TABLE OF CONTENTS

1

MATHEMATICS

NUMBERS, FRACTIONS, AND DECIMALS

2 Mathematical Signs and Commonly Used Abbreviations

3 Prime Numbers and Factors of Numbers

13 Continued and Conjugate Fractions16 Positive and Negative Numbers17 Powers, Roots, and Reciprocals17 Powers of Ten Notation19 Preferred Numbers

ALGEBRA AND EQUATIONS

20 Rearrangement and Transposition Formulas

21 Sequence of Performing Arithmetic Operations

21 Ratio and Proportion23 Inverse Proportion23 Percentage24 Simple and Compound Interest25 Nominal vs. Effective Interest

Rates32 Principal Algebraic Expressions

and Formulas32 Equations32 Solving First Degree Equations 33 Solving Quadratic Equations33 Cubic Equations33 Series34 Derivatives of Functions35 Solving Numerical Equations36 Coordinate Systems36 Rectangular, Cartesian

Coordinates36 Polar Coordinates36 Changing Coordinate Systems37 Spherical Coordinates38 Cylindrical Coordinates38 Imaginary and Complex Numbers38 Complex or Imaginary Numbers39 Operations on Complex Numbers40 Break-Even Analysis

GEOMETRY

43 Arithmetical & Geometrical Progression

56 Areas and Volumes56 The Prismoidal Formula56 Pappus or Guldinus Rules57 Area of Revolution Surface 57 Area of Irregular Plane Surface58 Areas Enclosed by Cycloidal

Curves58 Contents of Cylindrical Tanks60 Areas and Dimensions of Figures66 Volumes of Solids72 Circles within Circles77 Circles within Rectangles78 Formulas for Regular Polygons79 Diameters of Circles and Sides of

Squares of Equal Area80 Segments of Circles82 Distance Across Corners of

Squares and Hexagons

SOLUTION OF TRIANGLES

83 Functions of Angles84 Laws of Sines and Cosines84 Trigonometric Identities90 Degree to Radian Conversion

table92 Graphic Illustrations of the

Functions of Angles93 Trigonometric Functions97 Versed Sine and Versed Cosine97 Sevolute and Involute Functions

LOGARITHMS

102 Common Logarithms103 Inverse Logarithm104 Natural Logarithms104 Multiplication and Division by

Logarithms106 Powers of Number by Logarithms107 Roots of Number by Logarithms108 Tables of Logarithms

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MECHANICS

MECHANICS

113 Terms and Definitions114 Unit Systems114 Gravity116 Metric (SI) System118 Force Systems118 Scalar and Vector Quantities118 Graphical Resolution of Forces120 Couples and Forces121 Resolution of force systems122 Subtraction and Addition of Force126 Forces in Two or More Planes127 Parallel Forces128 Nonparallel Forces130 Mechanisms130 Inclined plane, Wedge132 Levers133 Toggle-joint134 Wheels and Pulleys135 Differential Pulley and Screw

MECHANICAL PROPERTIES OF BODIES

136 Properties of Bodies136 Formulas for center of gravity143 Moments of Inertia144 Polar moments of inertia146 Radius of Gyration151 Center and Radius of Oscillation151 Center of Percussion151 Velocity and Acceleration151 Constant Velocity152 Linear Motion with Acceleration153 Rotary Motion with Acceleration154 Force, Work, Energy, and

Momentum154 Accelerations by Unbalanced

Forces156 Torque and Angular Acceleration156 Energy158 Forces and Couples158 Work and Energy159 Force of a Blow160 Impulse and Momentum

MECHANICAL PROPERTIES OF BODIES (Cont.)

162 Work and Power163 Centrifugal Force167 Balancing Rotating Parts167 Static and Dynamic Balancing167 Balancing Calculations168 Masses in Same Plane170 Masses in Two or More Planes171 Balancing Lathe Fixtures

FLYWHEELS

173 Classification173 Energy by Velocity174 Flywheel Design174 Flywheels for Presses, Punches

and Shears176 Dimensions of Flywheel177 Simplified Flywheel Calculations178 Centrifugal Stresses in Flywheel179 Combined Stresses in Flywheel179 Thickness of Flywheel Rims180 Safety Factors180 Safe Rim Speeds181 Safe Rotation Speeds182 Bursting Speeds183 Stresses in Rotating Disks183 Steam Engine Flywheels184 Engine Flywheel184 Spokes or Arms of Flywheels185 Critical Speeds186 Critical Speed Formulas187 Angular Velocity187 Linear Velocity of Points on a

