Audel Automated Machines and Toolmaking

503 Pages·2004·23.059 MB·English

by  Rex Miller, Mark Richard Miller

Audel™
Automated Machines
and Toolmaking
All New 5th Edition

Audel™
Automated Machines
and Toolmaking
All New 5th Edition
Rex Miller
Mark Richard Miller
Vice President and Executive Group Publisher:Richard Swadley
Vice President and Executive Publisher:Robert Ipsen
Vice President and Publisher:Joseph B. Wikert
Executive Editorial Director:Mary Bednarek
Editorial Manager:Kathryn A. Malm
Executive Editor:Carol A. Long
Senior ProductionManager:Fred Bernardi
Development Editor:Kevin Shafer
Production Editor:Vincent Kunkemueller
Text Design & Composition:TechBooks
Copyright © 2004 by Wiley Publishing, Inc. All rights reserved.
Copyright © 1965, 1970, and 1978 by Howard W. Sams & Co., Inc.
Copyright © 1983 by The Bobbs-Merrill Co., Inc.
Copyright © 1986 by Macmillan Publishing Company, a division of Macmillan Inc.
Published simultaneously in Canada
No part of this publication may be reproduced, stored in a retrieval system, or transmitted
in any form or by any means, electronic, mechanical, photocopying, recording, scanning,
or otherwise, except as permitted under Section 107 or 108 of the 1976 United States
Copyright Act, without either the prior written permission of the Publisher, or authoriza-
tion through payment of the appropriate per-copy fee to the Copyright Clearance Center,
Inc., 222 Rosewood Drive, Danvers, MA 01923, [phone], fax [phone].
Requests to the Publisher for permission should be addressed to the Legal Department,
Wiley Publishing, Inc., 10475 Crosspoint Blvd., Indianapolis, IN 46256, [phone],
fax [phone], E-mail: [email protected].
Limit of Liability/Disclaimer of Warranty: While the publisher and author have used their
best efforts in preparing this book, they make no representations or warranties with respect
to the accuracy or completeness of the contents of this book and specifically disclaim any
implied warranties of merchantability or fitness for a particular purpose. No warranty may
be created or extended by sales representatives or written sales materials. The advice and
strategies contained herein may not be suitable for your situation. You should consult with a
professional where appropriate. Neither the publisher nor author shall be liable for any loss
of profit or any other commercial damages, including but not limited to special, incidental,
consequential, or other damages.
For general information on our other products and services, please contact our Customer
Care Department within the United States at [phone], outside the United States at
[phone], or fax [phone].
Trademarks:Wiley, the Wiley Publishing logo, Audel, and related trade dress are trade-
marks or registered trademarks of John Wiley & Sons, Inc., and/or its affiliates in the
United States and other countries, and may not be used without written permission. All
other trademarks are the property of their respective owners. Wiley Publishing, Inc., is not
associated with any product or vendor mentioned in this book.
Wiley also publishes its books in a variety of electronic formats. Some content that
appears in print may not be available in electronic books.
Library of Congress Cataloging-in-Publication Data:
ISBN: 0-764-55528-6
Printed in the United States of America
10 9 8 7 6 5 4 3 2 1
Contents
Acknowledgments xv
About the Authors xvii
Introduction xix
Chapter 1: Jigs and Fixtures 1
Jigs 1
Clamp Jig 1
Box Jig 6
Fixtures 11
Summary 13
Review Questions 14
Chapter 2: Helix and Spiral Calculations 15
Milling a Helix 15
Angle of Table Swivel 17
Lead of the Machine 19
Change Gears 20
Change-Gear Train 20
Change-Gear Ratio 22
Change-Gear Calculations 22
Milling a Spiral 25
Summary 28
Review Questions 28
Chapter 3: Spur Gear Computations 31
Evolution of Gears 31
Gear Teeth 33
Gear Tooth Terms 34
Spur Gear Computations 36
Involute Gears 48
v
vi Contents
Summary 50
Review Questions 51
Chapter 4: Gears and Gear Cutting 53
Development of Gear Teeth 53
Diametral and Circular Pitch Systems 54
American Standard Spur Gear Tooth Forms 55
Gear-Cutting Operations 59
Cutting Spur Gears 59
Cutting Bevel Gears 66
Cutting Helical Gears 82
Cutting Rack Teeth 86
Cutting Worm and Worm Wheel Teeth 89
Summary 93
Review Questions 94
Chapter 5: Cams and Cam Design 97
Cam Principles 97
Uniform Motion Cams 98
Uniformly Accelerated Motion Cams 99
How a Cam Operates 100
Cam Design 101
Displacement Diagrams 101
Design for Gas Engines 105
Design for Automatic Screw
Machines 107
Drawing the Cams 124
How to Machine Cams 137
Transferring the Cam Outline 137
Machining the Cam Outline 137
Summary 141
Review Questions 141
Chapter 6: Dies and Diemaking 143
Cutting or Punching Dies 143
Plain Die 143
Self-Centering Die 144
Contents vii
Shaping Dies 147
Plain Bending Die 147
Curling Die 148
Wiring Die 149
Bulging Die 150
Combination Punching and
Shaping Dies 151
Double-Action Dies 152
Plain Drawing Die 153
Redrawing Die 153
Gang and Follow Dies 155
Compound Die 156
Miscellaneous Dies 157
Diemaking Operations 160
Lubricants 160
Materials for Making Dies 161
Laying Out Dies 161
Laying Out the Design on the Die 165
Making the Die 166
Hardening and Tempering 168
Summary 169
Review Questions 170
Chapter 7: Grinding 173
Cylindrical Grinders 173
Centerless Grinders 179
Basic Principles 180
Abrasive-Belt Centerless Grinding 190
Advantages of Centerless Grinding 190
Internal Grinding 191
Rotating-Work Machine 191
Internal Centerless Grinding Machine 192
Cylinder Grinding Machine—Stationary
Work 193
Surface Grinders 194
Planer-Type Surface Grinders 196
Rotary-Type Surface Grinders 196
viii Contents
Cutter and Tool Grinding 197
Grinding Cemented Carbide Tools 198
Cutter Sharpening Machines 198
Barrel Finishing (Abrasive Tumbling) 199
Summary 204
Review Questions 205
Chapter 8: Laps and Lapping 207
Laps 207
Classification 207
Materials 207
Lapping Powders 210
Lapping Operations 210
Hand Lapping 211
Machine Lapping 212
Lapping a Cylinder 213
Lapping a Tapered Hole 214
Rotary Disc Lap 214
Honing 215
Summary 218
Review Questions 218
Chapter 9: Toolmaking Operations 221
Introduction 221
Allowances and Tolerances 223
Precision Measurements 224
Tolerance Limits 224
Fits and Fitting 226
Limits of Fits 227
Layout 229
Laying Out the Workpiece 253
Drilling Center Holes 256
Locating Center Points with Precision 256
Checking the Square 275
Sine Bar for Measuring Angles 275
Summary 284
Review Questions 285