FMFINAL_TradeSec 2 6/4/13 2:46 PM Page i A Guide to Manufacturing Machine Shop Practices Machine Shop Trade Secrets S E C O N D E D I T I O N James A. Harvey I N D U S T R I A L P R E S S FMFINAL_TradeSec 2 6/4/13 2:46 PM Page ii A full catalog record for this book is available from the Library of Congress. ISBN 978-0-8311-3477-8 Industrial Press, Inc. 32 Haviland Street South Norwalk, Connecticut 06854 Sponsoring Editor: John Carleo Developmental Editor: Robert Weinstein Interior Text and Cover Design: Janet Romano Copyright © 2013 by James A. Harvey All rights reserved.With the exception of quoting brief passages, no part of this publication ii may be reproduced or transmitted in any form without written permission from the copy- right owner and the publisher. No warranties are given in connection with the accuracy of the statements made in this publication and no responsibility can be taken for any claims that may arise. Nothing con- tained in Machine Shop Trade Secrets, Second Edition shall be construed as a grant of any right of manufacture or sale in connection with any method, process, apparatus, or product and nothing contained in this publication shall be construed as a defense against any alleged infringement of letters patent, copyright or trademark, or as a defense against any liability for such infringement. Comments, criticisms and suggestions are invited, and should be forwarded to: James A.Harvey 12112 St. Mark St., Garden Grove, CA 92845 FMFINAL_TradeSec 2 6/4/13 2:46 PM Page iii T A B L E O F C O N T E N T S List of Figures v Acknowledgements ix Introduction xi Chapter 1 Work Fast 1 Chapter 2 Get It Right 23 Chapter 3 Do It the Easy Way 43 Chapter 4 Make ‘Em Look Good 71 Chapter 5 Help for Novices 85 Chapter 6 More Shop Talk 107 Chapter 7 The Cutter Caper 137 Chapter 8 Threads and Things 161 Chapter 9 Help for Engineers 185 iii Chapter 10 Rotary Table Magic 197 Chapter 11 Taming Warp 205 Chapter 12 Be Square 211 Chapter 13 Mold Making Tips 219 Chapter 14 Get Your Grinder Goin’ 233 Chapter 15 The Incredible CNC 251 Chapter 16 Shop Math Wizardry 279 Chapter 17 Odds and Ends 283 Chapter 18 Tell Me Something I Don’t Know 295 Appendix 1: Project Drawings 303 Appendix 2: Chapter 16 Solutions 313 Appendix 3: More Trade Secrets 315 Index 317 FMFINAL_TradeSec 2 6/4/13 2:46 PM Page iv FMFINAL_TradeSec 2 6/4/13 2:46 PM Page v L I S T O F F I G U R E S Chapter 1 Work Fast Figure 3-16 Stop pins for machine table 53 Figure 1-1 Full-width cuts 3 Figure 3-17 Two vises on machine table 53 Figure 1-2 Modified drill bit shanks 4 Figure 3-18 Long parallels supporting part 54 Figure 1-3 Stub drills 5 Figure 3-19 Dressing edges 54 Figure 1-4 Speed chuck 6 Figure 3-20 Lining up center punch mark 55 Figure 1-5 Slide fixture 7 Figure 3-21 Hand drilling a perpendicular hole 56 Figure 1-6 Rough milling 8 Figure 3-22 Measuring ID with gauge pin 57 Figure 1-7 Mist sprayer 9 Figure 3-23 Silver soldering band saw blades 58 Figure 1-8 Cold cut saws 11 Figure 3-24 Counterboring with rotary table 59 Figure 1-9 Stack milling 12 Figure 3-25 Long part holding fixture 60 Figure 1-10 Tapping stack of parts 13 Figure 3-26 Tumbled part 60 Figure 1-11 End mill counter boring with lathe 13 Figure 3-27A Cutting angle on plate edge 61 Figure 1-12 Deep hole drilling 15 Figure 3-27B Aluminum nests 61 Figure 1-13 Angle-head die grinder 16 Figure 3-28 Angle fixture with tapped holes 62 Figure 1-14 Milling arc 17 Figure 3-29 Poor man’s universal angle fixture 63 Figure 1-15 Cutting spheres 17 Figure 3-30 Positioning end mill tangent 64 Figure 1-16 Stubby end mills 18 Figure 3-31 Indicating shaft center. 