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engineer-mechanical:machining [2019/06/11 01:01]
jjensen [Threading]
engineer-mechanical:machining [2019/07/30 16:47] (current)
jjensen [Ganesh GT-1640S Lathe]
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 +===== Kennedy Kit - Style No 520b =====
 +  * {{engineer-mechanical:​machining:​kennedy-kit-style520b.png|Kennedy Kit Style 520b}}
 +  * Top Storage - Lid
 +    * {{engineer-mechanical:​machining:​kennedy520-topstoragelid.png|Kennedy Top Storage Lid}}
 +    * Parts dish holder
 +    * magnetic clip
 +    * Angle Angle Gauge - Wixey
 +    * Digital clock
 +    * Flashlight
 +  * Top Storage
 +    * {{engineer-mechanical:​machining:​kennedy520-topstorage.png|Kennedy Top Storage Lid}}
 +    * Screw driver
 +    * Eye loupe set
 +    * Micrometer, 0-1"
 +    * Scissors
 +    * Plyers
 +    * Pocket Protector
 +      * center punch, spring loaded - [[https://​www.harborfreight.com/​spring-loaded-center-punch-621.html|Harbor Freight #621]]
 +      * highlighter - yellow
 +      * machinist rule - SPI 6" long flexible steel rule
 +      * pen - medium (1.0mm) blue BIC cristal
 +      * pencil
 +      * pocket paper pad/​notebook
 +      * sharpie - medium and fine (blue, red, black, green)
 +      * scribe with magnetic tip
 +    * Allen wrenches
 +    * Utility knife
 +    * tape measure
 +    * Opt-visor
 +    * Safety glasses
 +  * Drawer One Left
 +    * {{engineer-mechanical:​machining:​kennedy520-drawer1-left.png|Kennedy Drawer One Left side}}
 +    * Machinist square
 +    * radius gauges
 +    * ear plugs
 +  * Drawer One Right
 +    * {{engineer-mechanical:​machining:​kennedy520-drawer1-right.png|Kennedy Drawer One right side}}
 +    * Calculator
 +    * Pin Micrometer (possibly remove, limited use)
 +  * Drawer Two Left
 +    * {{engineer-mechanical:​machining:​kennedy520-drawer2-left.png|Kennedy Drawer Two left side}}
 +    * Thread Micrometer
 +    * Knurler
 +  * Drawer Two Right Top
 +    * {{engineer-mechanical:​machining:​kennedy520-drawer2-right-top.png|Kennedy Drawer Two right side - top}}
 +    * Screw Pitch Gauge
 +    * Thread Ring Gage
 +      * S.C.C. 3/​4"​-16UNF-2A from [[https://​www.ebay.com/​str/​Anderson-Tooling-Inc-2|Anderson Tooling, Inc.]] 641-469-6667,​ 200 N 6th St, Fairfield IA 52556
 +        * Go Pitch Diameter 0.7079"​
 +        * NoGo Pitch Diameter 0.7029"​
 +      * Shars 1/2-13 UNC from [[https://​www.ebay.com/​itm/​SHARS-1-2-13-UNC-GO-NO-GO-THREAD-RING-GAGE-2PCS-SET-NEW/​301657871590|ebay - discount_machine]]
 +        * Go Pitch Diameter
 +        * NoGo Pitch Diameter
 +  * Drawer Two Right Bottom
 +    * {{engineer-mechanical:​machining:​kennedy520-drawer2-right-bottom.png|Kennedy Drawer Two right side - bottom}}
 +    * surface roughness comparator
 +    * telescope bore gauge
 +  * Drawer Three
 +    * {{engineer-mechanical:​machining:​kennedy520-drawer3.png|Kennedy Drawer Three}}
 +    * carbide inserts
 +    * center drill
 +    * dial indicator
 +    * magnifier
 +    * dial calipers
 +    * bore micrometer
 +  * Drawer Four
 +    * {{engineer-mechanical:​machining:​kennedy520-drawer4.png|Kennedy Drawer Four}}
 +    * carbide insert
 +    * tool holders
 +    * CXA tool holders
 +
 ===== Machining Student Tool List ===== ===== Machining Student Tool List =====
   * Pocket protector   * Pocket protector
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   * Textbooks   * Textbooks
     * Machinist Handbook     * Machinist Handbook
-  * References+=== References ​for Tool List ===
     * MrPete222 - [[https://​www.youtube.com/​watch?​v=-AQtuvzx6a4|Beginners Machinist Tool Box pt2 Tips #443 tubalcain]]     * MrPete222 - [[https://​www.youtube.com/​watch?​v=-AQtuvzx6a4|Beginners Machinist Tool Box pt2 Tips #443 tubalcain]]
 +      * <​html><​iframe width="​560"​ height="​315"​ src="​https://​www.youtube.com/​embed/​-AQtuvzx6a4"​ frameborder="​0"​ allow="​accelerometer;​ autoplay; encrypted-media;​ gyroscope; picture-in-picture"​ allowfullscreen></​iframe></​html>​
