General Metals (McGraw-Hill Publications in Industrial Education)

514 Pages·1985·100.462 MB·English

by  John Louis Feirer

JohnL .F eirer
McGraw-HiBloio kC ompany
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ProductSiuopne rviLsauorre:n cCeh arnow
CoveDre signReern:e Kei lbride Edelman
CovePrh otograpKheenKr a:r p
LibroafrC yo ngrCeastsa loignPi unbgl icDaattiao n
FeireJro,h nL ouis
Generamle tals.
(McGrwa-Hiplulb ilcatiionni sn dusterdiuacla tion)
Includiensd ex.
SummaryA:n indusetdruicaalt itoenx tboionbk a sic
metalworking.
1.M etal-work-Juvelniitleer atu[r1e.M. e tal­
work]
I.T itleI.I .S eries.
TS205.F3179 85 671 85-184
ISBN0 -07-09280-39
SixtEhd ition
General Metals,
Copyrigh©t' 1986,1 981,1 974,1 967,1 959b y
McGraw-HiIlnlc,A. l ,lrighrtess ervCeodp.y rig©ht
1952b y McGraw-HilIln,c .A llr ightrse served.
Printiendt heU niteSdt ateosfA mericEax.c epats
permittuendd etrh eU niteSdt atCeosp yrigAhctt o f
1976n,o p arotf t hipsu blicamtaiyob ne r eproduocerd
distribiunt eadfn oyr mo rb ya nym eanso,rs torienda
datbaa soer r etriesvyaslt ewmi,t hotuhte p riowrr it­
tenp ermissoifot nh ep ublisher.
2 3 4 5 6 7 DO8C D9O C0 8 9 2 1 0 9 8 7 6
ISB0N- 07-020398-9
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TheM cGraw-HiPlulb licatiinIo nndsu stErdiuacla ticoonn stitau ftuen ctioannadpl r actiscearli es
oft extbodoekssi gnteocd o vetrh eb roaadr eaosfi ndusterdiuacla tiTohnep. u blisahnedrt hec onsulting
editaoirm t op rovitdheefi nesptu blicatpioosnssi bAlletl.h ea uthoarrsee xperatnsdh aved emonstrated
theiarb iliatsim eass tetre achetresa,c heedru catosrksi,l lweodr kerosr,c onsultaTnhtess e.v erbaolo ks
contacianr efuslellye catneddw elolr-ganizseudb jemcatt teTrh.e ya rew rittaenndp reparienda n i nter­
estisntgy latet hep roperre adabilleivteyTl h.e stee xtbocoakrse fuelxlpyl atienc hnitcearlm wsh ent hey
firsatp peaLri.n der awinagnsd p hotograaprheus s eedx tensitvoei llyl ustarnadct lea rimfayn ym eaning­
fuls tatemeanntdsp hraseTsh.i esd itimoank esu seo ft hes econcdo lotro a ccenitl lustraatnidto on s
emphasiszieg nificpaonitn atnsd t opichaela dinNgost.o nldyo esG enerMaelt alcson tamiann yi llustra­
tionbsu,ti tu setsh ema sa m ostp owerfaunlde ffectitveea chitnogo l.
Thes ixetdhi tioofGn e nerMaelt ailssb ased uapv oenr cya refaunla lyosfii sn troducmteotrayl work­
ingc oursienms a nys chooNlesw.t echniqiunte hse v asmte talworkiinndgu stry, refionfte hmebe anstisc
technoloag fyu,l lkenro wledogfei ndusttreicahln oyl,oa gndg reatienret resitnt hec areeorp portunities
int hefi elhda ven ecessitcahtaendg es.
Thea uthoerd,i toarn,dp ublishhoepre t hatth ipsu blicatwiiolsnlu ppltyh es tudewnitt hm any
contempormaertya lworkaicntgi viTthieeyst .r utshta ittw ilals sitshtes tudetnotr ealiazneda ppreciate
moref ultlhye i mpacatn ds ignificoafnm ceet alisnt hei ndusttreicahln ologsioccaileo tfty o day.
