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Tools and Patterns XV v J3 FACTORY MANAGEMENT COURSE AND SERVICE A Series of Interlocking Text Books Written for the Industrial Extension Institute by Factory Man- agers and Consulting Engineers as Part of the Factory Management Course and Service INDUSTRIAL EXTENSION INSTITUTE INCORPORATED NEW YORK ADVISORY COUNCIL NICHOLAS THIEL FICKER, PRES., CHARLES P. STEINMETZ, CMef Consulting Engineer, CHARLES E. FUNK, SECY., General Electric Co. CHAS. A. BROCKAWAY, TREAS., JERVIS E. HARBECK, Vice-Pres. American Can Co. ALWIN VON Auw, Gen. Mgr. Boorum-Pease Co. BENJ. A. FRANKLIN, Vice-Pros. Strathmore Paper CHARLES C. GOODRICH, Co., Lieut. Col. Ord- Goodrich-Lockhart Co. nance Dept. WlLLARD F. HlNE, CHARLES B. GOING, Consulting Appraisal Engi- Formerly Editor, The Engi- neer, Chief Gas Engr., neering Magazine, Con- Public Service Comm. sulting Industrial Engi- N. Y. neer, STAFF. C. E. KNOEPPEL, ORGANIZATION AND ADMINISTRA- Pres. C. E. Knoeppel & Co., TION. Consulting Engineers. MEYER BLOOMFIELD, LABOR AND COMPENSATION. Consultant on Personnel. GEORGE <S. ARMSTRONG, PLANNING AND TIME-STUDY. Consulting Industrial Engineer. H. B. TWYFORD, PURCHASING AND STORING. Purchasing Agent, Nichols Cop- per Co. NICHOLAS THIEL FICKER, INDUSTRIAL COST FINDING, Consulting Industrial Engineer. DWIGHT T. FARNHAM, EXECUTIVE STATISTICAL CONTROL, Consulting Industrial Engineer. WILLARD L. CASE, THE FACTORY BUILDING. Pres. Willard L. Case & Co., Consulting Engineers. DAVID MOFFAT MYERS, THE POWER PLANT. Origgs & Myers, Consulting Engineers. JOSEPH W. ROE, THE MECHANICAL EQUIPMENT. Prof. Machine Design, Sheffield Scientific School, Yale Univ. ALBERT A. DOWD, TOOLS AND PATTERNS. ConsuPing Engineer. WILLIAM F. HUNT, HANDLING MATERIAL IN FACTOR- Consulting Inaustrial Engineer. IES. CHARLES W. MoKAY, VALUING INDUSTRIAL PROPERTIES, Appraisal Engineer, Cooley & Marvin. TOOLS AND PATTERNS BY ALBERT A. DOWD Member A. S. M. E. Consulting Engineer, Specializing in Machine Shop Planning and Tool Designing VOLUME 10 FACTORY MANAGEMENT COURSE INDUSTRIAL EXTENSION INSTITUTE INCORPORATED NEW YORK Copyright, 1918, by INDUSTRIAL EXTENSION INSTITUTE INCORPORATED Copyright, 1920, by INDUSTRIAL EXTENSION INSTITUTE INCORPORATED PREFACE. Many factory executives are chiefly concerned with the commercial end of their business, and yet do not possess the technical training to enable them to judge of the relative value of the methods of production used in their own factory. In this they are at a decided disadvantage. Others, however, do attempt to obtain a technical training while engaged in the management of their plant, and profit largely thereby. A thorough training along mechanical lines may not be neces- sary, but it is an excellent thing for the executive to familiar- ize himself at least with the fundamental principles under- lying mechanical work. Tool equipment needed to produce a given piece of work need not be understood in detail, but the executive should know the difference between a boring bar and a milling cutter, for instance, and should understand something of the reasons why one type of tool is more suited to the work in hand than another. He should also know what reasons there are for planing a piece of work instead of milling it; or boring and reaming instead of drilling. He should know what class of work requires fitting of such a character that the surfaces must be scraped in order to produce a proper