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| موضوع: كتاب Machinery’s Handbook Pocket Companion الإثنين 13 مارس 2023, 12:02 am | |
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أخواني في الله أحضرت لكم كتاب Machinery’s Handbook Pocket Companion Compiled and Edited by Richard P. Pohanish A Reference Book for the Mechanical Engineer, Designer, Manufacturing Engineer, Draftsman, Toolmaker, and Machinist Christopher J. Mccauley, Senior Staff Editor Muhammed Iqbal Hussain, Associate Project Editor
و المحتوى كما يلي :
Table of Contents Mathematical Formulas and Tables 1 Areas and Dimensions of Figures 1 Circular Sector 1 Circular Segment 1 Circular Ring 2 Circular Ring Sector 2 Spandrel or Fillet 2 Ellipse 3 Parabola 3 Formulas for Polygons 4 Segments of Circles 6 Geometrical Propositions 10 Trigonometric Relationships 10 Signs of Trigonometric Functions 11 Relationships Among Angles 11 Law of Sines 11 Law of Cosines 13 Solution of Triangles 14 Solution of Right–Angle Triangles 15 Solution of Oblique–Angle Triangles 16 Tables of Trigonometric Functions 19 Formulas for Compound Angles 20 Length of Chords of Circles 21 Coordinates for Locating Equally Spaced Holes 22 Decimal Equivalents, Squares, Cubes, Square Roots, Cube Roots, and Logarithms 24 Diameter, Circumference and Area of Circles MEASUREMENT AND INSPECTION 25 Sine Bars 26 Calculation Using Sine Bars 27 Measuring Tapers with Vee–block and Sine Bar 28 Constants for Setting Sine Bar 35 Measurement of Angles and Tapers 35 Rules for Figuring Tapers 36 Tapers per Foot and Corresponding Angles 38 Gage Block Sets - Inch Sizes 38 Measuring Dovetail Slides MEASUREMENT AND (Continued) INSPECTION 39 Checking a V– shaped Groove by Measurement Over Pins 40 Diameters of Wires for Measuring Whitworth Screw Threads 41 Formulas for Checking Pitch Diameters of Screw Threads 42 Three-Wire Method Applied to Buttress Threads 43 Constants in Formulas for Measuring the Pitch Diameters STANDARD TAPERS 44 Morse Taper 44 Morse Standard Taper Shanks 46 Dimensions of Morse Taper Sleeves 46 Jarno Taper 47 Jarno Taper Shanks 47 Brown & Sharpe Taper 48 Brown & Sharpe Taper Shanks 49 Spindle Noses for Milling Machines 51 Dimensions for Spindle Nose with Large Flange 52 Dimensions of Tool Shanks for Milling Machines 53 Dimensions of V-flange Tool Shanks 54 Dimensions of V-flange Tool Shank Retention Knobs THREADS 55 Thread Classes 56 Sharp V-thread 58 Unified Internal and External Screw Thread Design Profiles 58 Fine-Thread Series 59 Unified Screw Thread Series 71 Basic Dimensions, Taper Pipe Threads 73 Metric Screw Threads M Profile 73 M Profile Definitions 74 Formulas for Limiting Dimensions 76 M Profile Data 77 Internal Metric Thread 79 External Metric ThreadTABLE OF CONTENTS vii FASTENER INFORMATION 83 Grade Identification Marks 84 Applicability of Hexagon and Spline Keys and Bits 85 Hexagon and Spline Socket Head Cap Screws 86 Socket Head Cap Screws Metric Series 87 Hexagon and Spline Socket Set Screws 88 Drill and Counterbore Sizes 89 Hexagon and Spline Socket Flat Countersunk Head Cap Screws 90 Slotted Flat Countersunk Head Cap Screws 91 Hardened Ground Machine Dowel Pins 92 Hardened Ground Production Dowel Pins 93 Chamfered and Square End Straight Pins 93 Standard Straight Pins 93 Standard Taper Pins 95 Parallel Steel Dowel Pins 97 Spring Pins 97 Slotted Type Spring Pins 98 T-Nuts 99 Wrench Openings 100 Wrench Clearences 101 Bolts and Screws Specification 101 Primary Criteria 101 British Unified Machine Screws and Nuts 104 British Standard Whitworth and Fine Machine Screws CUTTING FLUIDS 106 Recommendations for Turning and Milling 107 Recommendations for Drilling and Tapping DRILLING AND REAMING 108 Generally Used Drill Point Angles 109 US and Metric Size Commercial Drills 113 Drilling Difficulties 113 Combined Drills and Countersinks (Continued) DRILLING AND REAMING 114 Counterboring 115 Length of Point on Twist Drills 116 Solid Counterbores with Integral Pilot 116 Solid Carbide Square Boring Tools 117 Reamers 117 Reamer Terms 118 Reamer Difficulties TAPPING 119 Tap Terms 120 Tap Dimensions, Inch and Metric 121 Threading Formulas 122 Tapping Specific Materials 125 Tap Drill Sizes for Threads 126 Tap Drills and Clearance Drills 126 Tap Drills for Pipe Taps 127 Tapping Drill Sizes for ISO Metric 127 Tap Drill or Core Hole Sizes SPEEDS AND FEEDS 128 Cutting Speeds for Plain Carbon and Alloy Steels 130 Cutting Speeds for Ferrous Cast Metals 131 Cutting Speeds for Stainless Steels 132 Cutting Speeds for Tool Steels 133 Cutting Speeds for Light Metals 133 Cutting Speeds for Titanium Alloys 134 Cutting Speeds for Superalloys 135 Cutting Speeds for Copper Alloys 136 Adjustment Factors for Turning with HSS Tools 137 Feeds for Milling with HSS Cutters 139 RPM for Drills of Number and Letter Sizes 140 RPM for Various Cutting Speeds and Diameters 144 Speeds and Feeds in Diamond Grinding 144 Speeds and Feeds for Drilling Holes in Plastics 144 Sawing Plastics MaterialsTABLE OF CONTENTS viii MILLING CUTTERS 145 Milling Cutter Terms 145 End Mill Terms 146 Sharpening Milling Cutters 146 Grinding Wheels for Sharpening Cutters 147 Wheel Speeds and Feeds for Sharpening Milling Cutters 147 Clearance Angles for Milling Cutter Teeth 147 Rake Angles for Milling Cutters 148 Set-ups Used in Grinding Clearance Angle on Milling Cutter Teeth 149 Multiple- and Two-Flute SingleEnd Helical End Mills 150 Multiple-Flute Medium Helix Single-End End Mills 151 Form Relieved Corner Rounding