Rotating Body

PENDULUMS

188 Types of Pendulums189 Pendulum Calculations189 Pendulum Formulas

FRICTION

190 Laws of Friction191 Coefficients of Friction191 Rolling Friction191 Static Friction Coefficients

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STRENGTH OF MATERIALS

STRENGTH OF MATERIALS

195 Properties of Materials196 Yield Point, Elastic Modulus and

Poission’s Ratio196 Compressive, Shear Properties199 Fatigue Failure199 Stress199 Factors of Safety200 Working Stress200 Stress Concentration Factors204 Simple Stresses206 Deflections206 Combined Stresses207 Tables of Combined Stresses210 Three-Dimensional Stress212 Sample Calculations215 Stresses in a Loaded Ring215 Strength of Taper Pins

MOMENT OF INERTIA

217 Calculating Moment of Inertia217 Built-up Sections, Moments of

Inertia 218 Moments of Inertia, Section

Moduli and Radius of Gyration228 Rectangles Moments of Inertia

and Section Modulus229 Round Shafts Moments of Inertia

and Section Modulus235 Properties of Perforated materials

BEAMS

236 Beam Calculations237 Stresses and Deflections in Beam

Table249 Rectangular Solid Beams249 Round Solid Beams253 Limiting Factor254 Curved Beams255 Stress Correction Factor257 Stresses Produced by Shocks258 Stresses in Helical Springs259 Size of Rail to Carry Load260 American Railway Engineering

Association Formulas

COLUMNS

261 Columns261 Strength of Columns or Struts261 Rankine or Gordon Formula261 Straight-line Formula261 Formulas of American Railway

Engineering Association261 Euler Formula262 Eccentrically Loaded Columns267 AISC Formulas

PLATES, SHELLS, AND CYLINDERS

268 Flat Plate270 Thin-Walled Cylinders271 Thick-Walled Cylinders271 Spherical Shells273 Cylinders and Tubes

SHAFTS

275 Shaft Calculations275 Torsional Strength of Shafting277 Polar Moment of Inertia and

Section Modulus277 Torsional Deflections280 Linear Deflections280 Design of Transmission Shafting283 Effect of Keyways283 Brittle Materials283 Critical Speeds 283 Hollow and Solid Shafts

SPRINGS

286 Spring Materials286 High-Carbon Spring Steels287 Alloy Spring Steels287 Stainless Spring Steels288 Copper-Base Spring Alloys289 Nickel-Base Spring Alloys290 Spring Stresses290 Working Stresses 295 Endurance Limit 296 Working Stresses at Elevated

Temperatures297 Spring Design Data297 Spring Characteristics297 Compression Spring Design299 Formulas for Compression Spring307 Spring Characteristics

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SPRINGS (Cont.)

307 Extension Springs308 Bending Stress309 Extension Spring Design311 Tolerances for Compression and

Extension Springs315 Torsion Spring Design320 Torsion Spring Characteristics326 Torsion Spring Tolerances326 Miscellaneous Springs327 Flat Springs Formula328 Moduli of Elasticity328 Heat Treatment of Springs331 Causes of Spring Failure332 Music Wire

STRENGTH AND PROPERTIES OF WIRE ROPE

333 Strength and Properties of Wire Rope

333 Wire Rope Construction334 Properties of Wire Rope335 Classes of Wire Rope336 Weights and Strengths340 Sizes and Strengths341 Factors of Safety

STRENGTH AND PROPERTIES OF WIRE ROPE (Cont.)

341 Installing Wire Rope343 Wire Rope Drum and Reel

Capacities344 Radial Pressures for Drums and

Sheaves344 Cutting and Seizing345 Maintenance345 Lubrication of Wire Rope345 Slings and Fittings347 Fittings Clips and Sockets349 Capacities of Steel Wire Rope and

Wire Rope Slings

CRANE CHAIN AND HOOKS

351 Material for Crane Chains351 Strength of Chains351 Hoisting and Crane Chains351 Maximum Wear on a Link352 Safe Loads for Ropes and Chains352 Strength of Manila Rope355 Loads Lifted by Crane Chains357 Crane Hooks358 Eye-bolts359 Eye Nuts and Lift Eyes360 Sheave and Drum Groove

Dimensions360 Winding Drum Scores for Chain

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PROPERTIES, TREATMENT, AND TESTING OF MATERIALS

THE ELEMENTS, HEAT, MASS, AND WEIGHT

363 Elements364 Latent Heat364 Specific Heat368 Ignition Temperatures368 Thermal Properties of Metals370 Specific Gravity372 Weights and Volumes of Fuels372 Weight of Wood373 Weight of Natural Piles

