneous Cutters
Instruction Manual Section Five PHOTO 63 PHOTO 64 INC THE CUTTER) to allow for the cutter's radial rake. Once this align ment is accomplished, the Crossfeed is not moved during the facing operation. Initially set both swivels of the workhead at 0 degrees; then place the face of the tooth parallel to the face of the grinding wheel by swivelling the workhead in the horizontal plane to the desired axial rake. -
Page 95: T-Slot, Woodruff Keyseat And Keyway Cutters
Instruction Manual Section Five as shown in Photo 64. Note that an index disc is used in conjunction with a plain toothrest in order to facilitate accurate and "easy indexing of the teeth. If the saw is badly worn, if a tooth is broken off, or if it is in need of gumming, grinding the face of each tooth and the gullet between that tooth and back of the preceeding one is required. - Page 96 Section Five Instruction Manual Photo 66 shows the typical set-up for sharpening the periphery of a Wood ruff Keyseat cutter. These cutters are sharpened only on the periphery as the sides are relieved by a slightly concave surface. The cutter shank is most easily held by a collet in a universal workhead.
- Page 97 With the silicon carbide wheel dressed for rough grinding, grind a relief for the end and side. The K. O. Lee wheel provided is 100 grit which is suitable for both roughing and finishing of tools for many operations.
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Page 98: Salvaging Tools
6 x 1/16 or 1/32 inch cut-off wheel to the grinder spindle. Mount a wheel guard. A K. O. Lee wheel, such as the PR6AH70 (S.F.P.M. @ 6.000), can be used for this operation. Wheel bond may be shellac, rubber, or resin. -
Page 99: Salvaging Milling Cutters
Section Five Instruction Manual PHOTO 68 PHOTO 68A pleting the first operation, tilt the workhead up further for the secondary or chip clearance angle. The Wheelhead elevation must again be adjusted so that the O.D. of the wheel will blend in with tooth face and helix of the cutter. - Page 100 Instruction Manual Section Five Figure 68B Figure 68C Figure 68D First Operation in Third Operation, with a Third Operation, with a Salvaging a Cutter. Worn-Out Cup Wheel. Dish Wheel. neath the wheel, lower the wheel just short of the bottom of a gullet, and using the Crossfeed handwheel, place the tooth face at the original rake relative to the wheel.
- Page 101 Mount the cutter shank or arbor in the workhead. Mount a straight wheel about 5 or 6 inches in diameter, such as the K. O. Lee PV5FH60 or PV7GM46. Mount a wheel guard. Since the back side of each tooth forms an angle with the tooth face, it will be necessary to dress the periphery of the wheel relative to its side at this angle.
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Page 102: Surface Grinding Operations
Instruction Manual Section Five approximately at the center height of the mill and contacting the tooth face just preceeding the one on top to be ground by the wheel. The tip of the blade should preceed (TO THE LEFT IN THE PHOTO) the wheel periphery at the inside in order to start camming just prior to the wheel contacting the flute end. - Page 103 Instruction Manual Section Five PHOTO 71 PHOTO 72 Set-up for sharpening the periphery: 1. Position the cup wheel as shown in Photo 71. Mount a wheel guard and dress the wheel (SEE CHAPTER 3). Mount the fixture at the right end of the table as shown. Fixture swivels (horizontal and vertical) should be set at '0'.
- Page 104 Instruction Manual Section Five wheel, 1/16 inch to the right of the wheel edge. It is not necessary to unlock the hex nut fastening the Arm (B982-12) to the Toothrest Adjustment Collar before moving the arm by means of the knob (3015-A). The posi...
- Page 105 Instruction Manual Section Five Keep in mind that when this method is employed, each time the Toothrest Adjustment Collar is rotated, or micrometer toothrest lowered, the wheel centerline must be relocated at the same height as that of the cutter center.
