K. O. LEE B360 User manual

AHANDBOOKFORUSEWITHK.O.LEE
UNIVERSALGRINDERS
TOOLANDCUTTERGRINDERS
200 SouthHarrison
Aberdeen,SD57402-1416

Instruction
K.O.LEECOMPANY,ABERDEEN,S.D.57401
Manual
AHANDBOOKFORUSEWITH
K.O.LEE
UNIVERSALGRINDERSAND
TOOLANDCUTTERGRINDERS
Price $6.00

Acknowledgements
TheK.O.LeeCompanywishestothanktheNortonCompanyofWorcester,
MassachusettsfortheprivilegeofusingmaterialfromtheirhandbookToolRoom
Grinding.
Wealsowishtothankthefollowingindividualsfortheirspecialcontributionsof
technicaladvice,photographyandlayout,editing,andoutlinesuggestions:Mario
Swenson,DeloLee,PhilBraunstein,DonStablein,MarvinKoth,GeorgeUtech,
Jeanine Morevac,andDennisScott.
K.Lee,writer
copyright© 1979by
KO LEECOMPANY
AllrightsreservedNopartofthisworkmaybereproduced
ortransmittedinanyformbyanymeans,electronicor
mechanical,includingphotocopyingandrecording,orby
anyinformationstorageorretrievalsystem,withoutpermission
inwritingfromthepublisher.
PrintedintheUnitedStatesofAmerica

Instruction Manual Section One
PrefaceandContents
I.SCOPEANDPURPOSE
Thishandbookprovidesinformationforoperatingandmaintainingthefollowing
modelseriesofK.O.LeeUniversalGrindersandToolandCutterGrinders:B360,
BA960.BA962,B2060.B2062.B6060.B6062UniversalGrinders;B300,BA900.
B2000,ToolandCutterGrinders.
ModelsaremanufacturedwithvarioussuffixlettercombinationsRegardlessof
specificmodelnumber,inmostinstancesallportionsofthishandbookwillstillbe
applicable.Atthetimeofprinting,theinstructionsthatapplytoK.O.Leegrinders
wereaccurate,butduetoengineeringadvances,itispossiblethemachinedelivered
toyoumayvarysomewhatfromthedescriptionsinthisbook.Intheabovelisted
models,suffixes"X"and"Y"definecertainstandardmodelslesssomestandard
equipmentasdefinedinthecataloguesandpricesheets."H"standsforhydraulically-
powered-table-travel."B"standsforanti-frictiontabletravelor"ball-track"sys-
temwhichbecameavailablein1977.Priortothat,thedesignation"BB"wasused
formodelswhichhadballbearingmountedV andflatrollersastablesaddleways.
"M"standsformetrically-calibrated-feed-handwheels.
MODELANDSERIALNUMBERSarelocatedona stampednameplateattherear
orsideofthemachinebaseonmostmodels.
Whileitisthepurposeofthismanualtocoverthemosttypicaloperationsperformed
onuniversaltoolandcuttergrinders,andonK.O.Leemachinesspecifically,it
makesnoattempttobeexhaustive.Itshouldbetakenasa primeronthetechnology
andartoftoolroomgrinding,recognizingthatthereareoftenmanydifferent
approachestoa particulargrindingproblem.Ourgoalistoengenderfamiliarityand
satisfactionwithourmachinesandtoolsTothatend,wehopethisworkwillbe
ofvaluetothebeginneraswellastheexperiencedmachinist.
--i--

Instruction Manual Section One
--ii--
TableofContents
SECTIONONE
I.PrefaceandContents
II.ScopeandPurpose
III.TableofContents.
SECTIONTWO
INSTALLATIONINSTRUCTIONS
II.CompletingAssemblyofGrinderComponents2
III.FoundationandLevelingtheGrinder...2
SECTIONTHREE
LUBRICATION
I.Initial3
II.HydraulicallyPoweredMachines3
III.LubricationChart....5
SECTIONFOUR
GENERALOPERATIONINSTRUCTIONS
I.SafetyPrecautions
II.ElectricalControls
A.WheelheadandSpindleMotor
B.MotorizedWorkheads
C.HydraulicMachines
D.CoolantSystems
i
i
ii
I.Uncrating 1
E.SpecialElectricalControls
III.MachineOperation
A.TableTraverse
1.Manual.
2.Hydraulic
B.CrossfeedTraverse
C.ColumnElevation.
9
9
9
9
11
11
12
D.GrindingHeadsandWheelMountingProcedure. . . . 12
E.SwivelTableAdjustmentsforTaperandClearance...17
F.TailstocksandWorkheads18
C.GrindingWheelTruingandDressing18
H.ToothrestsandHeightGauges19
8
8
8
9
9
9

