Use of the One Sided Template

Tensilkut one sided templates are used of preparation of either very small specimens or specimens with odd contours.  One sided templates have set screws located in the top bar of the template which applies pressure to the clamping bar to hold the specimen steady during the machining operation.

Loosen the set screws to release the clamping bar, which slides up and down on the shoulder pins at either end of the template.  One Sided TemplateInsert the prepared specimen blank into the template through the side; be certain that it is pushed back such that one entire side of the specimen blank rests against the back wall of the template.  Tighten down the set screws to hold the blank firmly.  Due to the unique low cutting forces involved with Tensilkut, only moderate pressure is required to hold the sample during the machining operation.  The template is basically a holding fixture, and not a vise – excessive pressure in the socket screws could result in deformation of the template assembly.

The contour of the test specimen is controlled by the contour of the hardened top bar of the template, which is riding along the guide sleeve of the control unit. This guide sleeve determines the final width of the test specimen, while the master template controls the configuration of the gauge area.

The sleeve is adjusted by the micrometer dial measured in .001” divisions, with a complete revolution of the dial equal to .050”.  Turn the micrometer dial to full out (counterclockwise, as in unscrewing a bolt), until the stop is reached, and the indicator points to 50 on the dial.  This is the finishing position for the guide sleeve – it is in the closest proximity to the cutting bit when a sample is completely machined.  To machine a ¾” wide sample to .500” gauge width, a total of .250” must be taken off (.125” per side).  Starting with the dial on 50 and the guide sleeve closest to the cutter, turn the dial so that the slide moves outward .125”, or a distance equal to the total amount which must be taken off that side.  With the template against the guide sleeve, the sample will just contact the cutter.

Setting the dial on the Tensilkut machine

Setting the dial on the Tensilkut machine

Turn on the motor on the Tensilkut machine.  Bring the left end of the contoured section of the master template containing the sample in contact with the sleeve, and with moderate hand pressure and a continuous motion, move the template across the table top in contact with the sleeve until the right end of the contoured section is reached.  With the previous adjustment of the guide sleeve as above, the cutter will just touch the sample when the template is moved against the guide sleeve.  To begin the first actual contour cutting of the sample, the sleeve must be moved inward an amount equal to the depth of the first machining cut.  Again, bring the left end of the contoured section of the master template into contact with the sleeve, and move the template across the table top as described above, repeating this motion alternated with moving the sleeve inward an amount equal to the depth of the first cut until the machining of that side of the sample is complete.  Ideally, the final pass should be a light pass of approximately .001” to .003” depth, for the optimum surface finish. Tensilkut one sided template

Please note that, when the first side is complete, the sample’s finished edge will appear slightly oversized in relation to the contoured edge of the template

Upon completion of the first side, remove the partially machined specimen from the template and flip it over such that the contoured edge will be against the back bar of the template, and the uncontoured side will be visible.  Please note that we do not recommend flipping the specimen end for end as this could result in improper alignment of the shoulders and radii from side to side.

Reversing the sample within the template

Reversing the sample within the template

After the specimen has been turned around within the template, the micrometer control must be readjusted to its starting position, that is, with the guide sleeve as far forward as it was when the initial cut was made on the first side of the specimen.

The machining procedure used to prepare the first contoured edge should be repeated for the second side.  Please note that, again, the sample’s finished edge will appear slightly oversized in relation to the contours of the template.  The sample, when removed from the template, will have contours in accordance with the specification required.Tensilkut Template use

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