Machinery's Handbook, 28th edition, with additional material on CD

Front Matter......Page 2
Rope Splicing......Page 0
Preface......Page 4
Table of Contents......Page 6
Mathematics......Page 8
Fractional and Decimal Inch to Millimeter, Exact Values......Page 10
Positive and Negative Numbers......Page 11
Ratio and Proportion......Page 12
Percentage......Page 14
Reciprocals......Page 15
Dividing Fractions and Mixed Numbers......Page 16
Decimal Fractions......Page 17
Continued Fractions......Page 18
Conjugate Fractions......Page 19
Using Continued Fraction Convergents as Conjugates......Page 20
Powers of Ten Notation......Page 21
Multiplying Numbers Written in Powers of Ten Notation......Page 22
Dividing Numbers Written in Powers of Ten Notation......Page 23
Operations on Complex Numbers......Page 24
Combinations......Page 25
Prime Numbers and Factors of Numbers......Page 26
Rearrangement and Transposition of Terms in Formulas......Page 36
Principal Algebraic Expressions and Formulas......Page 37
Solution of Quadratic Equations with One Unknown......Page 38
Factoring a Quadratic Expression......Page 39
Solving Numerical Equations Having One Unknown......Page 40
Derivatives and Integrals of Functions......Page 41
Geometrical Progression......Page 43
Straight Line......Page 46
Coordinate Systems......Page 49
Circle......Page 52
Ellipse......Page 54
Spheres......Page 57
Hyperbola......Page 60
Pappus or Guldinus Rules......Page 72
Area of Plane Surfaces of Irregular Outline......Page 73
Find the Contents of Cylindrical Tanks at Different Levels......Page 74
Areas and Dimensions of Plane Figures......Page 76
Formulas and Table for Regular Polygons......Page 82
Circular Segments......Page 83
Segments of Circles for Radius = 1......Page 84
Distance across Corners of Squares and Hexagons......Page 87
Volumes of Solids......Page 88
Diameter of Circle Enclosing a Given Number of Smaller Circles......Page 94
Circles within Rectangles......Page 99
Rollers on a Shaft......Page 100
Functions of Angles......Page 101
Trigonometric Identities......Page 102
Solution of Oblique-Angled Triangles......Page 107
Conversion Tables of Angular Measure......Page 109
Graphic Illustrations of the Functions of Angles......Page 111
Tables of Trigonometric Functions......Page 112
Involute Functions......Page 116
Right-Angle Spherical Trigonometry......Page 121
Oblique-Angle Spherical Trigonometry......Page 123
Compound Angles......Page 125
Interpolation......Page 127
Common Logarithms......Page 128
Finding a Number Whose Logarithm is Given......Page 129
Obtaining the Powers of Numbers......Page 130
Extracting Roots by Logarithms......Page 131
Table of Logarithms......Page 132
Matrix Multiplication......Page 136
Determinant of a Square Matrix......Page 137
Adjoint of a Matrix......Page 138
Simultaneous Equations......Page 139
Compound Interest......Page 142
Nominal vs. Effective Interest Rates......Page 143
Annuities......Page 144
Cash Flow Diagrams......Page 145
Statutory Depreciation System......Page 147
Net Present Value......Page 148
Capitalized Cost......Page 149
Equivalent Uniform Annual Cost......Page 150
Break-Even Analysis......Page 151
Overhead Expenses......Page 154
Statistical Analysis......Page 155
Comparing Products with Respect to Average Performance......Page 157
Machinability and Hardness......Page 160
Mechanics and Strength of Materials......Page 161
Definitions......Page 163
The Use of the Metric SI System in Mechanics Calculations......Page 164
Graphical Representation of Forces......Page 167
Couples......Page 169
Algebraic Composition and Resolution of Force Systems......Page 170
Influence of Friction on the Efficiency of Small Machine Elements......Page 179
Coefficients of Friction......Page 180
Mechanisms......Page 181
Toggle Joint......Page 186
Pendulum Formulas......Page 187
Harmonic......Page 188
Linear Motion with Constant Acceleration......Page 189
Angular Velocity of Rotating Bodies......Page 190
Rotary Motion with Constant Acceleration......Page 191
Accelerations Resulting from Unbalanced Forces......Page 193
Energy......Page 195
Relation between Work and Energy......Page 196
Force of a Blow......Page 197
Impulse and Momentum......Page 198
Formulas for Work and Power......Page 200
Centrifugal Force......Page 201
Centrifugal Casting......Page 202
Formulas for Critical Speeds......Page 205
Mechanical Properties of Materials......Page 207
Fatigue Properties......Page 209
The Influence of Mean Stress on Fatigue......Page 210
Modes of Fatigue Failure......Page 211
Working Stress......Page 212
Stress Concentration Factors......Page 213
Simple Stresses......Page 217
Deflections......Page 218
Tables of Combined Stresses......Page 219
Three-Dimensional Stress......Page 223
Sample Calculations......Page 225
Stresses and Deflections in a Loaded Ring......Page 227
Strength of Taper Pins......Page 228
Center of Gravity......Page 229
Center of Gravity of Figures of Any Outline......Page 235
Radius of Gyration......Page 236
Center of Percussion......Page 239
Moment of Inertia......Page 240
Moment of Inertia of Built-up Sections......Page 241
Formulas for Moments of Inertia, Section Moduli, etc......Page 242
Mass Moments of Inertia, J_M......Page 252
Moments of Inertia and Section Moduli for Rectangles and Round Shafts......Page 257
Stresses and Deflections in Beams......Page 264
Deflection of Beam Uniformly Loaded for Part of its Length......Page 276
Beams of Uniform Strength Throughout Their Length......Page 278
Deflection as a Limiting Factor in Beam Design......Page 281
Curved Beams......Page 282
American Railway Engineering Association Formulas......Page 285
Stresses in Beams Produced by Shocks......Page 286
Stresses in Helical Springs Produced by Shocks......Page 287
Fatigue Stresses......Page 288
Formulas of American Railway Engineering Association......Page 289
Machine Elements Subjected to Compressive Loads......Page 290
