Note: Page numbers in italics - the-eye.eu Books/Machine Tool... · CNC cutting tools, 709, 710,...

781

Abbreviationsfor machining operations, 29–30

Abrasive sawing machines, 323, 323abrasives for wheels, 324cutoff saws, 303, 304operation, 324, 324, 325safety, 305, 306, 324selecting, 324wheel bonds, 324wheel speeds, 324

Absolute dimensioning, CNC, 671, 672Accuracy

in measurement, defined, 89with micrometers, 131when using steel rules, 107with vernier calipers, 117–119user accuracy, 89user accuracy, 89

Acme cutters, 507–510cutting on lathe, 507–510

Acme forms, 502–503, 503Acme taps, 70, 70Acme thread gages, 507, 507Acme threads, 507–510Acme tool gages, 507, 507Acute angles

defined, 174, 174measurement, 176in right triangles, 178, 178trigonometric functions, 257–258, 258

Adjustable face spanner wrenches, 50, 51Adjustable hook spanner wrenches, 50, 51Adjustable parallels, 148–149, 149, 150

use with sine bar, 180–181, 181Adjustable reamers, 64, 64Adjustable wrenches, 49, 50Air gages, 92–93, 93, 94, 95Alignment

of lathe centers, 415–450measurement, defined, 88

Alignment telescope, 101, 102Allen wrenches See Socket head wrenchesAlloy steels, 17, 18Alloys

approximate melting points listed, 762density and specific gravity, 761

Aluminum, 203, 204American National form, 466, 466American National standard taper pipe thread, 468, 469Angle milling machine, 535–537Angle vise, 368, 368Angles

acute, 174, 174

arithmetic, reviewed, 175, 759clearances, on milling cutters, 557, 645, 646face milling cutters, 582–583on lathe tools, 405–406, 405

terms and definitions, 406layout calculations, 260nose radius, 406, 406obtuse, 174, 174right, 174, 174right-hand and left-hand, 406–407, 406in right triangle, 257–258, 258tapers and (chart), 758

Angular measurement units, 174–175Angular measuring instruments

bevel protractors, 175, 176plate protractors, 175, 176sine bars, 178, 180–181sinometer angle gages, 175, 176universal bevel vernier protractors, 176–177, 176

Angularity, defined, 89, 89Annealing

of band saw welds, 328–329, 329normalizing and stress relieving, 221–223

Apprentice machinists, 4Aprons, on engine lathes, 392–393, 394Arbor driven cutters

plain types, 556, 556, 557side milling types, 557–560

Arbor presses, 37, 38uses of, 37–38, 38

Arborshorizontal mill, 553–555

setup, 571–572, 572spacing and bearing collars, 553, 554

for lathe, 444, 444support bearings, 554–555, 554

Arc versus chord length errors, 158, 159Area measurement rules, 759Arithmetic average, 190Assembly drawings, 28Autocollimators, 101, 101Automotive machinists, 4Auxiliary views, on drawings, 27–28, 28

Babbitt metals, 206, 206Back spotfacing, 375, 376Balancing, of grinding wheels, 609–610, 610Ball and roller bearings, 39Ball-bearing lathe centers, 435–436, 437, 437Ball peen hammers

for layout, 238, 239machinist’s, 48–49, 49

Index

Note: Page numbers in italics refer to figures and illustrations.

Z05_KIBB5087_09_SE_IDX.QXD 6/3/09 5:00 AM Page 781

782 INDEX

Band blade welders, 326, 326Band machines

advantages, 306–307high-tool velocity types, 309, 309, 310horizontal, 302, 302large-capacity type, 309, 310types of, 308–309vertical, 306, 308, 308

Band machining, 306–307Band saw welding, 326

annealing welds, 328–329, 329grinding welds, 329, 329, 330horizontal, safety, 304preparation of blade, 326–327, 328problems, 329, 330safety, 328, 328vertical, safety, 311, 311–312, 312

Bar chucker, CNC, 661, 662, 662Base, vertical mill, 514Bastard cut files, 59, 60

coarseness, 57, 57Bearing pullers, 39, 39Bearings, four types of, 716Bed, engine lathe, 392, 394Bed-type horizontal mill, 546Beryllium copper, 205Bevel protractors, 175, 176Bilateral tolerances, 28Bills of materials, on drawings, 31Blocks, CNC programs, 676–681Blueprinting, of drawings, 30Bolster plates, on shop presses, 39Bolt circles, geometric construction layout, 248–249Bolts

abbreviations on drawings, 30carriage, 17, 17defined, 16diameter of bolt circle (D.B.C. or B.C.), 30grade marking for, 19head markings, 19machine, 17, 17stud, 17, 17types, 17

Bore gage expansion plug, 94, 96Bores and shafts, 39–40Boring

blind hole, 455, 455CNC cutting tools, 709, 710, 710in lathe, 453–456thread relief, 455–456, 456through boring, 454–455, 455

Boring barsengine lathe, 403–404, 404for lathe

setup positions, 454, 454, 455types, 453, 453

toolholder, 400, 400Bottoming taps, 67–68, 68Box end wrenches, 49–50, 50Brass, 205Bridge reamers, 378–379, 378Brinell Hardness tester, use of, 231–233

Broachkeyway broaching, 40–42, 41

guide for, 41, 41production broaching, 42, 43push broaching recommendations, 42

Bronze, 205Bushings

guide, for pressing, 39, 39installing, 38–39, 39, 40special tooling, 39, 39

C-clamp, 367, 368C-clamp body

drilling procedure, 370–372C-clamp tools, 47, 47, 48CAD/CAM (Computer Aided Design and

Manufacturing), 2part programming with, 698–699

Cadmium, 204–205Calibration

defined, 131in measurement, 91micrometers, 131use of gage blocks, 139, 140, 161, 162

Calipersdial, 123, 123electronic (digital), 123–124, 124hermaphrodite applications of, 238, 238inside micrometers, 127, 127outside micrometers, 130, 130slide, 108, 109spring, 146, 147vernier, 117–119

CAM (Computer Aided Manufacturing), 2part programming with, 698–699post-processor, 699, 700

Camlock spindle nose, for lathe, 414, 414Capscrews, 17, 19Carbide face mills, 584, 584Carbide inserts, identification, 292, 296Carbide toolholders

identification systems, 292, 295, 296Carbide tools, 284–294

new technology, 294selection of, 285–292

Carbide-tipped chucking reamers, 379, 379Carbide-tipped helical flute chucking reamers, 379, 379Carbide-tipped straight flute chucking reamers, 379, 379Carriage bolts, 17, 17Carriages, engine lathe, 392–393, 394Carrying objects, safety aspects, 11–12Case hardening and tempering, 209–220

of steels, 215, 215–217Cast iron surface plates, 236, 236Cat heads, 498, 499, 500Cemented carbide cutting tools, 284–285Center drilling, lathe, 432, 432–433, 433Center drills, 350, 351, 366, 370, 373

countersinks, 374, 374Center punches

automatic center, 239, 240center, 239, 239


INDEX 783

hollow grinding, 83, 84optical, 239–240, 240

Centersdead, for lathe, 435, 437, 437lathe, 428, 429, 432–433lathe tailstock, 435–436, 436, 437live, for lathe, 435–436, 436, 437

Centerheadmachinist’s combination square set, 152–154, 152round stock center layout, 240, 241, 497

Centerless grinders, 589–591Center-type cylindrical grinders. See Cylindrical grindersCeramic tools, 288, 294, 297Cermets, 297Chamfer bushing bores, 39–40, 40Chamfer tap, 67, 67Chamfers

reading drawings, 29symbols, 31

Chatter, in boring operations, 453–454, 453, 454Chemical safety, 6–7Chip breakers

cemented carbide inserts, 292, 292, 293CNC, 706, 706Kenloc Chip-Control insert application, 294for lathe tools, 409–410, 409types of, 273, 274

Chip controllathe, 409–410, 409milling machine, 574

Chip formation, 266, 269, 270–271safety when turning, 442, 442

Chip removal,CNC, 667Chip structure analysis, 271–273Chisels

hollow grinding, 83, 84types, 52, 53

Chromium, 205Chucks

drill press, 350, 350independent four-jaw, for lathe, 414, 415installing camlock type, on lathe, 425, 426–427magnetic

lathe, 416, 417surface grinder, 621–622, 621, 622vertical spindle milling machine, 525–526, 526

six-jaw, for lathe, 414, 415tailstock, for lathe, 432, 432three-jaw universal, for lathe, 414–416, 415, 415two-jaw universal, for lathe, 414, 415vacuum, for surface grinders, 622, 622

