Audel Machine Shop Basics, All New 5th Edition

Acknowledgments xi

About the Authors xiii

Introduction xiv

Chapter 1: Benchwork 1

The Bench and Bench Tools 1

Vises 2

Hammers 3

Chisels 5

Flat Chisel 5

Cape Chisel 8

Diamond-Point Chisel 8

Round-Nose Chisel 9

Hacksaws 10

Files 11

How to File 11

Drawfiling 15

File Characteristics 17

Scrapers 20

How to Use a Scraper 21

Scraper Classifications 23

Summary 23

Review Questions 24

Chapter 2: Precision Measurement and Gaging 27

Micrometer Calipers 27

Vernier Micrometer Calipers 29

Vernier Calipers 31

Bevel Protractors 34

Dial Indicators 38

Gages 39

Surface Gage 40

Height Gage 42

Depth Gage 43

Snap Gage 43

Plug Gage 44

Ring Gage 45

Taper Gage 45

Center Gage 47

Screw-Pitch Gage 47

Tap and Drill Gage 49

Thickness or Feeler Gage 49

Wire Gage 50

U.S. Standard Gage for Sheet and Plate Iron and Steel 51

Effects of Temperature and Weight on Precision Tools 51

Electronic Caliper Depth Gages 55

Electronic Digital Micrometer 58

Summary 58

Review Questions 60

Chapter 3: Materials 63

Properties 63

Desirable Properties 63

Definition of Properties 63

Metals 65

Ferrous Metals 65

Nonferrous Metals 70

Refractory Metals 71

Nonferrous Alloys 73

Nonmetals 76

Tests of Materials 76

Elasticity and Plasticity 76

Stress and Strain 77

Tensile Strength 77

Ductility 77

Toughness 77

Hardness 78

Portable Hardness Tester 78

Brittleness 82

Relationship between Mechanical Properties and Hardness 82

Effects of Temperature 83

Summary 84

Review Questions 85

Chapter 4: Abrasives 89

Structure of Abrasives 89

Natural Abrasives 89

Manufactured Abrasives 90

Composition of Abrasives 90

Silicon Carbide 91

Aluminum Oxide 91

Diamonds 91

Use of Abrasives in Grinding Wheels 92

Silicon Carbide Abrasives 92

Aluminum Oxide Abrasives 93

Diamond Abrasive 94

Summary 94

Review Questions 95

Chapter 5: Grinding 97

Manufacture of Grinding Wheels 97

Natural Grindstones 97

Manufactured Abrasive

Grinding Wheels 97

Bond Types in Grinding Wheels 101

Vitrified-Bond Grinding Wheels 101

Organic-Bonded Grinding Wheels 102

Silicate-Bonded Grinding Wheels 105

Grinding Wheel Markings 105

Abrasive Type 106

Grain Size 106

Grade 106

Structure 106

Bond or Process 107

Bond Modification Symbols 107

Factors Affecting Grinding Wheel Selection 107

Hardness of Material to Be Ground 108

Amount of Stock to Be Removed and Finish Required 108

Operation (Wet or Dry) 108

Wheel Speed 108

Area of Grinding Contact 109

Severity of Grinding Operation 109

Summary 110

Review Questions 110

Chapter 6: Cutting Fluids 113

Coolant 113

Lubricants 113

Application of Cutting Fluids 113

Types of Cutting Fluids 114

Solid Lubricants 115

Summary 117

Review Questions 118

Chapter 7: Cutting Tools 119

Action of Cutting Tools 119

Materials 119

Shapes and Uses of Cutting Tools 120

Terms Related to Cutting Tools 121

Cutting Tool Angles 123

Tool Angles 123

Working Angles 128

High-Speed Steel Lathe Tools 130

Summary 135

Review Questions 136

Chapter 8: Cutter and Tool Grinders 137

Importance of Tool Sharpening 137

Cutter and Tool Sharpening 137

Lathe and Planer Tools 138

Twist-Drill Sharpening 138

Regrinding Tap Drills 143

Mounted Points and Wheels 144

Cutter-Sharpening Machines 144

Summary 149

Review Questions 149

Chapter 9: Drills 151

Drill Standards 151

Twist Drill Terminology 153

Types of Drills 157

Shank 157

Body 157

Point 161

Drill-Bit Point Design 163

Special-Purpose Drills 163

Socket and Sleeve 165

Using the Twist Drill 167

Secure the Work 167

Cutting Oil 167

Speeds and Feeds 167

Clearance Drills 176

Drill Problems and Causes 178

Summary 179

Review Questions 179

Chapter 10: Reamers 181

Types of Reamers 181

Hand Reamers 181

Machine Reamers 184

Use and Care of Reamers 192

Summary 193

Review Questions 194

Chapter 11: Taps 195

Types of Taps 195

Hand Taps 195

Machine-Screw Taps 202

Pipe Taps 205

Nut Taps 207

Pulley Taps 207

Taper Taps 207

Special-Purpose Taps 208

Tap Selection 209

Classes of Thread 210

Summary 212

Review Questions 213

Chapter 12: Threading Dies 215

Types of Dies 215

Solid Dies 215

Round-Split Dies 217

Two-Piece Adjustable Dies 218

Acorn Dies 218

Use of Dies to Cut Threads 220

Summary 222

Review Questions 223

Chapter 13: Milling-Machine Cutters 225

Milling Operation 225

Classification of Milling Cutters 226

General Types of Milling Cutters 226

Plain Milling Cutters 226

Side Milling Cutters 229

End Mills 231

Angle Milling Cutters 234

Slitting Saws, Slotting Saws, and Miscellaneous Cutters 235

Form-Relieved Cutters 239

Hobs 241

Care of Milling Cutters 242

Speeds and Feeds 242

Speeds 243

Feeds 246

Summary 250

Review Questions 250

Chapter 14: Milling-Machine Arbors, Collets, and Adapters 253

Arbors 253

Styles of Arbors 254

Methods of Driving the Cutters 255

Collets 257

Adapters 258

Summary 259

Review Questions 259

Chapter 15: Broaches and Broaching 261

Broaching Principle 261

Types of Broaches 262

Shapes of Broaches 262

Internal and External Broaches 263

Pull or Push Broaches 264

Care and Sharpening of Broaches 264

Broaching Machines 265

Broaching Operations 268

Pull Broaching 268

Push Broaching 268

Surface Broaching 269

Round Broaching 269

Summary 270

Review Questions 270

Chapter 16: Electrical Safety in the Machine Shop 273

Power Sources 273

Three-Phase Power 273

Power Panels 275

Raceways and Cable Trays 275

Motor Problems 278

Three-Phase Motor Symptoms 282

DC Motors 284

Motor Lubrication 286

Drum Switches 286

Safety in the Shop 288

Fire Extinguishers 288

Summary 288

Review Questions 292

Appendix: Reference Materials 293

Miscellaneous Useful Facts 293

Metric Conversions 294

Metric and English Equivalent Measures 295

Length 295

English Conversion Table 296

Standard Metric to English Conversions 297

Water Factors 300

Weights of Steel and Brass Bars 301

Index 303