Shop Reference for Students and Apprentices

by Christopher J McCauley, Edward G Hoffman

• ISBN13: 9780831130794
• ISBN10: 0831130792
• Edition: 2nd
• Format: Paperback
• Copyright: 2001-08-01
• Publisher: INDUSTRIAL PRESS

Summary

From the ability to understand and use shop mathematics to the reading and interpreting of shop drawings, the editor's intent is to provide the information and know-how that students will need as they prepare themselves for jobs in metalworking industries. It includes material taken from Machinery's Handbook and other authoritative sources and is presented in as clear, accurate, and easy-to-follow form as possible. The reader will find a wide range of useful formulas and data together with extensive text. As a proven and affordable handbook covering those critical areas of interest commonly encountered by machinists, toolmakers, diemakers, drafters, and other shop and manufacturing personnel, it is an essential reference for students in vocational schools, technical institutes, and apprenticeship courses. Discusses those aspects of applied mathematics needed on the job and covers the proper use of measuring instruments and methods. Outlines the standard methods of presentation and the conventions used in preparing engineering drawings. Offers detailed information on inch and metric standard tolerances, allowances, limits and fits, preferred numbers and sizes, as well as in-depth descriptions of the sizes, forms, dimensions of standard machine elements commonly encountered in and around the shop. Provides machining methods and materials selection, recommended speeds and feeds for various kinds of machining operations on different materials, and the types and compositions of metals commonly used in machine construction. Includes an extensive index that will enable the user to quickly and conveniently find the information and data that he or she requires.

Table of Contents

CONVERSION FACTORS
Metric Conversion Factors	1	(6)
Greek Letters and Standard Abbreviations	7	(1)
Decimal Equivalents of Fractions of an Inch	7	(2)
Use of Conversion Tables	9	(1)
Fractional Inch to Millimeter	10	(1)
Decimals of an Inch to Millimeters	11	(2)
Millimeters to Inches	13	(2)
Microinches to Micrometers	15	(1)
Micrometers to Microinches	16	(1)
Thermal Energy or Heat	17	(1)
Thermometer Scales	17	(1)
Absolute Temperature and Absolute Zero	17	(1)
Thermal Energy	17	(1)
Fahrenheit-Celsius Conversion	17	(3)
MATHEMATICS
Mathematical Signs and Commonly Used Abbreviations	20	(1)
Arithmetic	21	(1)
Common Fractions	21	(1)
Adding Fractions and Mixed Numbers	22	(1)
Subtracting Fractions and Mixed Numbers	22	(1)
Multiplying Fraction and Mixed Numbers	23	(1)
Dividing Fractions and Mixed Numbers	23	(1)
Decimal Fractions	24	(1)
Converting Common Fractions To Decimal Fractions	25	(2)
Principal Algebraic Expressions and Formulas	27	(1)
Solving First Degree Equations	27	(1)
Solving Quadratic Equations	28	(1)
Cubic Equations	28	(1)
Rearrangement and Transposition Formulas	29	(1)
Complex or Imaginary Numbers	30	(1)
Operations on Complex Numbers	31	(1)
Imaginary Quantities	32	(1)
Squares and Cubes of Numbers	33	(6)
Fractions of Pi	39	(1)
Weights and Volumes	40	(1)
Circumferences and Areas of Circles	41	(12)
Lengths of Chords for Spacing Off the Circumferences of Circles	53	(1)
Hole Coordinate Dimension Factors	54	(1)
