Modern Machine-Shop Practice Part 129

BY

JOSHUA ROSE, M.E.

ILl.u.s.tRATED WITH MORE THAN 3000 ENGRAVINGS

VOLUME II.

NEW YORK

CHARLES SCRIBNER'S SONS

1888

COPYRIGHT, 1887, 1888.

BY CHARLES SCRIBNER'S SONS.

Press of J. J. Little & Co.

Astor Place, New York.

CONTENTS.

VOLUME II.

PAGE

CHAPTER XXII.

=MILLING MACHINERY AND MILLING TOOLS.=

=The Milling Machine=; Advantages possessed by 1 The hand milling machine 1 Power milling machine 2 Universal milling machines 2, 3 The Brown and Sharpe Universal Milling Machine, general view of 4 The construction of the bearings and of the head 5 Sectional view of head 6 The dividing mechanism 6 The index plate 7 Table of index holes for gear cutting 7 The automatic feed motion 8, 9 Special index plate for gear cutting 9 The Brainard Milling Machine 9 The various attachments of 10 The rotary vise 10 Universal head and back centre 10 Universal head for gear cutting 11 The head for cutting spirals 12 The cam cutting attachment 12 The Lipe Universal Milling Machine 12 Sectional view of the Lipe machine 13 The feed motions of the Lipe machine 13 The index head of the Lipe machine 14 The adjustable centre rest 14 The Universal Milling Machine for heavy work 15 Construction of the driving gear and feed motion 15 Pratt and Whitney's double spindle milling machine 16 =Milling Cutters or Mills= 16 to 24 Cutters with spiral teeth 17 Table of sizes of Brown and Sharpe standard cutters 17 Table of standard sizes of Brainard cutters 17 Face cutters 17 Twin cutters and right and left hand cutters 18 Advantages and disadvantages of face cutters 18 Angular cutters 19 Right and left angular cutters 19 The Brown and Sharpe patent cutters 19 Shank cutters 19 The direction of the feed for shank cutters 20 Applications of shank cutters 21 Sizes of shank cutters 21 Fly cutters 21 Different methods of making fly cutters, and the advantages and defects of each method 21 Circular cutters, and holders for fly cutters 22 Matched cutters; methods of matching cutters 23 Gang or composite cutters; cutters with inserted teeth 24 =Cutter Arbors= 25 =Milling= 25 to 30 Comparison of the advantages of end milling, face milling, and twin milling 25 The length of feed in face milling 26 Cutting grooves in cylindrical work 27 Angular cutters for groove cutting 27 The crowding of grooving cutters and how to avoid it 27 The direction of the feed in cutting spiral grooves 27 Setting angular grooving cutters 28 Cutting right and left hand grooves and determining the direction of the feed for the same 29 Fluting twist drills 29 Finding the angle of the cutter in cutting spiral grooves 29 Producing different shaped grooves with the same cutter 29, 30 Holding work on the milling machine; milling taper work 30 =Chucks for Milling Machines= 31 =Vertical Milling Machine= 31 =Profiling Machine= 31, 32 =Grinding Machine=, for milling cutters 32 to 37 Fixture for grinding parallel cutters 32 Errors in grinding milling cutters 32 Grinding thin cutters 33 Grinding taper cutters 33 Fixture for grinding taper work 33 Fixture for taper cutters and for face cutters 34 The position of the emery wheel and clearance on the cutter 35 Grinding the teeth of spiral cutters 36 Positions of emery wheels in cutter grinding as affecting the strength of the cutting edges 36, 37

CHAPTER XXIII.

=EMERY WHEELS AND GRINDING MACHINERY.=

=Grinding Operations=; Cla.s.sification of 38 The qualifications of emery wheels 38 Cements used in the manufacture of emery wheels 38 Grades of coa.r.s.eness and fineness of emery wheels 38 Grades of wheels and the work they are suitable for 39 Speeds of emery wheels 39 Balancing emery wheels 39 =Emery Grinding Machines= 40 The Sellers drill grinding machine 41 The construction of the drill holding chuck 41 Varying the drill position to suit the diameter of the drill, and thus maintain equal conditions for all diameters of drills 41 Errors of construction in ordinary drill grinding machines 41 The construction whereby the Sellers machine maintains an equal degree of clearance from end to end of the cutting edge upon all sizes of drills 41, 42, 43, 44 The Sellers attachment for thinning the points of large twist drills 44 The front rake of twist drills 44 Emery grinder for true surfaces 45 For engine guide bars 45 For car axle boxes 45 Emery grinder with traversing emery wheel 46 For rough work 46 For planing machine knives or cutters 46 Emery wheel swing frame for dressing large castings, &c. 46 Emery belt grinding machine 47 Presenting emery wheels to the work, or the work to the wheels 47 Annular emery wheels 48 Recessed emery wheel 48 The wear of emery wheels 48 =Polis.h.i.+ng Wheels= 49 to 51 The construction of 49 Lapping the leather on 49 Method of keeping them true 50 Charging with emery 50 The speed of 50 Polis.h.i.+ng materials for 50 Brush wheels for polis.h.i.+ng 50 Speed of brush wheels 50 Polis.h.i.+ng materials for brush wheels for bra.s.s work 50 Solid leather wheels 51 Rag polis.h.i.+ng wheels 51 Polis.h.i.+ng materials for rag wheels 51 Polis.h.i.+ng device for engravers' steel plates 51 =Grindstones= and Tool Grinding 51 The various kinds of 51 Suitable for wood working tools 52 Suitable for saws or iron plates 52 The speeds of 52 The changes of pulley diameter necessary as the diameter of the stone decreases in order to maintain a nearly uniform circ.u.mferential speed of grindstone 52 Arrangement of, for saw plates 52 Hacking 53 Device for truing 53 Automatic traversing device for 53 Considerations that determine the position in which the work should be applied to 53 =Oil-stones=, the various kinds of 54 Truing oil-stones 54 Removing the feather edge left by 54 Oil-stoning edge tools 54

