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Summary
Summary
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
Author Notes
Mark Richard Miller is a Professor and Chairman of the Industrial Technology Department at Texas A&M University in Kingsville, Texas.
Table of Contents
Acknowledgments | p. xi |
About the Authors | p. xiii |
Introduction | p. xiv |
Chapter 1 Benchwork | p. 1 |
The Bench and Bench Tools | p. 1 |
Vises | p. 2 |
Hammers | p. 3 |
Chisels | p. 5 |
Flat Chisel | p. 5 |
Cape Chisel | p. 8 |
Diamond-Point Chisel | p. 8 |
Round-Nose Chisel | p. 9 |
Hacksaws | p. 10 |
Files | p. 11 |
How to File | p. 11 |
Drawfiling | p. 15 |
File Characteristics | p. 17 |
Scrapers | p. 20 |
How to Use a Scraper | p. 21 |
Scraper Classifications | p. 23 |
Summary | p. 23 |
Review Questions | p. 24 |
Chapter 2 Precision Measurement and Gaging | p. 27 |
Micrometer Calipers | p. 27 |
Vernier Micrometer Calipers | p. 29 |
Vernier Calipers | p. 31 |
Bevel Protractors | p. 34 |
Dial Indicators | p. 38 |
Gages | p. 39 |
Surface Gage | p. 40 |
Height Gage | p. 42 |
Depth Gage | p. 43 |
Snap Gage | p. 43 |
Plug Gage | p. 44 |
Ring Gage | p. 45 |
Taper Gage | p. 45 |
Center Gage | p. 47 |
Screw-Pitch Gage | p. 47 |
Tap and Drill Gage | p. 49 |
Thickness or Feeler Gage | p. 49 |
Wire Gage | p. 50 |
U.S. Standard Gage for Sheet and Plate Iron and Steel | p. 51 |
Effects of Temperature and Weight on Precision Tools | p. 51 |
Electronic Caliper Depth Gages | p. 55 |
Electronic Digital Micrometer | p. 58 |
Summary | p. 58 |
Review Questions | p. 60 |
Chapter 3 Materials | p. 63 |
Properties | p. 63 |
Desirable Properties | p. 63 |
Definition of Properties | p. 63 |
Metals | p. 65 |
Ferrous Metals | p. 65 |
Nonferrous Metals | p. 70 |
Refractory Metals | p. 71 |
Nonferrous Alloys | p. 73 |
Nonmetals | p. 76 |
Tests of Materials | p. 76 |
Elasticity and Plasticity | p. 76 |
Stress and Strain | p. 77 |
Tensile Strength | p. 77 |
Ductility | p. 77 |
Toughness | p. 77 |
Hardness | p. 78 |
Portable Hardness Tester | p. 78 |
Brittleness | p. 82 |
Relationship between Mechanical Properties and Hardness | p. 82 |
Effects of Temperature | p. 83 |
Summary | p. 84 |
Review Questions | p. 85 |
Chapter 4 Abrasives | p. 89 |
Structure of Abrasives | p. 89 |
Natural Abrasives | p. 89 |
Manufactured Abrasives | p. 90 |
Composition of Abrasives | p. 90 |
Silicon Carbide | p. 91 |
Aluminum Oxide | p. 91 |
Diamonds | p. 91 |
Use of Abrasives in Grinding Wheels | p. 92 |
Silicon Carbide Abrasives | p. 92 |
Aluminum Oxide Abrasives | p. 93 |
Diamond Abrasive | p. 94 |
Summary | p. 94 |
Review Questions | p. 95 |
Chapter 5 Grinding | p. 97 |
Manufacture of Grinding Wheels | p. 97 |
Natural Grindstones | p. 97 |
Manufactured Abrasive Grinding Wheels | p. 97 |
Bond Types in Grinding Wheels | p. 101 |
Vitrified-Bond Grinding Wheels | p. 101 |
Organic-Bonded Grinding Wheels | p. 102 |
Silicate-Bonded Grinding Wheels | p. 105 |
Grinding Wheel Markings | p. 105 |
Abrasive Type | p. 106 |
Grain Size | p. 106 |
Grade | p. 106 |
Structure | p. 106 |
Bond or Process | p. 107 |
Bond Modification Symbols | p. 107 |
Factors Affecting Grinding Wheel Selection | p. 107 |
Hardness of Material to Be Ground | p. 108 |
Amount of Stock to Be Removed and Finish Required | p. 108 |
Operation (Wet or Dry) | p. 108 |
Wheel Speed | p. 108 |
Area of Grinding Contact | p. 109 |
Severity of Grinding Operation | p. 109 |
Summary | p. 110 |
Review Questions | p. 110 |
Chapter 6 Cutting Fluids | p. 113 |
Coolant | p. 113 |
Lubricants | p. 113 |
Application of Cutting Fluids | p. 113 |
Types of Cutting Fluids | p. 114 |
Solid Lubricants | p. 115 |
Summary | p. 117 |
Review Questions | p. 118 |
Chapter 7 Cutting Tools | p. 119 |
Action of Cutting Tools | p. 119 |
Materials | p. 119 |
Shapes and Uses of Cutting Tools | p. 120 |
