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10.16 Grooving

Micky R. Jennings

A part off blade has freshly completed two grooves in the end of a part.
Figure 10.158. A part off blade has freshly completed two grooves in the end of a part. / Image Credit: Micky R. Jennings, courtesy of Wenatchee Valley College, CC BY 4.0

Grooving is the process of creating a recessed slot on the outside diameter (OD), inside diameter (ID), or face of a part. This slot can be made in as few as one plunging cut or in multiple cuts. A common purpose for grooving it is to create a recess for “O” rings or snap rings. Grooving can also be used to make custom shaped or tapered features, similar to the grooves of a pulley.

Step by step process for cutting a single plunge groove:

  1. Apply layout fluid to the outside diameter of the part.
  2. Using odd leg calipers, scribe lines that will define the groove.
  3. Calculate the spindle speed based on the largest diameter the tool will cut. Grooving is often done at a slower speed than turning. Reduce spindle speed to about 1/4 of general turning speed.
  4. Load a grooving tool into a holder and onto the tool post.
  5. Adjust the length of the tool.
  6. Reset the tool height.
  7. Start the spindle.
  8. Touch the grooving tool off to the face of the work, or wherever the groove is referenced from, and set the carriage handwheel to zero.
  9. Move over the axial distance needed to position the tool.
  10. Lock the carriage.
  11. Bring the tool close to the outside diameter and visually check the scribed lines.
  12. Gently bring the tool in with the cross slide and touch off the tool on the outside diameter.
  13. Set the graduated collar on the cross slide to zero.
  14. Lube the tool.
  15. Cut into the part about .020 and back out.
  16. Check the measurement from the shallow edges of the groove to the reference feature.
  17. Measure the diameter of the bottom of the groove and calculate remaining material to remove.
  18. Slowly cut the groove to the final depth. Keep a nice even feed and allow the chip to curl into a spiral shape on top of the tool while applying an occasional drop of cutting oil.
  19. Deburr the edges of the groove with a file.

Step 5: Adjust the length of the tool.

A hand uses a hex key to adjust the length of the part off blade.
Figure 10.159. A hand uses a hex key to adjust the length of the part off blade. / Image Credit: Micky R. Jennings, courtesy of Wenatchee Valley College, CC BY 4.0

Step 5: Adjust the length of the tool.

A hand uses the end of a pair of calipers to measure the length a part off blade sticks out of a tool holder.
Figure 10.160. A hand uses the end of a pair of calipers to measure the length a part off blade sticks out of a tool holder. / Image Credit: Micky R. Jennings, courtesy of Wenatchee Valley College, CC BY 4.0

Step 5: Adjust the length of the tool.

A close up view of a hand using the end of a pair of calipers to measure the length of a part off blade sticking out of a tool holder.
Figure 10.161. A close-up view of a hand using the end of a pair of calipers to measure the length of a part off blade sticking out of a tool holder. / Image Credit: Micky R. Jennings, courtesy of Wenatchee Valley College, CC BY 4.0

Step 6: Reset the tool height.

Checking the tool height by bringing it up to the tailstock center.
Figure 10.162. Checking the tool height by bringing it up to the tailstock center. / Image Credit: Micky R. Jennings, courtesy of Wenatchee Valley College, CC BY 4.0

Step 8: Touch the grooving tool off to the face of the work, or wherever the groove is referenced from, and set the carriage handwheel to zero.

Checking the alignment of the part off blade by bringing it up to the face of the part.
Figure 10.163. Checking the alignment of the part off blade by bringing it up to the face of the part. / Image Credit: Micky R. Jennings, courtesy of Wenatchee Valley College, CC BY 4.0

Step 8: Touch the grooving tool off to the face of the work, or wherever the groove is referenced from, and set the carriage handwheel to zero.

Step 18: Slowly cut the groove to the final depth. Keep a nice even feed and allow the chip to curl into a spiral shape on top of the tool while applying an occasional drop of cutting oil.

