Neil's supposition follows the standard explanation that the slight variation in the taper angle for different sizes of Morse Taper is due to errors in the master gauges. Plausible but I don't buy it. I think it deliberate policy.
Even in 1864, when the Morse Taper was invented, technology was well up to the task of producing accurately tapered master gauges. Albeit somewhat laboriously. Its setting the gauge plane that is difficult without accurate length measurement and adjustable standards. From a production viewpoint multiple tapers are a pain as needing separate masters and setting gear for each size. One size fits all, Jarno style, needs only one master calibration reference and one set up device.
The variations seem too large to be simple errors and the actual tapers per foot are extremely inconvenient dimensions. This suggests that the variation is deliberate. A plausible reason is that it would force firms wishing to make equipment to use Morse drills to buy gauging and maybe production equipment from Morse with obvious financial benefits. Single sourcing gauging equipment would also help maintain quality standards. Taper and similar self locking drill / tool holding systems had been introduced before and failed to become widely adopted due to machine to machine variations giving inconsistent performance. No proper drawing standards, or even drawings, in those days.
Another plausible reason for deliberate taper variation is to ensure that the system only works with the male taper fully inserted into the female one. Partial insertion of a too large male taper into a too small socket will not drive and is obviously wrong. Same taper throughout risked proliferation of odd sized and partial length variations. Probably accompanied by workers resorting to the BFH when things failed to behave. Still in the era of folk weighting down boiler safety valves!
Clive
Edited By Clive Foster on 20/05/2017 18:46:01