Machinery's handbook pocket companion : a reference book for the mechanical engineer, designer, manufacturing engineer, draftsman, toolmaker, and machinist

352 Pages·2016·8.54 MB·English

by  Muhammed Iqbal

A REFERENCE BOOK
FOR THE MECHANICAL ENGINEER, DESIGNER,
MANUFACTURING ENGINEER, DRAFTSMAN,
TOOLMAKER, AND MACHINIST
Machinery’s
Handbook
Pocket
Companion
COMPILED AND EDITED BY RICHARD P. POHANISH
CHRISTOPHER J. MCCAULEY, SENIOR STAFF EDITOR
MUHAMMED IQBAL HUSSAIN, ASSOCIATE PROJECT EDITOR
INDUSTRIAL PRESS, INC.
INDUSTRIAL PRESS, INC.
32 Haviland Street, Suite 3
South Norwalk, CT 06854 U.S.A.
Tel: [phone], Toll-Free: 888-528-7852
Email: [email protected]
COPYRIGHT © 2000, 2008, 2016, by Industrial Press, Inc.
Library of Congress Cataloging-in-Publication Data
Machinery's handbook pocket companion/Richard P. Pohanish and Christopher J.
McCauley, editors.
p. cm.
ISBN 978-0-8311-3095-4
1. Mechanical engineering—Handbooks, manuals, etc. I. Pohanish, Richard P.
II. McCauley, Christopher J.
TJ151.M355 2000
621.8—dc21 00-039669
All rights reserved. This book or parts thereof may not be reproduced,
stored in a retrieval system, or transmitted in any form
without permission of the publishers.
Production Manager/Art Director: Janet Romano
Printed and bound in the United States of America
Machinery's Handbook Pocket Companion
Revised First Edition
1 2 3 4 5 6 7 8 9 10
http://industrialpress.com
http://ebooks.industrialpress.com
Foreword
This volume has been prepared for the many users of Machinery’s Handbook who indi-
cated the need for a smaller, more convenient reference that provides immediate applica-
tion of fundamental and reliable data used by practitioners and students of the machine
trades.
Machinery’s Handbook Pocket Companion is a tool designed to provide years of bench-
side use. With its visual presentation and detailed information, it can be used daily and
quickly to save time and labor. Parts of the presented material have been carefully selected
from current and former editions of Machinery’s Handbook. Some of the subject matter
has been reorganized, distilled, or simplified to increase the usefulness of this book with-
out adding to its bulk.
To obtain the full value of this small handbook, the user must have sufficient knowledge
about the subject to apply the tables, formulas, and other data, whenever they can be used
with efficiency. Machinery’s Handbook Pocket Companion makes little attempt to
explain the various subjects in any detail. The publisher assumes that users of this hand-
book are acquainted with information and procedures necessary for the safe operation and
manipulation of machines and tools. Readers who require in-depth information, back-
ground on manufacturing operations and theory should refer to Machinery’s Handbook.
Various people have leant their support and expertise to this work. Acknowledgments
and thanks are due to Ken Evans of Layton, Utah, and editors emeritus of Machinery’s
Handbook, Henry Ryffel and Robert Green, for manuscript review and many helpful sug-
gestions. The generous efforts of Alex Luchars and John Carleo of Industrial Press are
greatly appreciated.
ANSI Standards are copyrighted by the American National Standards Institute, West
42nd Street, New York, NY 10017, from whom current copies may be purchased. Many of
the American National Standards Institute (ANSI) Standards that deal with mechanical
engineering, extracts from which are included in the Handbook, are published by the
American Society of Mechanical Engineers (ASME), and we are grateful for their permis-
sion to quote extracts and to update the information contained in the Standards, based on
the revisions regularly carried out by the ASME. Information regarding current editions of
any of these Standards can be obtained from ASME International, Three Park Avenue,
New York, NY 10016.
Special acknowledgments are due to Carr-Lane Manufacturing Company, The Norton
Company, and Sandvik Coromant Company for permission to use their material and for
the business courtesies they extended to the editors.