65 Figure 1-17 Single flute hex cutters 18 Figure 3-32 Indicating to find center 66 Figure 1-18 Wipe away gritty material 19 Figure 3-33 Setting vise angles 67 Figure 3-34 Flat bottom drills 67 Chapter 2 Get It Right Figure 3-35 Reverse boring 68 Figure 2-1 Dial calipers 24 Figure 2-2 Stoning table 26 Chapter 4 Make ‘Em Look Good Figure 2-3 Check tram for perpendicularity 27 Figure 4-1 Blending surfaces 73 Figure 2-4 Notifying next machinist 28 Figure 4-2 High helix end mills 74 v Figure 2-5 Jamming a vise handle 30 Figure 4-3 Honing tools with a diamond lap 75 Figure 2-6 Alignment holes 31 Figure 4-4 Scotch-Brite® finishing 76 Figure 2-7 Depth marker 32 Figure 4-5 Six jaw chucks 77 Figure 2-8 Leveling a lathe 33 Figure 4-6 Aluminum soft jaws 78 Figure 2-9 Indicating tailstock 34 Figure 4-7 Perishable vise jaws 79 Figure 2-10 Indicating before cutting a ramp 35 Figure 4-8 Orbital sanding 79 Figure 2-11 Cosine error 36 Figure 4-9 Sanding surface plate 80 Figure 2-12 Pecking against the quill stop 37 Figure 4-10 Filed corners 81 Figure 2-13 Clamping on cutter radius 38 Figure 4-11 Dedicated countersinks 81 Figure 2-14 Indicating ram 39 Figure 4-12 Deburring tools for small holes 82 Figure 2-15 Wrapping parts for heat treatment 40 Figure 4-13 Live centers 83 Chapter 3 Do It the Easy Way Chapter 5 Help for Novices Figure 3-1 Lining up vises and plates 44 Figure 5-1 Computer-aided machining 86 Figure 3-2 Modified Indicol® holder 45 Figure 5-2 Unsafe disk sanding 87 Figure 3-3 Grinding vise mounted in mill 46 Figure 5-3 Unsafe lathe condition 89 Figure 3-4 Cutting angle with lathe 47 Figure 5-4A Cleared lathe tool 89 Figure 3-5 Emergency collets 47 Figure 5-4B Quill of the mill 90 Figure 3-6 A screw in a collet stop 48 Figure 5-5 Hand stamping 90 Figure 3-7a Ultra thin parallels 48 Figure 5-6 Spreading Dykem® 91 Figure 3-7b Slot milling 48 Figure 5-7 Total indicator reading 92 Figure 3-8 Boring bar held in V-block 49 Figure 5-8 Drop indicator 93 Figure 3-9 Screw plate 50 Figure 5-9 Large vernier calipers 94 Figure 3-10 Cutting hole in sheet metal 50 Figure 5-10 Machining Plexiglas 95 Figure 3-11 Double sticky tape 51 Figure 5-11 Vertical band saw 96 Figure 3-12 Subplates 51 Figure 5-12 Tear drop file 97 Figure 3-13 Subplate in a vise 52 Figure 5-13 Drill gauge 98 Figure 3-14 Drywall screw removing chips 52 Figure 5-14 Tools for deburring holes 98 Figure 3-15 Clearing chips with wire cutters 52 Figure 5-15 Corncob cutters 99 FMFINAL_TradeSec 2 6/4/13 2:46 PM Page vi Figure 5-16 Folding a band saw blade 100 Figure 7-14 End mill grinding fixtures 149 Figure 5-17 An SLA model 101 Figure 7-15 Boring out broken taps 150, 151 Figure 5-18 Lofted surfaces 102 Figure 7-16 Perfect chip 152 Figure 5-19 Filing a part in a lathe 103 Figure 7-17 Inspecting a lathe tool radius 152 Figure 7-18 Shim stock template 153 Chapter 6 More Shop Talk Figure 7-19 Trepanning tool 153 Figure 6-1A Indexing with a V-block 108 Figure 7-20 Center cutting end mills 154 Figure 6-1B Indexing head 108 Figure 7-21 Sharpening taps 154 Figure 6-2 CNC indexing heads 109 Figure 7-22 Sharpening reamers 155 Figure 6-3 Clamping over air 110 Figure 7-23 High helix end mills 157 Figure 6-4 Four jaw chuck 111 Figure 7-24 Shortening center drill tips 157 Figure 6-5 Removing blind bushing 112 Figure 7-25 Left-hand brazed carbide lathe tool 158 Figure 6-6 Spring loaded band saw stop 113 Figure 7-26 Ejector pins 159 Figure 6-7 Slitting saws 114 Figure 7-27 Cutters from standard end mills 159 Figure 6-8 Angle reference cut 115 Figure 6-9 Setting lathe tool with scale 116 Chapter 8 Threads and Things Figure 6-10 Cleaning file 117 