Cutters 151 Two-Flute, High Helix SingleEnd End Mills with Weldon Shanks 152 Two-Flute, Medium Helix, Plainand Ball-End, Single-End End Mills 153 Three- and Four-Flute, Medium Helix, Center Cutting, SingleEnd End Mills 154 60-Degree Single Angle Milling Cutters 154 Key Size Versus Shaft Diameter 155 Keys and Keyways for Milling Cutters 156 Woodruff Keyseat Cutters KEYS AND KEYSEATS 157 Depth Control Values for Shaft and Hub 159 Fits for Parallel and Taper Keys 160 Plain and Gib Head Keys 161 Depth of Keyseat 161 Woodruff Keys and Keyseats 162 Woodruff Keyseat Dimensions BROACHING 164 Pitch of Broach Teeth 165 Data for Surface Broaches 165 Broaching Pressure 166 Causes of Broaching Difficulties CUTTING TOOLS FOR TURNING 167 Cutting Tool Terms 168 Chipbreakers 168 Chipbreakers 168 Identification System for Indexable Inserts 170 Standard Shank Sizes for Indexable Insert Holders 171 Letter Symbols for Qualification of Tool Holders 172 Numerical Control Tooling 172 Insert Radius Compensation 175 Threading Tool Insert Radius Compensation 175 Cemented Carbides 176 Classifications of Hardmetals MACHINING OPERATIONS 177 Machining Aluminum 178 Machining Magnesium 179 Machining Zinc Alloy DieCastings 179 Machining Monel and Nickel Alloys 180 Machining Copper Alloys 180 Machining Hard Rubber 181 General Turning Practical Tips 183 Tool Troubleshooting 185 Common Tool Faults, Failures, and Cures COMPUTER NUMERICAL CONTROL 188 Format Classification 189 G-Code Addresses 191 Letter Addresses 192 Miscellaneous FunctionsTABLE OF CONTENTS ix GRINDING WHEELS 193 Grinding Wheel Safety 193 Handling, Storage and Inspection 193 Machine Conditions 193 Grinding Wheel Mounting 194 Safe Operating Speeds 195 RPM of Various Grinding Speeds and Wheel Diameters 196 Portable Grinders 196 Maximum Peripheral Speeds for Grinding Wheels 197 Principal System of Surface Grinding Diagrams 198 Periphery of Wheel 198 Face (Side) of Wheel 199 Recommendations for Surface Grinding 200 Common Faults and Possible Causes in Surface Grinding 201 Grinding Wheel Markings 201 Sequence of Markings 201 Composition of Diamond and Cubic Boron Nitride Wheels 202 Conventional Abrasives Grinding Wheel Recommendations 212 Shapes and Sizes of Grinding Wheels 212 Standard Shapes and Inch Size Ranges 216 Standard Shapes and Metric Size Ranges 218 Standard Shapes of Grinding Wheel Faces 219 Diamond Wheel Core Shapes and Designations 219 Diamond Wheel Cross-sections and Designations 220 Designations for Location of Diamond Section 221 Designation Letters for Diamond Wheels 222 Wheel Type and Abrasive Specification 223 Standard Shapes and Inch Sizes of Mounted Wheels and Points 225 Standard Shapes and Metric Sizes of Mounted Wheels and Points 226 Lapping Lubricants 226 Sharpening Carbide Tools 227 Silicon Carbide Wheels (Continued) GRINDING WHEELS 227 Diamond Wheels, Grits and Grades 227 Diamond Concentration 228 Dry Versus Wet Grinding of Carbide Tools 228 Coolants for Carbide Tool Grinding 228 Peripheral Versus Flat Side Grinding 228 Lapping Carbide Tools 229 Chip Breaker Grinding GEARING 230 Gear Tooth Nomenclature 231 Gear Tooth Forms 232 Formulas for Standard Spur Gears 233 Circular Pitch in Gears 235 Series of Involute, Finishing Gear Milling Cutters 236 Gear Design Based upon Module System 236 Tooth Form for Spur and Bevel Gears 237 Tooth Dimensions Based Upon Module System 238 Module System of Gearing 239 Equivalent Diametral Pitches, Circular Pitches, and Metric Modules 240 Measurement of Gear Tooth 240 Checking Spur Gear Size by Chordal Measurement 241 Chordal Measurements over Spur Gear Teeth 242 Number of Teeth Included in Chordal Measurement 242 Formulas for Chordal Dimensions PROPERTIES OF MATERIALS 243 Standard Steel Classification 243 Classification of Tool Steels 244 System of Designating Carbon and Alloy Steels 245 Classification,Compositions, and Properties of Tool and Die Steels 247 Quick Reference Guide for Tool Steel SelectionTABLE OF CONTENTS x (Continued) PROPERTIES OF MATERIALS 249 Molybdenum High-Speed Steels 250 Hot Work Tool Steels 251 Tungsten High-Speed Tool Steel 252 Cold Work Tool Steels 253 Shock Resisting, Mold Tool Steels 254 Temperature of Steel as Indicated by Color 256 Comparative Hardness Scales for Steel 259 Weights of Various Metals and Shapes 262 Thermal Properties of Various Metals 264 Characteristics of Plastics 265 Working With Plastics STANDARDS FOR DRAWINGS 266 Shop Prints, Reading and Interpreting 267 Symbols for Section Lining 268 ANSI and ISO Symbols 269 Symbols for Datum Referencing SURFACE TEXTURE 272 Surface Texture Symbols 273 Roughness Sampling Length 274 Roughness Average Values 274 Waviness Height Values 275 Lay Symbols 275 Example Designations 276 Application of Symbols 278 Surface Roughness Produced by Common Production Methods ALLOWANCES AND TOLERANCES 279 Limits and Fits 279 Preferred Basic Sizes 279 Tolerances and Allowances 280 Standard Tolerances 280 Relation of Machining Processes to Tolerance Grades 280 Tolerances for Cylindrical Parts 281 Designation of Standard Fits 282 Graphical Representation of Limits and Fits 284 Running and Sliding Fits 286 Clearance Locational Fits ALLOWANCES AND (Continued) TOLERANCES 288 Transition Locational Fits 289 Interference Locational Fits 290 Force and Shrink Fits 292 Preferred Metric Limits and Fits 293 Preferred Metric Sizes 293 Preferred Fits 295 Terms for Preferred Fits 296 Preferred Hole Basis Metric Clearance Fits 298 Hole Basis Metric Transition and Interference