Terms Related to Cutting Tools | p. 121 |
Cutting Tool Angles | p. 123 |
Tool Angles | p. 123 |
Working Angles | p. 128 |
High-Speed Steel Lathe Tools | p. 130 |
Summary | p. 135 |
Review Questions | p. 136 |
Chapter 8 Cutter and Tool Grinders | p. 137 |
Importance of Tool Sharpening | p. 137 |
Cutter and Tool Sharpening | p. 137 |
Lathe and Planer Tools | p. 138 |
Twist-Drill Sharpening | p. 138 |
Regrinding Tap Drills | p. 143 |
Mounted Points and Wheels | p. 144 |
Cutter-Sharpening Machines | p. 144 |
Summary | p. 149 |
Review Questions | p. 149 |
Chapter 9 Drills | p. 151 |
Drill Standards | p. 151 |
Twist Drill Terminology | p. 153 |
Types of Drills | p. 157 |
Shank | p. 157 |
Body | p. 157 |
Point | p. 161 |
Drill-Bit Point Design | p. 163 |
Special-Purpose Drills | p. 163 |
Socket and Sleeve | p. 165 |
Using the Twist Drill | p. 167 |
Secure the Work | p. 167 |
Cutting Oil | p. 167 |
Speeds and Feeds | p. 167 |
Clearance Drills | p. 176 |
Drill Problems and Causes | p. 178 |
Summary | p. 179 |
Review Questions | p. 179 |
Chapter 10 Reamers | p. 181 |
Types of Reamers | p. 181 |
Hand Reamers | p. 181 |
Machine Reamers | p. 184 |
Use and Care of Reamers | p. 192 |
Summary | p. 193 |
Review Questions | p. 194 |
Chapter 11 Taps | p. 195 |
Types of Taps | p. 195 |
Hand Taps | p. 195 |
Machine-Screw Taps | p. 202 |
Pipe Taps | p. 205 |
Nut Taps | p. 207 |
Pulley Taps | p. 207 |
Taper Taps | p. 207 |
Special-Purpose Taps | p. 208 |
Tap Selection | p. 209 |
Classes of Thread | p. 210 |
Summary | p. 212 |
Review Questions | p. 213 |
Chapter 12 Threading Dies | p. 215 |
Types of Dies | p. 215 |
Solid Dies | p. 215 |
Round-Split Dies | p. 217 |
Two-Piece Adjustable Dies | p. 218 |
Acorn Dies | p. 218 |
Use of Dies to Cut Threads | p. 220 |
Summary | p. 222 |
Review Questions | p. 223 |
Chapter 13 Milling-Machine Cutters | p. 225 |
Milling Operation | p. 225 |
Classification of Milling Cutters | p. 226 |
General Types of Milling Cutters | p. 226 |
Plain Milling Cutters | p. 226 |
Side Milling Cutters | p. 229 |
End Mills | p. 231 |
Angle Milling Cutters | p. 234 |
Slitting Saws, Slotting Saws, and Miscellaneous Cutters | p. 235 |
Form-Relieved Cutters | p. 239 |
Hobs | p. 241 |
Care of Milling Cutters | p. 242 |
Speeds and Feeds | p. 242 |
Speeds | p. 243 |
Feeds | p. 246 |
Summary | p. 250 |
Review Questions | p. 250 |
Chapter 14 Milling-Machine Arbors, Collets, and Adapters | p. 253 |
Arbors | p. 253 |
Styles of Arbors | p. 254 |
Methods of Driving the Cutters | p. 255 |
Collets | p. 257 |
Adapters | p. 258 |
Summary | p. 259 |
Review Questions | p. 259 |
Chapter 15 Broaches and Broaching | p. 261 |
Broaching Principle | p. 261 |
Types of Broaches | p. 262 |
Shapes of Broaches | p. 262 |
Internal and External Broaches | p. 263 |
Pull or Push Broaches | p. 264 |
Care and Sharpening of Broaches | p. 264 |
Broaching Machines | p. 265 |
Broaching Operations | p. 268 |
Pull Broaching | p. 268 |
Push Broaching | p. 268 |
Surface Broaching | p. 269 |
Round Broaching | p. 269 |
Summary | p. 270 |
Review Questions | p. 270 |
Chapter 16 Electrical Safety in the Machine Shop | p. 273 |
Power Sources | p. 273 |
Three-Phase Power | p. 273 |
Power Panels | p. 275 |
Raceways and Cable Trays | p. 275 |
Motor Problems | p. 278 |
Three-Phase Motor Symptoms | p. 282 |
DC Motors | p. 284 |
Motor Lubrication | p. 286 |
Drum Switches | p. 286 |
Safety in the Shop | p. 288 |
Fire Extinguishers | p. 288 |
Summary | p. 288 |
Review Questions | p. 292 |
Appendix Reference Materials | p. 293 |
Miscellaneous Useful Facts | p. 293 |
Metric Conversions | p. 294 |
Metric and English Equivalent Measures | p. 295 |
Length | p. 295 |
English Conversion Table | p. 296 |
Standard Metric to English Conversions | p. 297 |
Water Factors | p. 300 |
Weights of Steel and Brass Bars | p. 301 |
Index | p. 303 |