Metalwork Technology METRIC EDITION

G. H. Thomas Head of Technical Dept .• WeS1 Tarring C.S. School. Worthing

Examiner in Engineering Workshop Theory and Practice

for the Associated Examining Board

John Murray 50 Albemarle Street London

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CONTENTS Preface vi

MATERIALS

2 HAND TOOLS 16

3 MARKING OUT AND MEASURING TOOLS 37

• HOLDING TOOLS 52

5 GAUGES 56

6 SOLDERING AND BRAZING 7.

7 SCREW THREADS AND SCREWCUTIING 80

8 RIVETS AND RIVETING 91

9 HAND FORGING 98

10 SHEET METALWORK 112

II HAMMERED METALWORK 117

12 DRILLS AND DRILLING J32

13 GRINDING 152

I. THE SHAPER 157

15 THE CENTRE LATHE 163

16 METAL CASTING 212

17 THEORY OF METAL CUTTING TOOLS 222

18 SAFETY IN THE WORKSHOP 230

Appendix I 232

Appendix /1 23.

Questions 236

Reference Data 246

Index 253

Abbrevi:lIions, 2S2 Abrafile,30 Abrasi\'cs, 117,152 Acid bath, 117 Acme threads, 85, 169 Age-hardening, 14 Alien screws, 81 AlIo)'1, chart giving composition, I ~

ferrous, 3 non-ferrous, 12

Aluminium, 10, II alloys, 13, 14 annealing of, 10

American National thread, 34 Angle plate, 47 Annealing, beaten work, 117

ferrous metals, 8 non-ferrous metals, 10

Anvil,98

Babbit metal, 14, IS Back gear, 166 Bed of lathe, 163, 165 Bell punch, 26 Belt drive, 132, 166 Bench vice, 52 Bending, lOO Bevel, adjustable, 40 Dick iron, I I I Birmingham Metal puge, 66 Blacksmith's forge, 98

tools, 99 vice, lOO

Blowpipe, 77 Blue, mechanic's, 35 Bond, of grinding wheel, 153 Bor.u,77 Boring, 192

bar. 192 Bossing mallet, 28, 118 Box hardening, 10 Boll square, 39 Brass, 12 Brazing, 77 Britannia metal, 15 British Association thread (B.A.), 83

making use of, 90 British Standard Fine thread (B.S.F.),

83 making use of, 90

British Standard Pipe thread (8.S.P.), 83

British Standard Whitworth thread (B.S.W.),83

Bronze, 13, 15 Buffs, 125 BUll weld, 107 Buttress thread, 53, 85

Ca11iper gauge, 72 Callipers, inside, 43

OOdleg, 44 outside, 42 vernier, 64

Carbides, 177 Carbon steels, 2, 4, 5 Carriage of lathe, 164, 166 Carrier, 172 Case-hardening, 10 Cast iron, 2 Cast steel, 2, 4 Casting, 212

precautions during, 221 Catchplate, 172 Centre lathe, 163 Centre punch, 24 Centre square, 39, 40 Centredrill, 1)9, 186 Centre-finding of the end of a bar,

25, 40, 44, .so Centres,Iathe,I71

turning bet .... 'CCn, 185 Change wheels. 169, 198 Chaplets, 216 Cha.scrs, 207 Chasing, 127 Chasing dial, 206 Chilled cast iron, 2 Chills, 217 Chisel, cutting action of, 223 Chisels, 21 Chocks, drill, 134

lathe, 173, 174 Clamping plates, 146 Clapper box, 1511 Clearance, cutting, ZZ2-4 Clearance size, 86 Collet, 174 Colkt hammer, 122, 124 Colouring metals, 126 Combination drill, 139, 186 Combination square, 39 Compound slide, 164, 167 Contracting, IZZ Coolants, 227 Cope, 212 Coping ~W, 30