CIM (Computer Integrated Manufacturing), 2Circular interpolation

CNC, 686–688, 688Circularity, defined, 88Circumference, general measurement techniques, 759Clamps

C types, 47, 47, 48parallel, 47, 47strap, 366, 367

Clearance angles, on milling cutters, measurement,645, 647

Climb millingangles, 583, 583horizontal mill, 571, 572vertical mill, 530

CNC (Computer Numerical Control)absolute dimensioning systems, 671, 672adaptive control (AC), 717–718advantages and capabilities, 660angular interpolation, 683, 683automatic tool changer (ATC), 663, 663, 676, 677,

714–715CAD and CAM, 660chip removal, 667circular interpolation, 686–688, 688color graphics, 667contour machining, 663, 665, 666coordinate tables, for drilling, 680cutter compensation, 685–686, 686developing programs, 676–681electrodischarge machining (EDM), 661flexible manufacturing systems, 664, 667fundamental programmable axes, on machine tools,

670–671G code table, 675helical milling, 663, 667history, 660horizontal spindle machining center, 663, 664, 667,

670, 670, 671human and robot-operated, 2incremental positioning systems, 671, 672laser, 661, 661, 722linear interpolation, 681–682, 681miscellaneous function commands (M codes), 674modal commands, 674, 675operating the machine tool, 702–703parabolic and cubic interpolation, 688polar coordinates, 668, 669, 670position dimensioning systems, 668–672preparatory function commands (G codes), 674,

675, 676program blocks, 676–681programmable axes, 668–672programmable rotary table, 663, 666programmable rotational axes, 671quadrants, 668, 669safety, 665, 666single-point threading, 663, 666standard programming code, 674tapping, 688–689tool and cutter grinding, 656, 658tool coatings, 706tool materials, 705tooling, 705–717turning centers, 661, 662turn/mill centers, 661, 662types and capabilities of machine tools, 661, 662,

663–667vertical spindle machining centers, 663, 663, 664, 665X-Y plane, 668–669, 669X-Z plane, 669Y-Z plane, 669Z-axis offsets, 670–671


784 INDEX

CNC cutting toolsboring, 709, 710, 710coatings, 706end mill ball nose chip thinning, 712–713, 713end mill chip thickness, 711–712, 712end mill rigidity, 713–714, 714high-speed machining, 706–707hole making, 707–708, 707indexable drills, 708, 708reaming, 709, 709roller burnishing, 711, 711spade drills, 709tapping, 689, 709–710trepanning, 709

CNC dimensioning systemsabsolute positioning, 671, 672Cartesian coordinates, 668coordinate tables, 679–680, 680incremental mode, 671, 672rectangular coordinates, 668, 669

CNC programmingcode, 674drilling, 673–703general technique, 673methods, 673offset files, 677part programming with CAD/CAM, 698–699programming example, 690–693prompted programming systems, 699–702single-point threading, 689–690, 697–698turning, 690

codes, 693–697CNC tooling

adaptive control (AC), 717–718EPROM offset data, 714–715, 715high speed spindles, 715, 716touch sensor inspections systems, 715, 715, 716

Coatings, CNC cutting tools, 706Coaxial dial indicators, vertical mills, 527, 527Code, CNC programming, 674Cold saws, 303, 304, 325, 325Collet chucks, 418, 418Collet sleeves, 418, 418Collets

R-8, for milling machine, 521rubber flex type, for lathe, 417, 417solid, for vertical mill, 521, 521split, 521, 521spring type, 418, 418steel-spring, for lathe, 417, 417

Column, vertical mill, 514Combination center drill and countersink,

374, 374Combination square set, 152–154, 152Combination wrenches, 50, 50Comparator

dial indicator, 161–162, 162electromechanical, 163–164, 164electronic, 100, 100, 161, 161micrometer, for threads measurement, 478, 478optical, 101, 101, 161, 161for visual surface roughness, 98, 98

Comparison measuring instrumentsadjustable parallels, 148–149, 149, 150dial test indicators, 159–161diemaker’s square, 154, 154indicators, 155–161machinist’s combination square, 152, 152planer gage, 151–152, 151–152precision beveled edge squares, 152–153, 153profile projector, 163, 163shop tip, 164small hole gage, 148, 149–150spring calipers, 146, 147squares, 152–154telescoping gages, 146–148, 147–149thickness gages, 149–151, 151

Compressed air, safety with, 10Computer Aided Design (CAD), 2, 3

part programming with, 698–699Computer Aided Manufacturing (CAM), 2Computer Integrated Manufacturing (CIM), 2Computer Numerical Control. See CNC

(Computer Numerical Control)Concentricity, defined, 88Contour sawing

vertical band saws, 339–340, 340Contouring, with band saw, 307, 307, 310, 310Controls

on lathe, 420–424clutch rod, 423, 423feed rates, 421–424quick change gear selector, 421, 422

Conventional millinghorizontal mill, 571, 572vertical mill, 530

Conversion charts (metric), 105, 753–754Conversion dials, 105, 105Conversion factors, metric system, 104–105Coolant separators, 283Coolants listed, 765Coordinate layouts

height gage, 256–257Coordinate layouts, for hole patterns, 249, 256–257, 258–259Coordinate measurement, calculations,

256–257, 258–259Coordinate measuring machines, 98, 99Copper and copper alloys, 205Cosine error, 158, 159Cosine ratio, of acute angles defined, 257Counterbores

interchangeable pilots, 375, 375multiflute, 375, 375two-flute, 375, 375

Counterboringdefined, 29symbols, 30

Countersinkingdefined, 29symbols, 30

Countersinks, 374, 374Crazing, prevention of, 293Crescent wrench, 49, 50Cross peen hammers, 49, 49


INDEX 785

Cubic boron nitride (CBN), 599, 599truing, 607–608, 608

Cubic boron nitride (CBN) cutting tools, 294, 297Curved tooth files, 59, 59Cutoff lathe tools, 407–409Cutoff machines

cold saws, 303, 304, 325, 325safety, 306, 306

horizontal band saws, 302, 302, 303reciprocating saws, 302tilt frame band saws, 302–303, 303, 304

Cutoff toolholders, engine lathe, 403, 403Cutter compensation, 685–686, 686Cutters

Acme threads, 507–510arbor driven, for horizontal mills, 556, 556–561carbide, for lathe, 285–297, 405, 405face milling, horizontal mill, 581–584hand grinding, 410–412high speed, lathe, 405–407involute gear cutters, 560–561, 560lead angle, 582, 582re-sharpening milling types, 650–656turning unified threads, 470–471types, 407–409, 410vertical milling machine, 517–521, 521Woodruff key, 519, 519

Cutting fluids, 765application methods, 281–283cutting oils, 280–281, 765drilling machines, 364effects, 279–280emulsions, 280gaseous fluids, 281for grinding, 604, 605, 612–616grinding machines, 364metal cutting, 264–265, 266, 270sawing with, 315semisynthetic fluids, 280synthetic fluids, 280types, 280–281vertical band saws, 339, 340

Cutting speeds (CS), 275–277calculations

drill press, 362–363for commonly used materials, 531, 531, 765defined, 530–531drilling, 362–363horizontal milling machine, 567lathe, 439–441sawing, 313vertical milling machines, 530–531

Cutting toolscemented carbides, 284–285ceramics, 288, 294, 297clearance, 294, 297cubic boron nitride, 294, 297diamond, 298drill press, 349–357engine lathe, 405

form cutters, 407, 407high speed steels, 405–407

high-carbon steels, 284horizontal mill, 556–561materials, 284–298vertical mill, 517–520, 521

CVSG grinding abrasive, 600Cyanogen compounds

precautions, 6Cylindrical grinders

accessories, 640capabilities, 637–639, 640major parts, 635–637, 635mandrel grinding, procedure for, 643–644setup, 641–642, 643–644, 643types, 588–592workholding on, 637, 637

Cylindrical ring gage, 91, 93Cylindrical squares, 153–154, 153, 154

Dead lathe centers, 437, 437Decibels (dB), safety aspects, 8

level of various sounds, 9Decimal angles, 175Decimal equivalents. See also Metric

for drill sizes, 354–355of fractional inches (table), 753inch/metric conversion tables, 753–754