Finally, thanks to all the individuals, associations, societies, educational institutions,
firms and their employees for providing invaluable technical information and illustration
material for this book
Anyone with suggestions for improving this book is requested to communicate in writing
with Industrial Press. Alternatively, the editors can be contacted through e-mail at
[email protected], or through its web site: www.industrialpress.com.
v
TABLE OF CONTENTS
MATHEMATICAL FORMULAS MEASUREMENT AND
AND TABLES INSPECTION
(Continued)
1 Areas and Dimensions of Figures 39 Checking a V– shaped Groove by
1 Circular Sector Measurement Over Pins
1 Circular Segment 40 Diameters of Wires for Measuring
1 Circular Ring Whitworth Screw Threads
2 Circular Ring Sector 41 Formulas for Checking Pitch
2 Spandrel or Fillet Diameters of Screw Threads
2 Ellipse 42 Three-Wire Method Applied to
3 Parabola Buttress Threads
3 Formulas for Polygons 43 Constants in Formulas for
4 Segments of Circles Measuring the Pitch Diameters
6 Geometrical Propositions
STANDARD TAPERS
10 Trigonometric Relationships
10 Signs of Trigonometric Functions
44 Morse Taper
11 Relationships Among Angles
44 Morse Standard Taper Shanks
11 Law of Sines
46 Dimensions of Morse Taper
11 Law of Cosines
Sleeves
13 Solution of Triangles
46 Jarno Taper
14 Solution of Right–Angle
47 Jarno Taper Shanks
Triangles
47 Brown & Sharpe Taper
15 Solution of Oblique–Angle
48 Brown & Sharpe Taper Shanks
Triangles
49 Spindle Noses for Milling
16 Tables of Trigonometric
Machines
Functions
51 Dimensions for Spindle Nose with
19 Formulas for Compound Angles
Large Flange
20 Length of Chords of Circles
52 Dimensions of Tool Shanks for
21 Coordinates for Locating Equally
Milling Machines
Spaced Holes
53 Dimensions of V-flange Tool
22 Decimal Equivalents, Squares,
Shanks
Cubes, Square Roots, Cube
54 Dimensions of V-flange Tool
Roots, and Logarithms
Shank Retention Knobs
24 Diameter, Circumference and
Area of Circles THREADS
MEASUREMENT AND 55 Thread Classes
INSPECTION 56 Sharp V-thread
58 Unified Internal and External
25 Sine Bars Screw Thread Design Profiles
26 Calculation Using Sine Bars 58 Fine-Thread Series
27 Measuring Tapers with Vee–block 59 Unified Screw Thread Series
and Sine Bar 71 Basic Dimensions, Taper Pipe
28 Constants for Setting Sine Bar Threads
35 Measurement of Angles and 73 Metric Screw Threads M Profile
Tapers 73 M Profile Definitions
35 Rules for Figuring Tapers 74 Formulas for Limiting
36 Tapers per Foot and Dimensions
Corresponding Angles 76 M Profile Data
38 Gage Block Sets - Inch Sizes 77 Internal Metric Thread
38 Measuring Dovetail Slides 79 External Metric Thread
vi
TABLE OF CONTENTS
FASTENER INFORMATION DRILLING AND REAMING
(Continued)
83 Grade Identification Marks 114 Counterboring
84 Applicability of Hexagon and 115 Length of Point on Twist Drills
Spline Keys and Bits 116 Solid Counterbores with Integral
85 Hexagon and Spline Socket Head Pilot
Cap Screws 116 Solid Carbide Square Boring
86 Socket Head Cap Screws Metric Tools
Series 117 Reamers
87 Hexagon and Spline Socket Set 117 Reamer Terms
Screws 118 Reamer Difficulties
88 Drill and Counterbore Sizes
TAPPING
89 Hexagon and Spline Socket Flat
Countersunk Head Cap Screws
119 Tap Terms
90 Slotted Flat Countersunk Head
120 Tap Dimensions, Inch and Metric
Cap Screws
121 Threading Formulas
91 Hardened Ground Machine Dowel
122 Tapping Specific Materials
Pins
125 Tap Drill Sizes for Threads
92 Hardened Ground Production
126 Tap Drills and Clearance Drills
Dowel Pins
126 Tap Drills for Pipe Taps
93 Chamfered and Square End
127 Tapping Drill Sizes for ISO
Straight Pins
Metric
93 Standard Straight Pins
127 Tap Drill or Core Hole Sizes
93 Standard Taper Pins
95 Parallel Steel Dowel Pins SPEEDS AND FEEDS
97 Spring Pins
