Apr. 29, 2024
Hardware
For more information, please visit DIN2185 Morse Taper Sleeves.
Drill chucks mounted by Jacobs tapers onto arbors with Morse tapers for the spindle. Spindle nose on a lathe headstock. The small female taper is a Morse taper to take a lathe center or a tool such as a twist drill. The large male taper takes a lathe chuck, which is retained by the large nut.
A machine taper is a system for securing cutting tools or toolholders in the spindle of a machine tool or power tool. A male member of conical form (that is, with a taper) fits into the female socket, which has a matching taper of equal angle.
Almost all machine tool spindles, and many power tool spindles, have a taper as their primary method of attachment for tools. Even on many drill presses, handheld drills, and lathes, which have chucks (such as a drill chuck or collet chuck), the chuck is attached by a taper. On drills, drill presses, and milling machines, the male member is the tool shank or toolholder shank, and the female socket is integral with the spindle. On lathes, the male may belong to the tool or to the spindle; spindle noses may have male tapers, female tapers, or both.
Explanation
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Machine tool operators must be able to install or remove tool bits quickly and easily. A lathe, for example, has a rotating spindle in its headstock, to which one may want to mount a spur drive or work in a collet. Another example is a drill press, to which an operator may want to mount a bit directly, or using a drill chuck.
Virtually all milling machines, from the oldest manual machines up to the most modern CNC machines, use tooling that is piloted on a tapered surface.
The machine taper is a simple, low-cost, highly repeatable, and versatile tool mounting system. It provides indexability, as tools can be quickly changed but are precisely located both concentrically and axially by the taper. It also allows high power transmission across the interface, which is needed for milling.
Machine tapers can be grouped into self-holding and self-releasing classes. With self-holding tapers, the male and female wedge together and bind to each other to the extent that the forces of drilling can be resisted without a drawbar, and the tool will stay in the spindle when idle. It is driven out with a wedge when a tool change is needed. Morse and Jacobs tapers are an example of the self-holding variety. With self-releasing tapers, the male will not stick in the female without a drawbar holding it there. However, with good drawbar force, it is very solidly immobile. NMTB/CAT, BT and HSK are examples of the self-releasing variety.
For light loads (such as encountered by a lathe tailstock or a drill press), tools with self-holding tapers are simply slipped onto or into the spindle; the pressure of the spindle against the workpiece drives the tapered shank tightly into the tapered hole. The friction across the entire surface area of the interface provides a large amount of torque transmission, so that splines or keys are not required.
For use with heavy loads (such as encountered by a milling machine spindle), there is usually a key to prevent rotation and/or a threaded section, which is engaged by a drawbar that engages either the threads or the head of a pull stud that is screwed into them. The drawbar is then tightened, drawing the shank firmly into the spindle. The draw-bar is important on milling machines as the transverse force component would otherwise cause the tool to wobble out of the taper.
All machine tapers are sensitive to chips, nicks (dents), and dirt. They will not locate accurately, and the self-holding variety will not hold reliably, if such problems interfere with the seating of the male into the female with firm contact over the whole conical surface. Machinists are trained on keeping tapers clean and handling them in ways that prevent them from being nicked by other tools. CNC tool-changing cycles usually include a compressed-air blast while one toolholder is being swapped with the next. The air blast tends to blow away chips that might otherwise end up interfering between the toolholder and spindle.
Use
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Tools with a tapered shank are inserted into a matching tapered socket and pushed or twisted into place. They are then retained by friction. In some cases, the friction fit needs to be made stronger, as with the use of a drawbar, essentially a long bolt that holds the tool into the socket with more force than is possible by other means.[citation needed]
Caution needs to be exercised in the usual drilling machine or lathe situation, which provides no drawbar to pull the taper into engagement, if a tool is used requiring a high torque but providing little axial resistance. An example would be the use of a large diameter drill to slightly enlarge an existing hole. In this situation, there may be considerable rotary loading. In contrast, the cutting action will require very little thrust or feed force. Thrust helps to keep the taper seated and provides essential frictional coupling.
The tang is not engineered to withstand twisting forces which are sufficient to cause the taper to slip, and will frequently break off in this situation. This will allow the tool to spin in the female taper, which is likely to damage it. Morse taper reamers are available to alleviate minor damage.
Tapered shanks "stick" in a socket best when both the shank and the socket are clean. Shanks can be wiped clean, but sockets, being deep and inaccessible, are best cleaned with a specialized taper cleaning tool which is inserted, twisted, and removed.
