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:
- Side one
- Load a face mill into the spindle.
- Load a rectangular block of material into a milling vise with the largest side in preparation to be faced.
- Place the part on parallels.
- Take a 1/64″ to 1/32″ facing cut to clean the surface.
- Remove the part and deburr all edges.
- Side two
- 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.
- Place the part on a single parallel.
- Use a round bar in between the movable jaw and the part when clamping.
- 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.
- Take a 1/64″ to 1/32″ facing cut to clean the surface.
- Remove the part and deburr all edges.
- Side three
- Load the block of material back into the milling vise, with side one against the solid jaw and side two against the single parallel.
- Use a round bar in between the movable jaw and the part when clamping.
- Tap the part down tight against the parallel.
- Take appropriate roughing and finishing facing cuts to bring the part to size.
- Remove the part and deburr all edges.
- Side four
- 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.
- Take appropriate roughing and finishing facing cuts to bring the part to size.
- Remove the part and deburr all edges.
- Side five
- 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.
- Place the part on a single parallel.
- Use a round bar in between the movable jaw and the part when clamping.
- Clamp gently.
- Use an indicator to dial the side of the part straight up and down. Tap it with a hammer to move it slightly.
- Fully tighten the vise.
- Take a 1/64″ to 1/32″ facing cut to clean the surface.
- Remove the part and deburr all edges.
- Side six
- Load the block of material back into the milling vise, with side one against the solid jaw and side five against the single parallel.
- Use a round bar in between the movable jaw and the part when clamping.
- Tap the part down tight against the parallel.
- Take appropriate roughing and finishing facing cuts to bring the part to size.
- Remove the part and deburr all edges.
Step 1-e: Remove the part and deburr all edges.
Step 1-e: Remove the part and deburr all edges.
Step 2-c: Use a ro