Instruction Manual Section One
TableofContents
SECTIONFIVE
CUTTERGRINDINGANDOTHERTOOLGRINDEROPERATIONS
CHAPTERI,IntroductiontoSharpeningHighSpeedandOtherCast
AlloyMulti-ToothCutters21
CHAPTER2.CutterNomenclatureandMeasurement....32
I.CutterNomenclature32
II.CutterRunoutTolerances35
III.WhentoSharpena Cutter......35
IV.CutterInspection-ClearanceAngleCheckbyIndicator35
CHAPTER3.PlainMillingCutters36
CHAPTER4.ShellEndMillsandOtherEndMills38
CHAPTER5.StraightToothSideMillingCutters40
CHAPTER6.StaggerToothCutters41
CHAPTER7.AngularCutters42
CHAPTER8.FaceMills43
CHAPTER9.FormRelievedCutters48
CHAPTER10.GrindingCutterswithSphericalEndsorCornerRadii. 54
CHAPTER11.Reamers64
CHAPTER12.Taps69
CHAPTER13.CylindricalGrindingandInternalGrinding...75
CHAPTER14.SpecialOperationsandMiscellaneousToolGrinderSetups82
I.Cylindrical& FaceGrindingofCarbideMillingCutters82
II.MiscellaneousCutters84
A.MetalCuttingSaws84
B.T-Slot,WoodruffKeyseatandKeywayCutters. 85
C.SinglePointTools— Useof
B945TiltingTableAttachment....86
III.SalvagingTools88
A.SalvagingEndMills— UseofCut-OffWheels. 88
8.SalvagingMillingCutters89
IV.SurfaceGrindingOperations92
A.B989UniversalWorkholdingFixture...92
B.MagneticChucks92
C.WetWheelGuards92
V.B982AirBearingFixture92
--iii--

Instruction Manual Section One
TableofContents
SECTIONSIX
GENERALINFORMATION,SPECIFICATIONS,FIXTURES& ACCESSORIES
I.GeneralSpecifications
UniversalToolandCutterGrinders
ToolandCutterGrinders
II.MachineStandardEquipment
A.UniversalToolandCutterGrinders
B.ToolandCutterGrinders
III.ToolingandFixturesandAccessories
AWorkheadsforModelSeriesB300,B360,BA900,BA960,
BA962,B2000.B2060,B2062
B.WorkheadsforModelSeriesB6060andB6062
C.CoolantSystems
D.ColumnExtension
E.SpecialToothrestSlideBladeandArm
IV.MachineAdaptability
A.Adaptinga MachinewithHeavyDutyGrindingHead
tousea HighSpeedSpindle
B.Adaptinga Machinewitha StandardGrindingHead
tousea HeavyDutySpindle
C.Adaptinga ToolandCutterGrindingMachine
tobecomea UniversalGrinder
V.RepairKitsandOrderingParts
SECTIONSEVEN
TABLEOFREFERENCE
I.ClearanceAngles—StraightWheels
II.ClearanceAngles— CupWheels
III.ClearanceAngles— Reamers
IV.ClearanceAngles--CarbideReamers
V.StandardClearanceAngleSettingsforH.S.S.Cuttersand
CarbideFaceMills....
VI.ClearanceAngles— Corner
VII.WheelR.P.M./S.F.P.M.Chart.
—iv—
95
96
99
99
VIII.StandardWheelShapes
IX.MetricandDecimalEquivalentsofCommonFractions
110
112
SECTIONEIGHT
GlossaryofTerms 113
104
105
106
107
107
108
109
99
100
100
100
100
103
103
103
103
103

PHOTO1
06183LIGHT
FIXTURE
MOTORDRIVEN
WORKHEAD
SWIVELTABLE
TABLEPOINTER
INDEXPLATE
TABLESTOPS
STOPBLOCK
THUMBNUT
CROSSFEED
HANDWHEEL
STORAGE
COMPARTMENT
DOOR
TILTING
HEAD
DOVETAILSLIDE
RIGHT
TAILSTOCK
TABLE
ADJUSTMENT
SCREWS
ELEVATION
HANDWHEEL
TABLETRAVERSE
HANDWHEEL
ELECTRICAL
CONTROLBOX
HEAVYCAST
IRONBASE
MODELB6062BWITHOPTIONAL
B9043MMOTORIZEDWORKHEAD

