Newnes workshop engineer’s pocket book

Newnes Workshop Engineer’s Pocket Book This Page Intentionally Left Blank Newnes Workshop Engineer’s Pocket Book Roger Timings OXFORD AUCKLAND BOSTON JOHANNESBURG MELBOURNE NEW DELHI Newnes An imprint of Butterworth-Heinemann Linacre House, Jordan Hill, Oxford OX2 8DP 225 Wildwood Avenue, Woburn, MA 01801-2041 A division of Reed Educational and Professional Publishing Ltd A member of the Reed Elsevier plc group First published 2000 © Roger Timings 2000 All rights reserved No part of this publication may be reproduced in any material form (including photocopying or storing in any medium by electronic means and whether or not transiently or incidentally to some other use of this publication) without the written permission of the copyright holder except in accordance with the provisions of the Copyright, Designs and Patents Act 1988 or under the terms of a licence issued by the Copyright Licensing Agency Ltd, 90 Tottenham Court Rd, London, England W1P 9HE Applications for the copyright holder’s written permission to reproduce any part of this publication should be addressed to the publishers British Library Cataloguing in Publication Data A catalogue record for this book is available from the British Library ISBN 7506 4719 Typeset by Laser Words, Madras, India Printed in Great Britain by Antony Rowe Ltd, Reading, Berkshire Contents Preface xiii Part Conversion Tables and Workshop Calculations 1.1 1.2 1.3 1.4 1.5 1.6 1.7 1.8 1.9 1.10 1.11 1.12 1.13 1.14 1.15 1.16 1.17 Conversion table: fractions to decimals Conversion table: millimetres to inches Conversion table: minutes of arc to degrees Circles: areas and circumferences Twist drills: nearest equivalent sizes Wire gauge equivalents 13 Mensuration of plane figures 14 Mensuration of solids 17 Taper systems (millimetre units) 20 1.9.1 Self-holding tapers 20 1.9.2 Quick-release tapers (milling machine tapers for spindle noses) 22 Taper systems (inch units) 22 1.10.1 Self-holding tapers 23 1.10.2 Quick-release tapers (milling machines) 24 Chordal distances on pitch circles 24 Useful workshop formulae 26 1.12.1 Heights above keyways 26 1.12.2 Radii on bolt ends 26 1.12.3 Hexagon: distance across corners 26 1.12.4 Square: distance across corners 26 1.12.5 Helix angles 26 1.12.6 Cutting speeds (inch units) 27 1.12.7 Cutting speeds (metric units) 27 1.12.8 Typical cutting speeds for HSS tools 27 Solution of triangles 34 1.13.1 Pythagoras 34 1.13.2 Trigonometry (right-angled triangles) 34 1.13.3 Trigonometry (any triangle) 35 Sine-bar (principle) 36 Sine-bar (use of) 37 Sine-bar constants (250 mm) 40 Measurement over precision balls and rollers 56 v 1.18 Measurement of external tapers 57 1.18.1 To find the angle  ° (the semi-angle of taper) 57 1.18.2 To find the major and minor diameters 59 1.19 Measurement of internal tapers 62 1.19.1 To find the angle q° (the semi-angle of taper) 62 1.19.2 To find the major and minor diameters 64 1.20 The dividing head – simple indexing 66 1.20.1 Sector arms 67 1.21 Differential indexing 69 1.22 Helical milling 70 1.23 Cam milling 74 1.24 Gear trains (simple) 77 1.24.1 Simple train 78 1.24.2 Simple train with idler gear 78 1.25 Compound gear trains 79 1.26 Belt drive (simple) 80 1.26.1 Open belt drive 80 1.26.2 Crossed belt drive 81 1.27 Belt drive (compound) 82 1.28 Typical belt tensioning devices 83 Part 2.1 2.2 2.3 2.4 vi Threaded Fasteners Introduction to threaded fasteners 87 Threaded fasteners 90 2.2.1 Drawing proportions 90 2.2.2 Alternative screw heads 91 2.2.3 Alternative scew points 92 2.2.4 Hexagon socket cap head screw 92 2.2.5 Applications of screwed fasteners 92 2.2.6 Acme thread form 93 2.2.7 Square thread form 93 2.2.8 Buttress thread form 93 2.2.9 V-thread form 94 2.2.10 Basic Whitworth (55° ) thread form: parallel threads 94 2.2.11 ISO metric and ISO (60° ) unified thread forms 95 ISO metric hexagon head bolts (coarse thread): preferred sizes: product grade