Decimal notation, 112Decimal rules, 112–113, 113Deep hole drilling machines, 344, 344Depth gage

dial indicator type, 123–124, 123vernier type, 121

Depth micrometerreading, 138–139, 139

Depth micrometers, 138, 138Depth of threads, 466, 467Desmond dresser, 82Detail drawings, 28, 31Diagonal cutters, 48, 48Dial bore gages, 94, 96Dial calipers, 123, 123Dial depth gages, 123, 123Dial indicating expansion plug bore gages, 94, 96Dial indicating inprocess grinding gages, 95, 97Dial indicating screw thread snap gage, 94Dial indicating screw thread snap gages, 94, 97Dial indicating snap gages, 94, 95Dial indicating thread plug gages, 94, 97Dial indicators

care and use of, 156–157, 157depth gages, 123–124, 123potential for error, 157–158, 159types, 155, 155–161, 156

Dial instruments, shop tip, 123Dial test indicators, 157, 157

use of, 159–161Dial thickness gages, 93, 95Diamond, as superabrasive, 599–600, 599, 604Diamond cutting tools, 298Die sinker’s riffler files, 59, 59Die threading

by hand, 79–80


786 INDEX

Die threading (Continued)on lathe, 79, 79, 459, 459

Die-cast metals, 205–206, 205Diemaker’s squares, 154, 154Dies

blanks, 77, 78button, 77markings, 77, 77rethreading type, 78, 78solid square, 78, 79thread cutting, 77–80two-piece, 77, 78

Diestock, 77, 78Digital readout (DRO)

horizontal mill, 547, 547vertical mill, 106, 106, 529, 529

Dimensional metrology, 88Dimensioning systems, in drawings, 28, 28

coordinate or absolute, 29, 29decimal inch notations, 29, 29dual system, 29, 30standard tolerances, 28tolerances, 28

Direct-reading micrometers, 127, 127Discrimination

10:1 rule, 90in measurement, 90micrometers, 131steel rules, 107

Disk micrometers, 125, 126Dividers, for layouts, 237–238, 238Dividing heads, 564, 564Dovetails

machining, 535–537Draw filing, 61, 61Drawings

assembly, 28, 31, 32auxiliary views, 27–28, 28bill of material, 31blueprinting, 30–31change blocks, 31, 31detail, 28, 31dimensioning systems, 28exploded, 26, 27finish, marks on, 29, 30formats, 30–31, 32hidden lines, 26–27, 27isometric, 26, 27oblique, 26, 27orthographic format, 26–28, 27pictorial formats, 26precision vise project drawings, 766–769reading and interpreting, 28–31sectioned views, 27, 28title blocks, 30, 31, 31

Dress safety, 8Dressing

grinding wheels on pedestal grinders, 82, 83surface grinder wheels, 606

Drift punch, for drill sleeve, 353, 356, 356Drill and hole gage layout, 244–247, 248

Drill chucks, for lathe tailstock, 401, 402Drill grinding procedure, 359–361Drill presses

chucks, 350, 350cutting tools, 349–357deep hole, 344, 344heavy duty, 342micro, 342, 343procedures, 364–366, 365, 366radial arm, 342, 342, 346, 347, 348, 348reaming with, 65–66, 65safety, 344–345sensitive, 342, 342, 346, 346table, 342turret, 342, 343, 343types, 342–344upright, 342, 342, 345, 346–347, 348vises, 367–368, 368workholding, 366, 367, 368–371

Drillingangle plates, 367, 368C-clamp body, procedure, 370–372jigs and fixtures, 370, 371lathe, procedures, 364–366, 365, 366, 451–452pecking, 364

Drilling machines, operation, 362–373Drill point gages, 358, 358, 361, 361Drill pointing machines, 356, 357

split-point design, 356, 357Drills

accuracy of drilled holes, 356burnishing, 350center, 350, 351drill sizes, decimal equivalent tables, 354–355gun, 352, 352hand grinding, 359–361hard steel, 352, 352high-helix, 349, 350high-speed, 349jobber’s, 350left-hand, 349, 350low-helix, 349, 350major parts, 349oil hole, 350selection, 351–353size series, 353spotting, 349, 351, 351standard helix jobbers, 349step, 351, 351tap, 72–73, 73taper shank, 349three-flute, 349twist, 351, 352twist, parts of, 349–350, 349, 350types, 349–351

Drive plates, 417, 417Drives

back gear systems, for lathe, 420–421band saws, 336, 337lathe headstock, 420, 421variable-speed, 420, 420


INDEX 787

Ear protection, sound suppressors for, 8, 8EBM machining, 720ECM machining, 721, 721Edgefinder, use on vertical mill, 526, 526EDM machining, 74, 718–720

CNC, 660as tap disintegrator, 74

Electrical safety, 11Electrochemical machining (ECL, ECDB), 721, 721Electrodischarge machining. See EDM machiningElectrolytic grinding (ELG), 720Electromechanical comparators, 163–164, 164Electron beam machining (EBM), 720Electronic calipers, 123–124, 124Electronic comparators, 100, 100, 161, 161Electronic digital comparators, 161, 161,

163–164, 163Electronic digital travel indicators, 99–100,

99, 100Electronic micrometers, 130–131, 131ELG grinding, 720–721ELG machining, 720–721End mill ball nose chip thinning tools, 712–713, 713End mill chip thickness tools, 711–712, 712End mill holders, 521, 521End mills

ball end, 519, 519checking cutting edges, 533corner rounding, 519, 519dovetail, 519, 519four-flute, 517–518helical flute, 518, 518high-speed steel feeds, 765high-speed steel helical, 518, 518indexable, 520, 520, 521leaning slots, causes for, 532, 532roughing, 518–519, 519sharpening, 654–656, 657shell, 535, 536single-angle dovetail, 519, 519size markings, 535straight flute, 518, 518tapered, 519, 519three-flute, 517t-slot, 519, 519two-flute, 517, 518Woodruff key, 519, 519

Engine lathes, 391aprons, 392–393, 394beds, 392, 394boring bars, 403–404, 404carriage, 392–393, 394parts, 392–394, 392

Engineers, professional, 4English system of measurement, 103–104EPROM offset data, 714–715, 715Expansion fits, 185Expansion plug bore gage, 94, 96Expansion reamers, 64, 64External threaded fasteners, 16–21Eye protection, 6, 7, 8

Face driver, for lathe, 417, 417Face milling, 538–539Face milling cutters

horizontal mill, 581–584use of, 581–584

Face plate for lathe, 417, 417Face shields, 7, 8, 8Facing

on lathe, 425–430, 431offset boring head, 542, 543setup, 425–427

Feathered key, 25Feed rates calculations

horizontal milling machines, 567–569vertical milling machines, 531–532

Feedsbreakage and, 264calculations, 277–278drilling, 363, 363, 364high-speed steel end mills, 765in metal cutting, 266milling, 567–568reaming, 379–380turning, 439–441

Filesbastard cut, 57, 57, 59, 60card for cleaning, 60, 60care and use, 60–62curved tooth type, 59, 59die sinker’s rifflers, 59, 59flat, 58, 58half-round, 59, 59handles, 60–61, 61knife, 58, 58lathe, 58, 58major parts, 57, 57mill, 58, 58pillar, 58, 58pinning, 60round, 59, 59square, 58, 58Swiss pattern, 59, 59tang, 57thread repair, 59, 60three square, 59, 59types, 57–60warding, 58, 58

Finish marks, on drawings, 29, 30Fire extinguishers, 10–11Fits, shrink and expansion, 183, 185Fixed face spanner wrenches, 50, 51Fixed gages, 91, 92Fixed thread gages, 91, 92Flash chrome plating, 71Flat files, 58, 58Flatness, defined, 88Flexible Manufacturing System (FMS), 3, 664, 667Flycutters, 520, 520Follower rests

for lathes, 500use of, 500

Z05_KIBB5087_09_SE_IDX.QXD 6/3/09 5:00 AM 87

788 INDEX

Foot protection, 7–8Footstock, horizontal milling

machines, 564, 564Form cutters, for lathe, 407, 407Four-jaw chuck

centering workpiece, 426for lathe, 414, 415

fpm (feet per minute), 313Friction sawing, 310, 311Fumes, control of, 6Furnaces, for heat treating, 212–213

G code table, 675Gage blocks

applications, 171–172, 172calculating stack height, 170–171checking surface, with optical flats, 169, 169, 170preparation for use, 167–168preparing for storage, 170sets with accessories, 164, 164tolerances, 167types and grades, 166use with sine bar, 180–181, 181value of, 167wear blocks, 171, 172wringing, 167–168, 169

