Machinery's Handbook Pocket Companion

377 Pages·2020·5.724 MB·English

by  Richard P. Pohanish, Christopher J. McCauley

Machinery’s Handbook Pocket Companion
A REFERENCE BOOK
FOR thE MANuFACtuRiNg ANd MEChANiCAl ENgiNEER,
dEsigNER, dRAFtER, MEtAlwORKER, tOOlMAKER,
MAChiNist, hOBByist, EduCAtOR, ANd studENt
Machinery’s
Handbook
Pocket
Companion
Second Edition
RiChARd P. POhANish ANd ChRistOPhER J. MCCAulEy
lAuRA BRENgElMAN, EditOR
iNdustRiAl PREss, iNC.
Copyright 2020, Industrial Press, Inc. ebooks.industrialpress.com
Machinery’s Handbook Pocket Companion
INDUSTRIAL PRESS, INC.
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South Norwalk, Connecticut 06854 U.S.A.
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Title: Machinery’s Handbook Pocket Companion, 2nd Edition
Authors and Compilers: Richard P. Pohanish and Christopher J. McCauley
Library of Congress Control Number: 2020931274
COPYRIGHT
© 2000, 2008, 2016, 2020 by Industrial Press, Inc.
ISBN PRINT: 978-0-8311-4431-9
ISBN ePDF: 978-0-8311-9567-0
ISBN ePub: 978-0-8311-9568-7
ISBN eMobi: 978-0-8311-9569-4
No part of this book may be reproduced or transmitted in any form or by any means,
electronic or mechanical, including photocopying, recording, or by any information
storage and retrieval system, without written permission from the publisher.
Limits of Liability and Disclaimer of Warranty
While every possible effort has been made to ensure the accuracy of all information
presented herein, the publisher expresses no guarantee of the same, does not offer any
warrant or guarantee that omissions or errors have not occurred, and may not be held
liable for any damages resulting from use of this text. Readers accept full responsibility
for their own safety and that of the equipment used in conjunction with this text.
Printed and bound in the United States of America
MACHINERY’S HANDBOOK
POCKET COMPANION
2ND EDITION
First Printing
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Machinery’s Handbook Pocket Companion
FOREWORD
Twenty years ago, the first edition of the Machinery’s Handbook Pocket Companion was
developed for users of the Machinery’s Handbookwhocouldbenefitbyhavingasmaller,
more convenient volume for bench- or desk-side quick reference. Containing key content
from the Machinery’s Handbook, it has evolved into a handy timesaver for anyone in man-
ufacturing,metalworking,andrelatedfieldsforwhomconvenientaccesstofundamental
and reliable data is essential. Over the years, the Pocket Companion has been perennially
popular with practitioners, educators, and students of the machine trades.
A tool designed to provide years of use, this book provides detailed information in a con-
cise package. The presented material has been carefully selected from current and former
editions of Machinery’s Handbook. Some of the subject matter has been reorganized, dis-
tilled,orsimplifiedtoincreasetheusefulnessofthisbookwithoutaddingtoitsbulk—though
this edition has grown, with replaced and extended material from the 31st edition and a new
list of useful online resources (see page345).
The intention has been to provide information of technical value where only a brief or no
introduction and essential data are needed to save time and labor. To obtain the full value of
thissmallhandbook,theusermusthavesufficientknowledgeaboutthesubjecttoapplythe
tables,formulas,andotherdatawheresuchinformationcanbeusedwithefficiency.The
Machinery’s Handbook Pocket Companion minimizes explanations of the various subjects,
based on the assumption that its users are acquainted with information and procedures nec-
essary for the safe operation and manipulation of machines and tools.
The Pocket Companion does not replace the Machinery’s Handbook, 31st Edition, but
instead serves as a handy and more portable distillation of just some of the Handbook’s
vastly larger collection of invaluable text, data, and standards. Readers who require in-depth
information, background on manufacturing operations, and theory should refer to discus-
sions in the 31st edition.
This book, like all of the Machinery’s Handbook product family, is the result of collabora-
tive efforts. Among those credited with the Pocket Companion becoming the valuable tool
it is today are authors and compilers Richard P. Pohanish and Christopher J. McCauley, as
well as Arief Era, John Carleo, Cara Chamberlain, Ken Evans, Robert Green, Steve Heather,
Jason Hughes, Kathy McKenzie, Gerald Murray, Julia Phelps, Henry Ryffel, Industrial
Press owner Alex Luchars, and the rest of the Machinery’s Handbook, 31st Editionteam.
