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9.11 Block Squaring

Micky R. Jennings

Block squaring is the process of performing face milling operations on each side of a block in a specific manner that transfers the precision of the mill vise into angular accuracy on the part. Each of the six sides of a rectangular block will be machined, creating the outer envelope of the overall size of the finished part.

Step by step process for block squaring:

  1. Side one
    1. Load a face mill into the spindle.
    2. Load a rectangular block of material into a milling vise with the largest side in preparation to be faced.
    3. Place the part on parallels.
    4. Take a 1/64″ to 1/32″ facing cut to clean the surface.
    5. Remove the part and deburr all edges.
  2. Side two
    1. Load the block of material back into the milling vise, with side one against the solid jaw and the second largest side in preparation to be faced.
    2. Place the part on a single parallel.
    3. Use a round bar in between the movable jaw and the part when clamping.
    4. The reason for the bar and the single parallel is to make sure the part conforms to sitting flat against the solid jaw plate and not the movable jaw plate or a pair of parallels.
    5. Take a 1/64″ to 1/32″ facing cut to clean the surface.
    6. Remove the part and deburr all edges.
  3. Side three
    1. Load the block of material back into the milling vise, with side one against the solid jaw and side two against the single parallel.
    2. Use a round bar in between the movable jaw and the part when clamping.
    3. Tap the part down tight against the parallel.
    4. Take appropriate roughing and finishing facing cuts to bring the part to size.
    5. Remove the part and deburr all edges.
  4. Side four
    1. Load the block of material back into the milling vise, with side one against a pair of parallels and side two against the solid jaw.
    2. Do not use a round bar.
    3. Tap the part down tight against the parallels.
    4. Take appropriate roughing and finishing facing cuts to bring the part to size.
    5. Remove the part and deburr all edges.
  5. Side five
    1. Load the block of material back into the milling vise, with side one against the solid jaw and the third largest side in preparation to be faced.
    2. Place the part on a single parallel.
    3. Use a round bar in between the movable jaw and the part when clamping.
    4. Clamp gently.
    5. Use an indicator to dial the side of the part straight up and down. Tap it with a hammer to move it slightly.
    6. Fully tighten the vise.
    7. Take a 1/64″ to 1/32″ facing cut to clean the surface.
    8. Remove the part and deburr all edges.
  6. Side six
    1. Load the block of material back into the milling vise, with side one against the solid jaw and side five against the single parallel.
    2. Use a round bar in between the movable jaw and the part when clamping.
    3. Tap the part down tight against the parallel.
    4. Take appropriate roughing and finishing facing cuts to bring the part to size.
    5. Remove the part and deburr all edges.

Step 1-e: Remove the part and deburr all edges.

A hand holds a part as a file is pushed against one edge of a freshly faced side.
Figure 9.148. A hand holds a part as a file is pushed against one edge of a freshly faced side. / Image Credit: Micky R. Jennings, courtesy of Wenatchee Valley College, CC BY 4.0

Step 1-e: Remove the part and deburr all edges.

A hand holds a block that has had the first side faced and deburred.
Figure 9.149. A hand holds a block that has had the first side faced and deburred. / Image Credit: Micky R. Jennings, courtesy of Wenatchee Valley College, CC BY 4.0

Step 2-c: Use a round bar in between the movable jaw and the part when clamping.

A hand holds a round bar horizontally to make contact with the part on the movable vise jaw side.
Figure 9.150. A hand holds a round bar horizontally to make contact with the part on the movable vise jaw side. / Image Credit: Micky R. Jennings, courtesy of Wenatchee Valley College, CC BY 4.0

Step 2-c: Use a round bar in between the movable jaw and the part when clamping.

A side view of a round bar being used on the movable jaw side of a mill vise.
Figure 9.151. A side view of a round bar being used on the movable jaw side of a mill vise. / Image Credit: Micky R. Jennings, courtesy of Wenatchee Valley College, CC BY 4.0

Step 2-e: Take a 1/64″ to 1/32″ facing cut to clean the surface.