CHAPTER XXIV.

=GEAR CUTTING MACHINES.=

=Gear Cutters=--The Brainard Automatic 55 Plan view of the mechanism 55 Method of operating the cutter slide 55 The arrangement of the positive feed s.h.i.+pping motion 55 Arrangement and construction of the dividing mechanism 55 The Brainard half automatic gear cutting machine 56 Gear cutting engine with vertical cutter spindle 56 Gear planing machine 56 Piat's French gear cutting machine 56 to 61

CHAPTER XXV.

=VISE WORK.=

=Definition of Vise Work= 62 =The Vise= 62 The height of vise jaws 62 The wood-worker's vise 62 The Stephens vise 62 Swivelling vises 62 The Prentiss vise 62 Leg vise with parallel motion 63 Various forms of vise clamps 64 =Hammers= 64 The effects of the speed of a hammer blow 65 Experiments by Robert Sabine on the duration of a blow 65 Machinists' hand hammers 66 Shapes of hammer eyes 66 The proper method of putting handles in 67 Paning of pening hammers 68 The plate straightener's and saw maker's hammers 69 The principles involved in straightening plates 69 The dog-head hammer 69 The effects of hammer blows upon plates 69 Saw straightening and saw hammering 70, 71 Machinist's sledge hammer 71 The file cutter's hammers 71 Riveter's hammer 71 The cooper's hammer 71 The mallet 72 Pening or paning 72 Applications of pening to straighten work or refit it 72 Riveting crank pins 73 =Chisels= 73 Forms of bar steel for chisels 73 The widths and thicknesses of the cutting ends of 74 Angles of the cutting edges of 74 Shapes of the cutting edges of 74 Chisel holders 74 Cape or cross-cut 74 Round nosed 75 The cow-mouthed 75 Curved or oil groove 76 The diamond point chisel 76 Applications of machinists' chisels 76 The carpenter's chisel 77 The angle of presentation of chisels 77 =Plane Blades= 77 The form of, necessary to produce a given shape of moulding 77 Finding the shape of knives, plane blades, or cutters necessary to produce given shapes upon the work 78 to 83 Scale for marking out the necessary shapes of moulding knives 83 Instruments for 84 =Files= 85 Shapes of file teeth 85 The cut of files 85 Sizes and kinds of flat files 86 Groubet files 87 Rasps, the kinds and cut of 88 The names of files 88, 89 Round, half-round, and three-square files 90 Knife files, cross files, reaper files, tumbler files 91 The selection of files 91 Putting handles on files 92 Instruction on holding files 92 Slim files 92 The warping of files 93 Using bent files 93 Cross filing 93 Draw filing 94 Cleaning files 94 Filing out round corners 95 Using round files 95 Files for soft metals 95 Resharpening files 95 The Sand Blast process 96 =Red Marking= for vise work 96 =Hack Saw= 97 =Screw Drivers= and their proper shape 97 =Sc.r.a.pers= for true surfaces 97 Angles for the facets of sc.r.a.pers 97 Various forms of sc.r.a.pers 97 =Reamers= 98 The s.p.a.cing of reamer teeth 98 Odd and even numbers of reamer teeth 98 Adjustable reamers 98 Taper reamers 99 Reamers for framing 99 Half-round reamers 99 Square reamers 99

CHAPTER XXVI.

=VISE WORK= (Continued).

=Examples in Vise Work= 100 to 113 The use of chisels 100 File cutting 100 Cutting key seats 101 Sinking feathers in shafts 101 Methods of securing feathers 102 Filing up a double eye or knuckle joint 103 Filing pins 103 Blocks for filing pins 104 Hand vise 104 Filing bolt heads and nuts 104, 105 Making outside calipers 105, 106 Fitting keys 107 Cutting keyways by hand 108 Cutting out keyways by drifts 109 Forms of drifts 109 Methods of using drifts 109 Templates 110 Making male and female templates 110 to 112

CHAPTER XXVII.

=VISE WORK= (Continued).