     * Tom Lipton - oxtoolco [[https://​www.youtube.com/​watch?​v=7xX69e0sawE|Machinist apprentice toolbox]]     * Tom Lipton - oxtoolco [[https://​www.youtube.com/​watch?​v=7xX69e0sawE|Machinist apprentice toolbox]]
 +      * <​html><​iframe width="​560"​ height="​315"​ src="​https://​www.youtube.com/​embed/​7xX69e0sawE"​ frameborder="​0"​ allow="​accelerometer;​ autoplay; encrypted-media;​ gyroscope; picture-in-picture"​ allowfullscreen></​iframe></​html>​
     * Keith Fenner - Turn Wright Machine Works [[https://​youtu.be/​RLcAg7CEKuA|What'​s in your Box]]     * Keith Fenner - Turn Wright Machine Works [[https://​youtu.be/​RLcAg7CEKuA|What'​s in your Box]]
 +      * <​html><​iframe width="​560"​ height="​315"​ src="​https://​www.youtube.com/​embed/​RLcAg7CEKuA"​ frameborder="​0"​ allow="​accelerometer;​ autoplay; encrypted-media;​ gyroscope; picture-in-picture"​ allowfullscreen></​iframe></​html>​
 ==== Tool Cart ==== ==== Tool Cart ====
  
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   * Step 3 - determine feeds and speeds   * Step 3 - determine feeds and speeds
     * Spindle speed, N in revolutions per minute (rpm) = 12V/πD, where V = cutting speed in feet per minute, D = diameter of workpiece (Machinery'​s Handbook 27th, p. 1016)     * Spindle speed, N in revolutions per minute (rpm) = 12V/πD, where V = cutting speed in feet per minute, D = diameter of workpiece (Machinery'​s Handbook 27th, p. 1016)
 +      * recommend max 100 RPM, too slow tears the metal, too fast and difficult to disengage thread cutting within the thread relief so you can easily damage the workpiece or tool.
     * "The feed used for tapping and threading must be equal to the lead (feed = lead = pitch) of the thread being cut" (Machinist Handbook, 27th, p. 1064)     * "The feed used for tapping and threading must be equal to the lead (feed = lead = pitch) of the thread being cut" (Machinist Handbook, 27th, p. 1064)
   * Step 3 - Machinery Handbook   * Step 3 - Machinery Handbook
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       * Minor Diameter Tolerance (External Threads) (1) UNR Classes. To intersection of rounded root with its centerline (see Figs. 2 and 3), equals pitch diameter tolerance for class of thread specified, plus 0.10825318P (see Table 5). (2) UN Classes 1A, 2A, and 3A. To intersection of flat root with flanks of threads (see Figs. 2 and 3), equals pitch diameter tolerance for class of thread specified, plus 0.21650635P (see table 5). (ASME B1.1-2003 UNIFIED INCH SCREW THREADS, p. 58)       * Minor Diameter Tolerance (External Threads) (1) UNR Classes. To intersection of rounded root with its centerline (see Figs. 2 and 3), equals pitch diameter tolerance for class of thread specified, plus 0.10825318P (see Table 5). (2) UN Classes 1A, 2A, and 3A. To intersection of flat root with flanks of threads (see Figs. 2 and 3), equals pitch diameter tolerance for class of thread specified, plus 0.21650635P (see table 5). (ASME B1.1-2003 UNIFIED INCH SCREW THREADS, p. 58)
       * {{engineer-mechanical:​machining:​thread-pitch-diameter-tolerance.png|Table 4 Increments in Pitch Diameter Tolerance - Class 2A}}       * {{engineer-mechanical:​machining:​thread-pitch-diameter-tolerance.png|Table 4 Increments in Pitch Diameter Tolerance - Class 2A}}
-    * Depth of cut is Major - Minor diameter (don't be confused with radius or diameter, lathe manufactures understand you can't cut a radius on the lathe, only can cut diameter so the dial dimensions are  +    * Depth of cut is Major - Minor diameter (don't be confused with radius or diameter, lathe manufactures understand you can't cut a radius on the lathe, only can cut diameter so the dial dimensions are for diameters) 
-for diameters)+    * Compound Rest/Slide measures true distance which is the radius 
 +    * Carriage Cross Slide and associated DRO measures diameter, because you can't cut radius on a lathe, half the distance of the Compound rest. So moving the cross slide 0.010 actually moves .005 and cuts the material .005 on each side.