American Institute of Steel Construction......Page 293
Plates, Shells, and Cylinders......Page 296
Torsional Strength of Shafting......Page 303
Torsional Strength of Shafting, Calculations in Metric SI Units......Page 304
Torsional Deflection of Circular Shafts......Page 305
Linear Deflection of Shafting......Page 306
Design of Transmission Shafting......Page 307
Formula for Shafts of Brittle Materials......Page 309
Shaft Couplings......Page 310
Comparison of Hollow and Solid Shafting with Same Outside Diameter......Page 311
Notation......Page 312
High-Carbon Spring Steels in Flat Strip Form......Page 313
Stainless Spring Steels......Page 314
Copper-Base Spring Alloys......Page 315
Nickel-Base Spring Alloys with Constant Moduli of Elasticity......Page 316
Allowable Working Stresses for Springs......Page 317
Endurance Limit for Spring Materials......Page 322
Working Stresses at Elevated Temperatures......Page 323
Helical Compression Spring Design......Page 324
Table of Spring Characteristics......Page 328
Extension Springs......Page 333
Extension Spring Design......Page 335
Tolerances for Compression and Extension Springs......Page 337
Torsion Spring Design......Page 339
Torsion Spring Design Recommendations......Page 345
Table of Torsion Spring Characteristics......Page 346
Torsion Spring Tolerances......Page 351
Miscellaneous Springs......Page 352
General Heat Treating Information for Springs......Page 353
Spring Failure......Page 356
Disc Spring Group Classification......Page 358
Disc Spring Materials......Page 359
Stacking of Disc Springs......Page 360
Force Generated by Disc Springs without Contact Surfaces......Page 362
Disc Spring Functional Stresses......Page 365
Fatigue Life of Disc Springs......Page 366
Example Applications of Disc Springs......Page 369
Viscosity......Page 373
Pressure......Page 374
Pressure on Inclined Plane Surfaces......Page 375
Forces on Curved and Compound Surfaces......Page 376
Properties, Treatment, and Testing of Materials......Page 377
The Elements - Symbols, Atomic Numbers and Weights, Melting Points......Page 379
Specific Heat......Page 380
Heat Loss from Uncovered Steam Pipes......Page 381
Ignition Temperatures......Page 384
Change in Radius of Thin Circular Ring with Temperature......Page 386
Specific Gravity of Liquids......Page 388
How to Estimate the Weight of Natural Piles......Page 390
Mol......Page 391
Mechanical Properties of Wood......Page 392
Effect of Pressure Treatment on Mechanical Properties of Wood......Page 393
Machinability of Wood......Page 394
Effect of Temperature on Strength and Elasticity of Metals......Page 402
Standard Steel Classification......Page 403
Numbering Systems for Metals and Alloys......Page 405
Damascus Steel......Page 406
Thermal Treatments of Steel......Page 414
Applications......Page 415
Carbon Steels......Page 417
Carburizing Grades of Alloy Steels......Page 420
Directly Hardenable Grades of Alloy Steels......Page 421
Characteristics and Typical Applications of Standard Stainless Steels......Page 422
Chromium-Nickel Austenitic Steels......Page 425
Stainless Chromium Irons and Steels......Page 426
High-Strength, Low-Alloy Steels......Page 427
Typical Mechanical Properties of Steel......Page 429
The Properties of Tool Steels......Page 440
Common Tool Faults and Failures......Page 443
The Effect of Alloying Elements on Tool Steel Properties......Page 444
Classification of Tool Steels......Page 446
The Selection of Tool Steels for Particular Applications......Page 452
Molybdenum-Type High-Speed Tool Steels......Page 453
Tungsten-Type High-Speed Tool Steels......Page 455
Hot-Work Tool Steels, Chromium Types......Page 456
Hot-Work Tool Steels, Molybdenum Types......Page 458
Cold-Work Tool Steels, Oil-Hardening Types......Page 459
Shock-Resisting, Mold, and Special-Purpose Tool Steels......Page 460
Mold Steels......Page 462
Water-Hardening Tool Steels......Page 464
Mill Production Forms of Tool Steels......Page 466
Advances in Tool Steel Making Technology......Page 467
Heat-Treating Definitions......Page 468
Hardness and Hardenability......Page 472
Surface Hardening Treatment (Case Hardening)......Page 474
Effect of Heating Fully Annealed Carbon Steel......Page 475
Effect of Rapid Cooling or Quenching on Carbon Steel......Page 476
Steel Heat-Treating Furnaces......Page 477
Basic Steps in Hardening......Page 478
Critical Points of Decalescence and Recalescence......Page 479
Hardening Temperatures for Carbon Tool Steels......Page 480
The Lead Bath......Page 481
Hardening or Quenching Baths......Page 482
Quenching in Molten Salt Bath......Page 483
Interrupted Quenching......Page 484
Tempering......Page 486
Tempering Temperatures......Page 487
To Prevent Lead from Sticking to Steel......Page 488
Annealing, Spheroidizing, and Normalizing......Page 489
Spheroidizing Practice......Page 490
Use of Carbonaceous Mixtures......Page 491
Ion Nitriding......Page 492
To Clean Work after Case Hardening......Page 493
Induction Hardening......Page 494
Through Hardening, Annealing, and Normalizing by Induction......Page 495
Induction Hardening of Gear Teeth......Page 496
Metallography......Page 499
Hardening of Tungsten High-Speed Steel......Page 503
Tempering or Drawing Tungsten High-Speed Steel......Page 505
Hardening Molybdenum High-Speed Steels......Page 506
Protective Coatings for Molybdenum Steels......Page 507
Equipment for Hardening High-Speed Steel......Page 508
Changes Resulting from Subzero Treatment......Page 509
Stabilizing Dimensions of Close-Fitting Machine Parts......Page 510
Order of Cooling and Tempering Periods for High-Speed Steel......Page 511
Brinell Hardness Test......Page 512
Vickers Hardness Test......Page 513
Comparison of Hardness Scales......Page 514
Durometer Tests......Page 516
Strength Data for Nonferrous Metals......Page 519
Cast Copper Alloys......Page 520
Wrought Copper Alloys......Page 525
Copper-Beryllium Alloys......Page 534
