Fabricating a lathe faceplate as a class project

The two basic methods of holding work for machining in the lathe are on the faceplate and between centers.  While currently little used in production machining, a face plate is one of the most versatile attachments for a lathe.  While more time consuming to set-up and "dial-in" than a chuck, it is both far cheaper and far more versatile.  

The Emco Compact 10 lathes have a D1-4 spindle nose mount.  FPC purchased an 8 inch flat-back chuck adapter to which the face plate will be mounted.

The material for face place is an 11 inch out-side diameter blind [or blank-off] stainless steel pipe flange.  This was generously donated by the employer of one of our students. The hole pattern was laid out by our students using a dial height gage and large right-angle iron.  The hole locations were prick punched by our students using a Skidmore optical center punch.  The faceplate will be bolted to the cast iron chuck adapter using 3/8 UNC socket head cap screws.  The faceplate mounting screw holes are 3/8 UNF for ease of tapping in the stainless steel and for vibration resistance..

Because of the large number of holes that must be accurately spaced, this is a time consuming project, but one that gave our students considerable experience in accurate lay-out and location, as well as hands on experience in drilling and tapping stainless steel.

This will be a valuable addition to the FPC machine shop capabilities.

A "teachable moment" -- Second-term student Paul looks at his new "Drill Doctor" drill pointer.  Paul has discovered the difficulties of drilling stainless steel with a dull drill.

 

Considering the differences between 118 degree and 135 degree drill points

 

Locating the 3/8 UNF "Q" tap drill for pointing.

 

Is all in the wrist -- Grinding a 135 degree high relief point on a "Q" drill.  Now how do I split the point?

STOP -- don't drill the 123 block!  The Drill Doctor allows students to directly experience the affects of changes in included angle, amount of relief, and point splitting on tool life and effort required.  Paul decided that in this stainless, a split-point 135 degree high relief geometry worked best, although it did require touching up the drill every few holes, which was easily and quickly done with the "Drill Doctor." Only 19 more holes to go!

 

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last updated by GmcD on 19-Mar-11 19:30
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