A part off blade has freshly completed two grooves in the end of a part.
Figure 10.164. A part off blade has freshly completed two grooves in the end of a part. / Image Credit: Micky R. Jennings, courtesy of Wenatchee Valley College, CC BY 4.0

Step by step process for cutting a multi-plunge groove:

  1. Apply layout fluid to the outside diameter of the part.
  2. Using odd leg calipers, scribe lines that will define the groove.
  3. Calculate the spindle speed based on the largest diameter the tool will cut. Grooving is often done at a slower speed than turning. Reduce spindle speed to about 1/4 of the general turning speed.
  4. Load a grooving tool into a holder and onto the tool post.
  5. Adjust the length of the tool.
  6. Reset the tool height.
  7. Start the spindle.
  8. Position the grooving tool in the center of the scribed lines.
  9. Set the graduated collar of the carriage to zero.
  10. Lock the carriage.
  11. Gently bring the tool in with the cross slide and touch off the tool on the outside diameter.
  12. Set the graduated collar on the cross slide to zero.
  13. Lube the tool.
  14. Cut into the part about .020 and back out.
  15. Measure the diameter of the bottom of the groove and calculate remaining material to remove.
  16. Slowly cut the groove .005 to .010 from the final depth. Keep a nice even feed and allow the chip to curl into a spiral shape on top of the tool while applying an occasional drop of cutting oil.
  17. Measure an edge for groove placement from a reference feature and calculate distance remaining in that direction.
  18. Make successive plunge cuts at about 75% to 95% step over of the tool’s width until desired groove edge placement is achieved.
  19. Note handwheel reading on final plunge cut.
  20. Measure the groove’s width and calculate the remaining material to remove.
  21. Make successive plunge cuts in the opposite direction from the starting point at about 75% to 95% step over of the tool’s width until desired groove width is achieved.
  22. On the last plunge cut, remove material to final depth.
  23. Unlock the carriage while at final depth and slowly feed the carriage towards the reading on the hand wheel where the opposite side of the groove finished. This will finish the bottom of the groove nicely and remove any inconsistent plunge marks.
  24. Deburr the edges of the groove with a file.

Step 1: Apply layout fluid to the outside diameter of the part.

A hand uses a brush to apply layout dye to a part.
Figure 10.165. A hand uses a brush to apply layout dye to a part. / Image Credit: Micky R. Jennings, courtesy of Wenatchee Valley College, CC BY 4.0

Step 5: Adjust the length of the tool.

A hand uses a hex key to adjust the length of the part off blade.
Figure 10.166. A hand uses a hex key to adjust the length of the part off blade. / Image Credit: Micky R. Jennings, courtesy of Wenatchee Valley College, CC BY 4.0

Step 5: Adjust the length of the tool.

A hand uses the end of a pair of calipers to measure the length a part off blade sticks out of a tool holder.
Figure 10.167. A hand uses the end of a pair of calipers to measure the length that a part off blade sticks out of a tool holder. / Image Credit: Micky R. Jennings, courtesy of Wenatchee Valley College, CC BY 4.0

Step 5: Adjust the length of the tool.

A close up view of a hand using the end of a pair of calipers to measure the length of a part off blade sticking out of a tool holder.
Figure 10.168. A close-up view of a hand using the end of a pair of calipers to measure the length of a part off blade sticking out of a tool holder. / Image Credit: Micky R. Jennings, courtesy of Wenatchee Valley College, CC BY 4.0

Step 6: Reset the tool height.

Checking the tool height by bringing it up to the tailstock center.
Figure 10.169. Checking the tool height by bringing it up to the tailstock center. / Image Credit: Micky R. Jennings, courtesy of Wenatchee Valley College, CC BY 4.0

Step 8: Position the grooving tool in the center of the scribed lines.

The part off blade is moved close to the position of the groove.
Figure 10.170. The part off blade is moved close to the position of the groove. / Image Credit: Micky R. Jennings, courtesy of Wenatchee Valley College, CC BY 4.0

Step 11: Gently bring the tool in with the cross slide and touch off the tool on the outside diameter.

Step 13: Lube the tool.

Step 16: Slowly cut the groove .005 to .010 from the final depth. Keep a nice even feed and allow the chip to curl into a spiral shape on top of the tool while applying an occasional drop of cutting oil.

Step 16: Slowly cut the groove .005 to .010 from the final depth. Keep a nice even feed and allow the chip to curl into a spiral shape on top of the tool while applying an occasional drop of cutting oil.

Step 22-23: On the last plunge cut, remove material to final depth. Unlock the carriage while at final depth and slowly feed the carriage towards the reading on the hand wheel where the opposite side of the groove finished. This will finish the bottom of the groove nicely and remove any inconsistent plunge marks.