Characteristics of Aluminum and Aluminum Alloys......Page 536
Temper Designations for Aluminum Alloys......Page 537
Aluminum Alloy Designation Systems......Page 540
Heat-Treatability of Wrought Aluminum Alloys......Page 548
Characteristics of Principal Aluminum Alloy Series Groups......Page 549
Type Metal......Page 550
Alloy and Temper Designation......Page 551
Titanium and Titanium Alloys......Page 554
Properties of Plastics......Page 557
Thermoplastic Structures......Page 558
Cellular Plastics......Page 559
Application and Physical Properties......Page 560
The Basics of Stress and Strain in Plastics......Page 565
Other Measures of Strength and Modulus......Page 572
Time-Related Mechanical Properties......Page 573
Thermal Properties......Page 576
Effect of Temperature on Mechanical Properties......Page 577
Electrical Properties......Page 578
End-Use Environmental Considerations......Page 580
Structural Analysis......Page 581
Thermal Stresses......Page 584
Manufacture of Plastics Products......Page 585
Processing of Thermosets......Page 587
Reinforced Plastics......Page 589
Injection Molding......Page 590
Design for Injection Molding......Page 591
Stresses and Deflections in Load-Bearing Parts......Page 594
Melt Flow in the Mold......Page 598
Design for Assembly......Page 599
Assembly with Fasteners......Page 603
Machining Plastics......Page 604
Development of Plastics Prototypes......Page 609
Plastics Gearing......Page 610
Bakelite......Page 613
Dimensioning, Gaging, and Measuring......Page 614
Line Conventions and Drawings......Page 615
Geometric Dimensioning and Tolerancing......Page 619
Definitions......Page 621
Datum Referencing......Page 625
Positional Tolerance......Page 626
GD&T and CAD Models......Page 629
Digital Product Definition Data Practices Terms......Page 630
Design Parameters......Page 631
ANSI and ISO Drawing Checklists......Page 632
Unilateral and Bilateral Tolerances......Page 634
Locating Tolerance Dimensions......Page 635
Allowance for Given Pressure......Page 636
Allowances for Shrinkage Fits......Page 637
Temperatures for Shrinkage Fits......Page 638
Definitions......Page 640
ANSI Standard Fits......Page 641
Description of Fits......Page 644
Modified Standard Fits......Page 645
Definitions......Page 654
Tolerances Designation......Page 655
Preferred Metric Fits......Page 656
British Standard for Metric ISO Limits and Fits......Page 668
Calculated Limits of Tolerance......Page 669
American National Standard for Preferred Numbers......Page 678
British Standard Preferred Numbers and Preferred Sizes......Page 679
Preferred Sizes for Flat Metal Products......Page 680
Reading a Vernier......Page 681
Dual Metric-Inch Vernier......Page 682
Reading a Micrometer......Page 683
Types of Sine-Bars......Page 684
Measuring Angle of Templet or Gage with Sine-Bar......Page 685
Using a Calculator to Determine Sine-Bar Constants for a Given Angle......Page 686
Dimensioning Tapers......Page 687
Constants for 100-Millimeter Sine-Bar......Page 695
Measuring Dovetail Slides......Page 702
To Find Taper T Measured at Right Angles to a Line through the Disk Centers Given Dimensions D, d, and Distance C......Page 704
To Find Diameter D of a Large Disk in Contact with a Small Disk of Diameter d Given Angle alpha......Page 705
Checking a V-Shaped Groove by Measurement over Pins......Page 706
Checking Radius of Arc by Measurement over Rolls......Page 707
Checking for Various Shaft Conditions......Page 708
Out-of-Roundness - Lobing......Page 710
Measuring by Light-Wave Interference Bands......Page 712
Gage Block Sets, Inch Sizes (Federal Specification GGG-G-15C)......Page 713
Determining Hole Coordinates......Page 714
Definitions of Terms Relating to the Surfaces of Solid Materials......Page 716
Definitions of Terms Relating to the Measurement of Surface Texture......Page 718
Sampling Lengths......Page 719
Roughness Parameters......Page 720
Relation of Surface Roughness to Tolerances......Page 721
Instrumentation for Surface Texture Measurement......Page 722
Drawing Practices for Surface Texture Symbols......Page 723
Surface Texture Symbol......Page 724
Applying Surface Texture Symbols......Page 725
Metric Dimensions on Drawings......Page 727
ISO Surface Finish (ISO 1302)......Page 730
Graphic Symbology Textural Descriptions......Page 731
Rules for Comparing Measured Values to Specified Limits......Page 733
Tooling and Toolmaking......Page 737
Terms and Definitions......Page 740
Relief Angles......Page 743
Rake Angles......Page 744
Nose Radius......Page 745
Chipbreakers......Page 746
Introduction......Page 747
Identification System for Indexable Inserts......Page 748
Indexable Insert Tool Holders......Page 749
Identification System for Indexable Insert Holders......Page 750
Selecting Indexable Insert Holders......Page 752
Single-Point, Sintered-Carbide-Tipped Tools......Page 755
Brazing Carbide Tips to Steel Shanks......Page 759
Carbide Tools......Page 762
Indexable Insert Holders for NC......Page 764
Carbides and Carbonitrides......Page 768
Ceramics......Page 773
Superhard Materials......Page 776
Hardmetal Tooling for Wood and Nonmetallics......Page 778
Forming Tools......Page 779
Number of Teeth in Milling Cutters......Page 791
Explanation of the "Hand" of Milling Cutters......Page 792
Setting Angles for Milling Straight Teeth of Uniform Land Width in End Mills, Angular Cutters, and Taper Reamers......Page 816
Wheels for Sharpening Milling Cutters......Page 819
Clearance Angles for Milling Cutter Teeth......Page 820
Eccentric Type Radial Relief......Page 821
Indicator Drop Method of Checking Relief and Rake Angles......Page 824
Relieving Attachments......Page 825
Distance to Set Tooth Rest below Cutter Center When Cup Wheel is Used......Page 826
Reamers......Page 827
Twist Drills and Counterbores......Page 849
Types and Styles of Taps......Page 887
Standard System of Tap Thread Limits and Identification for Unified Inch Screw Threads, Ground Thread......Page 889