Many of the American National Standards Institute (ANSI) standards that deal with
mechanical engineering, extracts from which are included in the Pocket Companion, are pub-
lished by the American Society of Mechanical Engineers (ASME). The editors thank ASME
for its exceptional collaboration in helping to identify and bring essential data up to date, in
both the Machinery’s Handbook, 31st Edition, and this companion volume, according to the
latest,definitiveindustrystandards.Informationconcerningotherstandardsandnomencla-
ture also is included in this book. Official standards and related publications are copyrighted
by the issuing organizations; contact them directly for further information regarding stan-
dards and to purchase copies. We also thank Carr-Lane Manufacturing, the Norton Company,
SandvikCoromant,andotherreferencedfirmsforpermissiontousetheirmaterial.
Finally, we wish to thank all of the associations, societies, companies, professionals, hob-
byists, scholars, educators, students, and other individuals who have provided invaluable
material and input for this book and the 31st edition.
We encourage readers with suggestions for improving or adding to the Pocket Compan-
ionto send us your thoughts and feedback. We also encourage you to share with us how
the Machinery’s Handbook product family supports and enhances your involvement in this
endlesslyfascinatingfield.
Laura Brengelman
Editor
xiii
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Machinery’s Handbook Pocket Companion
TTAABBLLEE OOFF CCOONNTTEENNTTSS
xiii FOREWORD MATHEMATICAL
FORMULAS AND TABLES
MATHEMATICAL
(Continued)
FORMULAS AND TABLES 27 Decimal Equivalents, Squares,
Cubes, Square Roots, Cube
1 Dimensions of Plane Figures
Roots, and Logarithms
1 Square
29 Diameter, Circumference, and
1 Rectangle Area of Circles
1 Parallelogram
MEASUREMENT
1 Triangle
AND INSPECTION
2 Trapezoid and Trapezium
3 Regular Hexagon and Octagon 30 Sine- Bar
3 Circle 31 Calculations Using Sine-B ars
4 Cycloid 32 Measuring Tapers with V-B lock
4 Circular Ring and Sine- Bar
5 Ellipse 32 Using a Calculator to Determine
5 Spandrel or Fillet Sine- Bar Constants
5 Parabola 33 Setting a Sine-B ar
6 Hyperbola 40 Measurement of Angles and
Tapers
6 Regular Polygons
40 Rules for Figuring Tapers
7 Segments of Circles
41 Tapers per Foot and
9 Diameters of Circles and Sides
Corresponding Angles
of Squares
43 Gage Block Sets— Inch Sizes
10 Propositions of Geometry
43 Measuring Dovetail Slides
15 Trigonometric Relationships and
44 Checking a V-S haped Groove by
Functions
Measurement Over Pins
16 Useful Relationships Among
45 Measuring American Standard
Angles
and British Whitworth Screw
16 Law of Sines Threads
16 Law of Cosines 45 Checking Pitch Diameters of
16 Trigonometric Functions and Screw Threads by Three-
Identities Wire Method
18 Solution of Triangles 47 Three- Wire Method Applied to
21 Trigonometry Tables Buttress Threads
24 Formulas for Compound 48 Measuring Pitch Diameters of
Angles Inch and Metric Screws
25 Length of Chords for Spacing Off STANDARD TAPERS
the Circumferences of Circles
26 Coordinates for Locating 49 Morse Taper
Equally-Spaced Holes 49 Morse Standard Taper Shanks
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Machinery’s Handbook Pocket Companion
TABLE OF CONTENTS
STANDARD TAPERS FASTENER INFORMATION
(Continued)
50 Morse Stub Taper Shanks 95 Grades and Mechanical Properties
51 Morse Taper Sleeves of Bolts and Screws
51 Jarno Taper 96 Hexagon and Spline Keys
52 Jarno Taper Shanks and Bits
52 Brown & Sharpe Taper 97 Hexagon and Spline Socket Head
53 Brown & Sharpe Taper Shanks Cap Screws
54 Spindle Noses for Milling 98 Socket Head Cap Screws—M etric
Machines Series