253

Copper, 11 alloys, 12

Core, 216 bolt,216 diameter, 80 print, 216

Counlerbore, 140 Countersink drill, 139 Creasing iron, 112 Cross slide, 164, 167 Crosscut chisel, 22 Crossfiling, 16. 18 Cutting action of tools. 222 Cutting solulion, 217 Cutting speeds, 225

D billi,I49 '·Dead" centre, 171 Decimal and metric equivalents,

25' Depth gauge, 59, 68 Depth SlOp of drill, 1J3 Dial indicator, 70, 187, 190 Diamond point chisel, 23 Diamond wheel dresser, 154 Die casting. 217 Die nut, 88 Dies. 88 Diestock, 88 Dip. acid, 117 Di\'i<krs,41 Dog, 172 Dolly, 94 001 punch, 25 Drag, 212 Dmwfiling, 16 Drawing down, 106, 107 Dressers, 153 Drift, blacksmith's, 102

drill ejection, IJ5 Drill, centre, 1J9

chuck, 134 counterbon.:, 140 eountersink,139 cutting action of, 224 nal, 1J8 ,grinding, 142 holding of, 114 parallel shank, 115 pilot, IJ6 pin, 138 sizcs, Jl6 speeds, 249

square shank, J35 straight fl uted, 140 taper shank, 135 twist, 140

Drilling, holding work for, 146 in lathe, 184 marking out for, 136 thin sheet, 145

Drilling machine, 132 Drills, faults, causes and remedies,

143 metric set of, 249

Driving plate, 164, 172 Ductility, 1 Duralumin, 14

lllsy-no' silver solder, 77, 233 Elasticity, 1 Engineer's b!.wel, 40

protractor, 47 square, 38

Expanding, 122

Faeeplate, 174 Faceplate .... ork, 188 Facing sand, 214 Facing up, 184 Feed,225

of drill, I J3 Feeler gauge, 68, 162, 191 FerroU'$ metals, 25

heat treatment of, 8 tests for, 4

File card, 17 Files, can: of, 17

cut and grade, 18 shapes and uses, 19 teeth and cutting action, 18, 223 tension, 30

Filing, 16 Fits, 73 Fi:ted neady, 175 Flask,212 Flat chisel, 21 Filii drill, 138 Flat flie, 19 Flat scraper, 35 Flat-bouom drill, 138 Flatler, 104 Flu.'(es,74 Folding bars, III Forge, 98 Forse tools, 101 Forging, 106 Form tools, 195 Four jaw chuck, 173, 185 Fuller, 103 Funl'ltl Slake, 112

Galvanized iron, 2 Gap bed, 165 Gap gauge, 71 Gate, 215 Gauge, clock, 70

depth, 59, 68 feeler, 68 gap, 71 height, 65 limit, 7 1 micrometer, 56 plug, 72 ring, 67 screwcutting, 69 ilCKWpitch, 69 slip, 67 surface, 48 vernier calliper, 64 wire, 66 wire tables, 247

Gauges, care o f; 73 metals for, 73

Gear trai~, 198 Gilding metal, 12 Grinding, 152

aids to correct, I S5 Grinding whocls, 152

dressing of, 153 filling of, 154

Grit,IS2 Groo\'ed seam, 116 Grooviog tool, 114 Grub screws, 81 Gunmetal,13

Hacksaw, 29 blades, 31

Halfcentre, 171 Half moon stake, 112 Half round chisel, 22 Half round file, 19 Hammered metalwork, 117 Hammers, 26 Hand forging, 98 Hand tools, 16 Hand vice, 54 Handfile, 19 Hard soldering, 77 Hardening, 3, 8

case, 10 \ ' point, 8 work, I

Hardie, 103 Hardie hole, 99 Hardness, I Hatchet stake, I J2 Headslock, 164, 165 Hearth, bruing, 78 Heal treatment, ferrous metals, 3, 8

non-ferrous metals, 10 Height gauge, 65 Helix angle, of drill, 141 Hermaphrodite ca.lliper$, 44