Gagesadjustable limit snap gages, 91, 92air, 92–93, 93, 94air plug, 92, 94bore, 94, 96CNC tool length, 678, 678column (flow-type), 92, 94, 95cylindrical plug, 91, 93cylindrical ring, 91, 93fixed, 91, 92fixed thread, 92go and no go, 79, 91height. See also Height gages

for layout, 242, 242–243, 243planer, 151–152, 151–152

for layout, 151–152, 151–152, 242, 243plug, 94, 97precision height gages, 159–160, 160pressure-type air snap gages, 92, 94radius, 149, 151rule depth, 109–110, 109, 110saw blades, 314, 314screw pitch, 466small hole, 148, 149, 149–150snap, 91, 92standard hook, 108, 108, 109surface, 240–241

for layout, 240–241taper plug, 91, 92taper ring, 91, 92, 492–493telescoping, 146–148, 147–149thickness, 149–151, 151thread plug, 91, 92, 483, 483thread ring, 91, 92, 477, 477thread roll snap, 477, 478wire gages and metric equivalents, 764

Galling, prevention of, 364

Gang drill presses, 342, 343Gantry vertical spindle machining center, CNC,

663, 664General machinists, 3–4Geometric construction layouts

for bolt circles, 248–249Geometric dimensions, 186–187Geometric tolerances

concentricity notations, 186datum and basic dimensions, 186–187drawing formats for, 187, 188–189feature location notations, 186least material condition (LMC), 187maximum material condition (MMC), 187orientation notations, 186regardless of feature size (RFS), 187symmetry notations, 186true position, 186

Gib adjustment screws, 516, 516Gib head keys, 25Grade markings, on bolt heads, 19Grades

gage blocks, 166, 167surface plates, 236

Granite surface plates, 236, 236Grinders. See Grinding machinesGrinding, CBN-plated grinding process, 548Grinding dust

collectors, 6, 7health hazard, 6

Grinding fluidsapplication methods, 613–614cleaning, 614–615grinding waste disposal, 615steps to follow, 616types, 604, 612–613

straight oil, 613water-soluble chemical types, 612water-soluble oil types, 612–613

Grinding machinesabrasive processes, 593–595adaptive machine controls, 593centerless, 588, 589–591cost effectiveness, 593cylindrical, 588–592, 591electrolytic, 720–721fluids for, 612–616free abrasive, 594, 594gear finishing, 592–593, 592, 593lapping and honing, 594, 594

superfinishing, 594, 595pedestal, 81–84

See also Pedestal grindersroll-type, 588–589, 590safety, 595selection and identification, 598–605superabrasives, 593–594surface, 586–587, 588

See also Surface grindersthread grinders, 592, 593universal tool and cutter, 591–592, 592vibratory deburring, 594, 595

Grinding twist drills, 358–361


INDEX 789

Grinding wheelsbalancing of, 609–610, 610concentration, 600FEPA and U.S. sizes compared, 602–603radius and form dressing, 609, 609, 610ring testing, 81–82, 82, 595–596, 596size and shape, 600, 600, 601standard wheel marking systems,

600–602truing and dressing, 606–609types of abrasives, 598–600

Groove micrometers, 130, 130Grooving, on lathe, 459–461Guide for broaching, 41, 41Gun drills, 352, 352Gun taps, 68, 68

Hacksawsblade sets, 54, 55cuts on workpiece, 56, 56hand, parts, 54–55power, 302use of, 55–56

Half round files, 59, 59Hammers

ball peen, 48–49, 49cross peen, 49, 49for layout, 238–239, 239lead, 49, 49maul, 48, 48soft, 49, 49straight peen, 49, 49toolmaker’s, 239, 239

Hand grinding, of drills, 358–361Hand grinding cutters, 410–412Hand protection, 9Hand reamers, 63–66

adjustable, 64, 64helical flute, 64, 64major parts, 63Morse taper socket, 64–65, 64, 65spiral flute taper pin, 64, 64straight flute, 64, 64use of, 65–66

Hand tap wrenches, 50, 52Hand tappers, 72, 73Hand tools

hacksaws, 54–56safety, 36

Hardening of metals, 209–210, 210Hardness, measurement of, 225, 226Headstock spindle, engine lathe, 391–392, 392Heat treating

case hardening, 215–217furnaces for, 212–213problems during, 217–220quenching media, 213–214, 215safety, 196of steels, 210–212tempering, 215–217

Height gageschecking zero reference, 252–253by coordinate measure, 256–257

dial, 242, 242digital, 242, 242gage blocks, 242, 243mechanical dial, 251, 251scribers, 250, 251vernier, parts, 250

Helical flute hand reamers, 64, 64Helical milling, CNC, 663, 667Helix angle, of threads, 468, 468Helpers, 4Hermaphrodite calipers, 238, 238Hidden lines, on drawings, 26–27, 27High speed bearings

types of bearings, 716High speed lathe cutters, 405–407High speed lathe tools

angle degrees for, 409High speed spindles, 715, 716

types of bearings, 716High-carbon steels, 284High-velocity band machines, 309, 309, 310Hole making cutting tools, 707–708, 707Hook rule, 108, 108, 109Hook spanner wrenches, 50, 51Horizontal band machines, 302, 302, 303

plate saws, 302, 303safety, 304–305, 304, 305

Horizontal band saws, 316installing blades, 315–316, 319, 320operation, 316–317, 318sawing problem, 320–321, 321workholding, 318, 319

Horizontal milling machinesarbor setups, 571–572, 572arbor support bearings for, 554–555, 554arbor types, 553–555attachment and accessories for, 547–548backlash eliminator, 546, 546bed type, 546controls, 550–551cutters, 556–561, 559–560cutting fluids, 569digital readout (DRO), 547, 547footstock for, 564, 564horsepower calculations, 568–569keyseat milling, 579–580knee and column, 546large CNC machining center, 547, 547locks, 551major parts, 549, 550milling cutters, 556–561plain milling, 567, 572–574, 574rotary tables, 564, 564routine maintenance, 551–552safety, 548setup, 567, 569–571side milling, 577–580, 580size, 549spacing and bearing collars, 553, 554spindle tapers, 553, 554squaring workpiece, procedure, 574–575, 575–576,

575, 576straddle milling, 580, 580


Horizontal milling machines (Continued)table, 546, 549, 549, 562–563, 563types, 546wipers to protect accuracy, 551workholding, 562–566, 569, 570–571

Horizontal spindle machining centers,CNC, 663, 664, 667, 670, 670, 671

Horizontal spindle surface grinders. See Surface grindersHorseplay in the shop, 9–10Hot metal safety, 196Housekeeping, in machine shops, 10HSS cutting tools, 284Hub micrometers, 127, 127Hydraulic presses, 37, 37Hydrojet machining, 721, 721Hypotenuse, in right triangle, 178

Inch/metric conversion tables, 753–754Indexable drills, 708, 708Indicating micrometers, 127, 127Indicating mill vise, procedure, 569–570Indicators

dial and dial test, 155–161, 157electronic digital travel, 99–100, 99, 100surface finish, 98, 99, 99

Infeed, 266Inserts, carbide, identification, 292, 296Inside micrometer calipers, 127, 127Inside micrometers, 136–138Inspectors, 4Interchangeable anvil micrometers, 127–128, 128Interference (press) fit, bushings, 39Interference fringes, 169, 170Interlocking joint pliers, 47, 47Internal infeed, calculation for threading, 482Internal micrometers, 127, 128Internal thread inserts, 21–22, 23Internal threads, cutting, 481–483Internally threaded fasteners, nuts, 20–22International System of Units (SI), 104Interrupted thread taps, 68, 68

Jig boring, 512Job opportunities, 2–4Job selector

horizontal band machines, 315, 315vertical band machines, 336, 337

Just-in-time production, 516

Kerfhandsaws, 54, 55of saw blades, 313, 314

Keysfeathered, 25gib head, 25square, 25taper, 25Woodruff, 25

Keyseatsbores and shafts, 39–40defined, 37–38

Keywaysbroaching, procedure for, 40–42milling

horizontal mill, 579–580vertical mill, 535, 535

Knee and columnhorizontal mill, 546vertical mill, 514

Knife files, 58, 58Knurling, on lathe, 461–463

toolholder types, 461, 461, 462Knurling tool, on lathe, 403, 403

Large capacity band machines, 309, 310Laser interferometer, 101, 102Laser machining, 722, 722Lathe centers

alignment, 415–450ball bearing, 435–436, 437dead, 435–436, 437half center, 430, 431pipe and tube, 437, 437types, 435–437