Fits 300 Preferred Shaft Basis Metric Clearance Fits 302 Preferred Shaft Basis Metric Transition and Interference Fits 304 Gagemakers Tolerances 305 Relation of Machining Processes to IT Tolerance Grades 305 Usage of IT Tolerance Grades CONVERSION FACTORS 306 Metric Conversion Factors 312 Factors and Prefixes of SI Units 313 Inch to Millimeter and Inch to Centimeter 314 Decimals of an Inch to Millimeters 316 Millimeters to Inches 318 Fractional Inch to Millimeter and Foot to Millimeter 319 Thousandths of an Inch to Millimeters 320 Greek Letters and Standard Abbreviations 320 Roman Numerals 320 Rounding off Numbers 320 Commonly Used Constants 321 Weights and Volumes INDEX 323 A ABS plastics 264 Acetal plastics 264 Acrylic plastics 264 Addendum,chordal 235 Addresses, letter, NC 191 Allowances and tolerances for cylindrical fits 279–305 fits 279–305 fits, preferred series 280 Alloy steels AISI-SAE designations 244 selection for making tools 247–248 Aluminum machining 177 melting point 262 Angles cutting tool 167 sine bar for measuring 25–27 taper per foot corresponding to 36 to find, for given taper per foot 35 ANSI Standard bolts, screws, and nuts, metric 86 datum referencing symbols 269 diamond wheels 144, 219–222 drawing and drafting practices symbols between 268 comparison to ISO 268 controlled radius 268 diameter 268 parallelism 268 part tolerance 268 perpendicularity 268 position 268 roundness 268 runout 268 section lining 267 statical tolerance 268 total runout 268 engineering drawings 266 gage makers, tolerances 304 gear tooth forms 231 geometric characteristic symbols 268– 269 geometric dimensioning and tolerancing 269 grinding wheel safety 193 ANSI Standard (continued) grinding wheels 201 keys and keyseats 154, 163 keys and keyways for milling cutters and arbors 155 limits and fits 279 metric screw threads, M profile 73 metric screws,bolts,nuts,and washers 86 milling cutters 145–152 pins 91–97 pipe thread 71 preferred basic sizes 293 fits 293 metric limits and fits 292 metric sizes 293 screws and bolts,metric 86 section lining symbols 267 set screws socket type 87 set-screw heads and points 87 socket head cap screws 85, 88–89 spline socket set screws 87 spur gear tooth forms 231 surface texture 272–278 surface texture symbols 272–276 symbols concentricity 268 datum referencing 269 for section lining 267 taps and threading dies 119 T-nuts 98 tolerances 280 gagemakers 304 symbols 268–269 tolerances and allowances 279–305 twist drills 115 unified threads 59 woodruff keys 162–163 wrench openings 99–100 Arbors keys and keyways for 155 standard milling machine 49–50 Arc, checking radius of 39 Area, circular ring 1 Area, circular ring sector 2 Austenite 254 B Base circle, spur gear, diameter 230 Base oils for metal cutting 106INDEX 324 Bevel gearing tooth form 236 Block, NC 188 Bolt head markings, inch 83 wrench and socket clearances 99–100 Bolt hole circles, coordinates for 20 Bolts and nuts ANSI inch dimensions, T-nuts 98 British Standard Whitworth 102, 104 grade markings for steel 83 spacing for wrench clearances 99–100 wrench clearances 100 wrench openings 99 Box wrench clearances 100 Briggs (now ANSI) standard pipe thread 72 Brinell hardness 256, 258 Brinell-Rockwell hardness conversion tables 256–258 British Standard countersunk head screws 102–104 dowel pins, metric 95 ISO metric tapping drill sizes 127 metric dowel pins 95 tapping drill sizes 127 Unified machine screws and nuts 101– 103 Unified screws and nuts 102 Broaches clearance angles for teeth 164 depth of teeth 164 face angle or rake 164 land width 164 pitch of teeth 164, 166 radius of tooth fillet 164 surface 165 total length 164 Broaching 164–166 depth of cut per teeth 164 difficulties 166 pressure 165 types of machines 164 Brown & Sharpe taper 48 Buttress threads, wire method of measuring 42 C Caliper, gear tooth 240 Cap screws 85–90 drill and counterbore sizes for 88 flat head 89 hexagon socket type 85, 89 spline socket type 85, 89 Carbide cemented 175 titanium 175 tungsten 175 tungsten-titanium 175 Carbide tools grinding 226–228 insert holders 170–172 insert type 168 materials for 176 sharpening 226 Carbides and carbonitrides 176 Carbon steels 243 Carbon steels, AISI-SAE designations 244 Carbonitrides and carbides 176 Cemented carbide 175–176 Cemented carbide tools grinding 227–228 Centering tools, length of point 115 Centimeter-inch conversion tables 313 Centipoises 312 Centistokes 312 Checking, radius of arc 39 Chipbreakers 168 grinding 228 Chord length for given number of divisions 20 Chordal thickness milled, full-depth gear teeth 234 Chordal thickness, gear teeth 235 Circle area 1, 24 chords for dividing circumference of 20 circumference 1, 24 diameter 24 geometry of 9 lengths of chords for dividing 20 Circular pitch gears, diameters of 233 ring sector, area 2 ring, area 1 sector segment 20 Circular Sector angles 1 area 1 length of arc 1 Circular Segment angles 1 area 1 length of arc 1 Circumference, chords for dividing 20 Clearance angles milling cutters 147 drill sizes, machine screw 126 for wrench 99–100 British Standard 127 CNC programming 188–192 Coiled type spring pins 96 Cold-form tapping 127 Compensation, insert radius, NC 172–174 Computer numerical control, CNC programming 188 Conductivity, thermal 262–263INDEX 325 Conversion tables cutting speed and diameter to rpm 139– 142 hardness 258 miscellaneous english units 312 Coolants for machining aluminum 177 magnesium 178–179 tool sharpening 228 zinc alloys 179–180 