ChriHs. G ronen1an
McGraw-HiPlulb licatiinoI nnsd ustrEidaulc ation
ChriHs. G ronemaCno,n sulting Editor
Bookisn S eries
GENERAL INDUSTRIAL EDUCATIONA ND TECHNOLOGY
Gronemaann dF eirer
GENERAL METALS
Feierr
GENERAL POWER MECH ANICS
CrousWeo,r thingtMoanr,g ulaensd,A nglin
GENERAL WOODWORKING
Groneman
GETTINGS TARTEDI ND RAWING AND PLANNING
Gronemaann dF eirer
GETTINGS TARTEDI NE LECTRICITYA ND ELECTRONICS
Gronemaann dF eirer
GETTINGS TARTEDI N METALWORKING
Gronemaann dF eirer
GETTINGS TARTEDI NW OODWORKING
Gronemaann dF eirer
TECHNICALE LECTRICITYA ND ELECTRONICS
Bubaann dS chmitt
TECHNICAL WOODWORKING
Gronemaann dG lazener
UNDERSTANDINGE LECTRICITYA ND ELECTRONICS
Bubaann dS chmitt
.... ..·., . ..·..· .,.... . .... ·
> 1
.C:( )NSN1IIlI"I.I".. Il.I,S.wl ."j "".,,.;
.;'" " • -,,�,.-., ..•...-. '_ .',"_.•,�; �.., w . ...u .�...:..:..., . . .
Preface . DeveloPpaitntge rns
VI 25. 155
CuttSihnegMe ett al
26. 161
Sectio1n: BendiSnhgeM eett ablyH and
27. 168
METALWORKING 1 BendiMnegt oanlt hBea r
28.
FoldoerBr r ake
172
IntrodutcoGt einoenrM aelt als
1. 1 FormiCnygl irincdPaalr otns
Safeitnty h Mee taSlh op 29.
2 .. 3 thFeo rmiRnogl ls
MetalwDoerski gn 176
3. 8 MakiSnega ms
Desigg nPiarn oduct 30. 178
4. 14 WirinagnE dgTeu,r naiB nugr r,
Measurement 31.
5. 17 BeadianngdC, r imping
ReadinagP rianntdM akian g 182
6. FastewniitnRhgi veStcsr,e ws,
Sketch 32.
22 andA dhesives
Metals 187
7. 30 SofSto ldering
PlannaiP nrgo duct 33. 193
8. 43 SpoWte lding
MeasurainndMg a rkiOnugt 34. 199
9. 49 Industrial CMoeltdh-oWdosr king
MakianS gi mple Layout 35. 201
10. 58
CareienrM se talworking
11. 64
Sectio4n: A RT
Sectio2n:
METALA ND JEWELRY 210
BENCHM ETAL 75
IntrodutcoAt riMtoe nt aalnd
IntrodutcoBt einocMnhe tal 36.
12. 75 Jewelry
CuttHienagv Mye tal 210
13. 77 MetaTla ppiCnhga,s ianngd,
DrilalnidnR ge aming 37.
14. 86 DesiSgtna mping
Filing 212
15. 99 ToolMientga l
BendianngdT wistMientga l 38. 214
16. 105 SawianngdP iercing
MachiBneen ding 39. 217
17. 112 AnneaalnidnP gi cklAirntg
DecoratthiSenu gr faancde 40.
18. Metals
EndosfM etal 219
121 SinkainndBg e atDionwgn A rt
GrindMientga ls 41.