Tapered shank tools are removed from a socket using different approaches, depending on the design of the socket. In drill presses and similar tools, the tool is removed by inserting a wedge shaped block of metal called a "drift" into a rectangular shaped cross hole through the socket and tapping it. As the cross section of the drift gets larger when the drift is driven further in, the result is that the drift, bearing against the foremost edge of the tang, pushes the tool out. In many lathe tailstocks, the tool is removed by fully withdrawing the quill into the tailstock, which brings the tool up against the end of the leadscrew or an internal stud, separating the taper and releasing the tool. Where the tool is retained by a drawbar, as in some mill spindles, the drawbar is partially unthreaded with a wrench and then tapped with a hammer, which separates the taper, at which point the tool can be further unthreaded and removed. Some mill spindles have a captive drawbar which ejects the tool when actively unscrewed past the loose stage; these do not require tapping. For simple sockets with open access to the back end, a drift punch is inserted axially from behind and the tool tapped out.
Types
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There are many standard tapers, which differ based on the following:
The standards are grouped into families that may include different sizes. The taper within a family may or may not be consistent. The Jarno and NMTB tapers are consistent, but the Jacobs and Morse families vary.
There are adaptors available to allow the use of one type of taper tooling, e.g. Morse, on a machine with a different taper, e.g. R8 or vice versa, and simpler adaptors consisting of an externally and internally tapered sleeve to allow a small Morse tool to be used in a machine of larger bore.
One of the first uses of tapers was to mount drill bits directly to machine tools, such as in the tailstock of a lathe, although later drill chucks were developed that held parallel shank drill bits.
Brown & Sharpe
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Brown & Sharpe tapers, standardized by the company of the same name, are an alternative to the more-commonly seen Morse taper. Like the Morse, these have a series of sizes, from 1 to 18, with 7, 9 and 11 being the most common. Actual taper on these lies within a narrow range close to .500 inches per foot (41.67 mm per meter).
Size Lg. Dia. Sm. Dia. Length Taper (in/ft) Taper (in/in) 1 0.2392 0.2000 0.94 0.5020 0.04183 2 0.2997 0.2500 1.19 0.5020 0.04183 3 0.3753 0.3125 1.50 0.5020 0.04183 4 0.4207 0.3500 1.69 0.5024 0.04187 5 0.5388 0.4500 2.13 0.5016 0.04180 6 0.5996 0.5000 2.38 0.5033 0.04194 7 0.7201 0.6000 2.88 0.5010 0.04175 8 0.8987 0.7500 3.56 0.5010 0.04175 9 1.0775 0.9001 4.25 0.5009 0.04174 10 1.2597 1.0447 5.00 0.5161 0.04301 11 1.4978 1.2500 5.94 0.5010 0.04175 12 1.7968 1.5001 7.13 0.4997 0.04164 13 2.0731 1.7501 7.75 0.5002 0.04168 14 2.3438 2.0000 8.25 0.5000 0.04167 15 2.6146 2.2500 8.75 0.5000 0.04167 16 2.8854 2.5000 9.25 0.5000 0.04167 17 3.1563 2.7500 9.75 0.5000 0.04167 18 3.4271 3.0000 10.25 0.5000 0.04167Jacobs
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The Jacobs Taper (abbreviated JT) is commonly used to secure drill press chucks to an arbor. The taper angles are not consistent varying from 1.41° per side for No. 0 (and the obscure #2+1⁄2) to 2.33° per side for No. 2 (and No. 2 short).
There are also several sizes between No. 2 and No. 3: No. 2 short, No. 6 and No. 33.
Taper Small End Big End Length No. 0 0.22844 in (5.8024 mm) 0.2500 in (6.3500 mm) 0.43750 in (11.113 mm) No. 1 0.33341 in (8.4686 mm) 0.3840 in (9.7536 mm) 0.65625 in (16.669 mm) No. 2 0.48764 in (12.386 mm) 0.5590 in (14.199 mm) 0.87500 in (22.225 mm) No. 2 Short 0.48764 in (12.386 mm) 0.5488 in (13.940 mm) 0.75000 in (19.050 mm) #2
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0.625 in (15.875 mm) 0.677 in (17.196 mm) 1.055 in (26.797 mm) No. 3 0.74610 in (18.951 mm) 0.8110 in (20.599 mm) 1.21875 in (30.956 mm) No. 4 1.0372 in (26.345 mm) 1.1240 in (28.550 mm) 1.6563 in (42.070 mm) No. 5 1.3161 in (33.429 mm) 1.4130 in (35.890 mm) 1.8750 in (47.625 mm) No. 6 0.6241 in (15.852 mm) 0.6760 in (17.170 mm) 1.0000 in (25.400 mm) No. 33 0.5605 in (14.237 mm) 0.6240 in (15.850 mm) 1.0000 in (25.400 mm)Jarno
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Jarno tapers use a greatly simplified scheme. The rate of taper is 1:20 on diameter, in other words 0.600" on diameter per foot, .050" on diameter per inch. Tapers range from a Number 2 to a Number 20. The diameter of the big end in inches is always the taper size divided by 8, the small end is always the taper size divided by 10 and the length is the taper size divided by 2. For example, a Jarno No. 7 measures 0.875" (7/8) across the big end. The small end measures 0.700" (7/10) and the length is 3.5" (7/2).