     * {{engineer-mechanical:​machining:​threads-shop-reference-p270.png?​500|Fig 1 - Cutting Screw Threads}}     * {{engineer-mechanical:​machining:​threads-shop-reference-p270.png?​500|Fig 1 - Cutting Screw Threads}}
   * Step 4 - face workpiece and if going to use the tail stock to hold the workpiece, add center drill   * Step 4 - face workpiece and if going to use the tail stock to hold the workpiece, add center drill
-  * Step 5 - turn workpiece to within major diameter range +  * Step 5 - turn workpiece to within major diameter ​(nominal diameter - allowance) ​range 
-  * Step 6 - cut thread relief groove/​undercut to the minor diameter +  * Step 6 - cut thread relief groove/​undercut to the thread ​minor diameter ​using parting blade 
-  * Step 7 - lathe - change gears to required TPI and reduce spindle RPM speed to 1/4 turning speed around 70 RPM for mild steel. +  * Step 7 - cut chamfer to depth of minor diameter at beginning of thread 
-  * Step - rotate compound rest in-feed to 29-29.5 degrees. Both cross slide and compound set to 0. Use center/​fishtail gage to verify 60 degree angle of cutting tool and proper alignment with workpiece. +  * Step 8 - lathe - change gears to required TPI and reduce spindle RPM speed to 1/4 turning speed around 70 RPM for mild steel. 
-  * Step - paint layout fluid (Dykem) on workpiece, touch off work piece and do a very light pass (0.001"​). Use thread gage to measure markings.+  * Step - rotate compound rest in-feed to 29-29.5 degrees. Both cross slide and compound set to 0. Use center/​fishtail gage to verify 60 degree angle of cutting tool and proper alignment with workpiece. 
 +  * Step 10 - paint layout fluid (Dykem) on workpiece, touch off work piece and do a very light pass (0.001"​). Use thread gage to measure markings.
     * engage half-nut lever at the same number to avoid problems     * engage half-nut lever at the same number to avoid problems
     * "​Usually,​ even-number threads per inch can be cut by engaging the half-nut lever at any number on the thread dial, and odd-number threads per inch are cut by engaging the half-nut lever at the odd numbers on the dial." (Precision Machining Technology, p. 425)     * "​Usually,​ even-number threads per inch can be cut by engaging the half-nut lever at any number on the thread dial, and odd-number threads per inch are cut by engaging the half-nut lever at the odd numbers on the dial." (Precision Machining Technology, p. 425)
     * MSC Direct [[https://​www.mscdirect.com/​product/​details/​01221043|screw pitch gage]]     * MSC Direct [[https://​www.mscdirect.com/​product/​details/​01221043|screw pitch gage]]
-  * Step 10 - depth of cut = compound-rest distance x cos 30 degrees, 0.010" cos 30 = 0.00866"​+  * Step 11 cross slide depth of cut = .75 H 
 +    * H = cos30 / TPI = .86602540 / TPI 
 +    * compound rest depth of cut = .75 Pitch (remember Pitch = 1/ TPI) 
 +      * depth of cut = compound-rest distance x cos 30 degrees, 0.010" cos 30 = 0.00866"​
     * Benefits of using compound rest     * Benefits of using compound rest
       * cut only on one side of the bit       * cut only on one side of the bit
-      * faster - only have to advance the compound-rest,​ don't have to worry about DRO, just turn cross feed out one full turn, move carriage back to start of the thread, advance cross fee back in one full turn, then advance compound rest 0.02" to make another pass on the threads+      * faster - only have to advance the compound-rest/slide, don't have to worry about DRO, just turn cross slide out one full turn, move carriage back to start of the thread, advance cross fee back in one full turn, then advance compound rest/slide (e.g. 0.002"to make another pass on the threads
