MSE
Machine Shop Essentials: Questions & Answers
By Frank M. Marlow, 2004, 528 pages, Paperback, ISBN 0-9759963-0-4
$55.00

A comprehensive and detailed presentation of manual machine tools and methods, machine shop know-how and practical shop tips. Machine Shop Essentials is for a wide range of users including machinists, engineers, model makers, R & D lab technicians, instrument makers, prototype builders, product designers and gunsmiths who need to make prototypes, models or spare parts, or need to modify existing equipment. This book can also be used to gain a basic understanding of machine tools before moving on to computer-controlled machine tools.

More than half the book is devoted to small and medium-size lathes and milling machines, such as Levin jewelers' lathes, Sherline miniature lathes and mills, Clausing lathes, and Bridgeport-style vertical milling machines. It examines how these machines are constructed, their cutting tools and accessories and how to use them.

This back-to-basics book contains all the information needed for a fundamental understanding of machine tools, and presents this information in the same straightforward, easy-to-read question-and-answer format used in the author's two successful welding books: Welding Essentials and Welding Fabrication & Repair.

Machine Shop Essentials features:

• A simple question-and-answer format.

• Material is divided into small, easy-to-understand blocks.

• Over 500 clear, concise drawings.

• Introduction to metal lathes, milling machines, drill presses and their cutting tools and accessories.

• Step-by-step instructions for many common machine shop operations, including typical problems and their solutions.

• Shortcuts, specialized tools and tips from expert machinists on indispensable shop-made tools that will quickly expand the user's capabilities.

• Machine tool accessories that simplify making complex parts.

• Screw threads and non-threaded fasteners.

• General shop safety issues and special precautions for each machine tool.

• A review of basic precision measuring and marking tools and methods.

• How to incorporate purchased components such as bearing, gears, snap rings and roll pins to quickly make sophisticated and durable devices.

• How to heat-treat steel in the machine shop.

• Guidelines for avoiding metal fatigue failures.

• Cutting, drilling, and shaping plastic, rubber and glass.

• Safety precautions and equipment for each machine tool.

• A comprehensive machine shop glossary.

Table of Contents
Acknowledgements

Introduction

Chapter 1 Measurement Tools, Layout & Job Planning
Layout Fluid, Scribers, Steel Rules, Squares, Dividers, Micrometers, Calipers, Height Gages, Dial Test Indicators, Toolmakers' Buttons, Gage Blocks.

Chapter 2 Basic Hand Tools
Bench Vise Jaw Covers, Screwdrivers, Allen & Torx Wrenches, Bench Blocks, Hammers, Punches, Chisels.

Chapter 3 Filing & Sawing
Files, Lathe Files, Hacksaws, Bandsaws.

Chapter 4 Grinding, Reaming, Broaching & Lapping
Grinding Mechanics, Bench, Pedestal, Disk & Hand-held Grinders, Reamer Mechanics, Designs & Procedures, Broaching Procedure, Lap Designs, Abrasives & Procedures.

Chapter 5 Drills & Drilling Operations
Drill Press Designs & Controls, Twist & Center Drills, Counter Bores, Drilling Mechanics, Hole Saws, Drill Sizing Systems, Drill Point Designs, Step Drills, Deep-Hole Drilling, Drill Shank Tapers, Chucks, Drilling Procedures, Pilot Holes, Making Extra-Long Drills, Drill Accessories, Other Hole-Making Tools.

Chapter 6 Threads & Threading
Thread Parts, Designs & Measuring Methods, Pipe & Machinery Threads, Coarse vs. Fine Threads, Tap Designs, Thread Engagement, Tap & Clearance Drill Sizing, Tapping Procedure, Blind Holes, Applying Male Threads, Bolt Pre-Tensioning, Removing Frozen or Broken Taps & Fasteners, Repairing Damaged Threads.

Chapter 7 Turning Operations
Lathe Sizing, Typical Modern Lathes, Lathe Components, Cutting Tools, Tool Posts, Positive & Negative Rake Angles, Centers, Face Plates, Drive Plates, Chucks, Dogs, Centering Work, Collets, Mandrels, Taper Attachments, Radii Cutters, Chatter, Metal Cutting Characteristics, Turning, Facing, Parting Off, Drilling, Grooving & Boring, Trepanning, Reaming, Threading Procedures, Multiple-Start Threads, Knurling, Grinding, Special Work-Holding Techniques, Lathe Installation & Maintainence.

Chapter 8 Milling Operations
Bridgeport-style Milling Machines & Their Advantages, Typical Modern Mills, Milling Machine Parts, Cutting Tools, Tool-Holding Methods, Boring Heads, Flycutters, Slitting Saws, Drilling Methods, Conventional vs. Climb Milling, Feeds & Speeds, Securing & Aligning Work, Tramming the Head, Angling the Head, Locating Work under the Head, Edge Finders, End Mills and Their Selection, Keyway, T-Slot & Dovetail Milling, Squaring Up Stock, Dividing Heads, Rotary Tables, Bolt-Hole Patters, Horizontal Milling Attachment.

Chapter 9 Fastening Methods
Threaded Fasteners, Screws vs. Bolts, Screw Drive & Bolt Drive Designs, Set Screws, Threaded Fastener Quality, Nuts, Thread Fit Classifications, Fastener Loosening Mechanics, Rivets, Taper & Roll Pins, Force Fits.

Chapter 10 Machine Shop Steel Metallurgy
Iron-Carbon Diagram, Hardening & Tempering Steel, Quenching Precautions, Tempering Colors, Annealing Steel, Fatigue Failures, Drill Rods and Blanks.

Chapter 11 Safety & Good Shop Practices
Good Shop Environment & Practices, Personal Safety Equipment, Fire & Electrical Safety, MSDS.

Chapter 12 Other Shop Know-how
Short-Cuts & Specialized Machining Methods.

Appendix I Sharpening Steel Lathe Tools

Appendix II Sources of Tools, Materials & Supplies

Glossary

Index

Credits