Workshop Machining: A Comprehensive Guide to Manual Operation

Description

Cover Page Half Title Page Title Page Copyright Page Contents Page Acknowledgements Page 1 Introduction 2 Degrees of freedom 3 Turning 3.1 Workpiece holding – the three-jaw chuck 3.2 Tooling 3.3 Initial tool set-up 3.4 Facing off 3.5 Parallel external turning 3.6 Turning to a known length 3.7 Use of revolving and dead centres 3.8 Parting off 3.9 Undercutting 3.10 Chamfering (formed and generated approaches) 3.11 Drilling, including tailstock set-up and drilling limitations 3.12 Boring 3.13 Boring angular features 3.14 Turning angular features (external) 3.15 Use of taper turning attachments 3.16 Measurement of tapers 3.17 Machine backlash issues 3.18 Turning between centres 3.19 Off-centre turning 3.20 Four-jaw chuck use 3.21 Use of collet chucks 3.22 Face plate work including constraints and use of weights 3.23 Screw cutting 3.24 Use of thread dial 3.25 Measuring threads 3.26 Cutting multi-start threads 3.27 Tooling constraints in multi-start threads 3.28 Issues with non-standard thread cutting 3.29 Use of workpiece supports 3.30 Manufacture of springs on a lathe 3.31 Knurling 3.32 Feeds and speeds 3.33 Use of coolants 3.34 Behaviour of differing materials 4 Milling 4.1 The milling machine and degrees of freedom 4.2 Machine constraints 4.3 Direction of cutter rotation 4.4 Machine backlash issues when climb milling 4.5 Workpiece set-up 4.6 Squareness 4.7 Clocking’ in workpiece/work-holding devices 4.8 Workpiece clamping 4.9 Use of registers 4.10 Workpiece overhangs 4.11 Use of machine parallels 4.12 Use of depth stops 4.13 Manipulation of head geometry 4.14 Trammelling in turret head 4.15 Feeds and speeds 4.16 Surface milling 4.17 Slot milling 4.18 End milling 4.19 Tee slot milling 4.20 Dovetail milling 4.21 Dividing head use 4.22 Rotary table use 4.23 Turret mill quill use 4.24 Drilling and threading 4.25 Gear cutting 4.26 Use of coolants 4.27 Tooling 4.28 Upcut and downcut (climb) milling 4.29 Tool changing 4.30 Collets 4.31 Behaviours of differing materials 4.32 Metrology 4.33 Use of sine bars 4.34 Digital read out systems 5 Surface grinding 5.1 The surface grinder 5.2 Grinding wheel types 5.3 Wheel mounting 5.4 Wheel dressing 5.5 The magnetic vice 5.6 Sine bar use 5.7 Machine operation 5.8 Setting feed stops for longitudinal feed 5.9 Workpiece support 5.10 Heat and workpiece warping 5.11 Grinding slots 5.12 Grinding to a shoulder 5.13 Cutting depth 5.14 Common grinding faults 5.15 Wheel changing 5.16 Grinding differing materials 5.17 Safety issues 6 Cylindrical grinding 6.1 The cylindrical grinder 6.2 Grinding wheel types 6.3 Wheel dressing 6.4 Mounting of workpieces between centres 6.5 Workpiece rotation speed selection 6.6 Use of coolant 6.7 Cutting depth 6.8 Traverse cylindrical grinding 6.9 Cylindrical grinding to a shoulder 6.10 Plunge/in-feed cylindrical grinding 6.11 Limitations of grinding cylinders 6.12 Radial limitations 6.13 Off-centre grinding 6.14 Taper grinding 6.15 Measurement 6.16 Common cylindrical grinding faults 6.17 Wheel changing 6.18 Safety issues 7 Drilling 7.1 The workshop drill 7.2 Machine constraints 7.3 Size of drill and power 7.4 Types of drill bit 7.5 Use of chucks and changing chucks 7.6 Use of trepanning tools 7.7 Workpiece holding 7.8 Use of vices 7.9 Use of fixtures 7.10 Table height 7.11 Safety and guarding 7.12 Feeds and speeds 7.13 Use of coolants 7.14 Basic drilling 7.15 Large diameter hole drilling 7.16 Drilling thin workpieces 7.17 Drilling deep holes 7.18 Drilling to a depth 7.19 Flat-bottom drilling 7.20 Counterbores 7.21 Countersinks 7.22 Reaming 7.23 Tapping and use of auto release tapping aids 7.24 Power feed drilling 7.25 Swarf clearance and continuous chip issues 7.26 Problems with drilling Appendix A: Nomogram for calculation of helical milling angles Appendix B: Simple turning exercise Appendix C: Simple milling exercise Index