1. Machining a V-Block Flexible Manufacturing Copyright © Texas Education Agency, 2013. All rights reserved. 1

2. V-Block Plans Copyright © Texas Education Agency, 2013. All rights reserved. 2

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7. V-Block Bill of Materials NameQuantityLengthWidthThicknessMaterialFinish Block11.500 AluminumPolished Yoke Arm21.5000.5000.375AluminumPolished Yoke Support12.2500.6250.500AluminumPolished Yoke Screw12.0000.500 dia.AluminumPolished Handle11.7500.250 dia.AluminumPolished Pan Head Screw 20.500#5-44 Copyright © Texas Education Agency, 2013. All rights reserved. 7

8. Manufacturing Steps for a V-Block V-Block Cut Sheet Cut the following pieces of metal 2” X 12” X 2” piece of aluminum ⅜” X ½” X 3 ½” piece of aluminum ½” X ⅝” X 2 ¼” piece of aluminum ½” diameter X 2” piece of aluminum ¼” diameter X 1 ¾” piece of aluminum Copyright © Texas Education Agency, 2013. All rights reserved. 8

9. V-Block Copyright © Texas Education Agency, 2013. All rights reserved. 9

10. Manufacturing Steps for a V-Block V-Block 1.Face all sides of the cube on the mill. 2.Mill a ⅛” (0.125”) wide slot ⅛” (0.125”) deep on one face of the cube. This slot is in the center of the face. Copyright © Texas Education Agency, 2013. All rights reserved. 10

11. Manufacturing Steps for a V-Block 3.Turn the cube to the opposite face of the cube and mill a matching slot. Copyright © Texas Education Agency, 2013. All rights reserved. 11

12. Manufacturing Steps for a V-Block 4.Turn the cube 90 degrees. The surface should be aligned with the side slots. Mill a groove in the face starting 0.312” from the edge. The groove should be 1.437” wide. Copyright © Texas Education Agency, 2013. All rights reserved. 12

13. Manufacturing Steps for a V-Block 5.Begin milling step slots to form the “V” in the block. 6.Move in 0.062” on each side and 0.03” deep for each step. Copyright © Texas Education Agency, 2013. All rights reserved. 13

14. Manufacturing Steps for a V-Block 7.Continue to cut slots, stepping in 0.062” and down 0.030” until the “V” is formed. Copyright © Texas Education Agency, 2013. All rights reserved. 14

15. Manufacturing Steps for a V-Block Copyright © Texas Education Agency, 2013. All rights reserved. 15

16. Mill Table Clamping System Clamp T-Bolt Step Block Mill Table Nut Copyright © Texas Education Agency, 2013. All rights reserved. 16

17. Parts of a Clamping System Clamp- a bar used to apply pressure on the part to be machined Step Block- a support for the clamp that allows the clamp to be placed parallel with the table T-Bolt- a special bolt made to slide into the slots on a milling table Nut- a fastener to fit the t-bolt and apply pressure to the part T-Slot- a groove machined in a milling table Copyright © Texas Education Agency, 2013. All rights reserved. 17

18. Clamping System Set-up Clamp T-Bolt Step Block Mill Table Nut T-Slot Copyright © Texas Education Agency, 2013. All rights reserved. 18

19. Manufacturing Steps for a V-Block Clamping the V-Block 8.Place the block to be milled into a v-block for the correct angle of 90⁰ (degrees). Copyright © Texas Education Agency, 2013. All rights reserved. 19

20. Manufacturing Steps for a V-Block 9.Place the two blocks on the mill table and adjust the t-bolt, step block, and clamp. 10.Tighten the nut to apply pressure to the clamp and secure the blocks in place. Copyright © Texas Education Agency, 2013. All rights reserved. 20

21. Manufacturing Steps for a V-Block 11.When finished with the first side, turn the block around, and mill the other side. 12.After the machining is done, sand and polish the block. 13.Store the block until the other parts are milled. Copyright © Texas Education Agency, 2013. All rights reserved. 21