Standard System of Ground Thread Tap Limits and Identification for Metric Screw Threads, M Profile......Page 894
Definitions of Tap Terms......Page 895
Entry Taper Length......Page 903
Drill Hole Sizes for Acme Threads......Page 927
Collapsible Taps......Page 930
Brown & Sharpe Taper......Page 931
American National Standard Machine Tapers......Page 932
British Standard Tapers......Page 939
Tapers for Machine Tool Spindles......Page 942
Usual Chuck Capacities for Different Thread Sizes......Page 944
V-Flange Tool Shanks and Retention Knobs......Page 950
R8 Collet......Page 951
Straight Grinding Wheel Spindles for Portable Tools......Page 955
Mounted Wheels and Mounted Points......Page 959
Types of Broaches......Page 962
Pitch of Broach Teeth......Page 963
Depth of Cut per Tooth......Page 965
Chip Breakers......Page 966
Ball-Broaching......Page 967
Broaching Difficulties......Page 968
Definitions of File Terms......Page 969
Classes of Files......Page 970
Effectiveness of Rotary Files and Burs......Page 972
Steel Wool......Page 973
Tool Wear and Sharpening......Page 974
Machining Operations......Page 982
Cutting Tool Materials......Page 986
Cutting Speed, Feed, Depth of Cut, Tool Wear, and Tool Life......Page 990
Selecting Cutting Conditions......Page 991
Cutting Speed Formulas......Page 993
Introduction to the Feed and Speed Tables......Page 999
Speed and Feed Tables for Turning......Page 1003
Speed and Feed Tables for Milling......Page 1017
Slit Milling......Page 1020
Using the Feed and Speed Tables for Drilling, Reaming, and Threading......Page 1037
Using the Feed and Speed Tables for Tapping and Threading......Page 1049
Cutting Speed for Broaching......Page 1051
Spade Drill Geometry......Page 1052
Spade Drilling......Page 1054
Power Consumption and Thrust for Spade Drilling......Page 1057
Trepanning......Page 1058
Estimating Speeds and Machining Power......Page 1059
Equivalent Chip Thickness (ECT)......Page 1070
Tool-Life Relationships......Page 1071
Taylor's Equation......Page 1072
The Generalized Taylor Equation......Page 1073
The Colding Tool-Life Relationship......Page 1074
The G- and H-Curves......Page 1075
The V-ECT-T Graph and the Tool-Life Envelope......Page 1076
Cutting Forces and Chip Flow Angle......Page 1077
Forces and Tool-Life......Page 1079
Surface Finish R_a and Tool-Life......Page 1081
Shape of Tool-Life Relationships for Turning, Milling, Drilling and Grinding Operations - Overview......Page 1083
Minimum Cost......Page 1084
The Cost Function......Page 1085
Global Optimum......Page 1086
Optimization Models, Economic Tool-Life When Feed is Constant......Page 1087
Global Optimum, Graphical Method......Page 1088
Global Optimum, Mathematical Method......Page 1089
Determination of Machine Settings and Calculation of Costs......Page 1090
Formulas Valid for All Operation Types Including Grinding......Page 1091
Calculation of Cost of Cutting and Grinding Operations......Page 1092
Variation of Tooling and Total Cost with the Selection of Feeds and Speeds......Page 1095
Selection of Optimized Data......Page 1096
High-Speed Machining - No Mystery......Page 1099
Chip Geometry in End and Face Milling......Page 1101
Formulas......Page 1102
Physics behind hm and ECT, Forces and Tool-Life (T)......Page 1104
Feed Rate and Tool-Life in High-Speed Milling, Effect of ECT and Number of Teeth......Page 1105
Process Econometrics Comparison of High-Speed and Slot End Milling......Page 1106
Screw Machine Feeds and Speeds......Page 1108
Cutting Rates for Band Saws......Page 1117
Band Saw Blade Break-in......Page 1119
Cutting Fluids for Machining......Page 1120
Water-Miscible Fluids......Page 1121
Selection of Cutting Fluids for Different Materials and Operations......Page 1122
Cutting Fluids for Turning, Milling, Drilling and Tapping......Page 1123
Cutting Fluids for Machining Magnesium......Page 1125
Occupational Exposures to Metal Working Fluids (MWFs)......Page 1126
Fluid Selection, Use, and Application......Page 1127
Fluid Maintenance......Page 1128
Machining Aluminum......Page 1130
Machining Magnesium......Page 1131
Machining Monel and Nickel Alloys......Page 1132
Formica Machining......Page 1133
Ultrasonic Machining......Page 1134
Wheel Life T and Grinding Ratio......Page 1135
ECT in Grinding......Page 1136
Wheel Life Relationships and Optimum Grinding Data......Page 1137
Surface Finish, Ra......Page 1139
Spark-out Time......Page 1140
Grinding Cutting Forces, Torque and Power......Page 1141
Grinding Data Selection Including Wheel Life......Page 1142
Side Feed, Roughing and Finishing......Page 1143
Relative Grindability......Page 1144
Procedure to Determine Data......Page 1145
User Calibration of Recommendations......Page 1151
Optimization......Page 1153
Abrasive Materials......Page 1154
Grinding Wheel Structure......Page 1155
Sequence of Markings......Page 1156
The Selection of Grinding Wheels......Page 1157
Variations from General Grinding Wheel Recommendations......Page 1172
Dressing and Truing Grinding Wheels......Page 1173
Guidelines for Dressing and Truing with Single-Point Diamonds......Page 1175
Size Selection Guide for Single-Point Truing Diamonds......Page 1177
Shapes of Diamond Wheels......Page 1178
Composition of Diamond and Cubic Boron Nitride Wheels......Page 1181
The Selection of Diamond Wheels......Page 1183
Safety in Operating Grinding Wheels......Page 1184
Grinding Wheel Mounting......Page 1185
Safe Operating Speeds......Page 1186
Portable Grinders......Page 1187
Work Holding on Cylindrical Grinding Machines......Page 1189
Selection of Grinding Wheels for Cylindrical Grinding......Page 1190
Operational Data for Cylindrical Grinding......Page 1191
High-Speed Cylindrical Grinding......Page 1192
Cylindrical Grinding Troubles and Their Correction......Page 1193
Centerless Grinding......Page 1197
Centerless Grinding Troubles......Page 1198