Figure 8-1 Unified thread 162 Figure 6-11 Broaching 117 Figure 8-2 Die button threading 168 Figure 6-12 Using punch marks to locate parts 118 Figure 8-3 Adjustable die buttons 169 Figure 6-13 Colored tape 119 Figure 8-4 Broken tap removers 169 Figure 6-14 Bench vise 119 Figure 8-5 Geometric die heads 170 Figure 6-15 Modifying soft jaws 120 Figure 8-6 External thread gauge 171 Figure 6-16 Installing a shop rag 121 Figure 8-7 Threading with tool inverted 172 Figure 6-17 Pinch-type quill stop 122 Figure 8-8 Hand tapping 173 Figure 6-18 Cutter and surface width 123 Figure 8-9 Tapping block 174 Figure 6-19 Writing on metal 124 Figure 8-10 Stick wax 175 Figure 6-20 Setting end mill with shim stock 124 Figure 8-11 Threaded part 175 Figure 6-21 Measuring ID 124 Figure 8-12 Clutch-type tapping heads 176 vi Figure 6-22 Holding a gear with soft jaws 125 Figure 8-13 Tap extension 177 Figure 6-23 Loosening a chuck 125 Figure 8-14 Repairing a damaged thread 178 Figure 6-24 Turning lathe part in mill 125 Figure 8-15 Knurling 179 Figure 6-25 Strap clamp in vise 126 Figure 8-16 Test knurl 181 Figure 6-26 Removing discoloration 126 Figure 8-17 Finishing a knurl 182 Figure 6-27 Criterion® boring head 127 Figure 6-28 Applying layer of cutting oil 128 Chapter 9 Help for Engineers Figure 6-29 Work stops 129 Figure 9-1 Welding a pin and base 186 Figure 6-30 Angling a boring bar 129 Figure 9-2 Internal corners 187 Figure 6-31 Eliminating chatter 130 Figure 9-3 Tapping holes 189 Figure 6-32 Single flute milling 131 Figure 9-4 Press fits 190 Figure 6-33 45° fly cutter 131 Figure 9-5 Diameters of a lathe part 191 Figure 6-34 Clamping parts with paper 132 Figure 9-6 Fillet dimensions on lathe parts 192 Figure 9-7 Knife edges 192 Chapter 7 The Cutter Caper Figure 9-8 Hidden lines 193 Figure 7-1 Deckel® cutter grinder 138 Figure 9-9 Flex type bar clamps 195 Figure 7-2 Single-flute cutters 139 Figure 7-3 Inserts in negative rake cutters 141 Chapter 10 Rotary Table Magic Figure 7-4 Web-thinned drill bits 142 Figure 10-1 Indicating part on a rotary table 198 Figure 7-5 Single-flute carbide cutters 143 Figure 10-2 Indicating spindle over a part 199 Figure 7-6 Hex cutters 144 Figure 10-3 Checking for concentricity 200 Figure 7-7 Square shanked boring bar 145 Figure 10-4 Counter boring with a rotary table 201 Figure 7-8 Boring bar grinding 145 Figure 10-5 Spring loaded scribe 202 Figure 7-9 Slitting saws 146 Figure 7-10 Stagger tooth key cutters 146 Chapter 11 Taming Warp Figure 7-11 Sheet metal drills 147 Figure 11-1 Shimming a warped part 206 Figure 7-12A Outside radius cutters 148 Figure 11-2 Indicating a long bar flat 207 Figure 7-12B Final sizing outside radius cutters 148 Figure 11-3 Indicating on a surface plate 208 Figure 7-13 Small form tools 149 FMFINAL_TradeSec 2 6/4/13 2:46 PM Page vii Chapter 12 Be Square Figure 15-8 Chamfering tool on edge 259 Figure 12-1 Square blocks 212 Figure 15-9 Chamfer tool offset from edge 259 Figure 12-2 Modified ball bearing 212 Figure 15-10 Inconsistent chamfer 259 Figure 12-3 Squaring process 213 Figure 15-11 Cutting holes into a tilted part 261 Figure 12-4 Side milling 214 Figure 15-12 Camworks® icon 261 Figure 12-5 Squaring a block with a fly cutter 215 Drawing 15-1 Views of an adapter plate 262 Figure 12-6 Machinist’s square 216 Figure 15-13 A part setup 262 Figure 12-7 Squaring gauge 217 Figure 15-14 Selecting a tool 263 Figure 15-15 Cutting time 264 Chapter 13 Mold Making Tips Figure 15-16 Override buttons 267 Figure 13-1 Small cutter extension 220 Figure 15-17 Center drill 267 Figure 13-2 Copper EDM electrode 221 Figure 15-18 Tool Length / Diameter Offsets 268 