254

High carbon stcel, 2-5 Hiah speed stccl, 3 Holding 100\S, 52 Hole ISaW, 139 Honowing, 118 Horse, 123 Hunlington dresser, 154

Imperial drills, making use of, 151 Imperial Standard Wire Gauge, 66,

247 Indicalor, dial, 70 Imide callipers, 43 Inside micrometer, 58 Iron carbide, )

caSI, 2, 4 galvanized,2 malleable cast, 2 wrought, 4

ISO metric thread, 84, 250 ISO lapping and clearance sizes, 90

Jenny callipers, 44 Johannson slips, 67 Joints, brazed, 77

riveted, 94, 97 Sheel metal, 114 soldered, 74

Jumping up, 110 Junior hacksaw, 30

Kascnil, 10 Killed spirits, 76 Knife file, 20 Knife 1001, 181 Knocked-up bottom, 116 Knurling, 194

Lacquerina:, 126 Lathe, 163

centres, 171 modification 10 cut metric, 210 operation), 184 parts of, 163 SCrtwcutting on!198 tools, 177 tools, angles of, 178, 180 tools, setting up, 183 tools, shape, 181

Lead, 11 alloys, 14

Lead, of thread, 80 Leadscrcw, 164, 169 Leg vice, lOO Limit gauge, 71 Limits, 7) Live centre, 171 Lubricants, 227

Machine reamer, 148 Machine screws, 82 Machine vice, 54 Malleability, 1 Malleable cast iron, 2 Mallets, 28 Mandrels, 195 Marking out table, 46 Marking out tools, 31 Measurina tools, 37 Metal cutting tools, theory of, 222 Metric dials, calibration of, 210 Metric drills, 249 Metric equivalents, 25l Metric machine screws, 82 Metric sizes of metal, 234-5 Metric threads, cuning of, 202 ~tails of, 84

Micrometer depth gauge, 59 inside,58 metric, 58 outside, 56 precautions in use of, 57 principle of, 57 readittJ of, 57

Mild steel, 2·5 Morsc taper, 135

centres, 171 shank drills, 135

Mould, making of, 218 Moulding, boltes, 212

operations, 215 sand,214 tools, 213

Moulds, 212 Multiple start threads, 80

Newall,7.3 Non·ferrous allo)'s, 12 Non·ferrous metals, 11 Nornplizlng, 10 Norton gear bolt, 169

Oddleg callipers, 44 Outside callipers, 42 Oltiue colours, 8

Parallel strips, 51 Partinl off, 193 Partina: land, 215 Partina: tool, 182 Patterns, 216 Phosphor broJ\U\, 13 Pickle, 117 Picrcina, 126 Piercing saw, 30 Pilot drill, 136 Pin or peg drill, 138 Pin punch, 25 Pinning, 17

Pipe thread, 83 Piping, 107 Pitch block, 128 Pitch of thread, 80 Plamshing, 123 Pliers, 55 Plug gauge, 71, 72 Point hardening, 8 Polishing, 125 Pozidriv screWll, 82 Properties of metals, I Protractor, engin~r's, 47 Punch, bell, 25

centre, 24 dot, 25 pin, 25

Quenching, when hardening, 8

Rack, J85 Radial drilling machine, 134 Raising, 120 Rake, 178, 222 Ramming, 215 Rapping iron, 213 Rawhide mallet, 28 Reamers, 148 Repousse, 128 Repousse hammer, 27,127 Revolving centre, 172 Ring gauge, 67 Risers, 212 Riveted joints, 94, 97 Riveting, 93

faults during, 95 Rivets, 91

preferred sizes of, 92 Round bottom stake, 112 Runners, 213, 215

Saddle, of latnc, 164 or shaper, 157

Safe edge, forming of, 114 ora file, 17, 19

Safety in the workshop, 230 Sand, core, 216

facina, 214 moulding, 214 patting,215

Sandbag, 118 Saw blades, 31 Scarfweld, l08 Scrapers, 35 Scrateh brush, 126 Screw pitch gauge, 69 Screw thread gauge, 69 Screw thread terms, 80 Screw threads, 83