The system was invented by Oscar J. Beale of Brown & Sharpe.
Jarno tapers Taper Large end Small end Length Taper/Morse
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Morse taper No. 2 (MT2)The Morse taper was developed by Stephen A. Morse, based in New Bedford, Massachusetts, in the mid-1860s.[1] Since then, it has evolved to encompass smaller and larger sizes and has been adopted as a standard by numerous organizations, including the International Organization for Standardization (ISO) as ISO 296 and the German Institute for Standardization (DIN) as DIN 228–1. It is one of the most widely used types, and is particularly common on the shank of taper-shank twist drills and machine reamers, in the spindles of industrial drill presses, and in the tailstocks of lathes. The taper angle of the Morse taper varies somewhat with size but is typically 1.49 degrees (around 3 degrees included).
Some modular orthopedic total hip implants use a Morse taper to mate components together.[2] Similarly, some dental implants use a Morse taper to connect components.[3]
Sizes
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Morse tapers come in eight sizes identified by whole numbers between 0 and 7, and one half-size (4 1/2 - very rarely found, and not shown in the table). Often the designation is abbreviated as MT followed by a digit, for example a Morse taper number 4 would be MT4. The MT2 taper is the size most often found in drill presses up to 1⁄2" capacity. Stub (short) versions, the same taper angle but a little over half the usual length, are occasionally encountered for the whole number sizes from 1 through 5. There are standards for these, which among other things are sometimes used in lathe head stocks to preserve a larger spindle through-hole.
End types
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Morse tapers are of the self-holding variety, and can have three types of ends:
Self-holding tapers rely on a heavy preponderance of axial load over radial load to transmit high torques. Problems may arise using large drills in relation to the shank, if the pilot hole is too large. The threaded style is essential for any sideloading, particularly milling. The only exception is that such unfavourable situations can be simulated to remove a jammed shank. Permitting chatter will help release the grip. The acute (narrow) taper angle can result in such jamming with heavy axial loads, or over long periods.
End-milling cutters with a Morse taper shank with a tang are occasionally seen: for security these must be used with a C-collar or similar, fitting into the neck between cutter and shank, and pulling back against the large end of the taper
The taper itself is roughly 5/8" per foot, but exact ratios and dimensions for the various sizes of tang type tapers are given below.
Dimensions
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taper Morse taper dimensions (mm) Morse taper number Taper A B (max) C (max) D (max) E (max) F G H J K 0 1:19.212 9.045 56.5 59.5 10.5 6 4 1 3 3.9 1° 29' 27" 1 1:20.047 12.065 62 65.5 13 8.7 5 1.2 3.5 5.2 1° 25' 43" 2 1:20.020 17.780 75 80 16 13.5 6 1.6 5 6.3 1° 25' 50" 3 1:19.922 23.825 94 99 20 18.5 7 2 5 7.9 1° 26' 16" 4 1:19.254 31.267 117.5 124 24 24.5 8 2.5 6.5 11.9 1° 29' 15" 5 1:19.002 44.399 149.5 156 29 35.7 10 3 6.5 15.9 1° 30' 26" 6 1:19.180 63.348 210 218 40 51 13 4 8 19 1° 29' 36" 7 1:19.231 83.058 285.75 294.1 34.9 – – 19.05 – 19 1° 29' 22"B Tapers
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B-series tapers are a DIN standard (DIN 238) typically used for fitting chucks on their arbors, like the older Jacobs taper series. Each taper in the B-series is effectively the small or large end of a Morse taper:
The number after the B is the diameter (D) of the large end of the taper to the nearest mm, and 'about' 1mm larger than the large end of the socket (~2mm in the case of B22 and B24) [5][6][7]
NMTB taper family
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The National Machine Tool Builders Association (now called the Association for Manufacturing Technology) defined a steep taper that is commonly used on milling machines. The taper is variously referred to as NMTB, NMT or NT. The taper is 3.500 inches per foot and is also referred to as "7 in 24" or 7/24; the computed angle is 16.5943 degrees.[8] All NMTB tooling has this taper but the tooling comes in different sizes: NMTB-10, 15, 20, 25, 30, 35, 40, 45, 50 and 60. These tapers were apparently also specified in ASA (now ANSI) B5.10-1943.