Advantages of Surface Grinding......Page 1199
Principal Systems of Surface Grinding......Page 1200
Selection of Grinding Wheels for Surface Grinding......Page 1202
Process Data for Surface Grinding......Page 1203
Oilstones......Page 1204
Swing-Frame Grinding......Page 1206
Abrasive Cutting......Page 1207
Amount and Rate of Stock Removal......Page 1210
Formula for Rotative Speeds......Page 1211
Material for Laps......Page 1212
Grading Abrasives for Lapping......Page 1213
Grading Diamond Dust......Page 1214
Effect of Different Lapping Lubricants......Page 1215
Summary of Lapping Tests......Page 1216
Knurls and Knurling......Page 1217
Machine Tool Accuracy......Page 1222
Manufacturing Processes......Page 1224
Designing Sheet Metal Parts for Production......Page 1227
Blanking and Punching......Page 1228
Blanking and Punching Clearance......Page 1230
Die Opening Profile......Page 1231
Stripper Force......Page 1232
Fine Blanking......Page 1233
Bending......Page 1235
Inside Bend Radius......Page 1236
Mechanics of Deep Drawing......Page 1242
Lubricants and Their Effects on Press Work......Page 1248
Joining and Edging......Page 1250
Steel Rule Dies......Page 1254
Making of Steel Rule Dies......Page 1256
Mandrel inside of Tube......Page 1257
Electrical Discharge Machining......Page 1258
Alloy Cast Iron......Page 1269
Ductile Cast Iron......Page 1270
Carbon Steel Castings......Page 1271
Alloy Steel Castings......Page 1272
Definitions......Page 1274
Removal of Gates and Risers from Castings......Page 1276
Woods for Patterns......Page 1277
Metal Patterns......Page 1278
Die Casting......Page 1279
Aluminum-Base Alloys......Page 1280
Magnesium-Base Alloys......Page 1281
Die-Casting Bearing Metals in Place......Page 1282
General Procedure in Making Investment Castings......Page 1283
Investment Materials......Page 1284
Design for Investment Casting......Page 1285
The Basic Process......Page 1286
Factors Affecting Design of Briquetting Tools......Page 1288
Methods of Application......Page 1289
Fluxes for Brazing......Page 1291
Brazing Symbol Application......Page 1296
Processes......Page 1298
Electrode Diameters......Page 1299
Shielding Gases for Short-Circuit Welding of Carbon Steels......Page 1300
Shielding Gases for GMAW Welding of Stainless Steels......Page 1301
Welding Controls......Page 1302
GMAW Spray Transfer for Metal Thicknesses 1/4 in. (6.4 mm) and Up......Page 1304
GMAW Spray Transfer with 0.062-in. (1.6-mm) Diameter Electrodes......Page 1305
Spray Transfer Voltage......Page 1306
All-Position, Gas-Shielded Electrodes......Page 1307
Selecting an FCAW Electrode......Page 1308
Settings for Gas-Shielded, All-Position, FCAW Electrodes......Page 1309
Welding with 0.052-in. (1.3-mm) Diameter All-Position Electrodes......Page 1310
High-Deposition, All-Position Electrodes......Page 1311
Electrode Diameters and Deposition Rates......Page 1312
The 0.062-in. (1.6-mm) Diameter, E70T-X Electrode......Page 1313
Shielded Metal Arc Welding......Page 1314
AWS E60XX Electrodes......Page 1315
AWS E70XX Electrodes......Page 1317
GTAW Welding Current......Page 1318
Selecting the Tungsten Electrode Type......Page 1320
Electrode and Current Selection......Page 1321
Gases for Plasma Arc Welding......Page 1323
Applications......Page 1324
Welding Aluminum......Page 1325
Plasma Arc Surface Coating......Page 1326
The Cutting Torch......Page 1327
Cutting Steel Castings......Page 1328
High-Speed Steels......Page 1329
Cobalt-Base Alloys......Page 1330
Copper-Base Alloys......Page 1331
Chromium Plating......Page 1332
Electron-Beam (EB) Welding......Page 1333
Pipe Welding......Page 1334
Use of Flux-Cored Electrodes......Page 1337
FCAW 5G (Non-Rotated) MIG Welding of Thick-Walled, Carbon-Steel Pipes, Procedure for Root Welding......Page 1338
FCAW 5G (Non-Rotated) MIG Welding of Thick-Walled, Carbon-Steel Pipes, Procedure for Fill and Cover Welds......Page 1339
FCAW 5G (Non-Rotated) Welding of Thin-Walled Carbon Steel Pipes, Procedure for Root, Fill and Cover Pass Welding......Page 1340
American National Standard Weld and Welding Symbols......Page 1341
Welding Codes, Rules, Regulations, and Specifications......Page 1343
Nondestructive Testing Symbol Application......Page 1350
Laser Beams......Page 1352
Beam Focusing......Page 1353
Industrial Laser Systems......Page 1354
Laser Beam/Material Interaction......Page 1355
Cutting Metal with Lasers......Page 1356
Cut Edge Roughness......Page 1357
Heat-Affected Zones......Page 1358
Cutting of Nonmetals......Page 1359
Laser Welding Theory......Page 1360
Processing Gas......Page 1361
Percussive Drilling......Page 1362
Cladding with Lasers......Page 1363
Scanned-Beam Marking......Page 1364
Deburring and Producing a Radius on the Tooth Profile of Gears......Page 1365
Polishing Wheels......Page 1366
Speed of Polishing Wheels......Page 1369
Etching Fluids for Different Metals......Page 1370
Coloring of Copper Alloys......Page 1371
Anodizing Aluminum Alloys......Page 1372
Surface Coatings......Page 1373
Flame Spraying Process......Page 1381
Fasteners......Page 1382
Primary Criteria......Page 1386
Supplementary Criteria......Page 1387
Torque and Tension in Fasteners......Page 1388
Inch Threaded Fasteners......Page 1405
Heavy Hex Structural Bolts......Page 1437
Heavy Hex Nuts......Page 1440
Flat Washers......Page 1443
Beveled Washers......Page 1444
Compressible Washer-Type Direct Tension Indicators......Page 1446
Metric Threaded Fasteners......Page 1448
Comparison with ISO Standards......Page 1466
Materials and Mechanical Properties......Page 1468
Types of Metric Prevailing-Torque Type Nuts......Page 1470
Metric Nut Designation......Page 1471
Metric Plain Washer Designation......Page 1474
Inch Fasteners......Page 1476
Recommended Substitute Drills......Page 1477
STI-Tapped Hole......Page 1479
Configuration and Dimensions......Page 1480
Inspection (Nondestructive)......Page 1483
Self-Locking Torque (Destructive)......Page 1484