Step 24: Deburr the edges of the groove with a file.

A hand uses a file to deburr a finished groove.
Figure 10.171. A hand uses a file to deburr a finished groove. / Image Credit: Micky R. Jennings, courtesy of Wenatchee Valley College, CC BY 4.0

Step 24: Deburr the edges of the groove with a file.

Attributions

  1. Figure 10.158: Finished grooves by Micky R. Jennings, courtesy of Wenatchee Valley College, for WA Open ProfTech, © SBCTC, CC BY 4.0
  2. Figure 10.159: Adjusting a part off blade. by Micky R. Jennings, courtesy of Wenatchee Valley College, for WA Open ProfTech, © SBCTC, CC BY 4.0
  3. Figure 10.160: Measuring a part off blade by Micky R. Jennings, courtesy of Wenatchee Valley College, for WA Open ProfTech, © SBCTC, CC BY 4.0
  4. Figure 10.161: Measuring a part off blade 2 by Micky R. Jennings, courtesy of Wenatchee Valley College, for WA Open ProfTech, © SBCTC, CC BY 4.0
  5. Figure 10.162: Checking tool height by Micky R. Jennings, courtesy of Wenatchee Valley College, for WA Open ProfTech, © SBCTC, CC BY 4.0
  6. Figure 10.163: Checking the alignment by Micky R. Jennings, courtesy of Wenatchee Valley College, for WA Open ProfTech, © SBCTC, CC BY 4.0
  7. Video 10.80: Micky R. Jennings, courtesy of Wenatchee Valley College, for WA Open ProfTech, © SBCTC, CC BY 4.0
  8. Figure 10.164: Finished grooves by Micky R. Jennings, courtesy of Wenatchee Valley College, for WA Open ProfTech, © SBCTC, CC BY 4.0
  9. Figure 10.165: Applying layout dye by Micky R. Jennings, courtesy of Wenatchee Valley College, for WA Open ProfTech, © SBCTC, CC BY 4.0
  10. Figure 10.166: Adjusting a part off blade by Micky R. Jennings, courtesy of Wenatchee Valley College, for WA Open ProfTech, © SBCTC, CC BY 4.0
  11. Figure 10.167: Measuring a part off blade by Micky R. Jennings, courtesy of Wenatchee Valley College, for WA Open ProfTech, © SBCTC, CC BY 4.0
  12. Figure 10.168: Measuring a part off blade 2 by Micky R. Jennings, courtesy of Wenatchee Valley College, for WA Open ProfTech, © SBCTC, CC BY 4.0
  13. Figure 10.169: Checking tool height by Micky R. Jennings, courtesy of Wenatchee Valley College, for WA Open ProfTech, © SBCTC, CC BY 4.0
  14. Figure 10.170: Positioning the tool by Micky R. Jennings, courtesy of Wenatchee Valley College, for WA Open ProfTech, © SBCTC, CC BY 4.0
  15. Video 10.81: Micky R. Jennings, courtesy of Wenatchee Valley College, for WA Open ProfTech, © SBCTC, CC BY 4.0
  16. Video 10.82: Micky R. Jennings, courtesy of Wenatchee Valley College, for WA Open ProfTech, © SBCTC, CC BY 4.0
  17. Video 10.83: Micky R. Jennings, courtesy of Wenatchee Valley College, for WA Open ProfTech, © SBCTC, CC BY 4.0
  18. Video 10.84: Micky R. Jennings, courtesy of Wenatchee Valley College, for WA Open ProfTech, © SBCTC, CC BY 4.0
  19. Video 10.85: Micky R. Jennings, courtesy of Wenatchee Valley College, for WA Open ProfTech, © SBCTC, CC BY 4.0
  20. Figure 10.171: Debur groove by Micky R. Jennings, courtesy of Wenatchee Valley College, for WA Open ProfTech, © SBCTC, CC BY 4.0
  21. Video 10.86: Micky R. Jennings, courtesy of Wenatchee Valley College, for WA Open ProfTech, © SBCTC, CC BY 4.0
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Introduction to Machining Copyright © by SBCTC is licensed under a Creative Commons Attribution 4.0 International License, except where otherwise noted.

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