NMTB is a "self releasing" or "fast" taper. Unlike the more acute self holding tapers above, such tapers are not designed to transmit high torque; high torques are carried by driving keys engaging slots on the flange.[9][10] The purpose is to allow a quick and easy change between different tools (either automatically or by hand) while ensuring the tool or toolholder will be tightly and rigidly connected to the spindle, and accurately coaxial with it. The larger end adjacent to the tool makes for more rigidity than is possible with Morse or R8 tapers fitted to comparable machines.
Patent 1794361 (filed 25 March 1927) describes milling machine spindle and tool shapes using a steep taper.[11] The patent was assigned to Kearney & Trecker Corporation, Brown & Sharpe, and Cincinnati Milling Machine Company. The patent wanted a taper that would freely release the tool and found that a taper of 3.5 in 12 had that property.[12] The patent also used the keys and slots and a tail on the tool shank to prevent the tool shank from falling out of a horizontal mill's spindle while the operator connected the drawbar.[12]
ANSI B5.18-1972 specifies some essential dimensions for milling machine spindles and tool shanks using taper sizes 30, 40, 45, 50, 60.[13] The specifications describe the position of the driving key and flange and the thread of the drawbar bolt that holds the shank in the spindle.
The tooling is referred to as Quick Change; National Machine Tool Builders' Association, 1927; NMTB; American Standard Machine Taper, ANSI B5.18; DIN 2080 / IS 2340; ISO R 290–2583.[14] There are slight variations in threads and flanges (JIS B 6339: MAS 403); and the European standards (e.g., ISO taper, DIN 2080) use metric drawbar threads. Aside from the drawbar threads the above standards are physically compatible with each other in most cases.
The NMTB tool shanks had the 7 in 24 taper, but they also had a constant diameter tail (pilot) at the end of the shank that was described in the 1927 patent.
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Related links:NMTB derivatives
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Toolholder for milling machine with CAT-40 taper.Subsequent design variations dropped the tail (making the shank shorter) and put a V-groove in the flange that aided automated tool changing. Modern designs started using power drawbars that gripped pull studs (also known as retention knobs) that were screwed into the tool shank rather than screw-in drawbars. The power drawbar would grip the pull stud rather than screwing into the tool shank, allowing for faster automatic tool changes.
The more modern toolholder designs became known as the Caterpillar "V-Flange", CAT, V-Flange, (ANSI B5.50,) this was later codified under ISO 7388-1.
Other derivatives include:
Once again, there are modest variations in the tooling.[14] Although the basic taper dimensions are the same, there are differences in the flanges, v-groove sizes, drive keyways, and pull stud dimensions; the international versions use metric sizes, and metric stud threads particularly.
HSK taper
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HSK A63 shank Drawing of HSK A63 shank Animation of HSK toolholderHSK toolholders were developed in the early 1990s. HSK stands for de:Hohlschaftkegel; German for "hollow shank tapers".
Steep tapers (e.g. NMTB and derivatives) tend to loose rigidity and accuracy at high speed, as their solid shanks are stiffer than the spindles they fit into. Under high centrifugal force, the spindle expands more than the toolholder which changes the overall length: That is, as the spindle 'expands' the toolholder tends to move deeper into the spindle in the z-axis which can cause the production of parts that are out-of-tolerance. Moreover, the thinnest part of the spindle interface is the front shoulder which tends to expand the most, it engages the stiffest part of the holder where radial forces are also the highest. This significantly reduces the stiffness of the spindle interface allowing more deflection of the holder under cutting load, particularly with long tools. The holder can "rock" or "walk" slightly from side to side, by way of elastic deformation. Usually this causes poor runout accuracy, more chatter, and unduly short tool life. In the most extreme case it can cause Fretting wear on the spindle surface due to slight relative motion of the holder against the female interface.
HSK's hollow shank is deliberately thin and flexible, so it expands more than the spindle and tightens when rotating at high speed. Furthermore, the HSK holder is dual contact: It engages with the spindle on both the taper and the top of the flange which resists axial movement when thermal growth and/or centrifugal force of the spindle occurs.
The flexibility is also used to provide accurate axial location. An HSK toolholder has both a tapered shank, and a flange with a mating surface. The shank is short (about half as long as other machine tapers), with a shallow taper (a ratio of 1:10), and slightly too large to allow the flange to seat fully in the socket. The thin walls, short shank and shallow taper provide a large opening in the back of the tool. An expanding collet fits in there, and mates with 30° chamfer inside the shank. As the drawbar retracts, it expands the collet and pulls the shank back into the socket, compressing the shank until the flange seats against the front of the spindle. This provides a stiff, repeatable connection because it utilizes the centrifugal force inside the spindle for security and rigidity. As centrifugal forces increase the expanding collet within the HSK forces the walls of the toolholder shank to stay in contact with the spindle wall.