A and B 96 ISO metric hexagon head bolts (coarse thread): preferred sizes: product grade C 102 2.5 2.6 2.7 2.8 2.9 2.10 2.11 2.12 2.13 2.14 2.15 2.16 2.17 2.18 2.19 2.20 2.21 2.22 2.23 Hexagon head screws (coarse thread): preferred sizes: product grade A and B 105 Hexagon head screws (coarse thread): preferred sizes: product grade C 112 ISO metric tapping and clearance drills, coarse thread series 117 Hexagon nuts (coarse thread) style 1: product grade A and B (preferred sizes) 117 Hexagon nuts (coarse thread) style 2: product grade A and B (preferred sizes) 119 Hexagon nuts (coarse thread) style 1: product grade C (preferred sizes) 121 Hexagon thin nuts (chamfered) – coarse thread – product grade A and B (also known as lock-nuts) 122 ISO metric hexagon head bolts (fine thread): preferred sizes: product grade A and B 123 Hexagon head screws (fine thread): preferred sizes: product grade A and B 126 ISO metric tapping and clearance drills, fine thread series 131 Hexagon nuts (fine thread) style 1: product grade A and B (preferred sizes) 131 Hexagon thin nuts (chamfered) – fine thread – product grade A and B (also known as lock-nuts) 133 Hexagon slotted nuts and castle nuts 134 Marking threaded fasteners 136 2.18.1 Symbols 136 2.18.2 Identification 136 2.18.3 Marking of left-hand thread 138 2.18.4 Alternative marking 139 2.18.5 Trade (identification) marking 139 ISO metric hexagon socket head screws 139 ISO metric screw threads, miniature series 141 ISO metric tapping and clearance drills, miniature series 142 ISO metric screw threads: constant pitch series 142 ISO pipe thread forms 144 2.23.1 Basic Whitworth thread form: parallel threads 144 2.23.2 Basic Whitworth thread form: taper threads 145 2.23.3 Terms relating to taper pipe threads 145 vii 2.23.4 2.24 2.25 2.26 2.27 2.28 2.29 2.30 2.31 2.32 2.33 2.34 2.35 2.36 2.37 2.38 2.39 Part 3.1 3.2 3.3 3.4 3.5 ISO pipe threads, parallel: basic sizes 146 2.23.5 ISO pipe threads, tapered: basic sizes 148 British Standard Whitworth (BSW) bolts and nuts 152 British Standard Whitworth (BSW) tapping and clearance drill sizes 154 British Standard Fine (BSF) bolts and nuts 155 British Standard Fine (BSF) tapping and clearance drill sizes 157 ISO unified precision internal screw threads, coarse series (UNC) 158 ISO unified precision external screw threads, coarse series (UNC) 161 ISO unified tapping and clearance drills, coarse thread series 163 ISO unified precision internal screw threads, fine series (UNF) 164 ISO unified precision external screw threads, fine series (UNF) 167 ISO unified tapping and clearance drills, fine thread series 169 BA thread form 170 BA threads: tapping and clearance drills 173 Model engineering threads (55° ME) 173 Model engineer clearance and trapping drills 174 Friction locking devices 175 Positive locking devices 177 Cutting Tools (HSS) and Abrasive Wheels Twist drill sizes, metric 183 Gauge and letter size twist drills 197 Hand reamer (normal lead) 200 Long flute machine reamers 202 Machine chucking reamers with Morse taper shanks 203 3.6 Shell reamers with taper bore 205 3.7 Hand taper pin reamer 209 3.8 Counterbores with parallel shanks and integral pilots 211 3.9 Counterbores with Morse taper shanks and detachable pilots 214 3.10 Detachable pilots for counterbores 217 viii 3.11 Countersinks with parallel shanks 218 3.12 Countersinks with Morse taper shanks 218 3.13 Single point cutting tools: butt welded high-speed steel 219 3.14 Tool bits: ground high-speed steel 224 3.15 Milling cutters 226 3.15.1 Cylindrical cutters 226 3.15.2 High helix cylindrical cutters 227 3.15.3 Side and face cutters 228 3.15.4 Staggered tooth side and face cutters 229 3.15.5 Slotting cutters 230 3.15.6 Metal slitting saws without side chip clearance: fine teeth 231 3.15.7 Metal slitting saws without side chip clearance: coarse teeth 233 3.15.8 Metal slitting saws with side chip clearance 236 3.15.9 Convex milling cutters 237 3.15.10 Concave