Material Strengths......Page 1490
Screw Thread Insert Taps......Page 1491
British Fasteners......Page 1492
Length of Thread......Page 1509
Designation......Page 1510
Machine Screw Cross Recesses......Page 1518
Head Types......Page 1519
Specifications......Page 1521
American National Standard Metric Machine Screws......Page 1524
Threads and Threading......Page 1531
American National and Unified Screw Thread Forms......Page 1535
International Metric Thread System......Page 1536
Definitions of Screw Threads......Page 1537
Thread Form......Page 1542
Thread Series......Page 1543
Constant Pitch Series......Page 1575
Coated 60-Deg. Threads......Page 1583
Screw Thread Designation......Page 1585
Internal Thread Minor Diameter Tolerances......Page 1586
Design Forms of Threads......Page 1587
ASME Unified Inch Screw Threads, UNJ Form......Page 1592
Purpose......Page 1593
Calculations from Formulas, General Rules......Page 1594
Thread Form Constants......Page 1595
Definitions......Page 1606
M Crest and Root Form......Page 1607
Standard M Profile Screw Thread Series......Page 1608
Limits and Fits for Metric Screw Threads - M Profile......Page 1610
Material Limits for Coated Threads......Page 1614
Formulas for M Profile Screw Thread Limiting Dimensions......Page 1616
Standard M Profile Screw Threads, Limits of Size......Page 1620
Metric Screw Thread Designations......Page 1627
Diameter-Pitch Combinations......Page 1628
Comparison of ISO and DIN Standards......Page 1631
Basic Profile......Page 1638
Tolerance System......Page 1639
Tolerance Classes......Page 1640
Designation......Page 1641
Fundamental Deviation Formulas......Page 1642
Crest Diameter Tolerance Formulas......Page 1643
Limits and Tolerances for Finished Uncoated Threads......Page 1646
General Purpose Acme Threads......Page 1649
Multiple Start Acme Threads......Page 1651
Centralizing Acme Threads......Page 1656
Designation of Centralizing Acme Threads......Page 1661
Stub Acme Thread Designations......Page 1667
Former 60-Degree Stub Thread......Page 1670
10-Degree Modified Square Thread......Page 1672
Lowenherz or Löwenherz Thread......Page 1673
7°/45° Buttress Thread Form......Page 1674
Buttress Thread Tolerances......Page 1675
Allowances for Easy Assembly......Page 1679
Designation Sequence for Buttress Inch Screw Threads......Page 1680
Whitworth Standard Thread Form......Page 1681
American National Standard Taper Pipe Threads......Page 1684
Tolerances on Thread Elements......Page 1686
Straight Pipe Threads for Mechanical Joints, NPSM, NPSL, and NPSH......Page 1688
Types of Dryseal Pipe Thread......Page 1690
Special Dryseal Threads......Page 1692
British Standard Pipe Threads for Non-Pressure-Tight Joints......Page 1693
British Standard Pipe Threads for Pressure-Tight Joints......Page 1694
ANSI Standard Hose Coupling Screw Threads......Page 1696
American National Fire Hose Connection Screw Thread......Page 1698
Interference-Fit Threads......Page 1701
Design and Application Data for Class 5 Interference-Fit Threads......Page 1702
SAE Spark-Plug Screw Threads......Page 1707
Lamp Base and Socket Shell Threads......Page 1708
British Association Standard Thread (BA)......Page 1709
American Microscope Objective Thread (AMO)......Page 1710
Swiss Screw Thread......Page 1713
Casing Thread......Page 1714
Harvey Grip Thread......Page 1715
Worm Threads......Page 1716
Measuring Screw Thread Pitch Diameters by Thread Micrometers......Page 1717
Measuring Screw Threads by Three-Wire Method......Page 1718
Accuracy of Formulas for Checking Pitch Diameters by Three-Wire Method......Page 1719
Wire Sizes for Checking Pitch Diameters of Screw Threads......Page 1720
Approximate Three-Wire Formulas That Do Not Compensate for Lead Angle......Page 1721
Bureau of Standards (Now NIST) General Formula......Page 1722
Why Small Thread Angle Affects Accuracy of Three-Wire Measurement......Page 1723
Buckingham Simplified Formula Which Includes Effect of Lead Angle......Page 1725
Buckingham Exact Involute Helicoid Formula Applied to Screw Threads......Page 1727
Accuracy of Formulas (3) and (4) Compared......Page 1728
Three-Wire Method for Checking Thickness of Acme Threads......Page 1729
Testing Angle of Thread by Three-Wire Method......Page 1730
Measuring Taper Screw Threads by Three-Wire Method......Page 1733
American National Standard for Gages and Gaging for Unified Inch Screw Threads ANSI/ASME B1.2-1983 (R2007)......Page 1735
Thread Gage Tolerances......Page 1738
Tapping and Thread Cutting......Page 1743
Fractional Threads......Page 1770
Change Gears for Fractional Ratios......Page 1771
Modifying the Quick-Change Gearbox Output......Page 1772
Lathe Change-Gears......Page 1774
Relieving Helical-Fluted Hobs......Page 1775
Thread Rolling......Page 1776
Thread Grinding......Page 1781
Thread Milling......Page 1786
Lead of a Milling Machine......Page 1788
Helix......Page 1789
Helix Angles......Page 1790
Helix Angle for Given Lead and Diameter......Page 1805
Lead of Tooth Given Pitch Radius and Helix Angle......Page 1806
Simple, Compound, Differential, and Block Indexing......Page 1807
Gears, Splines, and Cams......Page 1850
Gears and Gearing......Page 1853
Determining Proper Amount of Backlash......Page 1891
Control of Backlash Allowances in Production......Page 1894
Measurement of Backlash......Page 1895
Control of Backlash in Assemblies......Page 1896
Pressure for Composite Checking of Fine-Pitch Gears......Page 1897
Relative Sizes of Internal Gear and Pinion......Page 1898
British Standard for Spur and Helical Gears......Page 1900
BS 436, Part 3:1986 "Spur and Helical Gears"......Page 1901
ISO TC/600......Page 1902
Standards Nomenclature......Page 1903
Hypoid Gears......Page 1904
Types of Bevel Gears......Page 1905
Notes on the Design of Bevel Gear Blanks......Page 1907
Cutting Bevel Gear Teeth......Page 1908
Formulas for Dimensions of Milled Bevel Gears......Page 1909