The HSK design was developed as a nonproprietary standard. The working group that produced the HSK standard consisted of representatives from academia, the Association of German Tool Manufacturing and a group of international companies and end users. The results were the German DIN standards 69063 for the spindle and 69893 for the shank. The HSK working group did not adopt a specific product design, but rather a set of standards that defined HSK toolholders for different applications. The group defined a total of six HSK shank forms, in 9 sizes.
Sizes are identified by the diameter of the shank's flange in millimeters. These diameters are taken from the R10′ series of preferred numbers, from 25 to 160 mm.
Today, the shank forms are designated by the letters A through F and T. The main differences between the forms are the positions of the drive slots, gripper-locating slots, coolant holes and the area of the flange.
HSK forms A, C, E Nominal Dimensions[15] d1 mm forms d2 mm l1 mm l2 mm f1 mm f5 mm d8 b1 20 E 15.203 10 2.0 8 - - - 25 A, C, E 19.006 13 2.5 10 - - - 32 A, C, E 24.007 16 3.2 20 10.0 4.0 7.05 40 A, C, E 30.007 20 4.0 20 10.0 4.6 8.05 50 A, C, E 38.009 25 5.0 26 12.5 6.0 10.54 63 A, C, E 48.010 32 6.3 26 12.5 7.5 12.54 80 A, C 60.012 40 8.0 26 16.0 8.5 16.04 100 A, C 75.013 50 10.0 29 16.0 12.0 20.02 125 A, C 95.016 63 12.5 29 - - 25.02 160 A, C 120.016 90 16.0 31 - - 30.02 HSK forms B, D, F Nominal Dimensions[15] d1 mm forms d2 mm l1 mm l2 mm f1 mm d8 b1 25 - - - - - - - 32 - - - - - - - 40 B, D 24.007 16 3.2 20 4.0 10 50 B, D, F 30.007 20 4.0 26 4.6 12 63 B, D, F 38.009 25 5.0 26 6.0 16 80 B, D, F 48.010 32 6.3 26 7.5 18 100 B, D 60.012 40 8.0 29 8.5 20 125 B, D 75.013 50 10.0 29 12.0 25 160 B, D 95.016 63 12.5 31 12.0 32A is the basic form. The B-form shank is a variant for high-torque applications, and has a flange one size larger relative to its shaft diameter. (Thus, an A-40 shank will fit into a B-50 socket.)
Forms C and D are simplified variants of A and B for manual use, eliminating features to accommodate automatic tool changers like a V-groove and associated orientation slots, and a recess for an RFID chip.
Forms E and F flanges and tapers are similar to forms A and B, but designed for very high speed machining (20,000 rpm and up) of light materials by eliminating all asymmetric features to minimize imbalance and vibration.
ASME B5.62 "Hollow Taper Tooling With Flange-Face Contact"[16] and ISO 12164-3:2014 "Dimensions of shanks for stationary tools"[17] include an additional form T, which is bidirectionally compatible with form A, but has a much tighter tolerance on the widths of the keys and keyways used for angular alignment. This permits non-rotating lathe tooling to be held accurately.[18]
An HSK connection depends on a combination of axial clamping forces and taper-shank interference. All these forces are generated and controlled by the mating components' design parameters. The shank and spindle both must have precisely mating tapers and faces that are square to the taper's axis. There are several HSK clamping methods. All use some mechanism to amplify the clamping action of equally spaced collet segments. When the toolholder is clamped into the spindle, the drawbar force produces a firm metal-to-metal contact between the shank and the ID of the clamping unit. An additional application of drawbar force positively locks the two elements together into a joint with a high level of radial and axial rigidity. As the collet segments rotate, the clamping mechanism gains centrifugal force. The HSK design actually harnesses centrifugal force to increase joint strength. Centrifugal force also causes the thin walls of the shank to deflect radially at a faster rate than the walls of the spindle. This contributes to a secure connection by guaranteeing strong contact between the shank and the spindle. The automotive and aerospace industries are the largest users of HSK toolholders. Another industry that is seeing increasing use is the mold and die industry.
PSC
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PSC stands for "Polygonal Shank Conical." Originally developed in 1989 Ken Andersson working for the Swedish machine tool company Sandvik Coromant AB. PSC was introduced by Sandvik at the 1990 IMTS in Chicago, under the brand name "Capto."[19] In the early 2000s as various patent protections were set to expire, Sandvik was faced with the prospect of sub-standard copies being produced that mated poorly with previously sold Capto branded tooling and that produced by their licensees. Therefore, Sandvik sought certification for the style of interface from ISO international in the mid-2000s. In 2007 PSC was published under ISO 26623. Thus, toolholders and spindles that conform to ISO 26623 are fully compatible with brand name Capto tooling.
