Choosing & using the right metal shop lathe / Richard Rex.

Format:

Book

Author/Creator:

Rex, Richard (Technology writer), author.

Language:

English

Subjects (All):

Information technology.

Mechanical engineering.

Physical Description:

1 online resource (338 pages)

Place of Publication:

South Norwalk, Connecticut : Industrial Press, [2022]

Summary:

Investing in a new metalworking lathe is a big step for any shop (especially home shops), where there's usually no one around to help. Once the lathe is up and running, you should theoretically be able to make the special items you previously did without (or paid through the nose for), such as shafts, plain, tapered or threaded discs, bearings, and so on. But if you are new to this, you'll want to know a lot more than you can learn from the salesman or the manual. Does the lathe really match your needs, and if so, how much? Choosing & Using the Right Metal Shop Lathe is an essential source of information for lathe buyers and users at every level, from mini-size tabletops up to industrial machines weighing half a ton or more. It answers the question of what else you will need to get useful work from the machine. For instance, what comes as "standard equipment" with the lathe? Most include a chuck (usually a 4-jaw independent, not the self-centering 3-jaw you'll want to use most of the time), maybe a faceplate (rarely used), and a 4-way toolholder you will probably swap right away for a more sensible design. Never included is a tailstock drill chuck, an essential accessory you will need from day one--and the same goes for actual cutting tools. Almost certainly, there won't be a digital readout (DRO), which used to be regarded as a "maybe-someday" luxury--but not anymore. The work talks about cutting oils, cutting speeds and easier-to-machine materials, and it cautions against buying sets of anything, vs. buying the one accessory you'll truly need. Finally, there are chapters on building a tailstock drill press, a special toolpost for easy screw cutting, and a precision grinder for lathe tools that can be made from oddments of material in a couple of days or less. Features Differentiates between the truly essential features (screw-cutting) and the nice-to-have (power feeding), spindle speed selection from a gearbox (typical) or continuously variable (more convenient). Offers advice on screw-cutting US and metric threads, and handling the machinist's most trouble-prone actions, such as knurling and parting off. Provides a workpiece tutorial that demonstrates many of the commonplace lathe routines--ideal for first-time users.

Contents:

Cover (Choosing &amp

Using The Right Metal Shop Lathe)

Front Matter

Title Page

Copyright

Table of Contents

Acknowledgments

Note from the Author

Chapter 1

Choosing a Lathe

A Selection of Metal Shop Lathes

Mini Lathes

Larger-Model Shop Lathes

Lathe Size

How Big a Lathe Do You Need?

Weight

Bench or Stand Mounting

Handling the Lathe

Spindle Bearings

Spindle Bore

Spindle Speed

Power Requirement

Cross-Slide and Compound Dials

Chucks

What Size of Chuck?

Faceplates

How Do Chucks/Faceplates Attach to Spindles?

Steady Rest and Follower Rest

Lathe Centers

Other Workpiece Holding Accessories

Taper Turning

Screw Cutting and Power Feeding

Gearbox or External Gears?

Everyday Power Feeding Versus Screw Cutting

Saddle Controls

Power-Feed Direction and Left-Hand Threads

Power-Feed Key Facts

The Main Power-Feed Question to Ask

Lathe Refinements

Tailstock Chuck

QCTP Instead of a 4-Way Turret

Tailstock Digital Readout (DRO)

Saddle and Cross-Slide DRO

Installing a DRO

Saddle Stop

What Do You Intend to Do With Your Lathe?

Chapter 2

Turning Tool Basics

Cutting Fluids and Surface Finish Questions

Basic Terminology of Lathe Tools

Lathe Tool Materials

HSS Specifics

Shaping a Lathe Tool

End Relief

Side Relief

Don't Worry About Back Rake

Tool Angle Nomenclature

Tool Height

Think Small

Hone Those Edges

Tuning Up the Grinding Wheel

Tungsten Carbide

Grades of Carbide

Tungsten Carbide Tool Formats

Carbide-Tipped Tools

Indexable Carbide Tools

Screw Cutting Tools

Internal Cutting Tools

Are There Carbide Inserts for Internal Cutting?

Is the Hole the Right Size?

Grinding Internal Tools

Cut-Off Tools

Grooving Tools

Drill Bits

Drill Length

Drill Geometry.

Split-Point Geometry

Drilling Small Holes

Controlling Drill Depth

Deburring a Drilled Hole

Drilling Large Holes

Working with Oversize Drills

Drilling Deep Holes

Drilling a Flat-Bottomed Hole

Screw Cutting Basics

Taps

Hole Sizes for Tapping

Tapping Techniques

Dies

Reamers

Cutting Speeds for Knife Tools

Speeds for Drilling

Cutting Speed and Tool Life

Chapter 3

Add-Ons to Make Life Easier

Is the Compound Really Necessary?