Use of Table for Selecting Formed Cutters for Milling Bevel Gears......Page 1915
Offset of Cutter for Milling Bevel Gears......Page 1916
Adjusting the Gear Blank for Milling......Page 1917
American Standard Design for Fine-Pitch Worm Gearing (ANSI B6.9-1977)......Page 1919
Effect of Production Method on Worm Profile and Pressure Angle......Page 1921
Number of Threads or "Starts" on Worm......Page 1922
Helical Gearing......Page 1923
Elliptic Gears......Page 1938
Planetary Bevel Gears......Page 1939
Ratchet Gearing......Page 1943
Pitch of Ratchet Wheel Teeth......Page 1944
Gear Design Based upon Module System......Page 1945
Measurements for Checking External Spur Gears When Wire Diameter Equals 1.728 Divided by Diametral Pitch......Page 1949
Measurements for Checking External Spur Gears When Wire Diameter Equals 1.68 Divided by Diametral Pitch......Page 1958
Measurements for Checking Helical Gears Using Wires or Balls......Page 1963
Checking Spur Gear Size by Chordal Measurement over Two or More Teeth......Page 1964
Formula for Chordal Dimension M......Page 1966
Checking Enlarged Pinions by Measuring over Pins or Wires......Page 1967
Gear Materials......Page 1968
American National Standard Involute Splines......Page 1980
Terms Applied to Involute Splines......Page 1981
Tooth Proportions......Page 1984
Classes of Tolerances......Page 1986
Fillets and Chamfers......Page 1988
Effective and Actual Dimensions......Page 1989
Use of Effective and Actual Dimensions......Page 1990
Interchangeability......Page 1991
Estimating Key and Spline Sizes and Lengths......Page 1993
Formulas for Torque Capacity of Involute Splines......Page 1994
Crowned Splines for Large Misalignments......Page 1997
Involute Spline Inspection Methods......Page 1998
Measurements with Pins......Page 1999
American National Standard Metric Module Splines......Page 2000
Spline Machining Tolerances and Variations......Page 2004
British Standard Straight Splines......Page 2006
S.A.E. Standard Spline Fittings......Page 2007
Polygon-Type Shaft Connections......Page 2010
Cams and Cam Design......Page 2012
Machine Elements......Page 2038
Types of Journal Bearings......Page 2042
Modes of Bearing Operation......Page 2045
Methods of Sealing......Page 2047
Hardness and Surface Finish......Page 2049
Methods of Lubrication......Page 2050
Lubricant Selection......Page 2051
Heat Radiating Capacity......Page 2054
Journal Bearing Design Notation......Page 2055
Journal Bearing Lubrication Analysis......Page 2057
Use of Lubrication Analysis......Page 2063
Thrust Bearings......Page 2066
Thrust Bearing Design Notation......Page 2067
Flat Plate Thrust Bearing Design......Page 2068
Step Thrust Bearing Design......Page 2073
Tapered Land Thrust Bearing Design......Page 2075
Tilting Pad Thrust Bearing Design......Page 2080
Properties of Bearing Materials......Page 2084
Babbitt or White Metal Alloys......Page 2086
Leaded Bronze and Tin-Bronze......Page 2087
Cast Iron......Page 2088
Plastics Bearings......Page 2089
Carbon-Graphite......Page 2090
Types of Anti-Friction Bearings......Page 2093
Types of Ball Bearings......Page 2094
Types of Roller Bearings......Page 2096
Types of Ball and Roller Thrust Bearings......Page 2097
Types of Needle Bearings......Page 2098
Plastics Bearings......Page 2100
Standard Method of Bearing Designation......Page 2101
Radial Needle Roller Bearings......Page 2102
Metric Radial Ball and Roller Bearing Shaft and Housing Fits......Page 2110
Needle Roller Bearing Fitting and Mounting Practice......Page 2115
Mountings for Precision and Quiet-Running Applications......Page 2118
Squareness and Alignment......Page 2119
Soft Metal and Resilient Housings......Page 2120
Clamping and Retaining Methods......Page 2121
Friction Losses in Rolling Element Bearings......Page 2126
Selection of Ball and Roller Bearings......Page 2127
Method of Lubrication......Page 2128
Radial and Axial Clearance......Page 2129
General Bearing Handling Precautions......Page 2130
Ball and Roller Bearing Life......Page 2131
Limitations for Ball Bearings......Page 2132
Ball Bearing Rating Life......Page 2133
Roller Bearing Types Covered......Page 2137
Roller Bearing Rating Life......Page 2138
Life Adjustment Factors......Page 2142
Ball Bearing Static Load Rating......Page 2143
Roller Bearing Static Equivalent Load......Page 2146
Ordering Specifications......Page 2148
The Lubrication Film......Page 2156
Lubricants......Page 2159
Lubricating Oil......Page 2160
Oil Additives......Page 2163
Synthetic Based Oils......Page 2165
Temperature Effects on Oil......Page 2166
Lubricating Grease......Page 2167
Selecting a Suitable Lubricant......Page 2169
Grease Application......Page 2171
Lubrication Delivery Methods and Systems......Page 2172
Contamination Control......Page 2174
ISO Cleanliness Code......Page 2175
Water Contamination......Page 2176
Filtration Systems......Page 2177
Couplings, Clutches, Brakes......Page 2179
Formulas for Band Brakes......Page 2191
Calculating Horsepower from Dynamometer Tests......Page 2193
Friction Wheels for Power Transmission......Page 2194
Horsepower of Friction Wheels......Page 2195
Dimensions and Tolerances......Page 2196
Metric Square and Rectangular Keys and Keyways: Width Tolerances and Deviations Greater Than Basic Size......Page 2201
Preferred Lengths and Tolerances......Page 2202
Advantages of Woodruff Keys......Page 2205
ANSI Standard Inch Series Keys and Keyseats......Page 2208
ANSI Standard Woodruff Keys and Keyseats......Page 2213
Cotters......Page 2219
Pulley Center Distances and Belt Lengths......Page 2221
Pulley Diameters in Compound Drive......Page 2222
Length of Belt Traversing Three Pulleys......Page 2223
Flat Belting......Page 2224
Flat Belt Pulleys......Page 2225
Narrow V-Belts ANSI/RMA IP-22......Page 2226
Measuring Units......Page 2227
Greek Letters and Standard Abbreviations......Page 2228
The International System of Units (SI)......Page 2232