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Page 106: General Information, Specifications, Fixtures & Accessories
GENERAL INFORMATION, SPECIFICATIONS, FIXTURES and ACCESSORIES GENERAL SPECIFICATIONS UNIVERSAL TOOL AND CUTTER GRINDERS have either a High Speed Standard Spindle (B360. BA960. B2060 and B6060) or a Heavy Duty Spindle (BA962, B2062 and B6062). TOOL AND CUTTER GRINDERS have a Single Speed Motorized Spindle (Models B300. BA900 and B2000) - Page 107 Minimum Distance Centerline of Wheel Shaft to Top of Table 3¾" 3¾" 3¾" 5⅜" Maximum Distance Centerline of Wheel Shaft to Top of Table 10¾" 10¾" 15¼" 10¾" 3¾" Maximum Distance from Column to Outside of Straight Wheel; 3¾" 4½" Dovetail Slide Not Extended, Spindle 90°...
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Page 108: Universal Tool And Cutter Grinders
Section Six Instruction Manual MACHINE STANDARD EQUIPMENT A. UNIVERSAL TOOL AND CUTTER GRINDER STANDARD EQUIPMENT FOR MODELS B360, BA960, B2060 B922 with 2 A658 T-Slot Bolts MODELS B360 BA960 BA962 B2060 B2062 STANDARD EQUIPMENT FOR MODELS B360, BA960, B2060 A657 T-Slot Bolt, A660 T-Slot Bolt, B640K Diamond Dresser, B827 Plain Tooth Rest, B922 Tailstocks (Matched Set), B939 Center Gauge, BA940 Universal Tooth Rest. - Page 109 Instruction Manual Section II. MACHINE STANDARD EQUIPMENT UNIVERSAL TOOL AND CUTTER GRINDER (Cont) MODELS BA962 AND B2062 STANDARD EQUIPMENT FOR B955HD UNIVERSAL GRINDING HEAD A609A T-Slot Arm. A657 T-Slot Bolt, A659 T-Slot Bolt. B246C Wheel Guard 4", B246D Wheel Guard 6", B246E Wheel Guard 8", B628 Wrench, B855W Wrench, B923C Motor, B936C Collet (2).
- Page 110 Instruction Manual Section MACHINE STANDARD EQUIPMENT UNIVERSAL TOOL AND CUTTER GRINDER (Cont.) MODEL B6060 STANDARD EQUIPMENT FOR B6055 UNIVERSAL GRINDING HEAD B246C Wheel Guard 4 " , B246D Wheel Guard 6". B628 Wrench, B855W Wrench, B936P Wheel Puller, B936W Wrench, B6028 Wrench, B6055A Quill Assembly, B6055C Collet Chuck Assembly, B6055F Pulley and Wheel Arbor Assembly, B6055H1 Pulley 3 ½...
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Page 111: Tool And Cutter Grinders
S89l Extension Wrench for Stop and Reversing Screws. III. TOOLING, FIXTURES AND ACCESSORIES WORKHEADS FOR MODEL SERIES B300, B360, BA9C0, BA960, BA962, B2000, B2060, B2062: B942 Sensitive Workhead with No. 11I B & S Spindle Taper, B942XM Sensitive Workhead with No. 5 Morse Spindle Taper, B942XB Sensitive Workhead with No, 12 B &... -
Page 112: Workheads For Model Series B6060 And B6062
Instruction Manual Section Workhead with No. 11 B & S Spindle Taper, B2043M5 Variable Speed Motor (DC.) Driven Workhead with No. 5 Morse Spindle Taper, B2043B12 Variable Speed Motor (D.C.) Driven Workhead with No. 12 B & S Spindle Taper. WORKHEADS FOR MODEL SERIES B6060 AND B6C62: B7042 Sensitive Workhead with No. - Page 113 Section Instruction Manual III. TOOLING, FIXTURES AND ACCESSORIES Consult the Universal Tool and Cutter Grinding Catalog for complete listings of all Models and Sizes B S 4 2 B 9 4 3 B A 9 8 6 S E N S I T I V E W O R K H E A D M O T O R D R I V E N W O R K H E A D R A D I A L G R I N D I N G...
- Page 114 Instruction Manual Section III. TOOLING, FIXTURES AND ACCESSORIES Consult the Universal Tool and Cutter Grinding Catalog for complete listings of all Models and Sizes. B 6 4 8 D I N D E X D I S C S B 6 4 I C O L L E T F I X T U R E 2 4 U P T O 6 0 D I V I S I O N S FOR B 9 4 3 .