PSC shares many design characteristics of HSK such as a short hollow shank, additional contact of the flange with the face of the female spindle interface, and clamping by an internal expanding collet. However PSC features a unique non-circular shank with a cross sectional resembling a Reuleax Triangle with filleted corners, while the hollow central counterbore is cylindrical. PSC also features a shallow 2.88° taper of the triangular shank compared to 5.72°(1:10) of HSK. One aspect PSC shares with NMTB styles, and differs from HSK, in having a more limited number of sizes that are near identical in form, since it is designed to have a wider range of application. This improves interchangeability.
Torque transmission is accomplished by means of pressure on the corners of the shank, rather than drive keys and/or friction between the spindle & shank. In addition to axial and radial rigidity, this provides better angular repeatability and improved torsional rigidity over other interfaces. Pressures resulting from applied torque improve rigidity because they are applied over a much larger area of the shank. The conical tapered shank allows a slight interference fit with the spindle rather than requiring a clearance for disassembly, improving angular repeatability.
PSC is popular for combination turn-mill centers with a single 3-4axis tool spindle and also CNC Turret lathes due to its superior angular repeatability and off-axis torsional rigidity. It can support static/fixed off-axis turning tools and is also suitable for turret lathes with a large number of driven tool stations. This provides a single quick-change interface for both live cutters and static tools. It can replace conventional square or round shank static tools, resulting in a much faster setup time when swapping worn tools. PSC provides superior performance for live/driven boring heads, enabling higher feeds and better surface finishes.
PSC is available in the following sizes:
R8
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collets with R8 taperThis taper was designed by Bridgeport Machines, Inc. for use in its milling machines. R8 tapers are not self-holding, so they require a drawbar extending up through the spindle to the top of the machine to prevent loosening when lateral forces are encountered. They are also keyed (see image) to prevent rotation during insertion and removal, although it is the taper that transmits torque in use. The drawbar thread is typically 7⁄16″–20 tpi (UNF). The angle of the cone is 16°51′ (16.85°) with an OD of 1.25″ and a length of 15⁄16″.[20] (source, Bridgeport Manufacturer) The diameter of the parallel locating portion is not a "fractional inch" size like the other dimensions and is 0.949″ to 0.9495″.
Tools with an R8 taper are inserted directly into the machine's spindle. R8 collets are typically used to hold tooling with round shanks, although any shape can be held if the collet has the corresponding shape cut in it. The collets have a precision bore with axial compression slots for holding cutting tools and are threaded for the drawbar. The R8 system is commonly used with collets ranging in size from 1⁄8″ to 3⁄4″ in diameter or tool holders with the same or slightly larger diameters. The collets or tool holders are placed directly into the spindle and the drawbar is tightened into the top of the collet or tool holder from above the spindle. Other tools such as drill chucks, fly cutters, indexable insert cutters, etc. may have an R8 taper shank built into or added to the tool.
The R8 taper is commonly encountered on Bridgeport and similar turret mills from the US, or on (very common) copies of these mills from elsewhere. The popularity is due in large part to the success of Bridgeport and other mills that were closely modeled after it and produced throughout much of the 20th century.
See also
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References
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Sources
The Morse Taper was invented in 1864 by Stephen A. Morse, an enterprising mechanic, who developed it to reliably join two rotating machine components. The orthopaedic industry has adapted these tapers, under the generic name of Morse tapers, as a means of reliably joining modular components of total joints directly on the operation table. The principle of the Morse taper is that of the cone in the cone. The trunnion (the male portion) and the bore (the female portion) are both uniformly tapered. When the bore in the femoral head is tapped onto the trunnion of the femoral stem they come into intimate contact. The conical femoral taper compresses the walls in the bore as it expands. Thus, the stresses inside the materials keep both components fixed together.
Morse taper technology and design began with the ideas of one man. From his ideas a company grew to become the leader in the design and manufacture of metal cutting tools.
Stephen A. Morse, an enterprising mechanic, developed a new and better way to drill a hole in 1864 when he invented the twist drill. Machine tool operators must be able to install or remove tool bits quickly and easily. A lathe, for example, has a rotating spindle in its headstock, to which one may want to mount a spur drive or work in a collet. Another example is a drill press, to which an operator may want to mount a bit directly, or by using a drill chuck. Virtually all milling machines, from the oldest, manual machines up to the most modern machines use tooling that is guided on a tapered surface. The machine taper is a simple, low-cost, highly repeatable, and versatile tool mounting system that uses tool bits (or holders) with gradually tapered shanks and a matching hollowed-out spindle.