     * Disadvantage - have to calculate the thread depth using cos 30 degrees     * Disadvantage - have to calculate the thread depth using cos 30 degrees
     * {{engineer-mechanical:​machining:​thread-compound.jpg?​400|Figure 1-0 Thread Definition, Precision Machining Technology, p. 416}}     * {{engineer-mechanical:​machining:​thread-compound.jpg?​400|Figure 1-0 Thread Definition, Precision Machining Technology, p. 416}}
-    * Formula to calculate the depth of thread, d see Machinery'​s Handbook 27th Edition, p. 1725+    * Formula to calculate the depth of v-thread, d see Machinery'​s Handbook 27th Edition, p. 1725
       * {{engineer-mechanical:​machining:​depthofthread-machinery27-p1725.png|Figure 1-0 Machinery'​s Handbook 27th, p. 416}}       * {{engineer-mechanical:​machining:​depthofthread-machinery27-p1725.png|Figure 1-0 Machinery'​s Handbook 27th, p. 416}}
-  * Step 11 - measure pitch diameter+  * Step 12 - measure pitch diameter
     * MS Direct - Fowler [[https://​www.mscdirect.com/​product/​details/​06024491|screw thread micrometer]]     * MS Direct - Fowler [[https://​www.mscdirect.com/​product/​details/​06024491|screw thread micrometer]]
-  * Step 12 - screw on nut+  * Step 13 - screw on nut 
 +    * Not accurate, can have the nut fit but the no-go gage doesn'​t fit, thread cut to deep
   * {{engineer-mechanical:​machining:​thread-definition.jpg|Figure 1-0 Thread Definition, Precision Machining Technology, p. 416}}   * {{engineer-mechanical:​machining:​thread-definition.jpg|Figure 1-0 Thread Definition, Precision Machining Technology, p. 416}}
   * {{engineer-mechanical:​machining:​kennametal-threaddefinition.png|Figure 1-0 Thread Definition, Kennametal.com,​ p. D-82}}   * {{engineer-mechanical:​machining:​kennametal-threaddefinition.png|Figure 1-0 Thread Definition, Kennametal.com,​ p. D-82}}
Line 736: Line 816:
         * {{engineer-mechanical:​machining:​thread-helixangle.png|Helix Angle}}         * {{engineer-mechanical:​machining:​thread-helixangle.png|Helix Angle}}
           * see Machinery'​s Handbook, 27th Ed, p. 1966           * see Machinery'​s Handbook, 27th Ed, p. 1966
 +
 +==== Threading Videos ====
 +  * Overview of Thread Making - not helpful if wanting to learn how to cut threads on a manual lathe
 +    * <​html><​iframe width="​560"​ height="​315"​ src="​https://​www.youtube.com/​embed/​7PlZSFXupig"​ frameborder="​0"​ allow="​accelerometer;​ autoplay; encrypted-media;​ gyroscope; picture-in-picture"​ allowfullscreen></​iframe></​html>​
 ===== Drilling ===== ===== Drilling =====
   * {{engineer-mechanical:​machining:​fundmoderndraftp323-drilltypes.png|Figure 1-0 Typical types of machining operations depicted on working drawings, Fundamentals of Modern Drafting by Paul Ross Wallach, Chapter 18 - Working Drawings, p. 323}}   * {{engineer-mechanical:​machining:​fundmoderndraftp323-drilltypes.png|Figure 1-0 Typical types of machining operations depicted on working drawings, Fundamentals of Modern Drafting by Paul Ross Wallach, Chapter 18 - Working Drawings, p. 323}}
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     * \$11 [[https://​www.ebay.com/​itm/​SHARS-P2N-P-Type-5-64-x-1-2-x-4-1-2-HSS-Cut-off-Cut-Off-Parting-Blade-New/​301099665727?​hash=item461af0493f:​g:​mHUAAOSwy5ZXC6xw|ebay - Discount Machine]]     * \$11 [[https://​www.ebay.com/​itm/​SHARS-P2N-P-Type-5-64-x-1-2-x-4-1-2-HSS-Cut-off-Cut-Off-Parting-Blade-New/​301099665727?​hash=item461af0493f:​g:​mHUAAOSwy5ZXC6xw|ebay - Discount Machine]]