Figure 13-3 Graphite EDM electrodes 222 Figure 15-19 Part after running all the tools 270 Figure 13-4 Machining and holding electrodes 223 Figure 15-20 Completed adapter plate 270 Figure 13-5 Demagnetizing parts 224 Figure 15-21 Cutting surfaces with 3D moves 271 Figure 13-6 Measuring with gauge blocks 225 Figure 15-22 Important CNC machine features 273 Figure 13-7 Checking for concentricity 226 Figure 15-23 Power up / restart button 273 Figure 13-8 Checking cutter angle 226 Figure 15-24 Features for changing tools 274 Figure 13-9 Grinding pin diameters 227 Figure 15-25 EOB and Write / Enter buttons 275 Figure 13-10 Polishing with Simichrome® 228 Figure 15-26 Home button 276 Figure 13-11 Blending weld on mold parts 229 Figure 15-27 Cycle Start button 276 Figure 13-12 Ejector pin bushing 230 Chapter 16 Shop Math Wizardry Chapter 14 Get Your Grinder Goin’ Figure 16-1 Grinding material 280 Figure 14-1 Blending a surface with Dykem® 234 Figure 16-2 Ball height 280 Figure 14-2 Porous grinding wheels 235 Figure 16-3 Puzzle 281 Figure 14-3 Heavy cut with a surface grinder 236 Figure 16-4 Height and angle of a ladder 281 Figure 14-4 Blocking parts with radius gauges 237 Figure 14-5 Measuring part with gauge blocks 238 vii Figure 14-6 Dowel pin supports 239 Chapter 17 Odds and Ends Figure 14-7 Grinding angle and straight section 239 Figure 17-1 Stress/strain curve 284 Figure 14-8 Dressing angle on wheel 240 Figure 17-2 Tall vise jaws 285 Figure 14-9 Magnetic sine plates 241 Figure 17-3 Aluminum anodized surfaces 286 Figure 14-10 Grinding slender pins 241 Figure 17-4 Black oxidizing screws 286 Figure 14-11 Sliding gauges on and off a magnet 242 Figure 17-5 Electropolishing 287 Figure 14-12 Wheel dresser for pedestal grinder 243 Figure 17-6 Mapp® gas torches 290 Figure 14-13 Norbide® stone 243 Figure 17-7 Left-hand drill bits 292 Figure 14-14 Dressing the side of a wheel 244 Figure 17-8 Keenserts® 293 Figure 14-15 Versatile wheel dresser 245 Figure 14-16 Fence for back rail 245 Chapter 18 Tell Me Something I Don’t Know Figure 14-17 Side wheeling 246 Figure 18-1 Slinkys® 297 Figure 14-18 Abrasive cutoff wheels 247 Figure 18-2 Cone-shaped edge finder 298 Figure 14-19 Grinding on the skew 248 Figure 18-3 Kellering 299 Figure 18-4 Friction sawing a file 300 Chapter 15 The Incredible CNC Figure 18-5 Eyeballing a vise 301 Figure 15-1 Planning for fewest setups 253 Figure 15-2 Adding tap drill 254 Appendices Figure 15-3 Fixtures in a drawer 255 Figure A2-1 Solution to Problem 8 313 Figure 15-4 Clamping large remnants 256 Figure A3-1 Part requiring multiple setups 315 Figure 15-5 Tool holder interference 257 Figure A3-2 Center punch made from a tap 316 Figure 15-6 Long tools and tall parts 258 Figure A3-3 Dressing shop stones 316 Figure 15-7 Simulated chamfering tool 259 FMFINAL_TradeSec 2 6/4/13 2:46 PM Page viii FMFINAL_TradeSec 2 6/4/13 2:46 PM Page ix A C K N O W L E D G E M E N T S I’d like to thank my wife Reyna for putting up with the long hours I’ve spent in front of the computer instead of with her; my daughter Joanna, who inspired me to stick with the project; and my son Billy for the hours of entertainment he’s provided. I am grateful for the support of Ann Fahl, who did much of the editing for the 1st edition, and Robert Weinstein, whose masterful eye was indispensable for bringing together this 2nd edition. I’d also like to thank Janet Romano and John Carleo, from Industrial Press, whose hard work turned this edition into reality. And a salute to some of my direct and indirect mentors: Bob Pequinot, Bill Glaze, Mike Davis (deceased), Eugene Sterncorb, and Juvencio Arancibia. ix