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21.2 A key machine should be constructed so the key is almost parallel to the cutter. A long pivot (shown on the right) reduces the angle.
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Figure 21.3 Various cutter wheels.
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touch a key blank, or if it digs deeply into a key blank, the machine is out of alignment and needs to be adjusted. Figure 21.4 illustrates how to check a key guide. Framon s DBM-1 Flat Key Machine Framon Manufacturing Company s DBM-1 is a high-quality, flat-key duplicating machine. It s designed to duplicate a wide variety of flat and corrugated keys (Fig. 21.5). By understanding how it works, you ll be able to operate many similar machines.
Figure 21.4 The cutter wheel should barely touch the key
blank (left). (Keynote Engineering)
Figure
21.5 Framon s DBM-1 Flat Key Machine. (Framon Manufacturing Corp.)
Key Duplicating Machines
Cutting procedure
All keys should be set from the tip for spacing. Insert the pattern key in the right-hand vise with the tip of the blank protruding slightly beyond the left side of the vise (Figure 21.6). This position allows cutting of the tip guide on the blank if the blank tip is slightly different from the pattern key. In this position, the tip can be cut without the cutting vise. Push the guide shaft to the rear and lock it into this position by tightening the locking knob (Fig. 21.7). This relieves spring pressure so the tip setting is easier. Lift the yoke and set the tip of the pattern key against the right side of the guide. While holding this position, insert the blank and set the tip of the blank against the right side of the cutter (Figure 21.8). This procedure assures proper spacing.
Figure 21.6 Set key from tip for spacing. (Framon Manufacturing Corp.)
Figure 21.7 Tighten locking knob to lock guide shaft into position. (Framon Manufacturing Corp.)
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Figure 21.8 Set tip of blank against right-hand side of cutter. (Framon Manufacturing Corp.)
Figure 21.9 Set cut in pattern key against guide. (Framon
Manufacturing Corp.)
Release the guide by loosening the locking knob; the key is now ready to be cut. Look at the cut in the pattern key against the guide and lift the yoke into the cutter to make the cut (Fig. 21.9); lower the yoke and repeat for the next cut. Follow this procedure until all cuts (including the throat cut) are made and the key is complete. All cuts should be made with a straight-in motion. This ensures clean, square cuts. Notice that there is no side play in the guide assembly, so all cuts on duplicate keys will be the same width as pattern keys.
Adjustments
With tip setting for spacing, there is no problem with improper spacing. Depth setting can be checked by using two blanks that are the same. Check the depth by drawing the blank against the cutter guide. If depth adjustments are needed, simply loosen the set screw on the depth ring and adjust the ring
Key Duplicating Machines
until the cutter barely touches the blank. To make cuts deeper, rotate the depth ring counterclockwise. To make cuts shallower, rotate the depth ring clockwise. Tighten the set screw after the adjustment is made, but do not tighten it too far. Another way to check depth is to make one cut on the duplicate key; check the depth cut on both the pattern key and duplicate. As an example, if the cut on the duplicate key is 0.003 deeper than the cut on the pattern key, loosen the set screw on the depth ring, rotate the ring 0.003 clockwise, and tighten the set screw. Note: Calibrations on the depth ring are in increments of 0.001. Check the guide setting; the guide must be set to the same width of the cutter used. The DBM-1 is supplied with one 0.045-width cutter. This is the best width for general work. Cutter widths of 0.035, 0.055, 0.066, and 0.088 are available if needed. Cutter width of 0.100 (LeFebure) can be obtained by using a 0.045 and a 0.055 at the same time. All of these cutters are solid carbide. To set the guide, simply loosen the cap screw (DBM-42). Rotate the guide to cutter width and tighten the cap screw. The Detent screw in the guide shaft will align the guide. No adjustment is required when changing guide settings.
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