56 Spindle Nose with Large Flange 99 Hexagon and Spline Socket Set
57 Tool Shanks for Milling Screws
Machines 100 Drill and Counterbore Sizes for
58 V- Flange Tool Shanks Socket Head Cap Screws
59 V- Flange Tool Shank Retention 101 Drill and Counterbore Sizes for
Knobs Metric Socket Head Cap
Screws
THREADS 102 Hexagon and Spline Socket Flat
Countersunk Head Cap
60 Thread Classes
Screws
61 Sharp V- Thread
103 Slotted Flat Countersunk Head
63 Unified Internal and External
Cap Screws
Screw Thread Design
104 Hardened Ground Machine
Profiles
Dowel Pins
63 Fine- Thread Series
105 Hardened Ground Production
64 Unified Screw Threads—
Dowel Pins
Standard Series and Selected
106 Chamfered and Square End
Combinations
Straight Pins
73 Unified Screw Thread
106 Straight Pins
Calculations
82 Taper Pipe Threads 106 Taper Pins
84 Metric Screw Threads— 108 Parallel Steel Dowel Pins
M Profile 109 Spring Pins
85 M Profile Screw Thread Limiting 109 Slotted- Type Spring Pins
Dimensions 110 Coiled- Type Spring Pins
87 Metric Thread— M Profile Data 111 T- Nuts
88 M Profile Internal Metric Thread 112 Wrench Openings for Nuts
90 M Profile External Metric 112 Open- End Engineers Wrenches
Thread 113 Single and Double Hexagon
94 Metric Spark Plug Threads Socket Wrenches— Inch and
94 British Standard for Spark Plugs Metric
94 SAE Spark Plug Screw Threads 117 Box Wrenches— Inch and Metric
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Machinery’s Handbook Pocket Companion
TABLE OF CONTENTS
FASTENER INFORMATION TAPPING
(Continued) (Continued)
118 Bolts and Screws Specification 138 Tapping Specific Materials
118 British Unified Machine Screws 140 Tap Drill Sizes for Threads
and Nuts 142 Tap Drills and Clearance Drills for
121 British Whitworth and Fine Machine Screws
Machine Screws 142 Tap Drills for Pipe Taps
CUTTING FLUIDS 143 Tap Drill or Core Hole Sizes for
ISO Metric Threads
122 Recommendations for Machining,
SPEEDS AND FEEDS
Turning, and Milling
123 Recommendations for Drilling 144 Cutting Speeds for Plain Carbon
and Tapping and Alloy Steels
DRILLING AND REAMING 146 Cutting Speeds for Ferrous Cast
Metals
124 Generally Used Drill Point 147 Cutting Speeds for Stainless
Angles Steels
125 US and Metric Size Commercial 148 Cutting Speeds for Tool Steels
Drills 149 Cutting Speeds for Light Metals
129 Common Drilling Difficulties 149 Cutting Speeds for Titanium and
129 Combined Drills and Titanium Alloys
Countersinks— 150 Cutting Speeds for Superalloys
Plain and Bell Types
151 Cutting Speeds for Copper
130 Counterboring Alloys
130 Counterbores with 152 Adjustment Factors for Turning
Interchangeable Cutters and
with High-S peed Steel
Guides
Tools
131 Length of Point on Twist Drills
153 Feeds for Milling with High-
and Centering Tools
Speed Steel Cutters
132 Solid Counterbores with Integral
155 RPM for Drills of Number and
Pilot
Letter Sizes
132 Solid Carbide Square Boring
156 RPM for Various Cutting Speeds
Tools
and Diameters— Inch
133 Reamers
158 RPM for Various Cutting Speeds
134 Common Reamer Difficulties
and Diameters— Metric
TAPPING 160 Speeds and Feeds in Diamond
Grinding
135 Tap Terms and Designs 160 Speeds, Feeds, and Teeth for
136 Tap Dimensions, Inch and Metric Drilling and Sawing
137 General Threading Formulas Plastics
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Machinery’s Handbook Pocket Companion
TABLE OF CONTENTS
MILLING CUTTERS KEYS AND KEYSEATS
(Continued)
161 Milling Cutter Terms and Parts 177 Woodruff Keys and Keyseats
161 End Mill Terms and Parts 178 Keyseat Dimensions for
162 Wheels for Sharpening Milling Woodruff Keys
Cutters
BROACHING
163 Wheel Speeds and Feeds for
Sharpening Milling Cutters 180 Types of Broaches
