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temporary bracket beyond the head-
Optical Alignment
A SIMPLE AND PRECISE METHOD OF
LINING UP THE LATHE HEADSTOCK
By J. R. Mott
S
EVERAL readers of the article on
Concrete Lathe Heads, in the issue
of November 25th, 1954, having en-
auired about the optical methods of
alignment referred to therein, it is
hoped that a description of the methods
and apparatus used will be of general
interest. Such methods are common
in the assembly of scientific apparatus,
but may be a bit novel as applied to
model-making.
It will be noted that the front main
spindle bearing is heavily coned from
1-1/2 in. diameter to 3 in. over a length of
2-1/2 in. The other spindle bearing is
1-1/4 in. diameter, parallel, and the tail-
stock barrel a little over 1-1/4 in. diameter.
The apparatus required for lining up
was, first, four small cylinders of light
sheet metal with one closed end, such
as are used for spices and other domestic
goods, and sometimes for shaving
sticks. I was fortunate in finding some
with outside diameters at the closed ends,
about twenty-thou. over the basic size
(1-1/4 in.) so that they could be ground
down to a nice push fit in their required
positions. The “ skirts “-the parts of
these cylinders or sleeves remote from
the closed ends-were split, and ex-
panded slightly so as to spring against
the bores they were fitted into. The
closed ends of three were carefully
centred, and given a knife-edged pin-
hole at the centre, obtained by drilling
very fast arid very lightly with, say, a
3/16in. drill, until the “ nub ” protruded
on the other side. This nub then ground
down until a hole was just barely
showing, then swaged out and formed
with an actual pin, and all made
smooth.
Location
The other sleeve end was given a 1/2in.
hole at the centre, and a disc of ground
glass tightly fitted inside, against the
closed end, being held there with a
circlip. For location, two lines were
drawn across the ground glass in ink,
interesecting at the centre.
Next, a miniature tine-projector was
pressed into service, complete with
condenser, but otherwise stripped. The
condenser must be at least 1-1/2 in. in
diameter. Alternatively, a powerful
focussing torch would do. The essen-
tial thing is that it shall focus to a
parallel beam which can be tested against
any wall in the dark, when the bright
spot should be the same size as the
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torch reflector at any distance from the
wall. Of course, there is always a
penumbra-darker than the spot, but
still light. This can be ignored.
The final item was a fitment I had
already had in the front bearing to
provide one of the dead centres on
which the spindIe had already been
ground. This was a short (3 in.) length
of l-1/4in. steel tube,, with an ordinary
back-nut screwed tightly on one end,
to butt (with a fibre washer as protec-
tion) against the face of the small end
of the bearing, and with a 3/4 in. thick
disc of aluminium, having a tapered
diameter to suit the large end of the
bore, screwed on at the other so that
the assembly fitted snugly in the coned
bearing, locked in the position of easy
turning fit by another back-nut. The
\ SPANNERING
Front bearing fitment fitted with pinhole sleeve
bore of this 1-1/4in. tube had carried the
centre for grinding which was replaced
by one of the pinhole sleeves. This is
shown in the drawing.
The state of the lathe for the lining-up
operation was that, while all moving
parts had been made, none had been
finally assembled. That is, the two
spindle bearings were open, also the
barrel of the tailstock. The slide rest
was completely assembled on the end of
the bed. That is, the positions ‘of the
slide-rest and tailstock were inter-
changed.
A fine wire was strung taut from the
toolpost, right through the lathe, to a
stock through all -bores. This was
adjusted vertically over the centre-line
of the bed and parallel to it, also about
0.030 in. below the centre of the tail-
stock bore. With inside calipers, using
the alignment screws of the heads and
adjusting the packing beneath the head-
stock base, the bores of the latter were
set central to the wire. This was the
rough alignmenf, saving a lot of time
in the optical lming-up, also ensuring
that in any case the adjustment of
the tailstock would be downward,
for it is obtained by tiling down the
base.
3
Operation
The wire being removed, fix the source
of light (focussed parallel) on the bed
facing the coned bearing, fit the pinhole
sleeve in the bearing fitment if not u
already there, and a white card on the
headstock between the bearings. Turn
on the lamp, and mark the position of
the spot of light on the white card.