Lathe cuttersAcme threads, 507–510hand grinding procedure for, 410–412

Lathe dogs, 435, 435, 437–438, 438Lathe files, 58, 58Lathe operations

boring, 453–456center drilling, 432–433drilling, 400–401, 432–433, 451–453facing, 425–427grooving, 459–461knurling, 461–463parting, 459–461reaming, 456–457, 458recessing, 459–461tapping, 458–459threading, 470–480, 471–475toolposts, 399–400, 399, 400turning, 435–437

Lathesapron, 392–393, 394automatic, with CNC, 384–385backlash compensating adjustments, 396, 396bed, 392, 394camlock spindle nose, 414, 414carriage, 392–393, 394, 491, 491chip control, 410cleaning the lead screw, 395, 395CNC chuckers, 385, 386cutting fluid applications, 281–282cutting speed calculations, 439–441dead centers, 435–436, 437, 437files, 59, 59floturn, 385, 386follower rest, 500gib adjustment, 395–396, 396headstock, 391–392, 392headstock spindle, 391–392, 392

790 INDEX


INDEX 791

independent four-jaw chucks, 414, 415internal threading, 481–483magnetic chucks, 416, 417maintenance and adjustments on, 395–397on-site machining, 387, 387saddle, 392safety, 387–390setup, for threading, 471–472six-jaw chucks, 414, 415spindle, 392, 413–416spindle tooling, 413–418steady rest, 496–499swing, measurement, 394tailstock, 393–394, 394, 396–397, 397tracer, 385, 386types, 384–386vertical boring mills, 384, 385ways, 392

Layoutaccessories for, 243, 243basic precision practice, 255–259clamp frame, 255, 255, 256classifications, 236dividers, 237–238, 238drill and hole gage, 244–247, 248dyes, 237, 237geometric construction for bolt circles, 248–249position-one, 255, 255–256position-three, 255–256, 256, 257position-two, 255, 256precision practice, 250–260preparation of workpiece, 244round stock center, 497scribers for, 237–238, 237semiprecision, 244–249tables, 236tools for, 236–243trammel points for, 238, 238

Layout punches, 239–240, 240Layout tables, 236Layout tools

reshaping, 83Lead and lead alloys, 206, 206Least material condition (LMC), 187Length, 88–89, 88, 89

measurement rules, 759Lifting and hoisting, 195, 195

techniques for safe, 9, 10Light, measurements with, 100–102Lighting, importance of, 525Limit dimensioning, 184Limited machinists, 4Linear interpolation

CNC, 681–682, 681linear, CNC, 683, 683

Lock-out tag-out procedures, 11Long taper spindles, for lathe, 413, 414

M codes, CNC programming, 674Machinability, 266, 273–274Machine bolts, 17, 17

Machine hazards, 12Machine operators, 2–3Machine reamers, 377–379. See also Reamers; Reaming

arbor, 378, 378chucking

carbide tip, 379, 379helical flute carbide tipped, 379, 379

helical flute, 377, 378helical taper pin, 378, 378jobber’s, 377, 378Morse taper, 378, 378rose, 377, 378shell, 378, 378taper bridge, 378–379, 378taper shank helical flute, 377, 378taper shank straight flute, 377, 378types, 377–379

Machine reamingcutting fluids, 380problems, 380–381stock allowance, 380, 380

Machine screws, 17, 17Machine screws, head styles, 18Machine tools

CNC, 660, 661, 662speeds and feeds, 275–278

Machines, for layout, 242–243, 243Machining centers

CNC, 663, 663–664Machining operations defined, 267–269Magnesium, 206Magnetic chuck lathes, 416, 417Magnetic chuck surface grinder, 621–622, 621, 622Magnetic chuck vertical mill, 525–526, 526Maintenance machinists, 4Mandrel grinding procedure, 643–644Mandrels

expanding type, 444, 445gang, 444, 445stub, 444, 445, 446taper, for lathe work, 444

Marine machinists, 4Material Safety Data Sheets (MSDS), 7Materials

for cutting tools, 284–298hot metal safety, 196lifting and hoisting, 195, 195safety in carrying, 195safety in handling, 196selection and identification of steels, 197–202

Maul hammers, 48, 48Maximum material condition (MMC), 187Measurement. See also Decimal equivalents;

Metric systemarea, 759by comparison methods, 146decimal equivalents of fractional inches, 752electronic, 98–100, 98inch/metric conversion tables, 753–754length, 759reference points, 107


792 INDEX

Measurement. See also Decimal equivalents; Metric system systems, 103–106of tapers, 492–494of threads, 477–480volume and capacity, 760weight, 760

Mechanical dial measuring instruments, 93–97, 93, 94Mechanical dial travel indicators, 95–97, 98Mechanical hardware, 14–25Metal cutting, principles of, 266–271Metals. See also individual metals; Nonferrous metals

alloys, 194approximate melting points listed, 762classifying, 195density and specific gravity, 761hardening of, 210–212, 210machinability, 273–274oxidation reduction process, 194safety, 6space-age, 194

Meters, 104, 759Metric mechanical dial travel indicators, 106, 106Metric rules, 113–114, 114Metric system of measurement, 104–105

dual dimensioning of drawings, 29, 30equivalent measurements of length, 759inch/metric conversion table, 753–754volume and capacity, 760weight, 760wire gages and metric equivalents, 764

Metric threadsbasic designations, 751forms, 469, 469

Metrology, 88dimensional, 88general principles, 89–91

Micro drill presses, 342, 343Microinches, 29, 99Micrometer squares, 154, 155Micrometers

ball attachments, 130, 130blade type, 125, 125, 126caliper-type outside, 130, 130carbide-tipped, 132care of, 131–133collars, on lathe, 422–423, 423combination inch/metric, 125, 126comparator type, 125, 126, 478, 478depth type, 138–139, 138, 139digital electronic, 130–131, 131direct-reading, 127, 127discrimination of, 131disk type, 125, 126groove type, 130, 130hub, 127, 127indicating bench, 98, 98indicating type, 127, 127inside, 127, 127, 136–138interchangeable anvil, 127–128, 128internal type, 127, 128metric type, 139–142outside, 130, 130, 191

point comparator, 125, 126reading inch types, 133–134reliability and accuracy, 131screw pitch, 479screw thread comparator, 125, 126screw thread type, 128, 129shop tip, 135spline, 128, 128square, 154, 155taper, 130, 130for taper measurement, 494, 495thread comparator, 478, 478tubing, 129–130, 129, 130, 139–130turning to length, 444, 444turning to size, 442, 442types of, 125–131using, 124–125V-anvil, 129, 129vernier, 143–144, 143

Mill files, 58, 58Milling cutters

clearance angles, 645, 646, 647horizontal milling machines, 556–561safety, 557sharpening, 647, 648vertical milling machines, 517–521, 521

Milling machine tapers, 485–494Miscellaneous function commands (M codes), 674Modal commands, CNC programming, 674, 675Modified square threads, form of, 500, 500Mold makers, 4Molybdenum, 206Morse taper drill sockets, 353, 356Morse taper reamers, 64–65, 64, 65Morse taper twist drills, 349–350, 350Morse tapers

dimensions for, 485, 486drill chucks, 401, 402drill sleeves, 353, 356reamers, 378, 378

MSDS (Material Safety Data Sheets), 7Multiple lead threads, cutting of, 503–506Multispindle drill presses, 343, 343

Needlenose pliers, 48, 48Nickel, 206, 206Nickel-based alloys, 207Nonferrous metals

beryllium copper, 205brass, 205bronze, 205cadmium, 204–205chromium, 205copper and copper alloys, 205die-cast metals, 205lead and lead alloys, 206, 206magnesium, 206molybdenum, 206nickel, 206, 206nickel-based alloys, 207precious metals, 207safety, 6


INDEX 793

selection and identification, 203–208tantalum, 207tin, 207, 207titanium, 207, 208tungsten, 208zinc, 208zirconium, 208

Normalizing, 221–222, 221Nose

engine lathe spindles, 392, 393lathe spindles, types, 413–416

Nut taps, 70, 70Nuts, common types, 20–21, 21

Oblique drawings, 26, 27Obtuse angles, defined, 174, 174Occupational Safety and Health Act (OSHA), 7, 12Offset boring heads

controlling bore diameters, 542facing with, 542, 543feeds and speeds, 542parts of, 540, 541setup, 541, 541

