Audel Machine Shop Basics

Rex Miller was a Professor of Industrial Technology at The State University of New York, College at Buffalo for over 35 years. He has taught on the technical school, high school, and college level for well over 40 years. He is the author or co-author of over 100 textbooks ranging from electronics to carpentry and sheet metal work. He has contributed more than 50 magazine articles over the years to technical publications. He is also the author of seven civil war regimental histories. Mark Richard Miller finished his BS degree in New York and moved on to Ball State University, where he obtained a master’s degree and went to work in San Antonio. He taught in high school and went to graduate school in College Station, Texas, finishing a doctorate degree. He took a position at Texas A&M University in Kingsville, Texas, where he now teaches in the Industrial Technology Department as a Professor and Department Chairman. He has co-authored seven books and contributed many articles to technical magazines. His hobbies include refinishing a 1970 Plymouth Super Bird and a 1971 Roadrunner. He is also interested in playing guitar, an interest he pursued while in college as the lead guitarist of a band called The Rude Boys.

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