19. 123 Metal
SharpeHnainnTdgo ols 220
20. 127 RaisaiB nogw l
UsiAnbgr asfiovPreo sl ishing 42. 224
21. 130 PlanisahnidDn egc orating
CuttTihnrge ads 43. 227
22. 133 Etching
AssembwliitnMhge taFla steners 44. 231
23. 144 Metal Enameling
45. 234
SolidneAgrr Mte tals
Section 3: 46. 238
MakiLnega dSetda iGnleads s
SHEETM ETAL 153 47. 242
Buffinagn dC oloring
48. 243
IntrodutcoSt hieoMenet t al MetaSlp inning
24. 153 49. 247
•
IV
Sectio5n: Sectio1n0:
METALF INISHING 253 FASTENINGM ETHODS 383
IntrodutcoMt eitoanl FinishingI ntroidotunoc W teldinagn d
50. 253 72.
Opaq.au nedT ranspFairneinsth es OxygCeunt ting
51. 257 383
ElectroapnldBa ltaicnkg- Oxide GasW eldinCgu,t ting, and
52. 73.
Finishing Brazing
261 385
IndusFtirniiaslh ing ArcW elding
53. 264 74'. 394
IndusWterlidaiPlnr go cesses
75. 400
IndusAtsrsieamlMb eltyh ods
Sectio6n:
76. 405
FORGING 272
11:
SectionM ANUFACTURING
IntrodutcoFt oirogni ng
54. 272
HanFdo rging METALP RODUCTS 409
55. 274
MachiFnoer gainndOg t her
IntrodutcoMt eitoanl
56.
77.
Hot-ForPmrioncge sses
Manufacturing
281 409
OrganizoafIt nidouns try
78. 412
ProdEuncgti neering
Sectio7n:
79. 414
ProdiuocPntl anning
CASTING 286
80. 416
PeopalnedP roceisns es
81.
IntrodutcoFt oiuonnd ry
Manufacturing
57. 286
419
MakianM ge taCla sting
MarketMientgaP lr oducts
58. 289
82. 420
IndusCtasrtiialMn egt hods
MasPsr oducitnti hoSenc hool
59. 302
83.
Shop
422
Sectio8n:
MACHINING 309
Sectio1n2 :H IGHT ECHNOLOGY
IN METALWORKING 428
BasMiacc hinMientgh ods
60. 309
PreciMseiaosnu rement
Computientr hsMe e talworking
61. 321
84.
TheE ngiLnaet hIet-Ps-a rts
Industries
62.
428
andA ccessories
325 Industrial Robots
85. 437
Turnbientgew enC enters
63. 331 ManufactSuyrsitnegm s
86. 446
MachinWionrgk piHeecleidsn
64.
aC huck
339
13:
TheS haper Section
65. 344
TheM illMiancgh ine PROJECTS 458
66. 351
PreciGsriionnd ing
67. 357 BencMhe taaln dW rougMhett al
459
AdvanTceecdh niques in
SheMeett al
68.
465
�1etalworking
ArMte taanld J ewelry
361
473
MachiSnheo Fpo,u ndFroyr,g ing,
Sectio9n:� H EAT TREATING andH eat Treating
476
AND MATERAILST ESTING 367
AppendMiext:rC iocn version
Heat-TrMeeattailnsg TabfloeDr r ills
69. 367 482
HardnTeessst ing Glossary
70. 374 484
TestMientgaP lr operties Index
71. 377 498
v
JohnL .F eiriesra d istingufiaschueldst cyh olaatrW e ster�n; {ichUingiavne rsiinKt ayl maazooH.e
receivheidBs .S.d egrefer omt heU niversoifWt iys consin-wShteoruhete ,m ajoriednm etalworkHien g.
alshoo ldasn M.S.d egrefer omt heU niversoiftM yi nnesoatnad a doctoraftreo mt heU niversoift y
OklahomHai.sm anyy earosft eachienxgp erieinnccel updoes itiionan n su mbeorf j uniaonrd s enihoirg h
schooilnts h eM idwest.