For light loads (such as encountered by a lathe tailstock), tools are simply slipped onto or into the spindle; the pressure of the spindle against the workpiece drives the tapered shank tightly into the tapered hole. The friction across the entire surface area of the interface provides a large amount of torque transmission, so that splines or keys are not required. The tapered interference fits are used commonly in engineering practice such as Morse tapers, used to engage lathe bits.
With a new patent and a stockholder investment of $30,000, he opened the Morse Twist Drill and Machine Company in New Bedford Massachusetts in 1864. Recognising the need for a way to drive his twist drill, Morse created the taper shank series. Two sets of master gages were made up; one, sent to the Bureau of Standards in Washington, D.C., was accepted as a National Standard. The other remains with the Morse Company.
Differences with his board caused Morse to resign in 1868. Philadelphia’s 1877 Centennial Exhibition showcased the first exhibition of Morse tools. Morse products gained an international reputation for quality and were sold throughout the United States and in England, Russia and Germany. In the latter part of the 19th century, the company began a pattern of acquisition which resulted in enormous growth. Morse took over the Manhattan Fire Arms Company of Newark, New Jersey and the American Standard Tool Company of Danbury, Connecticut. Morse also acquired the Beach chuck patent of the Meridan Tool Company, Meridan, Connecticut, and the Schofield Patent Grinding Line, helping to ensure accuracy in drill grinding. In 1874, Morse purchased the machinery, patents and stock of the New York Tap and Die Company of Bridgeport, Connecticut. In 1897, Morse purchased the T & B Tool Company. T & B’s machines, used in the manufacture of constant angle twist drills, were designed by a former Morse employee who had gone into business for himself and were built by Pratt and Whitney. Entering the 20th century, Morse developed a grinding machine used in the manufacture of drills. Until the beginning of World War I, the company marketed a line of plain and universal grinders. Business continued to grow between the wars, and during World War II, Morse output increased four to five times normal production to contribute to the war effort. In the years since World War II, Morse has operated under the ownership of a number of companies, including Gulf and Western. The current owners, a group of American investors, purchased the company from a Scottish manufacturing concern, and are committed to upholding the Morse reputation for high-quality, American-made cutting tools. Today, Morse inventories over 25,000 varieties of cutting tools to serve our nation’s marketplace. Imagination, technological innovation and insistence on quality are built into every Morse product. And at Morse, our people wouldn’t have it any other way.
The Morse’s ideas jumped from design and manufacture of metal cutting tools to orthopaedic surgery 40 years ago when the ceramic head was introduced in hip surgery. Before the introduction of ceramic in hip arthroplasty, femoral head and stem were “mono-block”. Boutin [1], who worked in Pau in the southwest part of France, implanted the first ceramic-on-ceramic hip manufactured by Ceraver. He found that the problem of ceramic-on-ceramic was not related to wear or to the mechanical properties but the risk of fracture of the femoral head due to the difficulty of the fixation of the ceramic head on the metal component. In the beginning, the fixation of alumina on metal was done with glue, then screwed on the stem. This resulted in separation of the head from the stem with fractures. For the ball head fixation this was essentially solved in 1974 when Prof. Mittelmeier [4] adapted the Morse taper for ceramic heads with the manufacturer Ceramtec, which resulted in a large decrease in the rate of head fracture. In 1977 the manufacturer Ceraver with Daniel Blanquaert also adapted the Morse taper to fix the alumina on the metal.
The orthopaedic industry has now adapted these tapers for metal head, under the generic name of Morse tapers, as a means of reliably joining modular components at the operating table. They are now available in femoral and acetabutar component designs, in humeral head component designs, and even as intramedullary rods.
Morse tapers are not standardised in the orthopaedic industry; they vary from company to company. Thus, the trunion (male portion) and the bore (female portion) may appear to be compatible but might be totally incompatible. Extreme care must be taken in the use of these tapers at the time of revision procedures to be sure that products from different manufacturers are not mixed, as this may lead to dissociation.
The dependent characteristics of the interference fit, such as the pull-out and insertion forces and the stress distribution in the members, depend on the taper angle, contact length, inner and outer diameters of the members, depth of insertion, material properties and coefficient of friction, and also size and mass of the femoral head.
A question often asked within the clinical community is, “what specifically is a Morse taper and can it provide a stable connection between components?” A Morse taper is defined by the angle that the taper surfaces make relative to the longitudinal axis of the component and by the mismatch angle between the male and female part. The original Morse taper angle defined by Stephen Morse for tools was a relatively small angle of 2° 50′, with the mathematical relation that tang 2° 50 = 5 %.