Coordinates, for jig boring 20 Copper, linear expansion 262–263 Core drills 114 Corner-rounding milling cutters 151 Counterbores 116 Countersunk head screws 89 screws, British Standard 102–104 CPVC plastics 264 Cross section lining, ANSI Standard for drawings 267 Cutter clearance angles 147 compensation, NC 172–174 grinding 146–148 rake angles 147 tooth rest positions 148 wheels for sharpening milling cutters 146–147 Cutter compensation, NC 174 Cutters angular, milling 145–146 milling 145–152 milling, steels for 247–253 spur gear, formed type 235 woodruff keyseat 156 Cutting abrasive 225 fluids 106 chlorinated oils 106 mineral oil 106 selection 106 sulfurized oils 106 various alloys 106 tools 167–168 Cutting speeds and feeds 139–143 cutting speed calculations 136 cutting tool materials 248–253 drilling copper alloys 135 ferrous cast metals 130 light metals 133 plain carbon and alloy steels 128 stainless steels 131 superalloys 134 titanium and titanium alloys 133 tool steels 132 equivalent rpm for given cutting speed 139–143 Cutting speeds and feeds (continued) equivalent rpm for given drill sizes and speed 139 formulas for 136 milling feeds for high-speed steel cutters 137 ferrous cast metals 130 light metals 133 plain carbon and alloy steels 128 stainless steels 131 superalloys 134 tool steels 132 reaming copper alloys 135 ferrous cast metals 130 light metals 133 plain carbon and alloy steels 128 stainless steels 131 superalloys 134 tool steels 132 rpm for different speeds and diameters 140–143 tool angles 167–168 tool inserts 174 tool life,adjusting factors 136 turning copper alloys 135 ferrous cast metals 130 light metals 133 plain carbon and alloy steels 128 stainless steels 131 superalloys 134 titanium and titanium alloys 133 tool steels 132 Cutting tools 167–171 angles 167–174 application codes, ISO 176 carbide grade selection 176 cemented carbides 176 cubic boron nitride (CBN) 220 grades 176 inserts 172 single-point 167–168 specifications, ISO 176 trouble-shooting checklist 183–184 D Datum referencing 269 Decimal equivalents cube roots 22 cubes 22 logarithms of fractions 22 square roots 22 squares 22 Density, metals 262–263 Diametral equivalent circular pitch and tooth proportions 239 equivalent modules 239INDEX 326 Diametral (continued) pitch, gear teeth sizes 230–232 Diamond grinding wheels 144, 220, 222 wheels 144, 219–228 designation symbols 219–221 diamond concentration 227–228 feeds and speeds 144 grades, grit sizes 227 modifications 221 selection of 222 shapes of standard 219–220 speeds and feeds 144 Die blocks, steels for 246 Dies and taps tap drill size 125–127 metric 127 Unified 125–126 Dies, sheet metal heat-treatment, steels for 246 steels for various classes of die parts 246 Dimensioning and tolerancing, geometric 269 Double angle milling cutters 145 Dovetail slides, measuring 38 Dowel pins 91–92, 95 designation 92 ductility 92 hardened ground production 92 metric 95 shear strength 92 Drafting practices, ANSI Standard 269 Drawing ANSI Standard line conventions 266 line conventions 266 symbols ANSI Standard section lining 267 geometric 268 ISO 268 lines 266 materials 267 Drawings ANSI Standard drafting practices 269 surface texture symbols 272–276 symbols 269 Drill, sizes for tapping 125–127 Drilling cutting speeds for copper alloys 135 ferrous cast metals 130 light metals 133 plain carbon and alloy steels 128 stainless steels 131 superalloys 134 titanium and titanium alloys 133 tool steels 132 difficulties 113 Drills Drills (continued) angle of cutting point 108 combined drills and countersinks 114 cutting speeds and equivalent rpm 139 diameters of tap 125–127 for taper pin reamers 94 jobbers length 112 length of point 115 sharpening 226 straight-shank drill sizes letter 110–111 number 110 straight-shank, taper-length, drill sizes fractional 109 letter 110–111 metric 109 number 109–110 tap and clearance hole sizes 126 Drop-forging dies, steels for 247–248 Duranickel, machining 179–180 E—F Ellipse area 2 perimeter 2 End mills, ANSI Standard 153 Expansion coefficient of (linear) metals 262–263 Feet per minute into rpm 139 Fits cylindrical allowances and tolerances 279–305 cylindrical ANSI Standard 279–305 cylindrical British Standard 305 cylindrical clearance 282 cylindrical definitions 292 cylindrical forced 290 cylindrical preferred series 280 cylindrical running 282–284 cylindrical shrinkage 282, 290 cylindrical transition 283, 288 Fits and limits graphical representation 282–283 tolerances designation 293 Flat head cap screws 89 head machine screws 104 Forced fits, allowances 290 Format classification 188 detail, NC 191 word address, NC 188, 191 Formulas compound angles 19 polygon 3 trigonometric 11INDEX 327 G Gage blocks, precision 38 inch sizes 38 Gagemakers tolerances 304–305 Gages usage, ANSI Standard 304 G-code programming, NC 188–192 Gear tooth caliper, vernier 240–241 Gearing 230–242 calculating spur gears 232 chordal measurement of teeth 241 geometry of gear teeth 230 measuring 240–241 module system 236–239 Geometical formula 1 Geometric symbols for drawings 269 Geometrical propositions 6–9 symbols for drawings 268 symbols, comparison of ANSI and ISO 268 Geometrical dimensioning and tolerancing 269 Geometrical formula circular ring 1 circular ring sector 2 circular sector 1 circular segment 1 ellipse 2 parabola 3 spandrel or fillet 2 German standard gear tooth 236 Gib-head keys 160 Grade identification marks 83 Grade markings on bolts and nuts ASTM and SAE 83 inch 83 Greek