Binary Multiples......Page 2234
U.S. Customary Unit System......Page 2236
Units of Length......Page 2237
Units of Area......Page 2251
Units of Volume......Page 2254
Pitot Tube......Page 2258
Units of Mass and Weight......Page 2259
Units of Pressure and Stress......Page 2262
Units of Moment and Torque......Page 2265
Units of Energy, Power, and Heat......Page 2266
Fuel Oil, Coal and Gas Equivalents......Page 2270
Measures of the Quantity of Thermal Energy......Page 2271
Units of Velocity and Acceleration......Page 2274
Miscellaneous Measuring Units......Page 2275
A......Page 2277
B......Page 2303
C......Page 2350
D......Page 2407
E......Page 2422
F......Page 2433
G......Page 2456
H......Page 2481
I......Page 2500
K......Page 2515
L......Page 2520
M......Page 2533
N......Page 2571
O......Page 2577
P......Page 2581
Q......Page 2608
R......Page 2609
S......Page 2625
T......Page 2689
U......Page 2733
V......Page 2738
W......Page 2741
Y......Page 2758
Z......Page 2760
A......Page 2761
B......Page 2774
D......Page 2780
F......Page 2782
G......Page 2784
I......Page 2787
J......Page 2789
L......Page 2790
M......Page 2791
N......Page 2793
P......Page 2800
R......Page 2804
S......Page 2806
T......Page 2814
U......Page 2821
W......Page 2822
Z......Page 2823
A......Page 2824
B......Page 2826
C......Page 2829
D......Page 2832
F......Page 2833
G......Page 2835
M......Page 2837
P......Page 2841
R......Page 2842
S......Page 2843
T......Page 2845
V......Page 2847
W......Page 2848
A......Page 2849
B......Page 2953
C......Page 2956
D......Page 2991
E......Page 2993
F......Page 2995
G......Page 2997
H......Page 3000
I......Page 3001
L......Page 3005
M......Page 3007
N......Page 3016
O......Page 3021
P......Page 3023
Q......Page 3032
R......Page 3033
S......Page 3035
T......Page 3092
U......Page 3102
V......Page 3103
W......Page 3104
Y......Page 3107
Z......Page 3108
A......Page 3110
B......Page 3113
C......Page 3115
D......Page 3118
F......Page 3120
G......Page 3123
I......Page 3124
J......Page 3125
K......Page 3126
L......Page 3127
M......Page 3128
N......Page 3131
P......Page 3135
R......Page 3138
S......Page 3139
T......Page 3144
W......Page 3145
Z......Page 3149
Additional Only on the CD......Page 3150
Mathematics......Page 3157
Constants for 2.5-Inch Sine-Bar......Page 3202
Constants for 3-Inch Sine-Bar......Page 3209
Constants for 5-Inch Sine-Bar......Page 3216
Constants for 10-Inch Sine-Bar......Page 3223
Constants for 75-mm Sine-Bar......Page 3230
Constants for 125-mm Sine-Bar......Page 3237
Squares of Numbers......Page 3244
Squares and Cubes of Fractions......Page 3248
Fractions of Pi (pi)......Page 3254
Powers, Roots, and Reciprocals......Page 3255
Multiplication Tables for Fractions......Page 3295
Area and Volume of Spheres......Page 3298
Circumference and Area of Circles......Page 3301
Curves......Page 3314
Balancing Calculations......Page 3315
Counterbalancing Several Masses Located in a Single Plane......Page 3316
Counterbalancing Masses Located in Two or More Planes......Page 3318
Balancing Lathe Fixtures......Page 3319
Running Balance......Page 3320
Classification of Flywheels......Page 3321
General Procedure in Flywheel Design......Page 3322
Flywheels for Presses, Punches, Shears, Etc......Page 3323
Simplified Flywheel Calculations......Page 3325
Centrifugal Stresses in Flywheel Rims......Page 3326
Thickness of Cast Iron Flywheel Rims......Page 3327
Tables of Safe Speeds for Flywheels......Page 3328
Safe Speed Formulas for Flywheels and Pulleys......Page 3329
Tests to Determine Flywheel Bursting Speeds......Page 3330
Steam Engine Flywheels......Page 3331
Spokes or Arms of Flywheels......Page 3332
Inconel "X"......Page 3333
Metallography......Page 3334
K Monel......Page 3335
Nichrome......Page 3336
Plow-Steel Wire Rope......Page 3337
Lumber......Page 3338
Water Pressure......Page 3339
Flow of Water in Pipes......Page 3341
Properties of Air......Page 3345
Expansion and Compression of Air......Page 3348
Work Required in Compression of Air......Page 3349
Continuity Equation......Page 3350
Flow of Compressed Air in Pipes......Page 3354
Velocity of Escaping Compressed Air......Page 3355
Symbols for Drafting......Page 3356
Wheatstone Bridge......Page 3361
American National Standard Jig Bushings......Page 3363
Jig Borers......Page 3373
Jig-Boring Practice......Page 3374
Transfer of Tolerances......Page 3375
Hole Coordinate Dimension Factors for Jig Boring......Page 3377
Gage Blocks......Page 3393
Tooth-Rest for Cutter Grinding......Page 3396
Open-Loop Systems......Page 3397
Closed-Loop Systems......Page 3398
Control Function......Page 3400
Mechanical Stiffness......Page 3401
Electric Motors......Page 3402
Gearing......Page 3403
Feedback Transducers......Page 3404
Hydraulic and Pneumatic Systems......Page 3405
Hydraulic Fluids......Page 3406
Hydraulic and Pneumatic Control Systems......Page 3407
Hydraulic Control Systems......Page 3408
Proportional Control Systems......Page 3409
Pneumatic Systems......Page 3410
Feed Rate on Machine Tools......Page 3411
Cold Extrusion......Page 3412
Introduction......Page 3413
Numerical Control vs. Manual Operations......Page 3414
Numerical Control Standards......Page 3415
Programmable Controller......Page 3418
Adaptive Control......Page 3422
Flexible Manufacturing Systems (FMS)......Page 3423
Programming......Page 3424
Postprocessors......Page 3427
Format Classification......Page 3428
Preparatory Word (G-Word)......Page 3430
Miscellaneous Functions (M-Words)......Page 3434
Feed Function (F-Word)......Page 3435
Tool Function (T-Word)......Page 3436
Linear Interpolation......Page 3438
Circular Interpolation......Page 3439
Helical and Parabolic Interpolation......Page 3440
Subroutine......Page 3441
Parametric Expressions and Macros......Page 3442
Fixed (Canned) Cycles......Page 3443
Thread Cutting......Page 3447
APT......Page 3448
APT Geometry Statements......Page 3450
APT Motion Statements......Page 3455