Step 2-e: Take a 1/64″ to 1/32″ facing cut to clean the surface.

Step 2-f: Remove the part and deburr all edges.

A hand holds a block that has had the first and second sides faced and deburred.
Figure 9.152. A hand holds a block that has had the first and second sides faced and deburred. / Image Credit: Micky R. Jennings, courtesy of Wenatchee Valley College, CC BY 4.0

Step 3-d: Take appropriate roughing and finishing facing cuts to bring the part to size.

Step 3-d: Take appropriate roughing and finishing facing cuts to bring the part to size.

A hand uses a pair of calipers to measure the width after the third cut. The part is being measured while still secure in the vise to keep from disturbing the setup.
Figure 9.153. A hand uses a pair of calipers to measure the width after the third cut. The part is being measured while still secure in the vise to keep from disturbing the setup. / Image Credit: Micky R. Jennings, courtesy of Wenatchee Valley College, CC BY 4.0

Step 3-d: Take appropriate roughing and finishing facing cuts to bring the part to size.

A side view of calipers measuring the width after the third cut. The part is being measured while still secure in the vise to keep from disturbing the setup.
Figure 9.154. A side view of calipers measuring the width after the third cut. The part is being measured while still secure in the vise to keep from disturbing the setup. / Image Credit: Micky R. Jennings, courtesy of Wenatchee Valley College, CC BY 4.0

Step 4-a-c: Load the block of material back into the milling vise, with side one against a pair of parallels and side two against the solid jaw. Do not use a round bar. Tap the part down tight against the parallels.

Step 4-d: Take appropriate roughing and finishing facing cuts to bring the part to size.

Side four has been faced and is still in the vise ready for thickness measurement.
Figure 9.155. Side four has been faced and is still in the vise ready for thickness measurement. / Image Credit: Micky R. Jennings, courtesy of Wenatchee Valley College, CC BY 4.0

Step 5-c: Use a round bar in between the movable jaw and the part when clamping.

The block is placed in the vise on parallels with side one against the solid jaw and side five facing up. A round rod is used against the movable jaw.
Figure 9.156. The block is placed in the vise on parallels with side one against the solid jaw and side five facing up. A round rod is used against the movable jaw. / Image Credit: Micky R. Jennings, courtesy of Wenatchee Valley College, CC BY 4.0

Step 5-e: Use an indicator to dial the side of the part straight up and down. Tap it with a hammer to move it slightly.

An indicator is used on side two or three to adjust the vertical placement of the block for the facing of the fifth side.
Figure 9.157. An indicator is used on side two or three to adjust the vertical placement of the block for the facing of the fifth side. / Image Credit: Micky R. Jennings, courtesy of Wenatchee Valley College, CC BY 4.0

Step 5-e: Use an indicator to dial the side of the part straight up and down. Tap it with a hammer to move it slightly.

Step 5-e: Use an indicator to dial the side of the part straight up and down. Tap it with a hammer to move it slightly.

Step 5-e: Use an indicator to dial the side of the part straight up and down. Tap it with a hammer to move it slightly.

Step 5-e: Use an indicator to dial the side of the part straight up and down. Tap it with a hammer to move it slightly.

Step 5-g: Take a 1/64″ to 1/32″ facing cut to clean the surface.

Step 5-h: Remove the part and deburr all edges.

A hand holds a block that has had five sides faced and deburred.
Figure 9.158. A hand holds a block that has had five sides faced and deburred. / Image Credit: Micky R. Jennings, courtesy of Wenatchee Valley College, CC BY 4.0

Step 6-d: Take appropriate roughing and finishing facing cuts to bring the part to size.