letters 320 Grinders safety for 193 Grinding 198–222 abrasives 201 carbide tools 226–228 chip breakers 228 diagram 197 diamond wheel 144, 220–228 milling cutters 146–147 silicon carbide wheels 227–228 surface 198–200 tools, carbide 226–228 wheel safety 193 handling 193 portable grinders 196 storage 193 wheels 193–218 abrasive materials for 201 CBN 201 faces, shapes of 218 Grinding (continued) wheels markings, standard 201 mounted wheels and points 223–224 shapes and sizes, standard 212–218 wheel markings 201 Grinding wheel material alnico 202 aluminium 202 brass 202 chrome plating 203–204 copper 203 copper alloys 203 cutlery 203 cylinders 204 die forging 204 dies 204 drills ductile iron 205 manufacturing 204 resharpening 204 fasteners 205 forgings 205 gauges plug 205 ring 205 thread 205 gears, hardened steel 205 hastalloy 205 inconel 205 jet blades 205 lapping 205 lawn mowers 205 lucite 205 pistons 207 rotors 208 rubber hard 208 rubber soft 208 scissors and shears 208 shafts 208 shear blades 208 spline shafts 208 steel 208 steel castings 208 steel forgings 208 stellite 210 tappets 210 taps 210 tentalum 210 titanium 210 Grinding wheel characteristics centerless hard 202–211 soft 202–211 cylindrical 202–211 floor stands 202–211 internal 202–211 mounted wheels 202–211 offhand 202–211 portable grinders 202–211INDEX 328 Grinding wheel characteristics (continued) surfacing segments 202–211 straight wheel 202–211 Grinding wheel characteristics bars 202–211 G-word, NC 189 H Hard rubber, machining 180 Hardened ground machine dowel pins 91 Hardmetals 176 ISO classifications 176 Hardness testing 256–258 Brinell 256–258 diamond pyramid 256 Hultgren ball 256 Rockwell 256–258 scleroscope 256 vickers 256 tool steels 250–252 Heat treatment steel 254 steel quenching 254 Helical gearing chordal thickness and addendum 235 High-speed steels 249, 251 molybdenum 249 tungsten 250–251 High-strength, low-alloy (HSLA) steels 244 Holders for NC, insert 171–174 Honing process, carbide tools 228 Horsepower equivalents 311 Hot-working, tool steels for 250 HSLA steels 244 I—K Identities, trigonometric 11 Inch decimals of, into millimeters 313–317 Inch millimeters into decimals 318 Inches into centimeters and millimeters 313 Indexable carbide inserts 168 insert holders, NC 170–174 inserts, single-point tools 168 Insert holders for NC 171–174 Insert radius compensation, NC 174 Inserts hardmetal materials 176 Inserts indexable 168–174 Inspection methods 275–276 ISO Standard tapping drills for 127 Jarno taper 47 Jig boring equally spaced holes 21 Jobbers reamers drills 112 Keys and keyseats ANSI Standard 154–162 depths for milling keyseats 157–161 fitting 159 gib-head keys 160 key fitting 159 keyseat milling cutters, Woodruff 156 keyseats, depth of 157–161 parallel 157–160 plain 160 size vs. shaft diameter 154 taper 157–159 woodruff 162–163 L Lapping carbide tools 228 Lapping lubricants 226 Law of cosines 11 Law of sines 11 Lead angles of cutting tools 167–174 Letter addresses, NC 191 Light metals speeds, for drilling, reaming, turning and milling 133 Limits and fits cylindrical fits 279–292 definitions 292 gages, plain 304 graphical representation 282–283 holes and shafts 298 metric 292–303 preferred metric 292–305 tolerance designation 293 Line geometry of 8 Line of action, gearing 230 Linear expansion metals 262–263 Lubricants cutting 106 gasoline 226 kerosene 226 lapping 226 lard oil 226 machine oil 226 soda water 226 M Machine screw taps 119 Machine screws B.S.W and B.S.F 102, 104 British Metric 102 British Unified 101–102 tap and clearance drills 125–126 tap drill sizes 126 taps for 119 Machining aluminum 177 copper alloys 179–180INDEX 329 Machining (continued) hard rubber 179–180 magnesium 178–179 monel and nickel alloys 179–180 nonferrous metals 177–180 zinc alloy die castings 179 Machining processes effect on surface roughness 278 tolerance grade relationships 280 Machining processes, ANSI Standard tolerance grade relationships 305 Magnesium alloys cutting fluids for 178–179 machining 178–179 M-codes (M-words), NC 192 Measurement of angles and tapers 35 Measuring angles with sine-bar 25–34 dovetail slides 38 gear size 241 instruments and gaging methods 25, 36, 38, 272, 276 radius or arc, over rolls 39 surface texture 278 tapers 27, 35–37 threads buttress 42 by screw thread gage 42 by three-wire method 42 V-shaped groove, over pins 39 Mechanical properties bolts and screws 83 bolts, inch sizes 83 steel 246 Melting points various metals 262–263 Metal bonded grinding wheels 227 melting points 262–263 specific gravity and properties 262–263 Metric bolts and screws 127 conversion factors 306–312 tables 313–317 dimensions on drawings 276 dowel pins, British Standard 95 equivalents 306–315 fasteners, ANSI 86 ISO limits and fits 305 module, gear cutter teeth 236–239 Metric screw threads design profile 73 fundamental deviation 73 limiting dimensions 74 limiting profile 73 major diameter 55 minor diameter 55 M-profile 73 pitch diameter 55 profile 73 Metric screw threads (continued) sharp V- thread 56 thread class 55 Millimeters hundreds of, into inches 313 inches into 313 into inches 316–318 thousandths of an inch, into 314–317 Milling feeds for high-speed steel cutters 137 speeds and feeds copper alloys 138 Milling angular 145 Milling cutters 145–155 ANSI Standard 145–155 arbor keys and keyways 155 corner rounding 151 double angle 145 elements of 145 end mills 153 grinding or sharpening 146–147 keys and keyways for 155 rake angles 