shop theory by anderson

564 Pages·2016·29.95 MB·English

James Anderson
Earl E. Tatro
LNVM(NEEMRANA)
654
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Tata McGraw-Hill Edition 1975
36th reprint 2006
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About the Authors
JAMES ANDERSON began his long career in the EARL E_ TATRO has taught machine shop practice
machine trades as an indentured apprentice in in the. New York City school system for many years,
London, England. In the years since, he has been most recently at the Alfred E. Smith High School.
involved in almost every phase of machine shop He has also taught mechanical technology at Bronx
activity. He has taught in the New York City public Community College. Mr. Tatro served his apprentice
schools since 1942, most recently as instructor of ship in the machine trades with the General Electric
Instrument Technology at Queens Vocational High Company and subsequently worked for more than a
School,_ New York. He is active in the field of decade as an all-around machinist and toolmaker.
machine shop education both in the public schools He has been active in industrial on-the-job training
and in industry, having served as director of machine programs, having served as assistant director of
shop and foreman training for the Kollsman Instru training for the Fairchild Camera and Instrument
ment Corporation, New York, and instructor of Corporation, New York. Mr. Tatro is a past president
machine shop theory for S & S Corrugated Paper of the Machine Shop Teachers Association of New
Machinery Company, New York. Mr. Anderson was York City and a member of its executive board. He
the president of the New York City Machine Shop is the author of two machine shop study guides
Teachers Association and chairman of its executive used by the United States Armed Forces Institute,
board. He is the coauthor (with Henry D. Burghardt the author of a number of training manuals used
and Aaron Axelrod) of Machine Tool . Operation widely in the machine trades, and the coauthor of the
(McGraw-Hill) and Machine Tool Operation, Work syllabus for machine shop practice published by
book and Tests (with Aaron Axelrod). the New York City Board of Education. iii
Preface
Technological advancement m practically every field teachers, and students. Thus, chapters on safety,
of endeavor is closely allied with precision machine band machining, grinding machine processes,
tools and man's ability to measure and produce surface finish, and the fundamentals of numerical
parts to accuracies within millionths of an inch. control were included in the fifth edition. The book
Research and development within the machine tool was received with enthusiasm and soon became a
industry has resulted in more precise machine tools, standard in its field. It has served the needs of high
superior cutting tool materials, and faster methods of schools, colleges, vocational and technical schools,
production. Yet the search for improved production technical .i nstitutes, industrial apprentice training
methods is a continuous and changing process. programs, and the United States Armed Forces
The text material for Shop Theory originated at the schools, as well as students in foreign countries and
Henry Ford Trade School, Dearborn, Michigan. It those who have wished to improve their knowledge
was developed by members of the teaching staff of the trade by home study.
who were journeymen mechanics-craftsmen as In the sixth edition we have again kept in mind the
well as educators. Their material, a collection of needs of the students and the men in the shop.
instruction sheets, was eventually developed into a Developments in industry brought requests for
book and made available to schools throughout the discussions of new and expanded topics that made
world. When preparing the previous edition of this necessary the writing of new chapters. ·
textbook, the authors carefully reviewed the many The chapter "Careers in Machine Shop" has been
advances that had been made in the machine trades added to point out the opportunities that e~ist in the
industry. Wherever feasible, chapters were expanded world of manufacturing for those mastering the
to include the latest developments in the particular skills of the machinist. No longer is the use of
areas. Much of the existing material was rewritten in intricate precision measuring instruments confined
order to bring it into a closer relationship with the to the laboratory. Metrology, the science of measure
most recent trade· practices. New chapters were ment, and the instruments used for the purpose of
1v written to meet the changing needs of industry, measuring minute dimensions have been brought
into the shop to be used by the men who acwa11y under the illustrations. The authors wish to express
make the product. The machinist who understands their thanks to the members of the Machine Shop
the methods and the . instruments that will be Teachers Association and the many instructors
used to check and inspect his work will make an around the world who have used Shop Theory and
extra effort and will take greater pride in the quality have offered suggestions, corrections, and en
of his workmanship. Any study of the machine trades couragement. For their expert advice and sug
must consider and develop an understanding of the gestions, special appreciation is extended to
metric system. The new chapter "Metric Measure Whitey Wade, Aldrich Div., Ingersoll-Rand Com
ment" provides a clear explanation of the units of pany; Harry Stuber, Ford Instrument Company;
measurement and their application to machining. W.C. Grindrod and Hans Pauw, Cincinnati Milacron;
With the development of new materials has come Joseph E. Kochhan, Brown & Sharpe Manufacturing
the need for special processes. "Special Machining Company; Fred J. Helgren and Louis F. Sokol, Metric
Processes," another new chapter, includes develop Association, Inc.; F. W. Cooper, Rank Precision
ments of well-known processes such as honing and Industries, England; James Smith and John Bart,
broaching, as well as important developments in S & S Corrugated Paper Machinery Company; F. H.
lasers, electrochemical and electrolytic grinding, and Clarkson, Jr., LS. Starrett Company; W. E. Wenger,
electric-discharge machining. Cleveland Twist Drill Company; and Robert L.
The authors are indebted to the numerous leading Wilke, professional photographer. This book is
manufacturers · who have provided many of the dedicated to Mem Anderson, whose culinary skills
photographs and drawings used in the book. We did much toward sustaining the authors during the
take this opportunity to express our appreciation for preparation of the sixth edition.
thei.r cooperation and assistance. Their names appear
James Anderson
Earl E. Tatrc
V
Contents
Careers in Machine-Shop
2 Safety in the Machine Shop 17
3 Hand Tools for Bench Work 38
4 Basic Measuring and layout Tools 70
5 Metro logy 93
6 Metric Measurement 129
7 Drills and Drilling Processes 143
8 Engine Lathe Processes 171
9 Turret Lathes 225
10 Tapers and Angles 243
1 l Screw Thread Processes 254
12 Band Machining 277
1 '.\ Shaper and Planer Processes 301
14 Milling Machine Processes 329
15 Grinding Machine Processes 377
16 Gears and Gearing 436
1 7 Fundamentals of Numerical Control 457
1 R Special Machining Processes 485
1 ° Surface Finish and Surface Measurement 505
2n Heat-treatment and Testing of Metals 516
'\pperidix 537
Useful Data and Tables 538
Supplementary References 560,
vi 561
HOP
. THEO