163 Clearance Angles for Milling 180 Pitch of Broach Teeth
Cutter Teeth 181 Data for Designing Surface
163 Rake Angles for Milling Cutters Broaches
164 Set- Ups Used in Grinding 181 Broaching Pressure
Clearance Angle on Milling 182 Common Causes of Broaching
Cutter Teeth Difficulties
165 Multiple- and Two- Flute Single-
CUTTING TOOLS
End Helical End Mills
FOR TURNING
166 Multiple-F lute Medium Helix
Single- End End Mills 183 Single- Point Turning Tools
167 Form Relieved Corner Rounding 183 Chipbreakers
Cutters 184 Identification System for
167 Two- Flute, High Helix Single- Indexable Inserts
End End Mills 186 Standard Shank Sizes for
168 Two- Flute, Medium Helix, Plain- Indexable Insert Holders
and Ball- End, Single- End 187 Letter Symbols for Qualification
End Mills of Tool Holders
169 Three- and Four- Flute, Medium 188 Numerical Control Tooling
Helix, Center Cutting, 188 Insert- Radius Compensation
Single- End End Mills 191 Threading Tool Insert- Radius
170 60- Degree Single- Angle Milling Compensation
Cutters 191 Cemented Carbides
170 Key Size Versus Shaft Diameter 192 ISO Classifications of Hardmetals
171 Keys and Keyways for Milling
Cutters and Arbors MACHINING OPERATIONS
172 Woodruff Keyseat Cutters
193 Machining Aluminum
KEYS AND KEYSEATS 194 Machining Magnesium
195 Machining Zinc Alloy Die
173 Depth Control Values for Shaft Castings
and Hub 195 Machining Monel and Nickel
175 Fits for Parallel and Taper Keys Alloys
176 Plain and Gib Head Keys 196 Machining Copper Alloys
177 Depth of Keyseat 196 Machining Hard Rubber
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Machinery’s Handbook Pocket Companion
TABLE OF CONTENTS
MACHINING OPERATIONS GRINDING WHEELS
(Continued) (Continued)
197 Tool Troubleshooting and 218 Conventional Abrasives—
Practical Tips Grinding Wheel
199 Tool Troubleshooting Checklist Recommendations
201 Common Tool Faults, Failures, 228 Shapes and Sizes of Grinding
and Cures Wheels
COMPUTER NUMERICAL 228 Shapes and Inch Size Ranges
CONTROL 232 Shapes and Metric Size Ranges
234 Shapes of Grinding Wheel Faces
204 Format Classification
235 Diamond Wheel Core Shapes and
205 G- Code Addresses Designations
207 Letter Addresses
235 Diamond Wheel Cross Sections
208 Miscellaneous Function Words and Designations
GRINDING WHEELS 236 Location of Diamond Section on
Wheel
209 Grinding Wheel Safety 237 Letters for Diamond Wheel
209 Handling, Storage, and Inspection Modifications
209 Machine Conditions 238 Wheel Type Recommendations
209 Grinding Wheel Mounting and Abrasive Specification
210 Safe Operating Speeds 239 Standard Shapes and Inch Sizes
211 RPM for Various Grinding Speeds of Mounted Wheels and
and Wheel Diameters Points
212 Portable Grinders 241 Standard Shapes and Metric Sizes
212 Maximum Peripheral Speeds for of Mounted Wheels and
Grinding Wheels Points
213 Principal Systems of Surface 242 Lapping Lubricants
Grinding
242 Sharpening Carbide Tools
214 Periphery of Wheel
243 Silicon Carbide Wheels
214 Face (Side) of Wheel
243 Diamond Wheel Grits and
214 Wheel Recommendations for
Grades
Surface Grinding
243 Diamond Concentration
215 Data for Peripheral Surface
244 Dry versus Wet Grinding of
Grinding
Carbide Tools
216 Common Faults and Possible
Causes in Surface Grinding 244 Coolants for Carbide Tool
217 Grinding Wheel Markings Grinding
217 Sequence of Markings 244 Peripheral versus Flat Side
217 Composition of Diamond and Grinding
Cubic Boron Nitride 244 Lapping Carbide Tools
Wheels 245 Chipbreaker Grinding
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Machinery’s Handbook Pocket Companion
TABLE OF CONTENTS
GEARING PROPERTIES OF
MATERIALS
246 Gear Teeth Nomenclature and (Continued)
Comparative Size 263 Quick Reference Guide for Tool
