Colchester Lathe Company

[Music] when a production engineer sets out to examine and judge the performance of a center lays what are the main points you look for one of the features you look for is the ability of the machine to take a cut smoothly and of speed on the toughest of materials you look also for versatility the lathe must be able to handle a wide range of turning operations as quickly as possible this set up with a hydraulic profiler and capstan attachment added to a standard chip master vividly illustrates this point [Music] [Applause] and it rings above all the production engineer will look for accuracy finished boarding of this Bush's typical of those operations we're fine tolerances must be maintained no lathe leaves our factory until it's proved itself capable of meeting these fine tolerances and the purpose of this film is to show some of the many ways in which we ensure these standards of accuracy and combine them with a low capital cost we specialize in lathe we make always have made nothing but lathes and every one undergoes a series of rigorous checks throughout its entire process of manufacture continuous production methods ensure relatively low manufacturing and selling costs - which is coupled and insistence on the highest possible accuracy there are two main components most likely to interest the engineer the first is the headstock the second is the bed a rigid bed with extremely accurate slight waves is essential careful design ensures that the bed is rigid and 100 percent inspection guarantees the accuracy of the slight weight efficient production of an accurate bed requires an accurate casting and the basis of a good casting is a good path here made of aluminium for precision and durability the hardened sound mode made from this pattern is sprayed with a graphite he's fitted carrier for the graphite is flashed off leaving a hard skin on the sand which allows the costume to come away clean late the cause for the mold are made in separate units see sand bonded with sodium silicate is forced into the core box from the sand reservoir into which air is blown at high pressure quick and accurate filling of the core boxes is followed by chemical hardening of the sand by injecting carbon dioxide gas no heat is used and it is because the cores are made separately that they can all be hardened by this co2 method which saves a great deal of time and money [Music] taken from that box is the hardened claws joined the stock of different shapes waiting to be placed in position in the moat [Music] thus the internal shape of the casting is gradually built up by the insertion of the cause [Music] having reached the right temperature molten metal from the pupae is poured into ladle the bed is cast in the inverted position since this produces cleaner sideways at the base of the mold and more uniform hardness lastly the cup through which the molten metal is poured is fitted to the mouth [Music] and the bed is cost the settled bed casting comes from the foundry Aradia for the first operation Milly tungsten-carbide gang cutters completely machined the bed wave in one pass ready for Hut the bed is hardened using high frequency induction equipment to a hardness reading of 450 brunette the specially-designed intensifier operating at a frequency of 400 kilocycles per second incorporates simultaneous water quench and insists in achieving consistent hardness with a minimum of distortion after stabilizing Tyrion the birds pass to the grinding department this unique bed grinding machine has been developed to machine three beds at a time for machining operations are completed in one setting the bed including the bed form and the attachment phases for additional equipment such as profilers and paper terms [Music] random samples are checked for tracks with this special magnetic flux type back to them thus we ensure beds of high precision and perfect surface finish and serve to the headstock the heart of the lathe it's in the headstock that the greatest possible precision must be achieved to ensure this from the outset the rough castings must be properly seasoned when wanted the casting is brought into the shop for shot plastic a couple of minutes in this machine ensure that the services of the casting are clean and removed any molding sand from the critical surfaces it also gives a good key the subsequent painting operation in the fettling shop grinding wheels in a variety of abrasive equipment are used to remove dashes and rough spots zinc chromate primer forms a good base for the pain then a knife applied filler followed by wet rubbing down produces a good and clean surface a sealing coat inside and out and they're ready to move off the mill the headstock castings are milled on a fully automatic programming milling machine all side faces are roughed and finished at one setting and once the program is set the complete cycle of operations is carried out automatically this machine is typical of the equipment used to achieve accuracy allied to money-saving production techniques the bearing housing balls on our machine on double-ended multi spindle fine boarding machines specially designed at Colchester 10th tolerances are maintained and all bores finished in one cycle every headstock housing is carefully inspected for Oh Valatie taper and diameter before being passed through the assembly Department with the housing completed we move next to the headstock gears here again in order to combine accuracy with economy the latest production techniques are employed this six spindle auto insurer feed concentricity of blanks because the complete machining is carried out in one family this particular component gear blank is produced from high tensile steel in under three minutes typical of the high production techniques employed in our turning the party the teeth are initially capped on modern gear having machines enabling the use of to start hubs and climb cutting techniques accuracy at this stage of manufacture is vital as any errors cannot be fully corrected by subsequent machining operation after hobbing the gears are semi-finished by shaving as the term implies a very small amount of material is removed from the tooth blank by this process the object being to improve concentrate a tooth form and finish [Music] after shaving the teeth of the gear a hardened by an underwater high frequency induction present the gear to be hardened is mounted on a mantra supported in half bearings when the gear is set on the machine the water tank is raised by push-button control into the working position the workpiece is submerged and the cycle is controlled by the limit switches the gear is indexed automatically and each tooth is hardened individually by this method of induction hardening the distortion normally associated with other forms of gear hardening is eliminated in that the hardness pattern follows the contour of the two after hardening the gears are finished by Hagi the action of the abrasive impregnated gear like tool rotated in tight mesh with a hardened workpiece is to provide any slight correction that is needed to the form of the teeth [Applause] [Music] spot checks are carried out in the standards room to ensure consistent control of involute and lead in checking the involute the stylist Travis's along the profile of the gear and in the lead the length of the tooth a graphical recording is obtained and checked against permitted limits on another machine the test gear is run against a precision master and a