Dr.F eiriesra ctiivnei ndustarritaoslr ganizatainodhn ass w rittweind eliynt heh 0ldH.e isp ast
executeidviet oofrI ndustErdiuacla timoanga zinceo,- aut(hwoirt Ch. H .G ronemaonf)G enerIanld us­
triEadlu cataionndT echnol(oMgcGyr aw-Hi1l9l8,6a )n dt heG ettiSntga rtseedr i(eMscG rawH-il1l9,7 9),
anda uthoorfM achinTeo oMle talwork(iMcnGgr aw-Hi1l9l7,3 ).
GenerMaelt ahlass b eenw idelayc ceptaesad b asimce talworktienxgt bofookar l mostth redee cades.
Revisisoinnsc teh ep ublicaotfit ohnefi rsetd itihoanv eb eenf oundeudp ont wop rin1abrays e(s1:t) h e
resulotfqs u estionnsaeinrtteo ts e acheurssi ntgh eb ooka nd( 2e)x tensrievvei eowfl iteraitnum reet als
technoloWgiyt.ht hiasp proacthh,ea uthohra sm adee verayt temtpotk eepa breaosfbt o tehd ucational
andt echniacdavla nces.
Thist,h es ixetdhi tioofGn e neral Mreetparless,ea nntost hreerv isiHoonw.e vetrh,e m ajofre atuorfe s
theo rigiendailt iaorner etainTehdeb. a sisct ructiuser ses entitahlesl aym eT.h e boiosdk i vidiendt o main
sectiaonndsu nitesa,c hu nittr eattihnegb asic tmoaotlesr,i palrso,c essaensdr, e latiendf ormatfiooran
specisfitce ipnm etalworkTihnegb .o oks trestsheeis l lustraaptpirvoea tcohi nstrucatnidoe na,c ihl lustra­
tiohna sb eenc arefuslellye cftoetrd h ep urpo.s e
.W hilteh ifsu nctiopnaatlt ehrans b eenm aintainneudm,e roucsh angehsa veb eenm adet or eflect
contempordairrye ctiinotn hsefi eldi,n cluditnhgef ollowing:
1.T echnicianlf ormatiinto enx atn di llustrahtaisbo enesnu pdatetdh roughout.
2.M ajotre chnitcearlm asr ep rintiendb oldfatcyep aen dd efineodn fi rsuts eo;t hetre chnitcearlm asr e
italicainzded de fineAdl.lb oldfatceerdm asr ei ncludienad n ewg lossary.
3.I nformatointo hnem etriscy steomfm easuremheanstb eene xpandtehdr oughoMuett.r iecq uivalents
follcouws tomamreya suremeinntt hset exMte.t rics bheaevnae d detdo m ostt ablaensdm anyi llustra­
tions.
A newu niotn l eadesdt aingelda sasn dn ewm aterioanls sa fetcya,r eewresl,d inagn,dg atisnygs tems
4.
haveb eena dded.
Importannetw u nitosnc omputeirnms e talworkiinndgu striinedsu,s tJroibaolt asn,dm anufacturing
5.
systehmesl tph es tudelneta ranb ouctu rremnett atle chnology.
6.S evernaelw p roject suggaerseit nicolnusd ed.
GenerMaelt ailssp lannfeodtr h eg eneral-msehtoaapln dt heg eneral-metaolfg eanreersaah lo ipn a
rangoef c areer-educpartoigorna mWsh.i lbee ginnicnlga ssmeasyd oc reatiwvoerk o nliyn t hea reaosf
benchs,h eeatn,d a rmte taslt,u denhtasv ea no pportuntiort eya adb ouatl alr eaosfm etalwoArskt .i me
ande xperiepnecrem it, stmuadyem natkser epresentpartoijveeac ntdss tudoyc cupatiaonndts e chniques
ino thearr eaTsh.i nse we ditimoene ttso dayn'ese df oarn i ntroducyteotcr oym,p rehensmievtea,l working
text.