Spacing Off the Circumferences of Circles	55	(14)
Diameters of Circles and Sides of Squares of Equal Area	69	(1)
Distance Across Corners of Squares and Hexagons	70	(1)
Formulas for Regular Polygons	71	(1)
Areas and Dimensions of Figures	72	(6)
Segments of Circles	78	(2)
Volumes of Solids	80	(6)
Ratio and Proportion	86	(1)
Inverse Proportion	87	(1)
Powers, Roots, and Reciprocals	88	(1)
Powers of Ten Notation	88	(13)
Solution of Triangles	101	(1)
Trigonometric Relationships of Right Triangle Parts	102	(1)
Angular/Linear Relationships	102	(1)
Trigonometric Functions	103	(2)
Solution of Triangles	105	(5)
Degree to Radian Conversion Table	110	(2)
Trigonometric Functions	112	(1)
Laws of Sines and Cosines	113	(1)
Trigonometric Identities	113	(5)
Versed Sine and Versed Cosine	118	(1)
Sevolute and Involute Functions	118	(1)
Involute Functions Table	119	(4)
Compound Angles	123	(1)
Formulas for Compound Angles	123	(3)
ENGINEERING DRAWINGS
Fundamental Rules	126	(1)
Units of Measurement	127	(1)
Types of Dimensioning	127	(1)
Application of Dimensions	128	(5)
Dimensioning Features	133	(12)
Direct Tolerancing Methods	145	(1)
Tolerance Expression	146	(1)
Interpretation of Limits	147	(1)
Single Limits	147	(1)
Tolerance Accumulation	147	(9)
Geometric Tolerance Symbols	156	(3)
Feature Control Frame Placement	159	(1)
Definition of Tolerance Zone	160	(1)
Tabulated Tolerances	160	(1)
Drafting Practices	161	(1)
Sizes of Drawing Sheets	161	(1)
Control and Production of Surface Texture	161	(2)
Symbols for Section Lining	163	(4)
Sampling Lengths	167	(1)
Roughness Parameters	168	(1)
Waviness Parameters	168	(1)
Surface Roughness to Tolerances	169	(1)
Roughness Measurements	170	(2)
Surface Texture Symbols	172	(2)
Roughness Average Values	174	(1)
Lay Symbols	174	(3)
Surface Texture of Castings	177	(1)
Metric Dimensions on Drawings	177	(1)
Checking Drawings	177	(3)
INSPECTION
Measuring Instruments	180	(1)
Steel Rules	180	(2)
Micrometers	182	(3)
Verniers	185	(2)
Dial Calipers	187	(1)
Protractors	187	(2)
Sine-bar	189	(2)
Tables for Sine-bar Constants	191	(7)
Measuring Tapers	198	(1)
Measuring Dovetail Slides	198	(1)
Angles and Tapers	199	(1)
Tapers per Foot	200	(1)
Figuring Tapers	201	(1)
Simplified Taper Calculations	201	(3)
Measurement over Pins	204	(1)
ALLOWANCES AND TOLERANCES FOR FITS
Limits and Fits	205	(1)
Basic Dimensions	205	(1)
Tolerances	205	(3)
Preferred Basic Sizes	208	(3)
ANSI Standard Fits	211	(3)
Running and Sliding Fits	214	(2)
Clearance Locational Fits	216	(2)
Transition Locational Fits	218	(4)
Modified Standard Fits	222	(1)
Tolerances Designation	223	(2)
Preferred Metric Sizes	225	(1)
Preferred Fits	225	(3)
Hole Basic Metric Clearance Fits	228	(2)
Hole Basis Metric Transition and Interference Fits	230	(2)
Shaft Basis Metric Clearance Fits	232	(2)
Shaft Basis Metric Transition and Interference Fits	234	(2)
Gagemakers Tolerances	236	(2)
PINS
ANSI Straight Pins	238	(1)
ANSI Taper Pins	238	(1)
Drilling Specifications	239	(2)
Selection of Number and Sizes of Drills	241	(1)
ANSI Grooved Pins	242	(3)
STANDARD TAPERS
Morse Taper	245	(1)
Brown & Sharpe Taper	245	(1)
Jarno Taper	245	(1)
Morse Stub Taper Shanks	246	(2)
Morse Taper Sleeves	248	(1)
Brown & Sharpe Taper Shank	249	(1)
Jarno Taper Shanks	250	(1)
Machine Tool Spindles	250	(1)
Tapers for Machine Tool Spindles	250	(3)
KEYS AND KEYSEATS
Key Size Versus Shaft Diameter	253	(3)