22. Yoke Arm Copyright © Texas Education Agency, 2013. All rights reserved. 22

23. Copyright © Texas Education Agency, 2013. All rights reserved. 23

24. Machining Steps for the Yoke Arm 1.Place a piece of ⅜” X ½” X 2” into the mill vise. 2.Square the surfaces and mill the ⅛” (0.125”) away to make the finger fit in the slot. 3.Size the finger to slide in the slot milled in the side of the v-block. Copyright © Texas Education Agency, 2013. All rights reserved. 24

25. Machining Steps for the Yoke Arm 4.Drill the ¼” (0.250”) diameter counter bore ⅟₁₆” (0.062”) deep for the pan head screw head. 5.Drill the ⅛” hole for the #5-44 pan head screw. Copyright © Texas Education Agency, 2013. All rights reserved. 25

26. Yoke Support Copyright © Texas Education Agency, 2013. All rights reserved. 26

27. Copyright © Texas Education Agency, 2013. All rights reserved. 27

28. Machining Steps for the Yoke Support 1.Face all surfaces of a 2 ¼” (2.250”) X ⅝” (0.625”) X ½” (0.500”) to make the yoke support. 2.Mount the blank in the mill vise and machine the slot on the end of the yoke support. 3.Machine a slot on both ends. Copyright © Texas Education Agency, 2013. All rights reserved. 28

29. Machining Steps for the Yoke Support 4.Locate the hole for the yoke arm screws, drill them with a #37 drill ¼” (0.250”) deep, and tap to a #5-44 thread pattern. 5.Locate the center hole for the yoke screw ⅝” (0.312”) X ⅞” (0.875”). 6.Drill a hole using a #4 drill and then tap to ¼ - 20 threads. 7.Sand and buff to a shiny finish, and then place in storage container. Copyright © Texas Education Agency, 2013. All rights reserved. 29

30. Yoke Screw Copyright © Texas Education Agency, 2013. All rights reserved. 30

31. Copyright © Texas Education Agency, 2013. All rights reserved. 31

32. Machining the Yoke Screw 1.Take a ¼” (0.250”) rod 1 ¾” long from the storage area. 2.Place the rod in a lathe, face the end, and cut a ⅟₁₆” chamfer in the outside edge. 3.Flip the rod and repeat the step above (#2). 4.Sand and polish the rod for the handle of the screw. Copyright © Texas Education Agency, 2013. All rights reserved. 32

33. Machining the Yoke Screw 5.Take a ½” (0.500”) rod 2” long from the storage area. 6.Place the rod in a set of v-blocks and drill the ¼” (0.250”) hole for the handle. Copyright © Texas Education Agency, 2013. All rights reserved. 33

34. Machining the Yoke Screw 7.Place the rod in a lathe, face the end, and cut a ⅟₁₆” chamfer in the outside edge. 8.Flip the rod, face, and machine the shaft down to ¼” (0.250”) diameter for the threads. Copyright © Texas Education Agency, 2013. All rights reserved. 34

35. Machining the Yoke Screw 9.Machine the ¼ - 20 threads into the screw. 10.Sand and polish the screw and the handle until shiny. 11.Place the handle in the hole in the screw, and carefully drive the handle until the handle is centered in the screw. Copyright © Texas Education Agency, 2013. All rights reserved. 35

36. Assembling the Yoke Copyright © Texas Education Agency, 2013. All rights reserved. 36

37. Assembling the Yoke 1.Place the arm into the slot in the yoke support and tighten the pan head screw into the support. Copyright © Texas Education Agency, 2013. All rights reserved. 37

38. Assembling the Yoke 2.Place the second arm into the slot in the yoke support and tighten the pan head screw into the support. Copyright © Texas Education Agency, 2013. All rights reserved. 38

39. Assembling the Yoke 3.Place the screw into the threaded hole in the yoke support and tighten the screw. Copyright © Texas Education Agency, 2013. All rights reserved. 39

40. Assembling the V-Block 4.Slide the completed yoke into the slots on the v-block. Copyright © Texas Education Agency, 2013. All rights reserved. 40