milling cutters 238 3.15.11 Corner rounding concave milling cutters 239 3.15.12 Double equal angle milling cutters 240 3.15.13 T-slot cutters with Morse taper shanks 241 3.15.14 Shell end mills 243 3.15.15 Arbors for shell end mills 245 3.15.16 Screwed shank end mills: normal series 247 3.15.17 Screwed shank slot drills: normal series 249 3.15.18 Screwed shank slot drills, ball nosed: normal series 251 3.16 British Standard centre drill (60° ) 252 3.17 Engineers’ files – popular stock sizes 253 3.18 Miscellaneous files 255 3.18.1 Needle (Swiss) files 255 3.18.2 Milled tooth files 255 3.19 Hacksaw blades (high-speed steel – all hard) 256 3.20 Bonded abrasives 258 3.20.1 Example of the complete marking of an abrasive wheel 258 3.20.2 Classification of wheel and product shapes by type numbers 259 3.20.3 Maximum permissible peripheral speeds of abrasive wheels 263 ix Appendix Library sets of British Standards in the UK The following libraries hold full sets of British Standards in either paper, CD-ROM or microfiche formats The names of public libraries are shown in italics For other libraries, it is advisable to make prior written application in order to ascertain the hours and conditions for access These sets are for reference only and attention is drawn to Copyright Law ENGLAND Avon Bath Bristol Bedfordshire Bedford Cranfield Leighton Buzzard Luton Berkshire Reading Central Library University of Bath Commercial Library Central Library Cranfield University Public Library Central Library University of Luton Slough Central Library University of Reading Reading College Central Library Buckinghamshire Aylesbury High Wycombe Milton Keynes County Hall College of H & E Central Library Cambridgeshire Cambridge Peterborough Central Library Central Library Cheshire Crewe South Wirral Stockport Warrington Central Library Ellesmere Port Library Central Library Central Library Cleveland Cleveland County Library 362 Hartlepool Middlesbrough Cornwall Redruth Reference Library University of Teesside Truro Cornwall College of Further & Higher Education Reference Library Cumbria Barrow-in-Furness Carlisle Kendal County Library County Library County Library Derbyshire Chesterfield Derby Central Library University of Derby Devon Barnstaple Exeter Plymouth Central Library Central Library Reference Library Dorset Poole Durham Darlington Durham Essex Barking Chelmsford Colchester Ilford Romford Southend-on-Sea Gloucestershire Cheltenham Hampshire Basingstoke Farnborough Portsmouth Southampton Winchester Reference Library The Dolphin Centre College of Technology County Library University Library New College Central Library Central Library Anglia Polytechnic University Library Central Library Central Library College of Arts & Technology Southend Library County Library Public Library Public Library Central Library Highbury College of Technology University Library of Portsmouth Central Library County Library Hereford & Worcester Redditch Redditch Library 363 Hertfordshire Hatfield Stevenage Watford Central Library University of Hertfordshire Central Library Central Library Humberside Grimsby Hull Scunthorpe Central Library Central Library Central Library Jersey St Helier The Jersey Library Kent Bexley Heath Bromley Chatham Maidstone Margate Tonbridge Central Library Central Library Central Library County Library Public Library Central Library Lancashire Blackburn Bolton Preston Leicestershire Leicester Central Library Central Library Institute of Higher Education Central Library Lancashire Polytechnic Loughborough De Montfort University Information Centre University of Leicester University of Technology Lincolnshire Lincoln Central Library Greater London Battersea Chiswick City University Gower Street Hammersmith Haringey Hendon Holborn Islington Kensington Kingston Palmers Green Southwark 364 Reference Library BSI Library Reference Library University College London Central Library Middx University, Bounds Green