bearing. He should understand something about the various machining processes, and also something about grinding. When a turn- ing operation is indicated and when a surface needs to be ground to secure accuracy are all essential points regarding which a progressive executive should be posted. In addition to these, the production of interchangeable work should be grasped in its fundamentals. He should further know the possibilities of gauging work to produce it with a minimum tn PREFACE of expense and within the required limits of accuracy con- sistent with the commercial quality of the product. If the executive does not understand something of these details he must depend entirely on his subordinates for information. In order to assist the progressive man and to enable him to secure concise data on tool equipment in a single volume, this book has been written and arranged. The intention of this treatise has been to take up the points mentioned in such a way that a non-technical man can readily grasp the fundamental principles underlying the matters pertaining to tool equipment. It is the belief of the author that executives will find themselves vastly benefited in their work by a care- ful study of its contents; for it is evident that the man who knows the essential principles underlying the design and up- keep of his tool equipment will be much more likely to obtain maximum efficiency in his product than another who is not so well posted. ALBERT A. DOWD. TABLE OF CONTENTS. CHAPTER I HAND AND FORGED TOOLS PAGE The Details of Manufacturing 1 Manufacturing Conditions 2 Interchangeable Manufacture . 3 Tool Equipment 5 Classification of Hand and Forged Tools 7 Files 8 Hacksaws 10 Cold Chisels 12 Scrapers 15 Forged Tools 19 Grinding Tools 24 Tools for Holders 25 CHAPTER II DROP FORGING AND BLANKING DIES Principles of Drop Forging 26 Dies for Drop Forging 28 Blanking Dies 29 Follow Dies 30 Gang and Compound Dies 31 Forming Dies 32 Sub-Press Dies 34 vii viii TABLE OF CONTENTS CHAPTER III DRILLING, BORING, AND REAMING PAGE Drills 35 Core Drills 38 Counterbores 39 Reamers 41 Inserted-Blade Reamers 43 Taper Reamers 44 Boring Tools 46 Flat-Cutter Boring Bars 48 Adjustable Boring Tool for Tool-Room Work ... 48 Recessing Tools . 50 CHAPTER IV TURNING, FORMING, AND THREADING Hollow Mills 55 Turning Tools 57 Adjustable Turning Tools 58 Open-Side Turning Tools 60 Overhead Turning Tools 60 Turning Tools for Vertical Boring Mills 62 Cutting-off Tools 64 Threading Tools 65 Goose Neck Threading Tool 67 Forming Tools 68 CHAPTER V MILLING AND PLANING Milling Processes 72 Factors Influencing Machine Selection 73 Milling Cutters 75 Slotting Cutters 78 Angular and Special Cutters 79 TABLE OF CONTENTS ix PAGE Gear-Toothed and Form Cutters 81 Miscellaneous Cutters 83 Interlocking Cutters 86 Planing Tools 87 CHAPTER VI BROACHING The Purposes of Broaching 89 Preliminary Treatment 90 Broaching a Square Hole 91 Broaching a Round Hole 92 Four-way Keyway Broaches 94 Broaches for Irregular Holes 95 CHAPTER VII SURFACE AND CYLINDRICAL GRINDING Grinding Material 97 Grinding-Wheel Shapes 99 Surface Grinding Methods 100 Cylindrical Grinding 104 External Taper Work 106 External Form Grinding 106 Internal Grinding 107 Cylinder Grinding 108 CHAPTER VIII SHOP EQUIPMENT Standard Equipment . 