247 Gear Tooth Forms Steel Selection
248 Formulas for Standard Spur Gears 265 Molybdenum High- Speed
249 Circular Pitch in Gears Steels
250 Chordal Thicknesses and 266 Hot- Work Tool Steels
Addenda of Gear Teeth and 267 Tungsten High- Speed Tool
Milling Cutters Steel
251 Series of Involute, Finishing Gear 268 Cold- Work Tool Steels
Milling Cutters 269 Shock- Resisting, Mold, and
252 Gear Design Based upon Module Special- Purpose Tool
System Steels
252 Tooth Form for Spur and Bevel 270 Phase Diagram of Carbon Steel
Gears 270 Temperature of Steel as Indicated
253 Tooth Dimensions Based Upon by Color
Module System 272 Comparative Hardness Scales
for Steel
254 Rules for Module System of
Gearing 275 Weights of Various Metals and
Shapes
255 Equivalent Diametral Pitches,
Circular Pitches, and Metric 277 Aluminum Alloy Properties and
Modules Designations
256 Caliper Measurement of Gear 278 Typical Thermal Properties of
Tooth Various Metals
280 Characteristics of Plastics
256 Checking Spur Gear Size by
Chordal Measurement 281 Working with Plastics
257 Chordal Dimensions over Spur STANDARDS FOR
Gear Teeth DRAWINGS
258 Number of Teeth Included in
Chordal Measurement 282 Shop Prints, Reading and
258 Formulas for Chordal Dimension Interpreting
283 Symbols for Section Lining
PROPERTIES OF
284 ASME Geometric Symbols
MATERIALS
285 ISO Geometric Symbols
259 Standard Steel Classification 286 Symbols for Datum Referencing
259 Classification of Tool Steels SURFACE TEXTURE
260 System of Designating Carbon
and Alloy Steels 289 Surface Texture Symbols
261 Classification, Compositions, 290 Applying Surface Texture
and Properties of Tool and Symbols
Die Steels 290 Roughness Sampling Length
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Machinery’s Handbook Pocket Companion
TABLE OF CONTENTS
SURFACE TEXTURE ALLOWANCES AND
(Continued) TOLERANCES
291 Roughness Average (Ra) Values (Continued)
291 Waviness Height Values 316 Preferred Hole Basis Metric
Clearance Fits
292 Lay Symbols
318 Hole Basis Metric Transition and
292 Example Designations
Interference Fits
294 Surface Characteristics
320 Preferred Shaft Basis Metric
295 Surface Roughness Produced Clearance Fits
by Common Production 322 Preferred Shaft Basis Metric
Methods Transition and Interference
Fits
CORROSION
324 Gagemakers Tolerances
296 Types of Corrosion 325 Relation of Machining Processes
296 Methods of Protection to IT Tolerance Grades
325 Usage of International Tolerance
297 Galvanic Compatibility of Metals
Grades
in Select Environments
298 Sample Galvanic Series CONVERSION FACTORS
298 Anodic Index
326 Metric Conversion Factors
ALLOWANCES AND 332 Factors and Prefixes of SI Units
TOLERANCES 333 Inch to Millimeter and Inch to
Centimeter
299 Limits and Fits 334 Decimals of an Inch to Millimeters
299 Preferred Basic Sizes 336 Millimeters to Inches
299 Tolerances and Allowances 338 Fractional Inch to Millimeter and
300 Standard Tolerances Feet to Millimeter
300 Relation of Machining Processes 339 Thousandths of an Inch to
to Tolerance Grades Millimeters
301 Designation of Standard Fits 340 Rounding Off Numbers
303 Graphical Representation of 340 Fundamental Constants
Limits and Fits 340 Function of π
304 Running and Sliding Fits 341 Functions of g and e
306 Clearance Locational Fits 341 Weights and Volumes
341 Roman Numerals
308 Transition Locational Fits
341 Greek Letters and Standard
309 Interference Locational Fits
Abbreviations
310 Force and Shrink Fits
342 Conversion Factors
312 Preferred Metric Limits and Fits
343 Temperature Conversion
313 Preferred Metric Sizes
313 Preferred Fits 345 USEFUL ONLINE RESOURCES
315 Description of Preferred Fits 349 INDEX
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