composite check for concentricity pitch and tooth spacing is made once again a graphical recording is made passing from the headstock gears let us now look at some of the processes involved in the manufacture of the spindle after the rough forging has been board and the tool clamping positions accurately turn this machine faces both ends of the spindle turns them and rough tapers the nose the machine is double-ended and the tools not only rotate and feed in longitudinally but also feed transversely once the pacing is finished the tool changes speed and then roughs out the taper in the nerves air the tool at the other end faces the pour cones it and gives it a good machine service for holding in the next machine the spindle then passes to this modern copy a turning lathe which profiles the whole link to the spindle the series of roughing cuts are made before the final finishing cuts [Music] tools from the overhead slide machine the various undercuts for grinding which is the next operation the spindle is ground all ever very fine tolerances are maintained the bearing seedings in particular being controlled to a tolerance of 1/10 of a far meticulous care is taken with the spindles and everyone undergo stringent tests for concentricity ando Valatie as well as for size the internal and external tapers of the spindle are checked with blue engages the bluing must show the full length of the gauge on both internal and external tapers with all the care and production skill that goes into the making of the spindle however it is in the spindle bearings that precision reaches its peak coaches two layers are fitted with Gamay taper roller bearings the most accurate bearings in the world and designed specifically for machine tool spindles the very fine tolerances involved requires special manufacturing techniques to ensure these fine tolerances is special care must be taken at all stages in checking the components the bearing rings are subjected to 100% inspection yeah finished inner rings are being checked by air gauge to within two microns for roundness and taper and the sizing of the bore is between nominal and +5 microns the rollers passed through many inspection operations starting with an ocular check for surface defects this is followed by a series of extremely precise dimensional checks here rollers are being angle checked and segregated into groups which are later matched with inner and outer rings which have been similarly controlled these processes ensure the geometrical accuracy of the assembled berry finally the diameter roundness and form of the thrust face of the rollers is checked on an electronically controlled calibrating instrument capable of revealing deviations as small as four millionths of an inch in this way consistency of size and form is achieved in each bearing the dimensions of the rollers do not differ by more than ten millionths of an inch having been segregated into specified sized groups match sets of rollers are then assembled into the cage ready for assembly of the complete bury these standards of precision coupled to its unique design are the key to the unrivaled accuracy of the gamma bury a perfect spindle with perfect bearings and mounted on a perfect seating herein lies the secret of the accuracy of coaches to lathes now the lathe is ready to cut its test piece it must prove itself capable of turning this within a deviation from true roundness of no more than 1/10 of a third [Music] the test piece is turned and an identifying label is fixed to it ready for its check on the tally rod the machine designed expressed there for the purpose of measuring deviations from a true circle the test piece is mounted on the table and centered as soon as these adjustments are made and the test piece is centralized to the axis of the spindle the out of roundness is reproduced on a circular graph by means of electric pencil magnification can be varied here it's 5000 times so that each space between the lines is only 20 millionths of an inch inspectional competed the test pieces found to be accurate to within 30 millionths of an inch three times better than specification and this is only one of the many checks made to ensure the accuracy of every coaches to lathe before it leaves the factory let us now consider versatility the typical attachment is this taper Turner fitting this unit in no way interferes with the normal operation of the lathe the telescopic cross slide screw enables cuts to be made from the cross slide handy [Applause] this hydraulic profiling attachment enables the standard lathe to be converted simply and cheap played to a copying de models with either 60 degree or 90 degree slides are available [Laughter] threads can be cut at speeds up to 5 times faster than normal with the angel rapid threading UT it'll fed tight to a shoulder at maximum speed blind bores need no undercut it's impossible to engage the half nut in the wrong position versatility is further enhanced by this capstan attachment compete unit can be fitted in place of the tailstock in a matter of minutes and provision is made on every lathe leaving the factory for these and in many other items and the comprehensive coaches to arrange to be added to the machine whenever the customer desires [Applause] [Music] [Applause] turn from the solid bar in 45 seconds buyers are naturally interested in after sales service and based upon headquarters at Colchester we maintain a feat of well equipped vans ready to go anywhere at the shortest notice to deal with urgent service calls and so a network of agents conveniently cited all over the British Isles we keep in close touch with our friends and customers a full range of spare parts and accessories is always kept in stock and we pride ourselves in running an SOS service in a crisis any item in our catalog fully protected against corrosion will be on its way from our works in a matter of hours from receiving a call this service applies not only to knighted Kingdom for through our sales and service units in foreign countries we're in constant touch with our customers throughout the world to whom additional equipment or spare parts can be sent with the utmost dispatch our range of lathes is designed to meet the many and varied requirements of industry from the revolutionary five inch chip master on which we introduced infinitely variable spindle speeds up to 3000 rpm to be a six-inch student with specially built in safety features which have earned it an end verbal reputation as a training or production machine and on to the six and a half inch master a larger edition of the student and embodying all the well-tried features and the versatility of the student to the famous seven and a half inch triumph heavy duty lay which is equally at home as a tool room or a production machine and finally to our largest the eight and a half inch all geared mascot renowned all over the world for its rugged dependability under the most arduous conditions it is by high precision engineering allied to the money-saving continuous production techniques that we've shown you in this film that this range of machines enables us to make good our best that the world turns on coaches to late [Music]

Channel: RH

Views: 950,602

Keywords: Colchester, lathe, old school, vintage, England, Essex, machine, machinist, machine shop, shop, YouTube machinist, hobby shop, the world turns on Colchesters, best, number one, #one

Id: nQaAKUAzK0w

Length: 26min 44sec (1604 seconds)

Published: Mon Apr 15 2019