Open ended wrenches, 49, 50Optical center punches, 239–240, 240Optical comparators, 101, 101, 161, 161

for thread measurement, 479, 480, 481Optical flats, 100–101, 101, 169

for checking gage blocks, 169, 169–170Orthographic drawings, 26–28, 27Orthographic projections, on drawings, 26, 27Outside micrometers, 130, 130, 191

care of, 131–133major parts, 131

Parabolic and cubic interpolation, 688Parallax errors, 110, 110Parallel clamps, 47, 47Parallels

adjustable, 148–149, 149, 150drill press setup tools, 366–367, 367in layouts, 254

Parting, in lathe, 459–461Pedestal grinders

adjusting spark guard, 82, 82adjusting tool rest, 82, 82dressing wheel, 82, 83for drill grinding, 358–361replacing wheel, 81, 81safety, 82, 84setup, 81–82using, 82–83, 82

Percentage, of threads, 468Personal safety, 6–7Pillar files, 58, 58Pilots, for counterbore, 375, 375Pin punches, 52, 53Pins, types of, 24, 24Pipe and tube centers, 437, 437Pipe and tube lathe centers, 437, 437Pipe thread taps, 69, 69Pipe wrenches, 50, 51

Pitchbandsaw blades, 314, 314diameter, of threads, 468, 468hand hacksaw blades, 55, 55screw threads, 466

Plain milling, horizontal mill, 572–574, 574Planer gages, 151–152, 151–152

for layout, 242, 243Plasma beam machining, 721–722Plate protractors, 175, 176Plate saws, 302, 303Pliers

interlocking joint, 47, 47needlenose, 48, 48round nose, 47–48, 47side cutting, 48, 48slip joint, 47, 47vise grip, 48, 48

Plug gagesfor taper measurement, 492–493

Plug taps, 67, 68Plunge cutting, 533–534, 534Pneumatic comparators, 92–93

See also Air gagesPoint comparator micrometers, 125, 126Polar coordinates, CNC, 669, 670Position dimensioning systems, CNC machines, 668–672Position, of linear measurement instruments, 90, 90Power fed worktables, on band machines, 308–309, 309Power hacksaws. See Reciprocating cutoff machinesPrecious metals, 207Precision

layout, 244–260in measurement, 89–90

Precision beveled edge squares, 152–153, 153Precision height gages, 159–160, 160

with gage blocks, 171, 173Precision measurements, 90Precision vise project drawings, 766–769Press fits

dimensional allowance for, 185surface finish for, 185

Presses. See also Drill pressesarbor, 37–38, 38, 41, 42

hydraulic, 37mechanical, 37, 38

Pressingbearings, 39, 39bushings, 38–39, 40

Pressure-type air gages, 92, 93Prick punch, for layouts, 239, 239Primary clearance angles, milling cutters, 645, 647Process annealing, 222–223Product technicians, 4Profile projectors, 163, 163, 164Programmable axes, CNC machine tools, 668–672Programmable rotary table, 663, 666Programming, defined, 673Programming methods

CNC, 673prompted programming systems, 699–702

Projections, on orthographic drawings, 26, 27


794 INDEX

Pulley taps, 69–70, 70Punch layout, 239–240, 240Punches

drift, 353, 356, 356pin, 52, 53prick, for layout, 239, 239types, 52, 53

Quadrants, CNC, 668, 669Quenching media

heat treating, 213–215Quick change gear box, engine lathe, 394, 394, 422Quick change tool holders, engine lathe, 399–400, 399, 400Quick change tooling, drill press, 366, 366Quick change tooling system

for vertical mill, 521, 522

R-8 collets, for milling machine, 521Radial arm drill presses, 342, 342, 347, 348, 348

major parts of, 347, 348, 348Radian measurement, 174–175, 174Radius gages, 149, 151Rake, on cutting tools, 266, 269Ram turret lathes, 384, 385, 386Ram vertical mills, 514, 515Ratios, trigonometric, 257Reading drawings, 26–32Reamers. See also Machine reamers

adjustable, 64, 64carbide-tipped expansion, 379, 379carbide-tipped helical flute chucking, 379, 379chucking, 377, 378hand, 63–66machine, parts of, 377, 377shell, 378, 378taper pin, 378, 378

ReamingCNC cutting tools, 709, 709in drill presses, 377–381by hand, 65–66on lathe, 456–457, 458

Reaming cutting tools, 709, 709Reciprocating cutoff machines, 315

blade selection, 314–315operation, 315–316

Reciprocating saws, 302safety, 304

Recovery, recrystallization and grain growth, 223, 223Rectangular coordinates, CNC, 668, 669Regardless of feature size (RFS), 187Reliability

in measurement, 90using steel rules in measurement, 107–108

Remote gaging, 98–99, 99Re-sharpening milling cutters, 650–656Retaining rings, 24, 24Re-threading dies, 78, 78Right angle, defined, 174, 174Right-angle trigonometry, 177–178, 177–182Right-triangle solution formulas, 763Ring and rocker tool posts, for engine lathe, 403Ring gages, for taper measurement, 492–493

Ring test, grinding wheels, 81–82, 82, 595–596, 596Rockwell and Brinell Hardness testers, 225–233Rockwell hardness tester, use, 225–231, 228Roller burnishing tools, 711, 711Roll grinding machines, 588–589, 590Rose reamers, 377, 378Rotary tables, 537, 538

horizontal milling machines, 564, 564Roughing, 277Roughness average (Ra), 99Roughness profiles, 99Round files, 59, 59Round nose pliers, 47–48, 47Round stock center layout, 240, 241, 497Roundness, defined, 88RPM, formula for calculation

drill presses, 362lathes, 275, 431milling machines, 530–531, 567–568

Rule depth gages, 109–110, 109, 110Rule measuring instruments, 107–115Rules

applications of, in measurement, 110–111care of, 110decimal, 112–113, 113discrimination, 107flexible, 108, 108hook, 108, 108, 109metric, 113–114, 114narrow, 108, 108reading of, 111–114rigid steel, 108, 108short set, 108, 109slide caliper, 108, 109types, 108–110

Saddles, on engine lathes, 392Safety

abrasive sawing machines, 324checklist, for machines, 12chip formation when turning, 442, 442chip handling, 264, 387, 388, 389CNC machines, 665, 666cutoff machines, 304–306, 306drill presses, 344–345, 345federal laws, 12grinding machines, 596–597, 596, 597hand tools, 36hot metals, 196lathes, 387–390machine shop, 6–13milling machine, 512–513, 548pedestal grinders, 82, 84turning between chuck and center, 439

Safety glasses, types of, 7, 7, 8Saw blades

blade width, 314, 314gage of, 314, 314kerf, 313, 314materials, 313pitch, 314, 314saw tooth terminology, 314


INDEX 795

selection, 314–315set patterns, 314, 315tooth forms, 314, 314, 335, 335

Saw teeth, set of, 54, 55, 322Saws

cold saws, 325, 325safety, 306, 306

horizontal band saws, 302, 302, 303reciprocating saws, 302tilt frame band saws, 302–303, 303, 304

Scale, defined, 107Scale drawings, 107Scale measuring instruments, 107Screw pitch gage, 466Screwdrivers

hollow grinding, 83, 83offset, 50, 52Phillips, 50, 52standard blade, 50, 52

Screwscap, 17, 19defined, 16drive, 20, 22head styles, 18machine, 17, 17self-tapping, 21set, 18, 20thread-cutting, 20, 21thumbscrews, 20, 20wing, 20, 20

Screw thread micrometers, 128, 129, 479, 479Screw thread comparator micrometers, 125, 126Scribers

height gages, 250, 251layout, 237–238, 237

Secondary clearance angles, on milling cutters, 646, 647Sectioned views, on drawings, 27, 28Seizing, defined, 39, 40Selecting and identifying nonferrous metals, 203–208Selecting and identifying steels, 197–202Self tapping screws, 21Semiprecision layout, 244–249Sensitive drill presses, 342, 342, 346, 346

major parts of, 346, 347Serial taps, 68, 68Set screws, 18, 20

jackscrews, 18, 20points, 18–19, 20square head, 18, 20

Setup persons, 3Shapes, steel bars, 201, 201Sharp vee thread forms, 465, 466Sharpening drills, on pedestal grinders, 358–361Sharpening milling cutters, 647, 648Shear flow, 279, 279Shell reamers, 378, 378Shim, for keyway broach, 41–42, 42Shop hazards, identification of, 10–12