255

Scn:wcutting, by hand, 86 by machine, 198 to cut imperial threads on an

imperial lathe, 200 to cut metric threads on an

imperial lathe, 202 to cut metric threads on a metrie

lathe, 203 tool,204

ScreWll, 81 Scriber,37 Scribing block, 48 Seller's thread, 84 Sensitive drilling machine, 132 Set, ofa blade, 31 Set screws, 81 Sets, hot and cold, 101 Sets, rivet, 94, 96 Shaping, holding work for, 159

machine, 157 operations, 161 precautions during, 161

Shcetmetalworking, I I 2 Side rake, 178, 222 Silver soldering, 77, 79 Sinking, 119 Sintered carbides, 3, 177 Sizes of twist drills, 136 Sledge hammer, 101 Slip gauge, 67 Slocombc drill, 139, 171, 186 Smith's tools, 99 Snips, 113 Socket screWll, 8 1 Soldered joints for hammered metal·

work, 131 Soldering bits, 75

f\lucs, 74, 77, 79 Solders, hard, 77

silver, 77 soft, 74

Speed, cutting, 225 Speller, 77 Spirit level, 51 Split patterns, 220 Spot facing, 140 Sprue pins, 212 Square, centre, 40

combination, 39 try, 38

Square thread, 85 Stakes, tinman"s, 112 Star wheel dres.ser. 1S4 Steadies, 175 Steel ,2

silver, 3 stainless, 3; working of, 232

Steel rule, 37 Stocks, die, 88 Straightedge, 38 Stretching, 122 Striekle off, 218 Strips, parallel, 51 Studs,81

Surface gauge, 48 Surface plate, 46 Surfacing, 184 Swagt', 104 SWlIge block, 99 Sweating, 76

Tailstock. 164, 167 Tang, 18 Tank cutter, 139 Tap breakage, 87 Tap wrench, 86 Taper, drift. US

morsc, 13$ shanks, 13$ turning, 189

Tapping size, 86 Taps, 86 Temperina. 11 Tempering chart, 9 Tension files, 30 Terne plate, 2 Tests for ferrous metals. 4 Thread dial indicator, 206 Thread form, 83 Thread gauge, 69 Threading, Prec'dulions during, 119 Three jaw concentric chuck, 172, 185 Tin, 11

alloys, I]

Tinman's snips, 113 solders, 74 stakes, 112

Tinning,76 Tinplate,2 TinpJate joints, J 14 Tolerance, 71, 73 Tongs, smith's, 105 Tool angles, 178, 222 Tool bits" 177 Tool holders, 176 Toolmakers' clamps, 5$ Topslide, 167 Trammels, 41 Travelling steady, 17$ Try square, 38 Tuc::king hammer, 114 Tumbler gears, 169 Turning, holding work for, 170

operations, 184 Tu}~re, 98 Twist drills, JJ6, 141

faults, causes, remedies, 14] grindina, 142 sizes, 136

Twisting, 108

U.N.C. threads, S4 U.N.P. threads, 84 Unified thread, 84 Upsetting, 110

256

Vanadium, 3 V~ blocks, 4!5 V~ threads, 83 Venting,2" Vernier callipers, 6]

height gauge, 65 scales, 60

Vice, engineer's, $2 hand,54 leg, 100 machine, $4

Warding file, 19 Water of Ayr stone, 117 Web thinninl, 141, 145 Welding, forge, 108 White metals, 14 Whitworth threads, 83 Wire gauges. 66, 247 Wired edge. 11 $ Work hardeninl, I Working qualities of metals. 1 Workshop tables, 246 Wrought iron, 2

Zinc, 11 alloys, 12 ehloride,74

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