Side six has been faced and is still in the vise ready for length measurement.
Figure 9.159. Side six has been faced and is still in the vise ready for length measurement. / Image Credit: Micky R. Jennings, courtesy of Wenatchee Valley College, CC BY 4.0

Alternative side five and six steps for block squaring:

  1. Side five alternate
    1. Load a large end mill into the spindle.
    2. Load the block of material back into the milling vise, with side one against a pair of parallels and side two against the solid jaw. Let side five overhang the side of the vise.
    3. Tap the part down tight against the parallels.
    4. Take 1/64″ to 1/32″ material off using end mill side passes to clean the surface. One rough, one finish.
    5. Remove the part and deburr all edges.
  2. Side six alternate
    1. Load the block of material back into the milling vise, with side one against a pair of parallels and side two against the solid jaw. Let side six overhang the side of the vise.
    2. Tap the part down tight against the parallels.
    3. Take appropriate roughing and finishing side cuts to bring the part to size.
    4. Remove the part and deburr all edges.

Attributions

  1. Figure 9.148: Deburring the edges of a faced part by Micky R. Jennings, courtesy of Wenatchee Valley College, for WA Open ProfTech, © SBCTC, CC BY 4.0
  2. Figure 9.149: Side one complete by Micky R. Jennings, courtesy of Wenatchee Valley College, for WA Open ProfTech, © SBCTC, CC BY 4.0
  3. Figure 9.150: Round bar by Micky R. Jennings, courtesy of Wenatchee Valley College, for WA Open ProfTech, © SBCTC, CC BY 4.0
  4. Figure 9.151: Round bar 2 by Micky R. Jennings, courtesy of Wenatchee Valley College, for WA Open ProfTech, © SBCTC, CC BY 4.0
  5. Video 9.28: Micky R. Jennings, courtesy of Wenatchee Valley College, for WA Open ProfTech, © SBCTC, CC BY 4.0
  6. Video 9.29: Micky R. Jennings, courtesy of Wenatchee Valley College, for WA Open ProfTech, © SBCTC, CC BY 4.0
  7. Figure 9.152: Side two complete by Micky R. Jennings, courtesy of Wenatchee Valley College, for WA Open ProfTech, © SBCTC, CC BY 4.0
  8. Video 9.30: Micky R. Jennings, courtesy of Wenatchee Valley College, for WA Open ProfTech, © SBCTC, CC BY 4.0
  9. Figure 9.153: Measuring after side three by Micky R. Jennings, courtesy of Wenatchee Valley College, for WA Open ProfTech, © SBCTC, CC BY 4.0
  10. Figure 9.154: Measuring after side three by Micky R. Jennings, courtesy of Wenatchee Valley College, for WA Open ProfTech, © SBCTC, CC BY 4.0
  11. Video 9.31: Micky R. Jennings, courtesy of Wenatchee Valley College, for WA Open ProfTech, © SBCTC, CC BY 4.0
  12. Figure 9.155: Side four faced by Micky R. Jennings, courtesy of Wenatchee Valley College, for WA Open ProfTech, © SBCTC, CC BY 4.0
  13. Figure 9.156: Side five facing setup by Micky R. Jennings, courtesy of Wenatchee Valley College, for WA Open ProfTech, © SBCTC, CC BY 4.0
  14. Figure 9.157: Indicating for side five by Micky R. Jennings, courtesy of Wenatchee Valley College, for WA Open ProfTech, © SBCTC, CC BY 4.0
  15. Video 9.32: Micky R. Jennings, courtesy of Wenatchee Valley College, for WA Open ProfTech, © SBCTC, CC BY 4.0
  16. Video 9.33: Micky R. Jennings, courtesy of Wenatchee Valley College, for WA Open ProfTech, © SBCTC, CC BY 4.0
  17. Video 9.34: Micky R. Jennings, courtesy of Wenatchee Valley College, for WA Open ProfTech, © SBCTC, CC BY 4.0
  18. Video 9.35: Micky R. Jennings, courtesy of Wenatchee Valley College, for WA Open ProfTech, © SBCTC, CC BY 4.0
  19. Video 9.36: Micky R. Jennings, courtesy of Wenatchee Valley College, for WA Open ProfTech, © SBCTC, CC BY 4.0
  20. Figure 9.158: Side Five Complete by Micky R. Jennings, courtesy of Wenatchee Valley College, for WA Open ProfTech, © SBCTC, CC BY 4.0
  21. Figure 9.159: Side six faced by 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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