Depths for Milling Keyseats	256	(1)
Cotters	256	(1)
Plain and Gib Head Keys	257	(1)
Fits for Parallel and Taper Keys	258	(1)
Key Chamfer	259	(1)
Keyseat Tolerances for Electric Motor	259	(1)
Set Screws for Use Over Keys	259	(1)
Woodruff Keys and Keyseats	259	(3)
Keyseat Dimensions for Woodruff Keys	262	(2)
Depth of Keyseat	264	(1)
Preferred Lengths of Keys	265	(1)
SCREW THREAD SYSTEMS
Screw Thread Forms	266	(1)
Parts of a Screw Thread	266	(1)
Thread Designations	267	(2)
Cutting Screw Threads	269	(2)
Tap Drill Sizes and Percentage of Thread	271	(7)
Threading Formulas	278	(1)
Internal Metric Thread	278	(2)
External Metric Thread	280	(3)
Standard Series Selected Combinations	283	(24)
Measuring Screw Threads	307	(1)
Pitch and Lead of Screw Threads	307	(1)
Thread Micrometers	307	(1)
Ball-point Micrometers	308	(1)
Three-wire Method	308	(1)
Classes of Formulas	309	(1)
Screw Thread Profiles	309	(1)
Checking Pitch Diameters	309	(1)
Wire Sizes	310	(1)
Diameters of Wires	310	(1)
Measuring Wire Accuracy	311	(1)
Measuring of Contact Pressure	311	(1)
Formulas for Checking Pitch Diameters	312	(1)
COMMON HARDWARE
Fastener Grade Marks	313	(1)
Grade Identification Marks and Mechanical Properties of Bolts and Screws	313	(1)
Hexagon and Spline Socket	314	(1)
Drill and Counterbore Size	315	(1)
Hexagon and Spline Keys and Bits	316	(1)
Socket Head Cap Screws	317	(3)
Drill and Counterbore Sizes	320	(1)
Hardened Ground Machine Dowel Pins	321	(1)
GEARS AND GEARING
Gears	322	(1)
Definitions of Gear Terms	323	(4)
Sizes and Shape of Gear Teeth	327	(1)
Nomenclature of Gear Teeth	327	(1)
Properties of the Involute Curve	328	(1)
Diametral and Circular Pitch Systems	329	(1)
Caliper Measurement of Gear Tooth	329	(1)
Involute Gear Milling Cutter	330	(1)
Chordal Thickness and Chordal Addenda of Milled and Gear Milling Cutter	331	(1)
Finishing Gear Milling Cutters	332	(1)
Module System Gear Design	333	(1)
German Standard Tooth Form	333	(1)
Rules for Module System of Gearing	334	(1)
Tooth Dimensions Based Upon Module System	335	(1)
Equivalent Diametral Pitches, Circular Pitches	336	(1)
Spur Gear Calculations Formula	337	(1)
Helical Gear Calculations Formula	338	(2)
Bevel Gear Calculations Formula	340	(2)
Milling Bevel Gear	342	(4)
INDEXING
Milling Machine Indexing	346	(1)
Simple Indexing	346	(1)
Indexing Movements for Standard Index Plate	347	(1)
Angular Indexing	348	(2)
B & S Index Plates	350	(1)
CUTTING SPEEDS AND FEEDS
Work Materials	351	(3)
Cutting Speed, Feed, Depth of Cut, Tool Wear, and Tool Life	354	(1)
Selecting Cutting Conditions	354	(1)
Principal Feeds and Speeds Tables	355	(1)
Cutting Speed Formulas	355	(2)
Adjustment Factors for Turning with HSS Tools	357	(1)
Cutting Speed for Tapping	357	(1)
Cutting Speed for Broaching	358	(1)
Cutting Speed for Thread Chasing	359	(1)
Feed Rate for Milling	360	(1)
Feed Rates for Drilling	361	(2)
Cutting Speeds for Plain Carbon and Alloy Steels	363	(2)
Cutting Speeds for Ferrous Cast Metals	365	(1)
Cutting Speeds for Stainless Steels	366	(1)
Cutting Speeds for Tool Steels	367	(1)
Cutting Speeds for Light Metals	368	(1)
Cutting Speeds for Titanium Alloys	368	(1)
Cutting Speeds for Superalloys	369	(1)
Feeds for Milling with HSS Cutters	370	(5)
RPM for Various Cutting Speeds and Diameters	375	(4)
Tapping and Threading	379	(1)
Speeds for Metal-cutting Saws	380	(1)
Speeds for Turning Unusual Materials	381	(1)
CUTTING TOOLS