=Examples in Vise Work= 113 to 127 The various form of connecting rods 113 Solid ended connecting rods 113 Clip ended connecting rod 114 Strap ended connecting rod 115 Double gibbed connecting rod 115 Locomotive connecting rod 115 Bolted connecting rod straps 115 Marine engine connecting rod 116 Tapered connecting rod ends and their advantages 117 Stepped connecting rod straps and their advantages 117 Fitting up connecting rods 117, 119 Welding up stub ends of connecting rods 118 Aligning welded connecting rods 118 Fitting on connecting rod straps 119 Filing out connecting rod keyways 119 Fitting the keys and gibs 119 Fitting connecting rod bra.s.ses to their straps 120, 122 The joint faces of connecting rod straps 121 Disadvantages of joints left open to take up the wear 121 Obviating this disadvantage 121 Marking the lengths of connecting rods 122 Fitting up a fork end connecting rod 122 Aligning fork end connecting rods 123 Repairing connecting rods 124 Setting connecting rod bra.s.ses together 125 Lining up connecting rod bra.s.ses 126 Adjusting the lengths of connecting rods 126 Setting up the keys of connecting rods 126 Shapes of the crowns of bra.s.ses 127 Fitting up a link motion 127 Templates for filing the link slot 127 =Case-hardening= 128 to 133 Sheehan's case-hardening process 128 Preparing work for 129 Setting work after 129 Fitting bra.s.ses to pillow blocks or axle-boxes 130 Bedding bra.s.ses 132 The proper shape for the patterns of bra.s.ses 132 =Originating a True Plane= 133 Finding which of three surfaces is the nearest to a true plane 133 Methods of testing the surfaces 134 A new process of originating surface plates 134 The deflection of surface plates 134 =The Friction of Plane Surfaces= 135 =Oiling True Surfaces= 135

CHAPTER XXVIII.

=ERECTING.=

=Spirit-level= 136 =Plumb-level= 136 =Joints= 136 to 141 Filing or making joints 137 Ground joints 137 Sc.r.a.ped joints 137 Cylinder covered joints 137 Making a sc.r.a.ped joint with the studs in their places 138 Joints for rough surfaces 138 Gauze wire joints 138 Water joints 138 Joints to withstand great heat 138 Rubber joints 139 Boiler fitting joints 139 Easily removable joints 140 Rust or caulked joints; caulking tools 141 Thimble joints 141 Expansion joint 141 =Pipes, c.o.c.ks and Plugs= 141 to 145 Pipe cutters 141 Pipe vises 141 Pipe tongs 143 Erecting pipe work 144 Refitting leaky c.o.c.ks and plugs 144 Grinding c.o.c.ks and-plugs 145 =Boxes and Bra.s.ses= 145 to 149 Fitting bra.s.ses to their journals 145 Various forms of bearings and bra.s.ses or boxes 147 Locomotive axle boxes 148 Lead lined bra.s.ses 148 Open bra.s.ses 149 =Lubrication= 149 to 154 Examples of oil cavities and oil grooves for bra.s.ses 150 Qualities of lubricants 151 Testing lubricants 151 Best method of using thin oils 152 The influence of the atmosphere on oils 153 Longevity of lubricants 153 Testing oils for salts and acids 153 Swiss watchmakers' oil tests 153 The blotting paper oil test 154 =Friction and Wear= 154 Morin's experiments on 154 Order of the value of metals to resist wear 154 White metal or babbitt metal lined boxes 155 Methods of babbitting boxes 156 The pressure on journals 156 =Cranks= 156 Placing at right angles 156, 157 =Engine Cylinders= 158 to 161 Fitting 158 Setting 159 Reboring cylinders in their places 160 Sc.r.a.ping out cylinder ends 161

CHAPTER XXIX.

=ERECTING ENGINES AND MACHINERY.=

=Engine Guide Bars= 162 Setting 162 The spring of 162 Testing 163 Setting by stretched lines 163 =Heating and Knocking of Engines= 164 The ordinary causes of 164, 166 =Aligning New Engines= 166 to 171 Cla.s.sification of the errors in engine alignment 166 Testing the alignment of the crank 167 Showing separately the causes of beating and pounding 168 Methods of discovery and determining the errors of alignment 169 Errors of alignment in crank pins 170 Methods of discovering errors of crank pin alignment 170 Remedying errors of crank pin alignment 171, 172 =Slide Valves= 173 to 175 Finding the dead centre of the crank 173 Taking up the lost motion when setting the valve 174 Measuring the valve lead 174 Finding the dead centre with a spirit level 174 =Setting Eccentrics= on crank shafts 175 Setting double eccentrics by lines 175 =Erecting the Framework= of machinery 176, 177 =Repairing and Patching= broken frames 178 =Erecting an Iron Planer= 179 Foundations for an iron planer 180 Fitting up and erecting a lathe 181 =Testing Lathes= 181 Instruments for testing lathes 182 Testing lathe carriages 183 =Erecting Line Shafting= 184 to 186

CHAPTER x.x.x.

=LINE SHAFTING.=