See also SafetyShop presses

bending and straightening, 42–43safety, 43

installing bushings, procedure for, 38–39, 39, 40mandrels, 40, 40types of, 37–38, 38

Shop safety, 6–13. See also SafetyShrink fits, 185Side cutting pliers, 48, 48Side milling cutters, horizontal mill, 577–580, 580Silicon carbide, 598, 599Sine bar and gage blocks

for taper measurement, 493, 495Sine bars

angular measurements, 179–180, 181constant tables, 181–182

Sine ratioacute angles, defined, 257trigonometry, 177–182

Single depth threadsexternal, 466, 467, 480, 481internal, 483, 483

Single-point threading, 663, 666, 689–690, 697–698Sinometer angle gages, 175, 176Sintering, 284Six-jaw universal chucks, for lathe, 414, 415Sixty-degree thread, calculations for, 465–469, 466Slide caliper rules, 108, 109Slip joint pliers, 47, 47Small hole gages, 148, 149, 150Snap gages, 91, 92Socket head wrenches, 50, 51Socket sets, 50, 50Socket wrenches, 50, 50Soft jaws, for lathe chuck, 416, 416Solid beam square, 152, 153Solid collets, for vertical mill, 521, 521Solid square dies, 78, 79Spade drills, 351, 351, 352, 709Spanner wrenches, types of, 50, 51Spark guards, pedestal grinder, 82, 82SPC. See Statistical process controlSpeeds

reaming, 379tapping, 73–74

Speeds and feedscalculations for, 275–278for machine tools, 275

Sphericity, defined, 88Spheroidizing, 222, 222Spindle drill presses, 343, 343Spindle horizontal milling machines, 551Spindle lathe headstock, 391–392, 392Spindle lathes, tooling for, 413–416Spindle tapers

horizontal milling machines, 553, 554Spiral flute taper pin hand reamers, 64, 64Spiral fluted taps, 69, 69Spiral pointed taps, 68, 68Spline micrometers, 128, 128Spot drilling, 432–433, 433Spotfacing, 375–376, 376

defined, 29symbols, 30

Spotting drill, 351, 351


796 INDEX

Spring calipers, 146, 147Spring cleaner, for lathe, 414, 414Spring collets, 418, 418Square files, 58, 58Square keys, 25Square micrometers, 154, 155Squareness, defined, 89Squares

cylindrical, 153–154, 153, 154diemaker’s, 154, 154micrometer, 155precision beveled edge, 152–153, 153solid beam, 152, 153

Square threads, form of, 500, 500Squaring workpiece, horizontal mill, 574–576, 575, 576Stainless steels, 198Standard tolerances, 184–185Statistical process control (SPC), 183, 187, 189–191

tools for, 190–191Statistics, in process control, 187Steady rest

adjustment of, 496–497use of, 498, 499

Steady rest lathes, 496–499Steel bars, shapes, 201, 201Steel rules, 107–115Steels

alloy, 197approximate melting points, 762case hardening and tempering, 215–217costs of, 202heat treating, 210–213identification systems, 197–198pig iron, 195selecting and identifying, 197–202shafting, 202shop tests for identifying, 199–201stainless, 198tool, 198–200

Steel-spring collets, for lathe, 417, 417Step blocks, drill press workholding, 366, 367Step drills, 351Straddle milling, horizontal mill, 580, 580Straight flute hand reamers, 64, 64Straightness, defined, 88Straight peen hammers, 49, 49Straight pipe taps, 69, 70Straight shank machine reamers, 378Strap clamps, 366, 366, 367

drill press, 366, 366, 367Strap wrenches, 50, 51Stress relief anneal, 222, 222Stub mandrels, 444, 445, 446Stud bolts, 17, 17Subland drill, 351Superabrasives, 593–594

ratios contrasted, 625Supermicrometers, 98, 98Surface finish indicators, 99, 99Surface gages, 240–241Surface grinders, 586–588

accessories for, 618–619chucks

care of, 622, 623grinding-in, 626setups, 623–624types, 621–622, 621, 622

creep-feed grinding, 619holding thin workpieces, 623–624major parts, 617–618, 617, 618nonmagnetic workpieces, 623, 624odd-shaped workpieces, 623, 623problems and solutions in grinding, 632–634Type I surface grinder, 586–587, 587Type II surface grinder, 586, 587, 587Type III surface grinder, 586, 587, 587use, 625–631vee blocks grinding, 623, 626–631workholding, 621–622, 621, 622

Surface platesgrades of, 236types, 236

Surface roughness instruments, 99, 99Swing of engine lathe, measurement, 394Swiss pattern files, 59, 59

T-bolts, 366, 367T-slots, machining, 535–537T-handle tap wrenches, 50, 52, 72, 72Table horizontal mill, 546, 549, 562–563, 563Table surface grinders, 586–587, 587Table vertical mills, 514, 515Tailstock centers, alignment, 415–450Tailstock chucks, 432, 432Tailstock engine lathes, 393–394, 394, 396–397, 397Tailstock turrets, engine lathe, 400, 401, 401, 402Tang files, 59, 61Tangent ratio, of acute angle defined, 257Tang twist drills, 350, 350Tantalum, 207Tap drills, 72–73, 73

size chart, 755metric, 756

Tap wrenches, 50, 52, 72, 72Taper bridge machine reamers, 378–379, 378Taper micrometers, 130, 130Taper milling machine arbors, 486Taper per foot (tpf), 485–486Taper pin reamers, 378, 378Taper pipe thread

American National, 468, 469Taper plug gages, 91, 92Taper ring gages, 91, 92, 492–493Taper shank drill sleeves, 394Taper taps, 67, 68Tapers, cutting of

compound slide method, 486–487measurement of, 492–494offset tailstock, 487–490taper attachment, 490–492

plain taper, 490, 490, 491telescoping taper, 490, 490, 491


INDEX 797

taper length taper portion (chart), 757with angles, 758

uses of, 485–486Tapers, defined, 485Tapping

CNC cutting tools, 689, 709–710with drill presses, 74–76by hand, 74–76lathe, 458–459procedures, 72–76safety, 74speeds, 73–74tap extractors, 74, 74thread depth percentage, 73

TapsAcme threads, 70, 70, 509, 510blind hole defined, 68bottoming, 67–68, 68chamfer, 67, 67drill sizes, 73gun type, 68, 68identifying markings, 68, 68interrupted thread, 68, 68major parts, 67nut, 70, 70pitch diameter relief, 71, 71plug, 67, 68pulley, 69–70, 70rake and hook angles, 70, 70reducing friction when using, 70–71serial, 68, 68spiral fluted, 69, 69spiral point, 68, 68straight pipe, 69, 70surface treatments, 71taper pipe thread, 69, 69taper type, 67, 68thread forming type, 69, 69

Telescoping gages, 146–148, 147–149Tempering, of steels, 215–217Test indicators, 157, 157Thickness gages, 149–151, 151

dial type, 93, 95Thread cutting

infeed calculations, 467, 468Thread cutting dies, 77–80Thread cutting screws, 20, 21Thread engagement defined, 16Thread files, 59, 60Thread fit classifications, 467Thread forming taps, 69, 69Thread forms

Acme, 502–503, 503American National, 466

standard taper pipe, 468, 469American Standard Stub Acme,

503, 503buttress, 503, 504general purpose Acme, 503, 503lead, defined, 504metric, 16, 469, 469

modified square, 500, 500multiple lead, 503–506sharp vee, 465, 466square, 500, 500thread-chasing dial, 505, 505UNC, 15UNF, 15unified, 14, 466UNS, 15

Thread grinders, 592, 593Thread measurement, 477–480

external, 477–478internal, 483, 483methods, 91, 92, 477–480

new advanced methods, 478optical comparator, 480, 481plug gage, 91, 92, 483, 483ring gage, 91, 92, 92, 474, 477, 477sharp vee form, 465, 466symbols for, 31three-wire method, 478–480

Threading, on lathe, 470–475Threading dies, 459, 459

by hand, 79–80, 80lathe, 483types, 77–79

Threading tools, lathe, 408–409, 409Threaded fasteners

external, 16–21identification, 15internal thread inserts, 21–23standard series, 15, 15–16

Threaded spindle, for lathe, 413–414, 413Threads

classes of fits for, 15cutting, on lathe, 471–475designations, 467drawings notations, 29–30fit classifications, 467forms of, 14–15internal inserts, 21–22, 21, 23metric, 16, 751per inch, measurement, 466symbols on drawings, 31tolerance symbols, 751–752

