Audel Machine Shop Basics

Use the right tool the right way Here, fully updated to include new machines and electronic/digital controls, is the ultimate guide to basic machine shop equipment and how to use it. Whether you're a professional machinist, an apprentice, a trade student, or a handy homeowner, this fully illustrated volume helps you define tools and use them properly and safely. It's packed with review questions for students, and loaded with answers you need on the job. Mark Richard Miller is a Professor and Chairman of the Industrial Technology Department at Texas A&M University in Kingsville, Texas. * Understand basic machine shop practice and safety measures * Recognize the variations in similar tools and the purposes they serve * Learn recommended methods of mounting work in different machines * Obtain a complete working knowledge of numerically controlled machines and the operations they perform * Review procedures for safe and efficient use of cutting tools and cutters * Expand your knowledge with clear, step-by-step illustrations of proper equipment set-up and operation

Table of Contents:
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