Central Library The Burroughs The British Library Central Library Imperial College of Science Educational Libraries Kingston University Reference Library South Bank University Stratford Swiss Cottage Waltham Forest Westminster Woolwich Greater Manchester Ashton-under-Lyne Manchester Oldham Salford Wigan Merseyside Birkenhead Liverpool Newham Community College Reference Library Reference Library Waltham College University of Westminster Westminster Libraries Woolwich Central Library Public Library John Rylands University Library Metro University Library Public Library UMIST Library University of Manchester Reference Library College of Technology University of Salford Wigan & Leigh College St Helens Central Library Central Reference Library John Moores University University, Harold Cohen Library Gamble Institute Middlesex Uxbridge Brunel University W Midlands Birmingham Dudley Solihull Walsall West Bromwich Wolverhampton Aston University Chamberlain Square University of Birmingham University of Central England Central Library Coventry University Lanchester University Library University of Warwick Reference Library Central Library Central Library Central Library Central Library Norfolk Norwich County Hall Northamptonshire Northampton Central Library Coventry 365 Northumberland Ashington Nottinghamshire Nottingham Oxfordshire Didcot Oxford College of Arts & Technology County Library Trent University Library University of Nottingham Rutherford Appleton Laboratory Central Library Oxford Brookes University Shropshire Telford St Quentin Gate Somerset Bridgewater County Library Staffordshire Hanley Library Suffolk Ipswich Lowestoft County Library Central Library Surrey Croydon Guildford Sutton Woking Central Library College of Technology Central Library Public Library E Sussex Brighton Reference Library W Sussex Brighton Crawley University of Brighton Public Library Tyne and Wear Gateshead Newcastle Washington Central Library Central Library Polytechnic University of Newcastle Central Library Central Library South Tyneside College County Library University of Sunderland Central Library Warwickshire Rugby Central Library Wiltshire Trowbridge Public Library North Shields South Shields Sunderland 366 N Yorkshire Northallerton York S Yorkshire Barnsley Doncaster Rotherham Sheffield W Yorkshire Bradford Huddersfield Leeds Wakefield N IRELAND Antrim Ballymena Belfast County Library Askham Bryan College Central Library Central Library Central Library Central Library Central Library City Polytechnic Library University of Sheffield Public Library University Library Central Library University of Huddersfield Central Library Metropolitan University University, Edward Boyle Library Library Headquarters Newtonabbey Area Library Central Library College of Technology Science Library, Queens University University of Ulster Armagh Armagh Southern Education & Library Board Down Ballynahinch South Eastern Education & Library Board Tyrone Omagh County Library SCOTLAND Grampian Aberdeen Central Library Lanarkshire Hamilton Bell College of Technology Lothian Edinburgh Central Library Heriot-Watt University Napier Polytechnic University, Engineering Library 367 Strathclyde East Kilbride Glasgow Tayside Dundee Central Library Glasgow University Library The Mitchell Library Strathclyde University Library Forfar Central Library Institute of Technology Forfar Central Library WALES Clwyd Mold County Civic Centre Dyfed Llanelli Public Library S Glamorgan Cardiff Central Library W Glamorgan Swansea 368 Central Library University Library Appendix Contributing companies A J Reeves (Birmingham) Limited Holly Lane Marston Green Birmingham B37 7AW Tel: 0121 779 6831 Fax: 0121 779 5205 Suppliers to Model Engineering Addison Wesley Longman Edinburgh Gate Harlow Essex CM 20 2JE Tel: C44 (0) 1279 623623 Fax: C44 (0) 1279 431059 Website http://www.pearsoned-ema.com 369 This Page Intentionally Left Blank INDEX Abrasive wheels, see