147 setting angles for milling teeth in 146 single angle 145 spline shaft 146 steels for 247–248 terminology 145 Milling machine spindle noses 49–51 tapers for 49 tool shanks 52 V-flange, NC 53–54 Miscellaneous functions (M-words), NC 192 Module system of gear teeth 236–239 Molds, steels for permanent 253 Molybdenum high-speed steels tool steels 249 Molybdenum steels, SAE 244 Monel metals, machining 179–180 Monel, machining 180 Morse taper, stub taper shanks 45 Morse tapers 44–48 Mounted wheels and mounted points 223– 225 M-words, NC 192 N NC programming 192 Nickel alloys, machining 179–180 Nickel, melting point 262–263 Nitinol, machining 179–180 Nonferrous alloys, machining 177–180 Numbering systems for steel 244 Numerical control 172–192 addresses, letter 191 APT programming 174 automatically programmed tool (APT) 174INDEX 330 Numerical control (continued) block 188, 191 cutter compensation 174 cutter location data 188 G-code addresses 189 insert holders for NC 171, 174 insert radius compensation 174 letter addresses 191 miscellaneous functions, (M-Words) 192 part programming 188 part tolerance symbols compared to ISO 268 postprocessor 188 preparatory word 189 programming NC 174, 188–192 tool compensation 174 tool nose radius compensation 174 V-flange tool shanks 53–54 word 191 word address format 191 Nut taps 119 Nuts ANSI, inch dimensions,T-type 98 British Standard Fine 104 metric 102 Unified 102 Whitworth 102, 104 wrench clearances 100 wrench openings 99 O—P Oils and compounds, machining 106, 177– 180 mineral 106 sulfurized and chlorinated 106 Open-end wrench clearances 100 Parabola, length of arc 3 Parallel steel dowel pins 95 Parallelogram geometry of 8 Pearlite 254 PEEK plastics 264 Permanickel, machining 180 PET plastics 264 Phenolic plastics 264 Pin method for checking screw threads 39 V-shaped grooves 39 Pin method of checking gear sizes 242 Pins dowel 91–92, 95 metric dowel 95 spring 96–97 straight 92–93 taper 93–94 Pipe and pipe fittings dryseal taper 71 taps, dimensions British Standard 127 straight 119 taper 119 threads American National Standard 71 Pitch broach teeth 165–166 circular, of gears 232 diameters, gears circular pitch 233 pin method of checking 242 spur 232–233 diameters, thread M profile 75 diameters, thread checking 41 diameters, thread, Unified 59 diametral, of gears 232 gear 232 Planing tool grinding 167 Plastics materials 264 Plastics properties elasticity 265 safety 265 support 265 thermal expansion 265 Plastics work cutting off 265 drilling 265 milling 265 sawing 265 tapping and threading 265 turning 265 Poise 312 Polycarbonate plastics 264 Polygon area 3 circumscribed radius 3 Inscribed radius 3 length of side 3 Polypropylene plastics 264 Polysulphone plastics 264 Polyurethane plastics 264 Postprocessor, NC 188 Precision gage blocks 38 Preferred basic sizes, ANSI Standard 293 fits, ANSI Standard 293–294 hole basis metric fits 293–298 metric sizes ANSI Standard 293 series for tolerances and allowances 280 shaft basis metric fits 294–302 Preparatory word, (G-word) NC 189–190 Pressure angle, gearing 230 Pressure unit conversion 311 Programming G-code 189–192 numerical control 189–192INDEX 331 Properties of materials standard steels 243–244 thermal 262–263 tool steels 185–253 PTFE plastics 264 Pulleys (sheaves) speeds, rpm into feet per minute 140 Punches and dies steel for 247–248 steel for hot-working 247–248 Punches, steels for 247–248 PVC plastics 264 PVDF plastics 264 R Rack gear 231 Radius of arc, checking 39 Rake angles, turning tool 167 Reamer difficulties 118 cause 118 problem 118 solution 118 Reamers drills for taper pin 94 steels for 247–248 taper pin reamers, drills for 93–94 Reaming cutting speeds for copper alloys 135 ferrous cast metals 130 light metals 133 plain carbon and alloy steels 128 stainless steels 131 tool steels 132 Relationships among angles 11 Resinoid bonded wheels 227 Retention knobs, V-flange tool shanks 53– 54 Rockwell hardness test 256–258 Rockwell-Brinell hardness conversion tables 256–258 Roughness control of 272–278 cutoff 273 symbols indicating degree of 277 Round head machine screws 102 Rpm for various cutting speeds and diameters, inch units 140 metric units 143 Rpm for various grinding speeds and diameters 195 Running fits, allowances 282–284 S SAE Standards steel specification numbers 244 woodruff keyseat cutters 156 SAE steels basic numbering system 244 compositions 244 numbering system for 244 Scleroscope 256 Screw machines drills 111 Screw threads and thread systems 56, 73–75 ANSI M-profile 73–75 allowances 74 basic profile 73 coarse pitch 73 crest and root form 73 design profile, M series 73 limits of size 75 tolerance grades 74 ANSI Unified 56–57, 59 standard series, tables of 59 classes of tolerance 56–57 designation of Unified threads 56, 59 limits Class 2A and 2B 59 Class 3A and 3B 59 measuring 41–42 metric series threads ANSI M profile 73–75 pipe, ANSI Standard 71 pipe, taper 71 tap drill sizes 125–127 Unified allowances 56–57, 59 coarse thread series 59 coated 56–57 crest clearances 56–57 dimensions 59 fine and extra fine series 59 limits 56–57, 59 thread classes 56–57 tolerances 56–57 wire method of checking 41–42 Screw threads measuring diameters of wires 40 Screws British Standard inch 102–104 British Standard Whitworth 102–104 British Unified 102 cap 85, 88–89 grade markings for steel 83 set 87 tap drills 125–127 Unified Standard 102 Section lining, standard for drawings 267 Segments of Circles 4 Set-screws American