Add Guidelines for Specific Jobs

A New Way of Screw Cutting

Rough-Cutting Metal with a Bandsaw

Block Squaring the Easy Way

Spindle Indexing

Filing Flats on a Workpiece

Drilling from the Tool Post

Tool-Post Grinder

Tailstock Drill Press

Center Height Gauge

An Indispensable Finishing Tool

Workpiece Clean-Up

General Clean-Up in the Shop

Two More Must-Haves

Chapter 4

Things I Wish Someone Had Told Me

How to Level the Lathe

How to Deal With Unexpected Tapers

Aligning the Tailstock

Tailstock Alignment-Quick Method

Tailstock Alignment-Precise Method

When Headstock Alignment Really Matters

Checking Alignment by a "Cut-and-Try" Procedure

Where to Find Accessories and Materials

Do I Need Cutting Oil?

Industrial Cutting Fluids

Spray Bottle Instead of a Coolant Pump

Lubing Taps and Dies

Thread Cutting on Steel

Choosing the Right Kind of Steel

Think Hexagonal

Special Jigs, Fixtures, and Gadgets

Interim Part: Example #1

Interim Part: Example #2

Is It OK to Use a File on Lathe Work?

What Types of File?

Clean As You Go

Removing Broken Taps

Cutting Off

A Cutting-Off Checklist

Carbide Cut-Off Tools Make It Easier

Making a Better Washer

Making Very Thin Washers

Knurling Overview

4-Jaw Versus 3-Jaw Chucks

What Is TIR?

What Size of 4-Jaw Chuck?.

Centering an Odd-Shaped Workpiece

Centering a Round Workpiece

Copying Morse and Jacobs Tapers

Measuring Hole Size

Make a Plug Gauge for Better Predictability

Countersinking Holes

There's No Such Thing As a Simple Job

Planning: Example #1

Planning: Example #2

Planning: Example #3

A Low-Cost Modeling Method

Short Workpieces and Chucks

Scales and Micrometers

Common Steel Alloys

Cast Iron

Chapter 5

Cutting Screw Threads on the Lathe

Screw Thread Basics

Screw Cutting on the Lathe

Low-Cost Tool Blanks

The Screw Cutting Process

Metric Versus US Threads

Thread Depth

The Threading Dial

Setting Up the Compound (Standard Method A)

Setting Up the Compound (Method B)

Why B Versus A?

Method B Is Less Stressful

Making A "Scratch Cut"

Second Pass-Split Nut Engaged Full-Time

Second Pass-Split Nut Disengaged

Depth of Cut

Finishing the Thread

Single-Point Cutting of Internal Threads

Finishing the Thread (Internal)

Left-Hand Screw Cutting

How Small a Thread Can I Cut on the Lathe?

Checking the Thread: Everyday Methods

Checking the Thread: More Exact Methods

Commercial Thread Gauges

Measuring Pitch Diameter with Thread Triangles

Measuring Pitch Diameter with Three Wires

Using the Screw Thread Micrometer

Some of the Finer Points About Screw Threads

Chapter 6

Machinist's Precision Level

Off-the-Shelf Levels

Precision Levels

Zeroing the Level

Level Adjustment

Chapter 7

The Self-Centering Chuck

About the Self-Centering Chuck

Removing the Jaws

Reinstalling the Jaws

A Reliable Way to Correct Runout

Another Refinement

The 6-Jaw Chuck

Long Material

Chapter 8

Knurling

An Overview

Knurl Holders

Knurl Wheels

First, Measure the Knurl Wheel

Knurling Tips

Chapter 9.

Add Versatility by Indexing the Spindle

Unusual Lathe Operations

When the Need Arises for More Flexibility

A Quick-and-Easy Filing Rest

A Tool-Post Drill

Second Thoughts on Universal Joints

Chapter 10

Making a Tailstock Drill Press

Some Benefits

Some Specifics

MT3 Adapter Sleeve for the Tailstock

Arbor and Chuck

Machining the JT1 Chuck Taper

Back Stay and Link Components

Chapter 11

A Toolholder for Easy Screw Cutting

Background and History

Thinking of Making This Toolholder?

Dovetails and Other Details

A Trial Run Can Avoid Mistakes

A Word on Dovetail Cutters

Gib

Machining the Tool Slide

Machining the Base-QCTP Dovetail

Machining the Base-Tool Slide Dovetail

Retractor Block

Bobbin and Shoe

Spring Housing

Hub and Handle

Cam

Thimble

Lead Screw

Stamping the Numbers

Assembling the Toolholder

Chapter 12

Making a Precision Grinder for Lathe Tools

Key Points

Building the Precision Grinder

Motor

Grinding Wheel

Base Plate

Table

T-Square, Wedge, and Guide

T-Square Fittings

Assembling the T-Square And Wedge

Toolholder

Tool Slide

Safety Guard

Using the Tool Grinder

Grinding a Lathe Tool From Scratch

How Large a Blank Do You Need?

Grinding a Knife Tool

Grinding a Thread-Cutting Tool

Diamond Grinding Wheel Option

Appendix

Really New to All This?

The RH Knife Tool

Clamp the Material

First Cut: Facing the Workpiece-Step 1

Reducing the Diameter-Step 2

Turning the Large Diameter-Step 3

Cutting Off the Workpiece

Flipping The Workpiece-Step 4

11/64 Through Hole

Drilling the Counterbore-Step 6

Tapping the ThroughHole-Step 7

Index.

Notes:

Description based on print version record.

ISBN:

0-8311-9615-7