Morse taper angles used for arthroplasties generally fall in a range of 5–18°, and when interpenetrating parts of slightly different sizes or angles (called the mismatch angle) are assembled as an interference fit, they lock together. This is because of the high contact stresses that develop along the interface during forced assembly. So the orthopaedic angle is not exactly the angle choosen by Stephen Morse. From a mechanical point of view the smaller the angle is, the higher is the stability. The principle of the Morse taper is that of the cone into the cone. The trunnion (the male portion) and the bore (the female portion) are both uniformly tapered. When the bore in the femoral head is tapped onto the trunnion of the femoral shaft they come into intimate contact. The conical femoral taper compresses the walls in the bore as it expands.
This results in cointegration (locking), with material transfer across the zone of contact (cold welds). The degree of fit (interference) is determined by the relative dimensions of the two components (male and female regions) and a design decision to have interference along a specific part of the taper’s circumference and length. The area of interference contact must be adequate to maintain integrity under functional (loaded) conditions, while the surface finish of the components must be specific to the physical and mechanical properties of each component’s material.
A range of different Morse taper angles, component tolerances and sizes, and surface finishes exist within commercially available arthroplasties. Combinations or exchanges of components at the time of surgery (when specified by the manufacturer) to optimise lengths, offsets, diameters, shapes, and materials represent a significant opportunity for modular systems while maintaining reasonable inventories. However, except for unique circumstances, an exchange of Morse taper component parts between different devices or from different manufacturers is contraindicated.
Existing design parameters including taper region diameter, length, conicity, surface finish, area of interference, and relative angle should be known by orthopaedic surgeons to understand the limits of the various device systems. This is necessary to avoid phenomena responsible for loosening, unintended disassembly, or fracture. Other complications such as fretting mediated have been reported. Fretting and fretting-corrosion phenomena were found to be most critical with varience of manufacturing tolerances plus design and clinical conditions that introduced larger magnitude interfacial micromotions during function.
Morse tapers introduced in orthopaedic surgery have also some disadvantageous sides. First, the dimensions of Morse tapers are not standardised, they vary from company to company. Thus the male parts manufactured by company A must not be mixed with the female part manufactured by company B. They may appear identical, but they are not! A total hip system assembled from such components is at great risk to dissociate.
Second, the Morse taper connects two different materials, thus fretting and corrosion [2] can be a problem with Morse tapers. To avoid such problems the surgeon must be sure to have the joining surfaces clean and dry before tapping them together. Some taper designs have almost no interlocking at all when wet.
Third, Morse tapers joining the ceramic femoral heads with the femoral shafts produce stresses within the ceramic material. These so-called hoop stresses can cause catastrophic fractures of the ceramic femoral head if they exceed a certain level. This happens when the products of two different manufacturers are coupled together. It is thus especially important that a ceramic head is always coupled with a matched femoral stem manufactured by the same manufacturer. This may seem obvious, but it has been reported at revision operations that the surgeons used new ceramic heads from a new manufacturer on the old femoral shaft components, produced by another (old) manufacturer. This was often the cause of ceramic head fractures in the past.
Modular components add significantly to the surgeon’s armamentarium, but also increase the potential for mismatch and mechanical failure. The use of modular components greatly increases flexibility during total hip arthroplasty, but also introduces the risks of failure at the interfaces and of intraoperative errors in matching. Modular femoral heads can dissociate [3] as a result of trauma. When revision of a modular hip is planned, it is important to be certain of the manufacturer and the head size of the original hip before operation. The head may be damaged or a change in length may be required. The specifications of the Morse taper vary with different manufacturers, and it is essential that new components come therefore from the same manufacturer as well as being of the appropriate head diameter and allowing the neck length to be changed.
An error at operation is another category of complication. Most modular systems provide three or four head diameters with matching liners. Although modularity makes a mismatch more likely, it also makes it easier to correct without disturbing well-fixed components. It is important that surgeons are aware of this potential pitfall and take care to check the size of all components before they are implanted.
Our rough estimate of the incidence of complications relating to modularity is based on the estimated number of arthroplasties performed by the surgeons contributing cases, which is low, at 0.1–0.2 %. The fact, however, that we have collected 20 such complications in five years leads us to believe that the extent of the problem is not fully appreciated. Operative errors are avoidable with careful attention to detail, but the avoidance of mechanical failure will require improvements in manufacture.
In conclusion, the Morse taper allows the combination of different materials in one total hip model. It is now possible to combine a ceramic femoral head with a titanium femoral shaft. To appreciate the benefits of the Morse taper, remember that the first ceramic femoral heads were pasted on the stem component with acrylic glue! The main cause of failure in these early ceramic total hips was failure of the glue.
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