128 Cutting Speeds for Plain Carbon
97 Slotted Type Spring Pins
and Alloy Steels
98 T-Nuts
130 Cutting Speeds for Ferrous Cast
99 Wrench Openings
Metals
100 Wrench Clearences
131 Cutting Speeds for Stainless
101 Bolts and Screws Specification
Steels
101 Primary Criteria
132 Cutting Speeds for Tool Steels
101 British Unified Machine Screws
133 Cutting Speeds for Light Metals
and Nuts
133 Cutting Speeds for Titanium
104 British Standard Whitworth and
Alloys
Fine Machine Screws
134 Cutting Speeds for Superalloys
CUTTING FLUIDS 135 Cutting Speeds for Copper Alloys
136 Adjustment Factors for Turning
106 Recommendations for Turning and
with HSS Tools
Milling
137 Feeds for Milling with HSS
107 Recommendations for Drilling and
Cutters
Tapping
139 RPM for Drills of Number and
Letter Sizes
DRILLING AND REAMING
140 RPM for Various Cutting Speeds
108 Generally Used Drill Point Angles and Diameters
109 US and Metric Size Commercial 144 Speeds and Feeds in Diamond
Drills Grinding
113 Drilling Difficulties 144 Speeds and Feeds for Drilling
113 Combined Drills and Holes in Plastics
Countersinks 144 Sawing Plastics Materials
vii
TABLE OF CONTENTS
MILLING CUTTERS BROACHING
145 Milling Cutter Terms 164 Pitch of Broach Teeth
145 End Mill Terms 165 Data for Surface Broaches
146 Sharpening Milling Cutters 165 Broaching Pressure
146 Grinding Wheels for Sharpening 166 Causes of Broaching Difficulties
Cutters
CUTTING TOOLS FOR TURNING
147 Wheel Speeds and Feeds for
Sharpening Milling Cutters
167 Cutting Tool Terms
147 Clearance Angles for Milling
168 Chipbreakers
Cutter Teeth
168 Chipbreakers
147 Rake Angles for Milling Cutters
168 Identification System for
148 Set-ups Used in Grinding
Indexable Inserts
Clearance Angle on Milling
170 Standard Shank Sizes for
Cutter Teeth
Indexable Insert Holders
149 Multiple- and Two-Flute Single-
171 Letter Symbols for Qualification
End Helical End Mills
of Tool Holders
150 Multiple-Flute Medium Helix
172 Numerical Control Tooling
Single-End End Mills
172 Insert Radius Compensation
151 Form Relieved Corner Rounding
175 Threading Tool Insert Radius
Cutters
Compensation
151 Two-Flute, High Helix Single-
175 Cemented Carbides
End End Mills with Weldon
176 Classifications of Hardmetals
Shanks
152 Two-Flute, Medium Helix, Plain- MACHINING OPERATIONS
and Ball-End, Single-End End
177 Machining Aluminum
Mills
178 Machining Magnesium
153 Three- and Four-Flute, Medium
179 Machining Zinc Alloy Die-
Helix, Center Cutting, Single-
Castings
End End Mills
179 Machining Monel and Nickel
154 60-Degree Single Angle Milling
Alloys
Cutters
180 Machining Copper Alloys
154 Key Size Versus Shaft Diameter
180 Machining Hard Rubber
155 Keys and Keyways for Milling
181 General Turning Practical Tips
Cutters
183 Tool Troubleshooting
156 Woodruff Keyseat Cutters
185 Common Tool Faults, Failures,
KEYS AND KEYSEATS and Cures
157 Depth Control Values for Shaft COMPUTER NUMERICAL
and Hub CONTROL
159 Fits for Parallel and Taper Keys
160 Plain and Gib Head Keys 188 Format Classification
161 Depth of Keyseat 189 G-Code Addresses
161 Woodruff Keys and Keyseats 191 Letter Addresses
162 Woodruff Keyseat Dimensions 192 Miscellaneous Functions
viii
TABLE OF CONTENTS
GRINDING WHEELS GRINDING WHEELS
(Continued)
193 Grinding Wheel Safety 227 Diamond Wheels, Grits and
193 Handling, Storage and Inspection Grades
193 Machine Conditions 227 Diamond Concentration
193 Grinding Wheel Mounting 228 Dry Versus Wet Grinding of
194 Safe Operating Speeds Carbide Tools
195 RPM of Various Grinding Speeds 228 Coolants for Carbide Tool
and Wheel Diameters Grinding
196 Portable Grinders 228 Peripheral Versus Flat Side
196 Maximum Peripheral Speeds for Grinding
Grinding Wheels 228 Lapping Carbide Tools
197 Principal System of Surface 229 Chip Breaker Grinding
Grinding Diagrams
GEARING