JohnL .F e irer
•
VI
1
SECTION
contmaaniynm etpaalr Dtisyd.o euv esrt op
toc onsihdowe treh steh isnc gamteo b e
madeT?h ea nswietsrh t at ehya rteeh p rod­
ucotfts h sek ainlcdlo oepriaotnt hoofu sands
oefn igenesrt,ce hnicainasdnk si,wl olkreedr s
who kmeua soefm etaalnosdt hmeatre arlis.
TheU nietdS ttaeissa h uegw okrshop
Arwee l viinignt he tmaaelg, et ehe lec­
from eatlwkoirnTgh.em etlawokrinignu ds­
troangitech, ae t omaiegct, h jeea tg, eo rt eh
tyre mpylsaog raet mnbueorfw okrer.Ts he
aeorsapcaege ?A ctluyaw,le alvriien igna ll
valoufies tfi nishperdo duecxtcsete hdtao sf
oft heasgee s a.Ht o woenvceterhp,eor ducts
mosott hiednru stMreiteaislts. h rea mwa te­
ofto adyt'esc hnyao rldeoe gpenodnep nartt s
rioaftl h iidnsu tsrEyel.c triiiscts isotc uyeor f
madeo fm etl(a Fi1g-..1L o)oku p!T hel oud
powerS.ic nes om anyp orducts maardeoe f
blsayto u hceolaudbr e a j tea,r oectko,ra
metla,t he fiemledat lwokofigr n isv eyr
missTihleems.aec heisna rmea deo fm etla.
lrag.eT hikn oi-ftt hceha ncaersme ore
Thea ttcrteain vewb udiilsni gny oucriy t
thnao ne tietnnh aytowu i blelw okrinign
thmee atlwkonirgi dnursyst omeyd.a
Fi.1g 1- Thimsod erhne loiptceirsa n
011-
metavleh icbluei mlostlt yo flg ihtm ateri­Whati gs enrealm etals?
alssu cahsa lumuimn dat nitiaunm.n i(tUed
Geenarlm etasil tsh set yuo dfa lals pects
TechnolsoC goripe).
ofm etlawkoirnTgh.e sien cel buedcnh,
sheaentda, r mte tlaj;we eyl;rm etafilni s­h
infgro;gn ig;c astmiacnhgi;n hienatgtr; e at­
inmga;t earltisse tiwnegl;d ainnodgt hfesar­
tenimnegt hsoa;dn md etlma anuafcutring.
Youw idlolw okrs ilmrait ot hadto nbeyt he
milonlsio fe ngeirn,se tecihcnnisa,a nd
skillseedm iasnwkdoi rlklieentrd hs me e tal­
wornkgii nudsyt( rFi1g2-)..
Whyt akae c oursei n
genearlm eta?l s
Theer miushc moret og enemreatla ls
thamnak inagf we smalll o mjbecetttash at
1
J
5.Y ouw ilhlav et hoep protnuiyt to
applyt y wohhuaav el eraneidnm athmeat­
icasn sdc ience.
6.Y oum ayd eevloaph obby.
7.Y ouw illler anh ow toc onuscttr
metpaorld ucatnshd o w tos elaepcpotrp ri­
atmea terials.
8.Y ouw ielxlop erlc raeetrhsea xti isnt
thfiee lodfm etlawonrgk.i
9.Y ou wilblu iilnedter stiprnjogce ts
witthh ei lyslouksa qcueia rnfdee plr iidnae
jbow eldlo en.
Fig1.2- Thsis klilde aricfrtaw orkmeurs t Youw illelra nt olv iea nwdo rwki th
10.
knwo how tou she antdo oTlhsje.o obfa i­r ohte.r s
carfwto rkieosrn eo ft hmea nyc aresei rn
them etlasi dnustr(yoL.c hkeedA ircfrta Skislb laisc
Company) tom etalwroknig
Beofryeo cua bne gtiomn a kea p orjcet
youc atnka eh omeH.er ei s twy houa will
inm eatlwoyroksu,oh ullder anh ow tow okr
accpolmi isnyho u rc ourisnge e nemreatll:as
saefliynt hseh ohpow, t os elaencddte isng
1.Yo u wilgla iannu nedrsdtiannogf
porjcet,hs ow troe addrw ainsgh,o wt op lna
Amernii cdnausyt( rFi1g3-.) .
ap rjoceth,o wt oc hoomseet aalnshd,o w to
2.Y ouw ialclq uhiarnead n mda chei n
measeau nrmda kel yaoutWsh.e yno huav e
skills.