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Page 115: Machine Adaptability
ADAPTING A MACHINE W I T H HEAVY DUTY GRINDING HEAD TO USE A HIGH SPEED SPINDLE. (See K. O. Lee Univ. Tool & Cutter Grinder Cata log or Grinding Wheel Sheet for listing of available wheel sizes and shapes.) -
Page 116: Clearance Angles -Straight Wheels
Instruction Manual Section Seven TABLES OF REFERENCE CLEARANCE ANGLES —STRAIGHT WHEELS Relief Tables for High-Speed Steel Cutters I—Using Straight Wheels C = Distance in inches to set center of cutter and tip of tooth rest below (or above) center of wheel when grinding with a straight wheel. -
Page 117: Clearance Angles -Cup Wheels
Instruction Manual Section Seven CLEARANCE ANGLES —CUP WHEELS II—Using Cup Wheels C = Distance in inches to set tip of tooth rest below or above center of cutter when grinding the peripheral teeth of cutters with a cup wheel. Cutter C for 5º... - Page 118 Instruction Manual Section Seven I I I . CLEARANCE ANGLES —REAMERS Vertical Adjustment of Tooth-rest for Grinding Clearance on Reamers Chucking Hand Reamer Hand Reamer Reamer for for Cast Iron Rose for Steel. Cut Cast Iron and and Bronze. Chucking ting Clearance Bronze.
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Page 119: Clearance Angles--Carbide Reamers
Instruction Manual Section Seven CLEARANCE ANGLES —CARBIDE REAMERS RECOMMENDED PRIMARY (RELIEF) & SECONDARY (CLEARANCE) ANCLES: Reamer Diameter Relief Angle Clearance Angle 20° to 15° 40° to 30° ¼" to ⅜" ⅜" to ⅝" 15° to 10° 30° to 20° 10° to 8° 20°... -
Page 120: Clearance Angles -Corner
Instruction Manual Section Seven CLEARANCE ANGLES —CORNER After determining the necessary clearance angle and corner angle, read the correct settings for radial roll and axial tilt of the universal workhead at the horizontal and vertical intersection of these values. EXAMPLE: For 7 degrees of clearance and a 45 degree corner angle, the radial roll is 5 degrees and the axial tilt is 5 degrees. -
Page 121: Vii. Wheel R.p.m. / S.f.p.m. Chart
Instruction Manual Section Seven VII. WHEEL R.P.M. / S.F.P.M. CHART Table of Grinding Wheel Speeds To find the number of revolutions of the wheel spindle, having been given the surface or peripheral speed and the diameter of the wheel, divide the surface speed in feet per minute by the circumference (diameter x 3.14) in feet. -
Page 122: Viii. Standard Wheel Shapes
Instruction Manual Section Seven VIII. STANDARD WHEEL SHAPES Standard Shapes of Grinding Wheel Faces When no face is specified a straight "A" face wheel is furnished. different faces which are regularly supplied are designated by letters as shown below: —110-... - Page 123 Section Seven Instruction Manual VIII. STANDARD WHEEL SHAPES Key to Letter Dimensions = Flat Spot of Beveled Wall. = Diameter of Flat Inside. = Diameter (Over All). = Large Diameter of Bevel. = Center or Back Thickness. = Diameter of Recess. = Depth of Recess.
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Page 124: Ix. Metric And Decimal Equivalents Of Common Fractions
Instruction Manual Section Seven IX. METRIC AND DECIMAL EQUIVALENTS OF COMMON FRACTIONS DECIMAL FRACTION FRACTION DECIMAL MILLIMETERS MILLIMETERS OF INCH OF INCH OF INCH OF INCH 1/64 .015625 33/64 0.3969 .515625 13.0969 1/32 .03125 17/32 0.7938 .53125 13.4938 3/64 .046875 35/64 .546875 1.1906... -
Page 125: Glossary Of Terms
Instruction Manual Glossary of Terms Glossary of Terms Abrasive: A substance used for abrading — grinding, polishing, lapping — such as the natural materials, corundum, emery, diamond, etc., and the manufactured or electric furnace materials, such as: aluminum oxide (Al ), silicon carbide (SiC), boron carbide (B C), and cubic boron nitride (BN). - Page 126 Instruction Manual Glossary of Terms such as the hardness or toughness of metals being cut On lathe cutting tools, the rake angles (top and side) are located on the top of the tool bit. The rake angle is positive if the face slopes downward from the point toward the shank and negative if the face slopes upward toward the shank Backing Off: A shop term meaning to put a relief or clearance land on a cutter back of the cutting edge or the primary relief land.