110 Surface Plates Ill Straight-edges and Parallels 112 Hand Vises 114 C-Clamps 116 V-Blocks 116 Bench and Pipe Vises 117 x TABLE OF CONTENTS CHAPTER IX MACHINE EQUIPMENT PAGE Necessity for Proper Tools 119 Drill Chucks and Sockets 120 Tapping Attachment for Drill Press 123 Collets and Chucks 125 Step Chucks 126 Two-Jawed Chucks 127 Geared Scroll Chuck 129 Air-Operated Chucks 130 Four-Jawed Independent Chuck 132 Machine and Manufacturing Vises 134 Taps, Dies, and Holders 136 CHAPTER X FIXTURES FOR PLAIN AND STRADDLE MILLING Nature and Variety of Fixtures . 139 Necessity for Proper Holding 140 Milling Fixture for a Connecting Rod 141 Straddle Milling Fixture Working from a Finished Surface 143 Gang Milling 145 End Milling a Slotted Bracket 145 Fixture for Angular Milling 147 Fixture for Form Milling 148 Index Milling a Pair of Levers 149 Index Milling Fixture for Quantity Production . , 150 CHAPTER XI FIXTURES FOR CONTINUOUS MILLING The Value of Simplicity 154 Continuous Milling Fixtures for Cylinder .... 156 TABLE OF CONTENTS xi PAGE " Fixture for Becker" Continuous Milling Machine . 158 Spline-Milling Fixture 160 CHAPTER XII FACE-PLATE FIXTURES Fixtures for Single Pieces 164 Fixtures for Quantity Production 165 Fixtures for Cutting Packing Rings 166 Face-Plate Fixture for a Hub Flange 167 Self-Centering Fixture for a Rough Casting .... 168 Fixture for Thin Aluminum Castings 169 Fixture for an Irregular Bracket 172 Counterbalanced Fixture for a Connecting Ro$ . 173 Fixture with Adjustable Counterbalance .... 175 Eccentric Fixture for a Ring Pot 177 Swinging Eccentric Fixture 178 CHAPTER xni ARBORS AND MANDRELS Definition of Terms 181 Arbor with Expanding Shoes . 183 Split Ring Expanding Arbor 184 Expanding Arbor for Automobile Flange .... 186 Expanding Arbor for an Adjusting Nut .... 188 Expanding Arbor for a Bevel Pinion 189 Expanding Pin Chuck for a Piston 192 Threaded and Knock-off Arbors 194 Knock-off Arbor for Threaded Collars 196 Special Arbor for an Eccentric Packing Ring . 198 CHAPTER XIV GENERATING AND FORMING ATTACHMENTS Generating Curved Surfaces 200 Simple Radius Generating Attachment , . , , . 201 xii TABLE OF CONTENTS PAGE Radius Forming Attachment for Crowning Pulleys . 203 Piston Forming and Grooving Attachment .... 206 Angular Generating Cross-Slide 208 Eccentric Turning Device for Packing Rings . 209 Bevel Generating Attachment for a Turret Lathe . 211 Radius Generating Attachment for a Vertical Turret Lathe 214 Angular Generating Attachment for Vertical Turret Lathe 216 Internal Radius Boring Attachment 217 CHAPTER xv VERTICAL BORING MILL FIXTURES Fundamental Construction Features 220 Vertical Boring Mill for Thin Work 221 Special Fixture with Tapered Plug Locator .... 224 Expanding Arbor and Faceplate for Vertical Boring Mill 226 Vertical Boring-Mill Fixture for a Fragile Aluminum Casting 228 Simple Fixture for Machining an Eccentric .... 231 Sliding Fixture for Boring a Pair of Cylinders . 233 Threaded Knock-off Arbor for Vertical Boring Mill . 235 CHAPTER XVI GRINDING FIXTURES Adaptability of Cutting Fixtures ....... 238 Magnetic Chucks 240 Grinding Fixture for Universal-Joint Part .... 241 Piston Grinding Fixtures 243 Internal Grinding Fixtures 244 Grinding Fixture for Universal Joint Member . 246 TABLE OF CONTENTS xiii PAGE Adaptable Fixture for Grinding Spur Gears .... 248 Adjustable Fixture for Grinding a Bevel Pinion . 250 Grinding Fixture for a Large Bevel Spring Gear . 251 CHAPTER XVII OPEN DRILL JIGS Functions and Operation 253 A Simple Plate Jig 256 Plate Jig with Supplementary Supporting Ring .
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