Instruction Manual Section Two
INSTALLATIONINSTRUCTIONS
I.UNCRATING
A.Afterthetopandsidesofthecratehavebeenremovedfromtheskidleaving
themachinestandingfree,removeallwrappingmaterialsandreadunskidding
andliftinginstructionsattachedtomachine.
B.Removeboltsholdingmachinetotheskidbyholdingthebottomofbolt-heads
(underskid)witha wrenchandturningoffthenutsfromtheinsideofthebase
ofthemachine.Exportedmodelsmayhaveboltspassedthroughskidmembers.
Boltnutsmustbeturnedoffinsidethebaseandmachineliftedfromtheskid.
C.Lifting,MovingandLevelingInstructionsforModelsexceptB300:
1.Ifpossible,avoidremovingtable/saddleholddownboltsuntilmachineis
movedtofinallocation.
2Donotattempttopickupmachinebyitssaddleortable.Usethetwo
holeson eithersideof thebasecabinetforliftingwithcablesor ropes
whenholesareaccessible.Useblocksofwoodonsideofbaseorbetween
cabletokeepthemawayfromsaddlesidesortable.Seesuggestedpro-
cedureforliftingwith
twocablesbyforklift
below,
3.Afterthemachinehas
beenliftedbycables
orropesandmovedto
itsfinalposition,do
notloweruntilsquare
headsetscrewsinside
thebasecabinethave
beenturneddownbe-
lowthebottomofthe
base,approximately¾
inch.Placethewasher
andhexjamnuton
eachofthesetscrews
protrudingthroughthe
cabinet,butdonot
tightenagainstbottom
ofbase.Levelingpads,
nutsandwashersare
inmarkedcartonin
basecabinet.
D.Removetheholddown
rodsandclamps.Remove
anyprotectingboards.On
modelswithballbearing
mountedtables,donotre-
moveholddownsuntilma-
chineislocatedatfinal
spotandleveled.
--1--
½x 2½"NCSquareHeadSetScrew.CupPt
½" ShakeproofWasher
½" NC HexJam
Nut
BA905G LevelingPad

Instruction Manual Section Two
HANDPOWEREDTABLETRAVELGRINDERSWITHBALLTRACK:Assoon
asyouhavereceivedyourmachine,movethetabletotheextremerightside
ofthemachine,andcheckthelevelofwaylubeinthechannelareasurround-
ingthehardenedwaysinthesaddle.Thisshouldbemaintainednearthetop
oftheoverflowspacecutintothesaddleextensioncasting.Theoilprovides
awashingactionontheballs,thuskeepingthemandwaycontactlinefreeof
dust.Addwaylubeasnecessary.ExtralightwaylubePartNo.2671must
beused.
E.Removetheshippinganti-rustlubricantfromallnon-paintedsurfacesbyusing
astandardsolvent.
II.COMPLETINGASSEMBLYOFGRINDERCOMPONENTS
A.Refertothismanual,pages96to99,ortoothergrinderliteratureforcorrect
standardequipmentbreakdown.Dothesameforanyfixturesortoolingwhich
arenotstandardwiththemachine.NOTE:Checkallcardboardcartonsfor
itemswhicharepicturedandlisted.Checkinsideofallcoolanttanksforparts.
Occasionallystandardaccessoryequipmentwillbeincludedinthesecartons.
B.Pulleysandbelts:PlaceV pulleysonthemotorandthequillshafts,usingkeyed
washersandspecialnuts.NOTE:CHOOSEPULLEYSONLYAFTERCON-
SULTINGTHEMACHINER.P.M.CHART.Visuallycheckthealignmentby
rotatingthemotorshaftbyhandorbypowerwiththebeltinplace.
C. ConsultSectionFour,PartIII,pages13 to 17 fortheinstallationof wheeland
pulleyarborsontospindleshafts.
D.HydraulicMachines:Seepages6,11,12of"InstructionManual"HPL-3for
installationandtrouble-shootinginformation.SeeSectionFour,PartIII,page
11foroperatinginstructions.
IIl.FOUNDATIONANDLEVELING
A.Readanyset-upinstructioncardsonthemachine.Thebaseofmostmodelsis
supportedbyfourcastpadsonthefloorandfourlevelingscrewsturnedinto
eachcornerofthebase.Ifa spiritlevelrevealsthatthetableisnotlevel,
makeadjustmentsaccordingtomachinetagsor"B"below,
B.LEVELING:Placelevelingpadsonfloorunderneaththeboltlocationsand
lowermachinecarefully.Adjustthesetscrewsbywrenchontheirsquare
head,insideofbasecabinet,andwhenmachineislevel,lockthehexjamnut
underneaththecabinetonallfourscrews.Seediagramonpage1.Allfour
screwsmustbefirmlycontactingpadsinorderformachinetofunctionproperly.
C.B300seriesgrindershavethreeintegralbasecabinetpads.Levelingmustbe
accomplishedbyplacingmetalplatesunderoneormoreofthepads.
-1A-