Three-jaw chucks, for lathe, 414, 415, 415Three-square files, 59, 59Three-view drawings. See Orthographic drawingsTilt frame band saws, 302–303, 303, 304Tin, 207, 207Titanium, 207, 208Tolerance limits, 183Tolerance symbols, 751Tolerances

bilateral, 28decimal inch notations for, 184, 752defined, 28effect on mating parts, 184, 184geometric, 186–187limit notations for, 183, 183metric notations for, 184


798 INDEX

Tolerances (Continued)plus–minus, 183–184standard, 184–185unilateral, 28

Tool and cutter grindersadditional capabilities of, 656, 657clearance angles, 650CNC advances, 656, 658cutter tooth rests for, 648, 649major parts of, 645, 646setup for cutter grinding, 650, 650sharpening

cup wheel method, 651–652end mills, 654–656, 655, 657form-relieved cutter, 652–653, 654plain milling cutter, 647, 648safety, 655slitting saw on, 652, 652staggered-tooth cutter on, 652, 653, 654straight-wheel method, 652

wheel abrasives for, 647–648Tool and die makers, 4Tool bit, lathe, grinding of, 410–412Tool breakdown, 264Tool length gages, CNC, 678, 678Toolhead vertical mill, 515, 515

major parts of, 514–515, 514Toolholders

carbide, identification systems for, 292, 295, 296CNC machining center, 663, 663engine lathe, 399–400, 399, 400engine lathe tailstock, 401–404milling machine, 521, 521offset, 403, 403straight shank, 402–403, 403

Tooling, CNC, 705–717Tool rest, on pedestal grinders, 82, 82Toolmaker’s hammers, 239, 239Toolmaker’s microscopes, 100, 100Tool steels, 198–200Tools

ceramic, 288, 294, 297dimensional measurement, 91–102drilling, 349–357hand, 45–53shapes most often used, 407, 407

Tools, cuttingdrill press, 349–357, 350horizontal milling machine, 556–561lathe, 405–407materials for, 284–298metal-ion implantation, 520vertical milling machine, 517–520, 521

Tooth forms, for saw blades, 314, 314Torque wrenches, 50, 51Touch sensor inspections systems, 715, 715, 716TPI (threads per inch), 466Trammel points, for layout, 238, 238Transfer measurement, 146Travel error, 158, 158Travel indicators, 99–100, 99, 100, 106, 106Trepanning cutting tools, 709

Triangles, right, 257–260solution formulas, 763

Trigonometrycalculations for, in layouts, 258cosine ratio, 257definitions, 177–179, 257ratios for acute angles, 258sine ratio, 177–182, 257tangent ratio, 257

Truing, of grinding wheels, 606, 607Tubing micrometers, 129–130, 129, 130, 138–139Tungsten, 208Turning

center CNC, 661, 662, 663between centers, setup, 435chip safety, 442, 442drive (dog) plate, 435, 436finishing, 443, 443intermittent cuts, 441to length, procedure for, 443–444, 444safety, 439to size, procedure for, 442–443speeds and feeds, 439–441tapering wear, 443time for roughing and machining, 441

Turning lathe operations, 435–437Turn/mill centers, 663Turret drill presses, 342, 343, 343Turret lathe tailstock, 400, 401Turret lathe toolpost, 401, 401, 402Turret lathes, 384, 385, 386Twist drills, 264, 264, 349–350, 349, 350, 351, 352Two-jaw universal chucks, for lathe, 414, 415Type I surface grinder, 586, 587Type II surface grinder, 586, 587Type III surface grinder, 586, 587

Ultrasonic machining, 721, 721Unified external thread, cutting, 470–480Unified thread form, 466–467, 466

major parts, 14Unilateral tolerances, 28Universal bevel vernier protractors, 176–177, 176Universal chucks, for lathe, 414–416, 415Universal tool and cutter grinders. See Tool and cutter

grindersUniversal vise, milling machine, 537, 537Upright drill presses, 346–347, 348

heavy duty, 342, 342, 345User accuracy, 89

V-anvil micrometers, 129, 129Vacuum chucks, for surface grinders, 622, 622Variables, in measurement, 91Vee blocks

defined, 42drill press workholding, 369, 369grinding, 623, 626–631use in layouts, 243, 243, 253, 254

Verniercoincident line, 116, 117principle of, 116, 117


INDEX 799

reliability and expectation of accuracy, 117shop tip, 119use of, 116

Vernier bevel protractors, reading of, 177Vernier calipers

depth gage, reading of, 121inch, 119, 119metric, 119–121, 121procedure for use, 119reading of, 119–121

Vernier height gages, 250–251applications of, in layouts, 253, 253–254checking zero reference, 252–253discrimination and application, 116–117, 159reading of, 251–252, 251–252

Vernier micrometers, 143–144, 143Vertical band machines, 302, 306, 306Vertical band saws

adjusting coolant nozzle, 331–332, 332, 339, 340applications of, 310, 310, 311bands

adjusting tension, 333, 333adjusting tracking, 333, 333installing band guides, 330–331, 330, 331selecting, 335–336, 336setting velocity, 336–337, 337welding, 326

contour sawing, 310, 310, 339–340, 340friction sawing, 310, 311operation, 335–340other adjustments, 334, 334safety, 311–312, 312setting speed ranges, 337–338, 338straight sawing, 338–339, 338, 339

Vertical milling machinesbacklash, 526base and column, 514climb milling, 530CNC, 512, 512coaxial dial indicators, 527, 527conventional milling, 530cutter holding on, 521, 522cutting fluids for, 532–533cutting speed calculations, 530–531cutting tools, 517–520, 521digital readout (DRO), 106, 106, 529, 529face milling, 538–539feed rate calculations for, 531–532hole center locating, 526–527, 527keyseat milling, 535, 535locks, adjustment and maintenance of, 516machining holes in vise body, 527–529machining steps and squaring, 533major parts, 514–515, 514mill vise, 525–526milling a cavity, 534–535milling cutters, 517–520, 521offset boring head, 540–543operations, 530, 532, 533–539plunge cutting, 533–534, 534quill, 514, 515ram, 514, 515

rotary tables, 537, 538saddle, 514, 514safety, 512–513setups, 523–529spindle on, 514, 515squaring tool head, 523–524standard, 512, 512table, 514, 515toolhead, 515, 515touch-sensing probes, 527, 527workholding on, 525–526

Vertical spindle machining centerCNC, 663, 664, 665

Vise bodymachining holes in, 527–529

Vise grip C-clamps, 48, 48Vise grip pliers, 48, 48Vises

care of bench, 46cutaway view, 46drill press work holding, 367–368, 368mill, 569milling machine, 563, 563precision vise drawing project, 766–769soft-jaw, 525, 526types of, 45uses of, 45–46

Volume and capacity, measurements of, 760

Warding files, 58, 58Washers

flat, 23, 23lock, 23–24, 23types, 23–24, 23

Wear blocks, 171, 172Web, on twist drills, 358, 359Weight, measurements of, 760Welds, band saw blades, grinding, 329, 329, 330Wigglers, use in drill press, 369–370, 370Wire gages and metric equivalents, 764Wires, for thread measurement, 478–480Woodruff keys, 25Woodruff keyseat cutters, 519, 519Workholder turning lathe operations, 438, 439Workholding drill presses, 366, 367, 368–371Workholding grinding machines, 621–622, 621, 622Workholding hand tools, 45–48Workholding horizontal band saws, 318, 319Workholding horizontal mill, 562–566Workholding lathes, 413, 417

centering accuracy in inches, 418Workholding vertical milling machines, 525–526Wrenches

adjustable, 50, 51box end, 49–50, 50combination, 50, 50crescent, 49, 50hand tap, 50, 52open-ended, 49, 50pipe, 50, 51safety, 53socket, 50, 50


800 INDEX

Wrenches (Continued)spanner, types, 50, 51strap, 50, 51T-handle for taps, 50, 52, 72, 72tap, 50, 52, 72, 72torque, 50, 51

X-axis, CNC, 668, 669X-Y plane, CNC, 668–669, 669X-Z plane, CNC, 669

Y-axis, CNC, 668, 669Y-Z plane, CNC, 669

Z-axis, CNC, 668–669, 669Z-axis tool offsets

CNC, 677, 677Zero reference, on height gages, 252–253Zinc, 208Zirconium, 208


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