Turn the whole fitment (not the sleeve
only) in the bearing, marking successive
positions of the light spot on the card.
until a locus circle has been formed.
Mark the centre of this focus, which is
the centre of rotation, and draw a line
through it, parallel with the cross
surface of the bed. Turn the fitment
again until the light spot is upon this
line, in the position nearest you.
Repeat this operation for the other
bearing, shifting the source of light to
that side of the headstock, and using the
same position for the white card. The
line joining the two pinholes is now a
horizontal, parallel to the axis of
revolution of the spindle, and may be
used to set the headstock bearings
parallel to the bed by sighting from a
white screen held in a milling fixture
(or other means of adjustment up or
down), fixed on the slide-rest, the lamp
being left where it was for the last
operation. The screen must have a
pinhole through it, and black cross
lines drawn through the pinhole for
 LIGHT BEAM TRAVELLING
COMPLETELY THROUGH LATHE
IN FINAL OPERATION.

A-Source of light; B-White card fixed in wooden bracket set between bearings of head--
stock. Removed after 1st operation: C-Alternative position of source of light for first part
of first operation only; D-White card with pin-hole in centre, fixed to bracket on a milling
fixture to give vertical adjustment: E--” Pin-hole Sleeves “: F---Sleeve with ground-glass
window: G-Lead screw hand feed.’ Gear for auto feed at other end of lead screw replaced
by nut and distance-piece

locating the latter in poor light. Even
in the dark, it may be difficult to pick
up the vague blob of faint light on the
screen, but an ordinary hand magnifying
glass moved about in the beam will
help greatly, concentrating the beam
and so strengthening the light. It must
only be used for “ finding,” however,
for it bends the beam. Actual sighting
through the pinholes must be the final
observation.
With the light sighted, move the
carriage slowly up towards the head. If
the beam goes “ off sight ” downward,
it is divergent to the bed, if upward,
it is convergent. When sighting through
can be done from any point along the
bed, the beam is parallel, and the head-
I stock lined up. Vertical adjustment of
the line is applied by packing the head-
P stock base, as in the rough alignment,
but this time it may be no more than a
piece of foil or even paper. Horizontal
adjustment can, of course, be effected at
any time by the alignment screws at
L the side of the base.
When all is well so far, the tailsock
can be returned to its proper place, a
pinhole sleeve fitted in the front end of
the barrel (tested as previously to give
the centre of rotation) then lined up to
the light beam by reducing the base
bearing-pads. Only partial correction barrel. Thus the tailstock centre-line
should be made before testing the rear can be worked down at the front and
end, which should be done by removing rear alternately, until a sight can be
the sleeve from the front, and placing obtained in a pinhole sleeve placed
the special one with the ground glass in either front or rear end of the
in it at the rear end of the tailstock barrel.
_ _ _ _
A Miniature Turbo-Generator
(Continued from page 279)
cement, attach one of the insulating wind 26 turns in the opposite direction.
washers to each end of the laminated If some small stranded wire with light
assembly. Roll small cylinders of insulation is available, solder a short
0.005 in. electrical insulating paper, length to the end of the winding, so that
and put through each of the Q-in. the joint will come within the last
$alse;erlseaving flush with the insulating 1/8 in. winding hole. The end of the
winding can be tied with sewing thread.
About seven feet of No. 26 enamelled Dip in varnish and bake. When the
wire is required for the winding. Solder varnish has completely hardened, the
one end to the head of one of the outside of the assembly should be
1/16in. rivets of the lamination assembly. cleaned. This is best done by placing
Start the winding in the two centre holes on a 3/8in. mandrel in the lathe and a
of the series, by putting the end of the very light cut taken off the outside.
wire through one hole and back through The coil is now ready for assembly in
the other, and drawing all the way the unit.
through to- the soldered end. Wind Many of the readers of the Miniature
13 turns in these two holes, then cross Locomotive have built these units, and
over to the two outside holes and wind I have first-hand knowledge of more
13 more turns in these. Bring across than thirty of them being successfully
to the other series of 1/8in. holes and completed.
281