National Standard 87INDEX 332 Set-screws (continued) fluted socket type 87 hexagon socket type 87 spline socket type 87 Shafts allowances and tolerances for fits 279–305 Shanks, taper 44–48 Shapes of grinding wheels 212–218 Shapes of mounted wheels and points 223– 225 Sharpening carbide tools 226 drills 108 Shears steel for hot-working 250 Shock 253 Shore's scleroscope 256 Shrinkage fits 282, 290 Signs of trigonometric functions 10 Silicon carbide grinding wheels 226–227 Sine bar checking angle of templet 26 checking taper per foot 26 finding angle when height is known 26 gage 26 measuring angle of templet 26 setting to a given angle 26 10-inch 26 Sine bar, use of 25, 27 Single-angle milling cutters 145 Single-point cutting tools 167–168 chipbreakers 168 definitions and terms 167 indexable inserts 168 insert toolholders 170–174 lead angles 167 nose radius 167 numerical control tool compensation 174 planing tools 168 side cutting edge angles 167 tool contour 167 tool holders, indexable inserts 168–171 Sintered carbide tools, ANSI Standard 176 Sleeves, Morse taper 46 Socket head, screw type drill and counterbore sizes for 88 keys and bits for 84 set 87 head, screw type, cap 85–90 taper shank 44–48 wrench clearances 100 Solution of oblique angle triangles 13, 15 right angle triangles 13–14 Spacing holes on jig borer 20 Spandrel or fillet area 2 Speeds calculating cutting speeds 139–143 rpm for different diameters and cutting speeds 139–143 Speeds and feeds, machining cutting 139–143 drilling drilling copper alloys 135 ferrous cast metals 130 light metals 133 plain carbon and alloy steels 128 stainless steels 131 superalloys 134 titanium and titanium alloys 133 tool steels 132 drilling diameters and rpm 139–143 grinding with diamond wheels 144 milling ferrous cast metals 130 light metals 133 plain carbon and alloy steels 128 stainless steels 131 superalloys 134 tool steels 132 nonferrous metals 177–180 reaming copper alloys 135 ferrous cast metals 130 light metals 133 plain carbon and alloy steels 128 stainless steels 131 superalloys 134 tool steels 132 surface grinding 199–200 turning copper alloys 135 ferrous cast metals 130 light metals 133 plain carbon and alloy steels 128 stainless steels 131 superalloys 134 titanium and titanium alloys 133 tool steels 132 Speeds and feeds, machining, tool life, adjusting factors 136 Spindle noses 49–54 Splines, involute milling 146 socket keys and bits 84 Spring pins 96–97 coiled type 96 Spur gearing 230–235 American National Standard tooth forms 231 caliper measurement of tooth 240 checking gear size 240, 242 chordal addenda and thicknesses for milled full-depth teeth 235 chordal addendum 235 chordal addendum measurement 240– 242 chordal thickness 235 circular pitch system 233 composite teeth 231–232INDEX 333 Spur gearing (continued) diametral pitch system 230 diametral pitches shown full size 230 dimensions, formulas for 232 full-depth, teeth 231, 235 gear milling cutters, series of 235 gear tooth parts 231–232 checking 241–242 German standard tooth form 236 measurement of tooth with caliper 240 module system 236–239 outside and root diameters 233 pitch diameters, tabulated 233 pressure angles 230, 232 root and outside diameters 233 tooth dimensions 231 tooth forms 231 tooth thickness measurement 235, 242 wire method of checking 242 Standard fits 281 basic shaft 282 bilateral hole 282 close running 281 close sliding 281 force 282 force or shrink 282 free running 281 heavy drive 282 light drive 282 locational clearance 281 locational interference 282 locational transitional 281 loose running 281 medium drive 282 medium running 281 precision running 281 running and sliding clearence 281 Standard steels 243–244 classification 243–244 Steel carbon steel structure 254 compositions for tools 253 compositions of SAE 244 heat treatment 254 high-speed 243 high-strength, low-alloy 244 hot-working, for dies, shears 250 manganese, SAE compositions 244 molybdenum compositions 244 molybdenum nickel 244 molybdenum nickel-chromium 244 molybdenum, high-speed 249 numbering systems for 244 properties of heat-treated 246 SAE compositions 244 SAE specification numbers 244 taps 247–248 tool 185–253 tool and die 246 tools of different types 247–248 tungsten Steel (continued) compositions 251 high-speed 250–251 Stoke 312 Straight pins 93 Stub tooth gearing 231 former American Standard 231 outside and root diameters 232 Superalloys speeds, for drilling, reaming, turning and milling 134 Superhard tool materials (CBN) 220 Surface grinding 198–200 common faults and possible causes in 200 principal systems 198 process data for 199 selection of grinding wheels for 198– 218 roughness 278 roughness relationship to tolerances 278 speeds, diameters and rpm cutting speeds formula 139–143 grinding wheels 195 texture applying symbols 272–276 castings 276 drawing practices for symbols 272 Symbols ANSI Y14.5M 267–268 applying surface texture 272–276 between, ANSI 268 concentricity, ANSI 268 controlled radius, ANSI 268 diameter, ANSI 268 diamond wheel marking 219–221 drawing practices for surface texture 272 geometric characteristic 268 grinding wheel markings 201 lines for drawings 266 parallelism, ANSI 268 perpendicularity, ANSI 268 roundness, ANSI 268 runout, ANSI 268 section lining aluminum 267 bronze 267 cast and malleable iron 267 earth 267 insulation 267 magnesium 267 materials 267 rock 267 sand 267 steel 267 white metal 267 statical tolerance, ANSI 268 surface profile, ANSI 268 surface texture 