OPPORTUNITIES IN THE
MACHINE TRADES
The tools, the machines, and the skilled workers in
the machine trades have played a most important
part in every step that man has taken as he ha~
traveled from medieval times to the space age.
C
Everything from the kitchen utensil to the most com
plicated instrument in a space capsule owes its
existence to the skillful use of a machine tool.
Machine twls and their operators are required in
the development and manufacture of almost every
thing used in our present-day lives. Machines are
used in the manufacture of newspapers, books,
washing machines, automobiles, airplanes, type
writers, telephones, radios, television sets, and many,
many more of our everyday conveniences. Machines
are used to dig foundations and to build houses,
factories, colossal office buildings, and the furnish
ings within them. All of these machines are made by
a special family of machines-rr\achine tools. In
· that family can be found lathes, milling machines,
drilling machines, shaping and planing machines,
grinding and polishing machines, gear-cutting
machines, and many more with specialized purposes.
All of these machine tools are operated by men
and women with specialized skills. The one impor
tant common skill that these operators must have is
an understanding of measurement because precision
and accuracy are the most impartant characteristics
of their work. The tools with which they measure
their work are graduated to one ten-thousandth
(0.0001) of an inch, and the finished machined sur
faces :nust meet a required smoothness measured in
millionths of an inch. Such accuracy is· necessary
not only for the effective functioning of the part
within a specific machine, but also if the part is to
be interchangeable in any one of thousands of
similar machines.
TYPES OF SHOPS
There arc many divisions in the machine trades.
There are divisions in .the grouping of machines,
divisions in the skills required of machine operators,
and divisions in the types of shops wnere the work
is done. These shops can be divided into three
groups: job shops, limited production shops, and
mass-production shops.
1. What is a job shop?
A job shop is a machine shop that is equipped with
machines and workers that can undertake a wide
range of machining jobs of limited quantity and
usually of a very specialized nature (Fig. 1-1 ). (In
this case, the word "job" refers to the product that
has to be made and not to the fact that the worker is
employ~d.) A job shop may be called upon to de
velop the prototype of an raea thought upby a design
engineer or an inventor. It may be employed to
make a single piece or a dozen or a hundred pieces
in a standard or a special shape. Job shops are often
used to repair machinery for manufacturers who do
not have a mechanical maintenance department.
Speed is frequently an important factor in work of Fig. 1-1. A typical job shop. (Tris Manufacturing
this kind, and overtime work is often necessary to Corp.)
complete a job on schedule.
The machine tools used in a job shop must be 2. Wh;:it is a limited production shop?
adaptable to a wide variety of work; they must A limited production shop falls between a job shop
also be rugged and reliable. and a mass production shop (Fig. 1-2). It specializes
in producing identical parts in limited quantities
fig. 1-2. An example of a limited production shop.
(Warren Pumps Inc. and the Wi!king Studio.)