198 Periphery of Wheel
198 Face (Side) of Wheel
230 Gear Tooth Nomenclature
199 Recommendations for Surface
231 Gear Tooth Forms
Grinding
232 Formulas for Standard Spur Gears
200 Common Faults and Possible
233 Circular Pitch in Gears
Causes in Surface Grinding
235 Series of Involute, Finishing Gear
201 Grinding Wheel Markings
Milling Cutters
201 Sequence of Markings
236 Gear Design Based upon Module
201 Composition of Diamond and
System
Cubic Boron Nitride Wheels
236 Tooth Form for Spur and Bevel
202 Conventional Abrasives Grinding
Gears
Wheel Recommendations
237 Tooth Dimensions Based Upon
212 Shapes and Sizes of Grinding
Module System
Wheels
238 Module System of Gearing
212 Standard Shapes and Inch Size
239 Equivalent Diametral Pitches,
Ranges
Circular Pitches, and Metric
216 Standard Shapes and Metric Size
Modules
Ranges
240 Measurement of Gear Tooth
218 Standard Shapes of Grinding
240 Checking Spur Gear Size by
Wheel Faces
Chordal Measurement
219 Diamond Wheel Core Shapes and
241 Chordal Measurements over Spur
Designations
Gear Teeth
219 Diamond Wheel Cross-sections
242 Number of Teeth Included in
and Designations
Chordal Measurement
220 Designations for Location of
242 Formulas for Chordal Dimensions
Diamond Section
221 Designation Letters for Diamond PROPERTIES OF MATERIALS
Wheels
243 Standard Steel Classification
222 Wheel Type and Abrasive
243 Classification of Tool Steels
Specification
244 System of Designating Carbon
223 Standard Shapes and Inch Sizes of
and Alloy Steels
Mounted Wheels and Points
245 Classification,Compositions, and
225 Standard Shapes and Metric Sizes
Properties of Tool and Die
of Mounted Wheels and Points
Steels
226 Lapping Lubricants
247 Quick Reference Guide for Tool
226 Sharpening Carbide Tools
Steel Selection
227 Silicon Carbide Wheels
ix
TABLE OF CONTENTS
PROPERTIES OF MATERIALS ALLOWANCES AND
(Continued) TOLERANCES
249 Molybdenum High-Speed Steels
(Continued)
250 Hot Work Tool Steels 288 Transition Locational Fits
251 Tungsten High-Speed Tool Steel 289 Interference Locational Fits
252 Cold Work Tool Steels 290 Force and Shrink Fits
253 Shock Resisting, Mold Tool Steels 292 Preferred Metric Limits and Fits
254 Temperature of Steel as Indicated 293 Preferred Metric Sizes
by Color 293 Preferred Fits
256 Comparative Hardness Scales for 295 Terms for Preferred Fits
Steel 296 Preferred Hole Basis Metric
259 Weights of Various Metals and Clearance Fits
Shapes 298 Hole Basis Metric Transition and
262 Thermal Properties of Various Interference Fits
Metals 300 Preferred Shaft Basis Metric
264 Characteristics of Plastics Clearance Fits
265 Working With Plastics 302 Preferred Shaft Basis Metric
Transition and Interference Fits
STANDARDS FOR DRAWINGS
304 Gagemakers Tolerances
266 Shop Prints, Reading and 305 Relation of Machining Processes
Interpreting to IT Tolerance Grades
267 Symbols for Section Lining 305 Usage of IT Tolerance Grades
268 ANSI and ISO Symbols
CONVERSION FACTORS
269 Symbols for Datum Referencing
306 Metric Conversion Factors
SURFACE TEXTURE
312 Factors and Prefixes of SI Units
272 Surface Texture Symbols 313 Inch to Millimeter and Inch to
273 Roughness Sampling Length Centimeter
274 Roughness Average Values 314 Decimals of an Inch to
274 Waviness Height Values Millimeters
275 Lay Symbols 316 Millimeters to Inches
275 Example Designations 318 Fractional Inch to Millimeter and
276 Application of Symbols Foot to Millimeter
278 Surface Roughness Produced by 319 Thousandths of an Inch to
Common Production Methods Millimeters
320 Greek Letters and Standard
ALLOWANCES AND Abbreviations
TOLERANCES 320 Roman Numerals
320 Rounding off Numbers
279 Limits and Fits
320 Commonly Used Constants
279 Preferred Basic Sizes
321 Weights and Volumes
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
x