Bonded abrasives Acme thread form, see Threaded fasteners Balls, precision, measurement over, 56 Belt drive: crossed, 81 compound, 82 simple, 80 tensioning devices, 83 Bolts: British standard fine (BSF), 155 British standard whitworth (BSW), 152 ISO metric hexagon head, coarse thread, grades A and B, 96 ISO metric hexagon head, coarse thread, grade C, 96 ISO metric hexagon head, fine thread, grades A and B, 123 ISO unified precision external screw threads, coarse thread series (UNC), 161 ISO unified precision external screw threads, fine thread series (UNF), 167 Bonded abrasives: aximum permissible speeds of abrasive wheels, 263 wheel classification, 259 wheel markings, 258 Buttress thread form, see Threaded fasteners Cam milling, see Dividing head Castle nuts, see Nuts Centre drill, British Standard, 252 Chordal distances on pitch circles, 24 ircles, areas and circumferences, Circlips: external (metric), 300 internal (metric), 304 Conversion tables: fractions to decimals, millimetres to inches, minutes of arc to degrees, Cosine, see Trigonometry Counterbores: detachable pilots, 216 371 Counterbores (continued) morse taper shanks for, 218 with morse taper shanks and detachable pilots, 214 with parallel shanks and integral pilots, 211 Countersinks: morse taper shank, 218 parallel shank, 218 Cutting speeds, calculation of, 27 Cutting speeds, typical values for HSS tools, 27, 30 Dividing head: cam milling, 74 differential indexing, 69 helical milling, 70 sector arms, 67 simple indexing, 66 Files: Dreadnought, 255 engineer’s, 253 millenicut, 256 needle (Swiss), 255 Formulae, useful workshop, 26 Friction locking devices, see Threaded fasteners Gear trains: compound, 79 simple, 77 Grinding wheels, see Bonded abrasives 372 Grooved seam joint, see Self secured joint Hacksaw blades (HSS, all-hard), 256 Heat treatment (plain carbon steels): annealing (softening), 348 hardening, 346 tempering, 346 Heights above keyways, calculation of, 26 Helical milling, see Dividing head Helix angles, calculation, 26 Hexagon, distance across corners, calculation of, 26 Joints, see Riveted joints; Self-secured joints Knocked up joint, 342, 344 Locking devices, 175, 177 Lock-nuts, 1232, 133 Measurement: external tapers, 57 internal tapers, 62 balls and rollers, use of, 56 Mensuration of plane figures: circle, 15 ellipse, 16 irregular shapes, 16 parallelogram, 14 rectangle, 14 sector of circle, 16 square, 14 trapezium, 15 triangle, 15 Mensuration of solids: cone, 18 cylinders, 17 frustum of cone, 18 irregular solids, 20 pyramid, 19 regular solids, 19 rectangular prisms, 17 sphere, 18 zone of sphere, 19 Milling cutters (HSS): concave, 238 convex, 237 corner-rounding, concave, 239 cylindrical, 226 double equal angle, 240 end mills, screwed shank, normal series, 247 metal slitting saws with side chip clearance, 236 metal slitting saws without side chip clearance (fine teeth), 231 metal slitting saws without side chip clearance (coarse teeth), 234 shell end mills, 243 shell end mills, arbors for, 245 shell end mills, retaining bolts for, 246 side and face, 228 side and face (staggered tooth), 229 slot drills, screwed shank, normal series, 249 slot drills, screwed shank, ball nose,normal series, 251 slotting, 230 T-slot with morse taper shank, 241 Milling machine spindle nose tapers, see Quick-release tapers Nuts (hexagon): British standard fine (BSF), 155 British standard whitworth (BSW), 152 ISO castle nuts, 134 ISO metric coarse thread, style 1, grades A and B, 117 ISO metric coarse thread, style 1, grade C, 121 ISO metric coarse thread, style 2, grades A and B, 119 ISO metric fine thread, style 1, grades A and B, 131 ISO metric slotted nuts, 134 373 Nuts (continued ) ISO metric thin nuts (lock-nuts) chamfered, coarse thread, grades A and B, 122 ISO metric thin nuts (lock-nuts) chamfered, fine thread, grades A and B, 133 ISO unified precision internal coarse thread series (UNC), 158 ISO unified precision internal fine