462 Modern Metalworking Copyright Goodheart-Willcox Co., Inc. 26.7.2 Squaring Stock A definite sequence of operations must be followed to machine several surfaces of a piece square with one another. The sequence is similar to that used to mill flat surfaces. Squaring Stock on a Horizontal Milling Machine 1. Machine the first surface, Figure 26-47A, and remove burrs. 2. Place the first machined surface against the fixed vise jaw. Insert a length of soft metal rod between the work and the movable jaw if necessary, Figure 26-47B. 3. Machine the second surface and remove burrs. 4. Reposition the work as shown in Figure 26-47C, then machine the third surface. This side must be machined to the specified dimension. Take a light cut and measure for thickness. The difference between this measurement and the required thickness is the amount of material that must be removed. 5. Repeat the above operation to machine the fourth side, Figure 26-47D. 6. If the piece is short enough, the ends may be machined by placing it in a vertical position. Otherwise, use a side mill as shown in Figure 26-48. 26.7.3 Face Milling Face milling uses a cutter that machines a surface at right angles to the spindle axis and parallel to the face of the cutting tool. Face Milling on a Horizontal Milling Machine 1. Select a cutter that is 3/4″ to 1″ ″ (19 mm to 25 mm) ″ larger in diameter than the width of the surface to be machined, Figure 26-49. 2. The work should project about 1″ (25 mm) beyond ″ the edge of the worktable to provide ample clear- ance. Mount it to the worktable or in a suitable hold- ing device. 3. Adjust the machine for correct speed and feed. 4. Slowly feed the cutter until it starts to remove metal. Use an adequate supply of cutting fluid. 5. After completing the cut, stop the cutter and return the work to the starting position for additional cutting if needed. 6. Make the finishing cut. 7. Tear down the setup. Use a brush to remove chips and cutting fluid. Do not use your hands or com- pressed air. 26.7.4 Side, Straddle, and Gang Milling Side milling refers to any milling operation that uses g side milling cutters. When the cutters are used in pairs to machine two opposite sides of a job at the same time, the setup is called straddle milling, g g Figure 26-50. Goodheart-Willcox Publisher Figure 26-47. Sequence for squaring stock on the milling machine. A—Square top. B—Square side. C—Square bottom. D—Square other side. 1 1 2 1 2 3 1 2 3 4 D B C A Goodheart-Willcox Publisher Figure 26-48. Another technique for squaring work ends. The solid jaw must be checked with a dial indicator to be certain it is parallel with the arbor. Be sure there is adequate clearance between the work and arbor.