- Page 127 Instruction Manual Glossary of Terms Burning (the work) : A change in the work being ground caused by the heat of grinding, usually accompanied by a surface discoloration. Burr: A turned over edge of metal resulting from punching a sheet and sometimes from grinding or cutting off operations.
- Page 128 Instruction Manual Glossary of Terms Chaser: A thread cutting tool that fits into a die head used on a turret lathe or screw machine. Usually a hardened steel plate with several teeth of the correct pitch cut into it. Three or four chasers are used in a die head. Chatter Marks: Surface imperfections on the work being ground usually caused by vibrations between the wheel and the work.
- Page 129 Instruction Manual Glossary of Terms Cutters (cutting tools): Usually of high-speed steel or carbide material. Cutting Angle: The angle measured between the cutting face of a tool and the surface of the material on which the tool operates. Cutting-Off Wheel: A thin wheel, usually made with an organic bond, for cutting off.
- Page 130 Instruction Manual Glossary of Terms Expansion Reamer: A type of hand or machine reamer in which the diameter may be slightly increased. An expansion chucking reamer which has become worn may be enlarged and then re-ground to the original size. Face: That part of the wheel which does the grinding.
- Page 131 Instruction Manual Glossary of Terms cutting tool is ground to the shape desired and reproduces this shape on the work piece. Sometimes called a "slab forming tool" for use in lathes Gauge: A tool used for checking parts to determine whether they are made within specified limits.
- Page 132 Instruction Manual Glossary of Terms Hob: A special type gear cutter designed to cut gear teeth on a continuous basis. Honing: A process used to produce the final fine surface finish on a part after all other operations. Honing permits a closer fit on critical parts. Abrasive blocks are forced against the work surface under very light spring pressure in a rotary motion and at the same time moved back and forth.
- Page 133 Instruction Manual Glossary of Terms Lead Angle: The angle of the helix of a screw thread or worm thread. It is the measure of the inclination of a screw thread from a plane perpendicular to the axis of the screw. Lead of Thread: On a single threaded screw, the distance the screw or nut advances in one complete revolution.
- Page 134 Instruction Manual Glossary of Terms O.D.: An abbreviation for outside diameter. O.D. Grinding: Abbreviation for cylindrical grinding. Oilstone: A natural or manufactured abrasive stone impregnated with oil and used for sharpening keen edged tools. Operating Speed: The speed of revolution of a grinding wheel expressed in either revolutions per minute or surface feet per minute Organic Bond: A bond made of organic materials such as the synthetic resins, rubber or shellac.
- Page 135 Instruction Manual Glossary of Terms Reamer: A cutting tool used to produce a smooth, accurate hole by removing a small amount of metal from a drilled hole. Recessed Wheels: Grinding Wheels made with a depression in one side or both sides to fit special types of flanges or sleeves provided with certain grinding machines.
- Page 136 Instruction Manual Glossary of Terms Saw Cummer: A grinding wheel used for gumming or sharpening saws. Scleroscope: An instrument for determining the relative hardness of materials by a drop and rebound method. Scratches: Marks left on a ground surface caused by a dirty coolant or a grinding wheel unsuited for the operation.
- Page 137 Instruction Manual Glossary of Terms Slotting Wheel: A thin grinding wheel, usually organic bonded, used for cutting slots or grooves in the work piece. Spanner Wrench: A type of wrench having a hook or equipped with pins for tighten ing or loosening threaded circular collars which have either slots or holes to receive the hook or pins on the wrench.
- Page 138 Instruction Manual Glossary of Terms centers. A principal part of the engine lathe used for supporting the ends of work- pieces by means of a center point held in the spindle. May be moved along the ways and clamped in different positions and offset from the true axis of the lathe for turning tapers.
- Page 139 Instruction Manual Glossary of Terms Universal Vise: A work-holding device usually used on the milling machine which has either two or three swivel settings so that workpieces may be set at any de sired angle, including compound angles. Also, called a toolmaker's vise. The K. 0. Lee B989 fixture is an adaptation of this principle for tool grinding machines.