3.Y ouw ildle vleospae wf orknigh ab-
its. Fi1g4.- Thsui nqiueh otiebsl u imlostt loyf
Youw illl eranw hagtoo dd esing is metaaln dp lsaitcsA.g reaatm ounotfl aed
4.
iuss efdo srou nd barersrib etweenr oosm.
anhdo wt op lna,d esiagnncd,o tnrsupcorjt­
(eLadI dnusrtisAe sosciation)
ec(tFsi 1g4-.) .
Fi1g.3- Thsees utdnetaser laernign how
idnustyrp roudcsem etlap roucdts(.Ut neid
TehcnolgoiseC orp).
2
laerdn tehetshneig sy,o uar ea dryfero t he
itnerteisenxgp ieencreo fm akisnogmt ehing@ EXTRCAR EDIT
wortihlwoehfm et.aT lhuoghy omua yn ot
1.F idno uatl ylou c ana bouotn eo ft hfeo ­l
havet htei e:p1o rs klilto m akep orjcetisn
lowgi pneoplRee.p too rnt htap esron's
evyea rrae,y owui hlalve a c hancteol a ern
acvtiitsi inteh mee tawlorkifnige Pladu:l
abotuehtm a ll. Revere,E lWih ityn,Te hmoas Edison,
Henyr Fodr,W alteCrh yrselr,W ililam
Knudsen,H enyr Bessemre,J an Matezl­
(1) QUESTIONS iegra,nd E jlaiMhc Coy.
2.T altko a f rieonrnd e ihgbor wwhoors ki n
thmee tawlorknigi dnustrAys.kt hpee r­
1 .N amet haeer aso fm etalwrokicnogv ­
soanb outth jeo abn da bouttr naiinfgo r
erebdy t htee rgme nearlm etals.
it. tRo enpt ohsrii nc als.s
2.L sit1 0r esaonsw hy yous houtladek a
cousrei ng enermaetlas l.
Youw iglelmt o reo uotfs hoapci tvities
andy ourf utuer craeeirfy o u avoiadc ci­
den.It tsi s asrtmto cbraeeu flf,roa na cci­
dencta cnha negy ourl ei.f
Safteyi is mprotainnat li ln dtursieadlu ­
catiaocntt iivWeihse.ny o gute jabo ini n­
dustyor rb useisnysou, w illr qebueei drt o
obsertvhee e tssyat farnddtsah twa eere stab­
lsihebdyt hUe. SC.on rgseisn 1 790w itthh e
pasasgeo ft heO ccupatinoalS afteya nd
HeatlhA ct( OSHA)T.h esset rrieclgt­ua Fi.g2 -1T hsiw omani s mae cahniicna
setemlil Slh.ei ws e arisnagf egtalys saens d
tiopnorsvd iep ortcetiforonb otthh eem ­
a harhda tF.o wro rako rundn oiys ma­
polyeaen dt hee1n p olyeirna lals peocft s
chnies,t heea prr otesco tnto hrhea dr hat
worMka.n ys tahtaveesp asselwdas s iimlr a
mustb el woeretdoc ovetrhe ea sr.(n Ilad n
tot hfede earllw a.M orea nmdo r,et ehsree g­
StelCe ompany)
uloantsia pplyt ob oth irinedasun sdt
scohlos. galssoersg ogegslb,u ta lssaotn dardfros
Safetsytn adrad,es sbtlsaihebdyl wa are gudarsn,o iasneda rip olilo,une tlcetircal
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3