thread series (UNF), 164 O-rings, see Toroidal sealing rings Paned down joint, 342, 344 Pitch circles, chordal distances on, 24 Positive locking devises, 177 Pythagoras, 34 Quick release (milling machine) tapers – inch units, 24 Quick release (milling machine) tapers – metric units, 22 Radiant temperatures, 348 Radii on bolt ends, calculation of, 26 374 Reamers: hand (normal lead), 199 long flute machine, (metric), 202 machine chucking, morse taper shank, (metric), 203 taper pin (hand), 209 shell, arbors for, 206 shell, with taper bores, 205 Riveted joints: proportions for hole diameter and rivet length, 36 rivet head and shank types, 334 types of, 334 Rivets: cold forged, snap-head, 337 hot forged, snap-head, 339 Roller, precision, measurement over, 56 Screwed fasteners, see Threaded fasteners Screws: ISO metric hexagon head, coarse thread, grades A and B, 105 ISO metric hexagon head, fine thread, grades A and B, 126 ISO metric hexagon head, fine thread, grade C, 112 Self-holding tapers (inch), 22 Self-holding tapers (metric) 20 Self-secured joints, 342 allowances for, 343 Shell reamers, see Reamers Silver (hard) solder and fluxes, 351 Sine, see Trigonometry Sine-bar: constants (250 mm and 125 mm), 40 principles of, 36 use of, 37 Single point cutting tools (turning, shaping and planing) butt-welded, 219 Slotted nuts, see Nuts Socket screws, ISO metric, 139 Soft solders: fluxes for, 349 types of, 349 Sparking plug threads (60° ) SAE, 353 Square, distance across corners, calculation of, 26 Square thread form, see Threaded characters Tangent, see trigonometry Taper pin reamers, see Reamers T-bolts and T-nuts, dimensions for, 290 Taper pins (unhardened), 297 Taper systems (inch units), 22 Taper systems (metric) units, 20 Tapping and clearance drills: British Association (BA) thread series, 173 British standard fine (BSF), 157 British standard whitworth (BSW) thread series, 154 ISO metric coarse thread series, 117 ISO metric fine thread series, 131 ISO metric miniature series, 142 ISO unified coarse thread series, 163 ISO unified fine thread series, 169 Model engineer (ME) thread series, 174 Threaded fasteners: acme thread form, 93 applications of, 92 British Asssociation, 170 Buttress thread form, 93 drawing proportions, 90 friction locking devices, 175 introduction to, 87 ISO metric, constant pitch series, 142 ISO metric miniature series, 141 ISDO pipe threads (parallel and tapered), 144 375 Threaded (continued) Marking, 132 model engineering threads (55° ME), 173 positive locking devices, 177 sparking plug threads (60° SAE), 353 square thread form, 93 V-thread form, 94 Tool bits, ground HSS, 224 Toroidal (O-ring) sealing rings and their housings (inch series), 308 Toroidal (O-ring) sealing rings and their housings (metric series), 314 Triangles, solution of, 34 Trigonaometry: any angle (cosine rule and sine rule), 35 right-angle triangle, 34 T-slot tenons, dimensions for, 295 376 Twist drills: wire gauge (number) and letter sizes, 197 metric sizes, 183 nearest equivalent sizes, V-thread form, see Threaded fasteners Washers: ISO crinkle, 287 plain black (metric), 274 plain bright (metric), 273 serrated, 283 spring, double coil rectangular section, 278 spring, single coil rectangular section, 276 spring, sindle coil square section, 275 toothed, 279 Wire gauge equivalents, 13 Wood screws, hole sizes for, 353 .. .Newnes Workshop Engineer’s Pocket Book This Page Intentionally Left Blank Newnes Workshop Engineer’s Pocket Book Roger Timings OXFORD AUCKLAND BOSTON JOHANNESBURG MELBOURNE NEW DELHI Newnes. .. Blank Preface This pocket book has been prepared as an aid to practising workshop engineers The tables have been selected to provide a quick day-to-day reference for useful workshop information... this book However, wherever this has been done, the reference code for the full Standard is included should this be required For easy reference this book is divided into four parts, namely: workshop