   * Knurling tool   * Knurling tool
 +
 +==== Ganesh GT-1640S Lathe ====
 +  * Speeds (RPM) - 30, 55, 70, 95, 160, 200, 325, 540, 700, 1000, 1600, 2000
 +  * Feeds
 +<​html>​
 +<​table>​
 +<tr>
 +  <​th>​Setting</​th>​
 +  <​th>​1</​th>​
 +  <​th>​2</​th>​
 +  <​th>​3</​th>​
 +  <​th>​4</​th>​
 +  <​th>​5</​th>​
 +  <​th>​6</​th>​
 +  <​th>​7</​th>​
 +  <​th>​8</​th>​
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 +  <​td>​IATX</​td>​
 +  <​td>​.0012</​td>​
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 +  <​td>​.0015</​td>​
 +  <​td>​.0016</​td>​
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 +  <​td>​.0018</​td>​
 +  <​td>​.0020</​td>​
 +  <​td>​.0022</​td>​
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 +  <​td>​IASX</​td>​
 +  <​td>​.0024</​td>​
 +  <​td>​.0028</​td>​
 +  <​td>​.0030</​td>​
 +  <​td>​.0032</​td>​
 +  <​td>​.0034</​td>​
 +  <​td>​.0036</​td>​
 +  <​td>​.0040</​td>​
 +  <​td>​.0044</​td>​
 +</tr>
 +<tr>
 +  <​td>​IARX</​td>​
 +  <​td>​.0048</​td>​
 +  <​td>​.0056</​td>​
 +  <​td>​.0060</​td>​
 +  <​td>​.0064</​td>​
 +  <​td>​.0068</​td>​
 +  <​td>​.0072</​td>​
 +  <​td>​.0080</​td>​
 +  <​td>​.0088</​td>​
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 +  <​td>​IIAJX</​td>​
 +  <​td>​.0096</​td>​
 +  <​td>​.0112</​td>​
 +  <​td>​.0120</​td>​
 +  <​td>​.0128</​td>​
 +  <​td>​.0136</​td>​
 +  <​td>​.0144</​td>​
 +  <​td>​.0160</​td>​
 +  <​td>​.0176</​td>​
 +</tr>
 +<tr>
 +  <​td>​IIARX</​td>​
 +  <​td>​.0192</​td>​
 +  <​td>​.0224</​td>​
 +  <​td>​.0240</​td>​
 +  <​td>​.0256</​td>​
 +  <​td>​.0272</​td>​
 +  <​td>​.0288</​td>​
 +  <​td>​.0320</​td>​
 +  <​td>​.0352</​td>​
 +</tr>
 +</​table>​
 +</​html>​
 ===== Help ===== ===== Help =====
  
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 === Idaho Schools and Colleges === === Idaho Schools and Colleges ===
 +  * Idaho State University
 +    * [[https://​www.isu.edu/​tech|isu.edu/​tech]]
 +    * [[https://​www.isu.edu/​computerizedmachining/​|www.isu.edu/​computerizedmachining/​]]
 +    * [[https://​www.isu.edu/​computerizedmachining/​meet-your-instructors/​|Computerized Machining Technology]]
   * [[http://​www.cwidaho.cc|College of Western Idaho]] - Machine Tool Technology. Dave Sperry - Program Chair 208-562-2346,​ Bill Starkey - Assistant Professor 208-562-2347. DeLynn Bute (delynnbute@cwidaho.cc,​ 208-562-2381) is the Learning Community Coordinator in Professional Technical Education.   * [[http://​www.cwidaho.cc|College of Western Idaho]] - Machine Tool Technology. Dave Sperry - Program Chair 208-562-2346,​ Bill Starkey - Assistant Professor 208-562-2347. DeLynn Bute (delynnbute@cwidaho.cc,​ 208-562-2381) is the Learning Community Coordinator in Professional Technical Education.
     * program accepts about 16 students every fall. Classes are only offered in Fall and Spring semesters. According to Pat Neal, CWI Director (patneal@cwidaho.cc,​ 208-562-2336) all graduates have jobs waiting for them, the demand in the industry is greater than the graduation rate.     * program accepts about 16 students every fall. Classes are only offered in Fall and Spring semesters. According to Pat Neal, CWI Director (patneal@cwidaho.cc,​ 208-562-2336) all graduates have jobs waiting for them, the demand in the industry is greater than the graduation rate.
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