272–276 tolerances 293 total runout, ANSI 268INDEX 334 T Tap dimensions cut thread 119, 121 ground thread 119, 121 Tap drill diameters 125–127 cold form tapping 127 machine screw sizes 126 Tap drill sizes 125–127 Taper pins, standard 94 drills for 94 pipe threads 71–72 Tapers applications of standard 47 Brown & Sharpe 48 Jarno 47 keys 154–159 machine tool spindles 47 measurement methods 27–37 measuring with V-block and sine bar 27 milling machine spindles, arbors and spindle noses 49–52 Morse 44 per foot and corresponding angles 36 rules for figuring 35 Tapping alloys 122 aluminium 122 brass 122 bronze 122 copper 122 high speed 123 iron cast 122 ductile 122 malleable 122 nodular 122 magnesium 122 monel metal 122 plastics 123 rubber 123 steel high speed 123 molybdenum 123 stainless 123 titanum 123 Tapping and thread cutting 125–127 British Standard drill sizes 127 cold form 127 tap drills clearance drills for machine screws 126 for American form threads 125–126 for ISO metric threads 127 Taps hand, types of 119 nut 119 pipe 119 pulley 119 Taps (continued) removing broken 127 spiral pointed 119 types of 119 Temperature critical, heat treating of steel 254 melting point metals 262–263 Thermal conductivity 262–263 expansion coefficients 262–263 Threads and threading ANSI Standard M profile thread profile data 76 ANSI Standard M profile thread data 76 limiting dimensions 77 profile data 76 pipe taper 72 Three wire method buttress threads 42 formulas for checking pitch diameter 40 helix angle 40 lead angle 40 measuring pitch diameter 43 measuring pitch diameter of metric screws 43 pitch diameter 43 thread angle 40 Three-wire measurement of screw threads 41–42 Throwaway carbide inserts 168 Titanium and titanium alloys speeds, for drilling, reaming, turning and milling 133 Titanium carbides as cutting tool materials 176 T-nuts, ANSI Standard 98 Tolerance grades, relative to machining processes 280, 305 Tolerances ANSI Standard 280 symbols 268, 293 cylindrical fits 279–305 designation of limits and fits 293 indicating on drawings 269 keys and keyways 160, 162 obtainable by various operations 280 preferred series of 280 relationship to surface roughness 278 symbols 268 taps 119 Tolerancing and geometric dimensioning 269 Tool compensation, NC 174 contour, cutting tools 167 grinding, angles 167–168 holders 170–171 indexable inserts 168–174 materials 176INDEX 335 Tool (continued) NC machines 53–54 nose radius compensation, NC 174 shanks, ANSI Standard for milling machines 52 sharpening carbide tools 226 grinding wheels 226–228 grinding wheels for 227–228 twist drills 108, 226 single-point 167–168 steels 243 air hardening 252 carbon 246 chromium types 250 classification of 243–246 faults and failures, common 185 hot work 250 mold 253 molybdenum types 249 oil hardening 252 selection of 247–248 shock resisting 253 special purpose 253 tungsten types 251 Tool life, adjusting factors 136 Tool steels speeds, for drilling, reaming, turning and milling 132 Tool trouble-shooting checklist 183 Tooling, carbide 176 Tooth rest position, milling cutter grinding 148 Torque, calculating, for tightening bolts 83 Triangle geometry of 6 Triangles solution 11 Trigonometric formulas 11 functions 11 functions of angles 11 identities 11 Trigonometric relations 10 Trouble-shooting broaching 166 tools 185 Tungsten steels 251 compositions 246 tool steels 251 Tungsten-carbide tools grinding 227–228 Tungsten-carbide tools grinding 226–228 Turning built up edge 181 chip hammering 181 crater wear 181 cutting speeds for copper alloys 135 ferrous cast metals 130 light metals 133 cutting speeds for plain carbon and alloy steels 128 Turning (continued) stainless steels 131 superalloys 134 titanium and titanium alloys 133 tool steels 132 flank and notch wear 181 frittering 181 grinding tools for 167–168 insert breakage 181 problems 181 problems causes 181 problems remedy 181 slice fracture 181 thermal crack 181 Turning, cutting speeds for copper alloys 135 Twist drill 109–114 equivalent of gage or letter size 110 grinding (sharpening) 108 U—Z Unified internal and external thread 58 Unified screw thread standard ANSI 56–59 Velocity converting to rpm 139–143 V-flange tool shanks and retention knobs 53–54 Vickers hardness 256 Vitrified bonded wheels 227 V-shaped groove, checking by pins 39 Weight metals 262–263 Weights and measures 306–312 Weights of carbon bar steel hexagonal shape 260–261 octagonal shape 260–261 round shape 260–261 square shape 260–261 Weights of various materials flat shape 259 hexagon shape 259 octagon shape 259 round shape 259 round tubing 259 square shape 259 Weights of various shapes aluminium 259 beryllium 259 brass 259 cast iron 259 copper 259 gold 259 lead 259 magnesium 259 molybdenum 259 monel 259 nickel 259 silver 259 steel 259 tantalum 259INDEX 336 Weights of various shapes (continued) tin 259 titanium 259 tungsten 259 zinc 259 zirconium 259 Weldon shanks, dimensions of 153 Wheels abrasive cutting 225 diamond 144, 193–228 grinding 144, 193–222 silicon carbide 226–227 Whitworth standard bolts, screws, nuts, washers, and studs 104 Wire checking screw threads 41 buttress threads 42 Woodruff key 161 number 161 seat 161 seat milling cutter 161 Woodruff keyseat cutters 156 Word address format, NC 188, 191 Word, NC 188, 191 Wrench clearances for box wrenches 99 for open end wrenches 100 for socket wrenches 100 for spacing of bolts 99–100 Wrench openings, ANSI Standard 9
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