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Machine Shop Essentials Questions & Answers by Frank Marlow

Machine Shop Essentials covers the use of manually controlled metal lathes, milling machines, and drill presses to make one-of-a kind parts, prototypes, and industrial models, and to modify and repair existing equipment.

Although NC machines dominate today's production environment, manually controlled machine tools are indispensable to R&D labs, tool and die makers, industrial model makers, scientific instrument makers, prototype designers, auto racers, custom motorcycle and car builders, and gunsmiths.

When just a few parts or modifications are needed, manual machines can do the job faster than an expert can write the NC code. Also, manual machines are the best way to learn machine tool basics before going on to NC machines.

Every day valuable engineering developments are made by machinists who, using their ability to make and modify devices, turn a back-of-the-matchbook sketch into a practical and elegant working model. This back-to-basics book will help you accomplish this too.

Machine Shop Essentials includes:

A simple question-and-answer format.

Material divided into small, easy-to-understand blocks.

Over 500 clear, concise drawings.

Step-by-step instructions for common operations on the lathe, drill press, and milling machine, including typical problems and their solutions.

Short cuts, specialized tools, and expert tips on indispensable shop-made tools that will quickly expand the user's capabilities.

The use of machine tool accessories to simplify making complex parts.

Screw threads and non-threaded fasteners.

How to incorporate purchased components such as bearings, gears, snap rings and roll pins to quickly make sophisticated and durable devices.

How to heat-treat steel in the machine shop.

A review of basic precision measuring and marking tools and methods.

General safety issues and special precautions for each tool.

Guidelines for avoiding metal fatigue failures.

Cutting, drilling, and shaping plastic, rubber, and glass are also covered.

An extensive listing of machine shop tools, materials, equipment suppliers, and their web sites.

Machine Shop Essentials is written for a machine shop equipped with a drill press, lathe, milling machine, vertical band saw, bench grinder, and disk grinder. Several hand-held power tools are also needed. They include a Vs-inch variable-speed reversible electric drill, a die grinder, (Dremel®-type grinder, pencil-style electric- or air-driven die grinder) and a Sawzall®-type reciprocating saw.

This book does not cover commercial production where time, tooling, and material costs are paramount. These considerations are not important when making a prototype, model, or replacement part. For this reason the book covers carbide insert cutters and HSS toolbits, and does not go into cutting tools with exotic, wear-resistant coatings. These tools, though great for production, are rarely justified in the prototype shop.

The following list of publications should be on the bookshelf of anyone interested in machine shop work. These books provide valuable information, an excellent overview of tools, supplies, components, and techniques. With the exception of Machinery's Handbook, Table Top Machining, and The Machinist's Bedside Reader Series, all are free upon request. (See Appendix II for details.)

Machinery's Handbook from the Industrial Press Inc.

Table Top Machining by Joe Martin

The Machinist's Bedside Reader Series by Guy Lautard

The Starrett Catalog

The Airgas/Rutland Tool Catalog-Solutions in Tools

The Reid Tool Supply Company Catalog

The Small Parts Inc. Engineering Findings Catalog & Resource Manual

McMaster-Carr Supply Company

Brownells Catalog

The opinion of you, the reader, is valuable, and I am happy to hear your comments and suggestions. Send to: suggestions(g),metalartspress.com

Huntington Beach, California

Frank Marlow

October, 2004

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