Tool Contour	382	(1)
Terms and Definitions	382	(4)
Relief Angles	386	(1)
Rake Angles	386	(2)
Nose Radius	388	(1)
Chipbreakers	388	(1)
Planing Tools	389	(1)
Indexable Inserts	389	(1)
Insert Identification System	390	(2)
Indexable Insert Tool Holders	392	(1)
Standard Shank Sizes	392	(2)
Indexable Insert Holders	394	(4)
Single-Point Turning and Boring Tools	398	(3)
Arbor-Mounted Side and Slot Mills	401	(3)
High-Speed-Steel Peripheral and Slotting End Mills	404	(2)
High-Speed-Steel Twist Drill Tool	406	(3)
Length of Point on Twist Drills	409	(1)
Tool Troubleshooting	410	(2)
Machining Methods	412	(1)
TOOL WEAR
Sharpening Twist Drills	413	(1)
Relief Grinding of the Tool Flanks	413	(1)
Drill Point Thinning	414	(1)
Sharpening Carbide Tools	414	(1)
Silicon Carbide Wheels	415	(1)
Diamond Wheels	415	(2)
Peripheral Versus Flat Side Grinding	417	(1)
Lapping Carbide Tools	417	(1)
Chip Breaker Grinding	417	(1)
Summary of Miscellaneous Points	418	(1)
CUTTING FLUIDS FOR MACHINING
Types of Cutting and Grinding Fluids	419	(1)
Cutting Oils	419	(1)
Water-Miscible Fluids	420	(1)
Cutting Fluids for Different Materials and Operations	420	(1)
Cutting Fluids for Turning, Milling, Drilling and Tapping	421	(1)
Cutting Fluids for Machining Operations	422	(1)
Application of Cutting Fluids to Carbides	423	(1)
Cutting Fluids for Machining Magnesium	424	(1)
Coolants for Carbide Tool Grinding	424	(1)
MACHINING NONFERROUS METALS
Machining Magnesium	425	(1)
Machining Aluminum	426	(1)
Machining Plastics	427	(2)
Machining Non-metallic Gear Blanks	429	(1)
Zinc Alloy Die-Castings	430	(1)
Monel and Nickel Alloys	430	(1)
High Strength, Low Alloy Steel	431	(2)
Materials
Carbon Steels	433	(2)
Free Cutting Steels	435	(1)
Carburizing of Steels	435	(3)
Chromium Nickel Austenitic Steels	438	(1)
Stainless Chromium Irons and Steels	439	(3)
Unified Numbering System	442	(2)
Standard Steel Numbering System	444	(1)
Classification of Tool Steels	445	(1)
Quick Reference Guide for Tool Steel Selection	446	(1)
Molybdenum High-Speed Steels	447	(2)
Tungsten High-Speed Tool Steels	449	(1)
Hot-Work Tool Steels	450	(1)
Cold-Work Tool Steels	451	(1)
Shock-Resisting, Mold, and Special-Purpose Tool Steels	452	(1)
Classification, Compositions, and Properties of Tool and Die Steels	453	(2)
Heat Treatments for SAE Carbon Steels	455	(1)
SAE Alloy Steels	456	(4)
Composition and Physical Properties of Bronzes	460	(1)
Wrought Copper and Copper Alloys	461	(1)
Aluminum Bronze Rods, Bars, and Shapes	461	(1)
Hardness and Ultimate Strength of Brass	462	(3)
Copper-Silicon and Beryllium Copper Alloys	465	(1)
Nominal Composition and Properties of Everdur	465	(2)
Aluminum and Aluminum Alloys	467	(1)
Temper Designations for Aluminum Alloys	468	(3)
Designation Systems	471	(2)
Composition of Casting Alloys	473	(1)
Clad Aluminum Alloys	474	(1)
Characteristics of Principal Aluminum Alloy Groups	474	(1)
Cast Magnesium Alloys	475	(1)
Wrought Magnesium Alloys	475	(2)
Nickel and Nickel Alloys	477	(2)
Inconel	479	(1)
Titanium and Titanium Alloys	479	(1)
Powder Metallurgy	480	(2)
HARDNESS TESTING
Brinell Hardness Test	482	(1)
Rockwell Hardness Test	482	(1)
Shore's Scleroscope	483	(1)
Vickers Hardness Test	483	(1)
Knoop Hardness Numbers	483	(1)
Monotron Hardness Indicator	484	(1)
Keep's Test	484	(1)
Comparative Hardness Scales for Steel	484	(5)
Creep	489	(1)
Creep Rupture	489	(1)
Identifying Metals	489