PROPERTIES OF WOOD, CERAMICS, PLASTICS, METALS,

WATER, AND AIR

375 Properties of Wood375 Mechanical Properties376 Density of Wood377 Machinability of Wood379 Properties of Ceramics, Plastics and

Metals380 Properties of Investment Casting

Alloys383 Properties of Compressed and

Sintered Powdered Metal Alloys384 Elastic Properties of Materials385 Tensile Strength of Spring Wire 386 Pressure and Flow of Water386 Water Pressure388 Flow of Water in Pipes390 Flow through Nozzle392 Friction Loss393 Properties of Air393 Volumes and Weights394 Density of Air395 Expansion and Compression397 Horsepower Required to

Compress Air401 Flow of Air in Pipes401 Flow of Compressed Air in Pipes

STANDARD STEELS

403 Numbering Systems404 Unified Numbering System 406 Steel Classification406 Compositions of Steels

STANDARD STEELS (Cont.)

409 Standard Steel Numbering System413 Standard Stainless Steels415 Hardness and Hardenability417 Case Hardening418 Applications of Steels420 Carbon Steels422 Free Cutting Steels423 Carburizing of Steels424 Hardenability of Alloy Steels425 Characteristics of Stainless Steels428 Chromium Nickel Austenitic

Steels 429 Stainless Chromium Irons and

Steels430 Mechanical Properties of Steel440 High-Strength, Low-Alloy Steels

TOOL STEELS

444 Tool Steels444 Properties of Tool Steels448 Tool Faults, Failures and Cures450 Tool Steel Properties451 Classification452 Tool Steel Selection457 High-Speed Tool Steels457 Molybdenum-Type 458 Tungsten-Type 460 Tungsten High-Speed460 Hot-Work Tool Steels462 Tungsten Types464 Molybdenum Types464 Cold-Work Tool Steels466 Oil-Hardening Types466 Air-Hardening Types467 Shock-Resisting Tool Steels469 Mold Steels469 Special-Purpose Tool Steels470 Water-Hardening Tool Steels471 Finished Bars472 Tolerances of Dimensions472 Allowances for Machining472 Decarburization Limits473 Physical Properties475 Strength of Steels 475 Temperature effects on Strength

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HARDENING, TEMPERING, AND ANNEALING

479 Heat-Treating Definitions484 Slow Cooling 484 Rapid Cooling or Quenching485 Heat-Treating Furnaces486 Hardening486 Hardening Temperatures488 Heating Steel in Liquid Baths488 Salt Baths489 Quenching Baths489 Hardening or Quenching Baths489 Quenching in Water490 Quenching in Molten Salt Bath490 Tanks for Quenching Baths493 Tempering495 Color Indicates Temperatures 497 Case Hardening498 Carburization498 Pack-Hardening498 Cyanide Hardening499 Nitriding Process500 Flame Hardening501 Induction Hardening504 SAE Carbon Steels505 SAE Alloy Steels

HEAT-TREATING HIGH-SPEED STEELS

508 Cobaltcrom Steel508 Tungsten High-Speed Steel511 Molybdenum High-Speed Steels514 Subzero Treatment of Steel517 Brinell Hardness Test518 Rockwell Hardness Test518 Shore’s Scleroscope518 Vickers Hardness Test519 Knoop Hardness Numbers519 Monotron Hardness Indicator519 Keep’s Test520 Hardness Scales524 Creep

NONFERROUS ALLOYS

525 Copper and Copper Alloys525 Cast Copper Alloys526 Properties of Copper Alloys533 Wrought Copper Alloys542 Aluminum and Aluminum Alloys542 Characteristics 543 Temper Designations 546 Designation Systems547 Clad Aluminum Alloys548 Composition of Casting Alloys549 Principal Alloy Series Groups550 Mechanical Property Limits556 Compositions557 Magnesium Alloys558 Alloy and Temper Designation561 Nickel and Nickel Alloys561 Titanium and Titanium Alloys562 Designations, Compositions564 Mechanical Properties 565 Copper–Silicon and Copper–

Beryllium Alloys565 Everdur565 Copper–Beryllium Alloys

PLASTICS

567 Properties of Plastics567 Characteristics of Plastics 568 Plastics Materials568 Structures568 Mixtures569 Physical Properties571 Mechanical Properties576 Strength and Modulus577 Time Related Properties578 Thermal Properties579 Coefficient of Thermal Expansion581 Electrical Properties583 Chemical Resistance584 Design Analysis584 Structural Analysis584 Design Stresses586 Thermal Stresses587 Design for Injection Moldings591 Design for Assembly595 Assembly with Fasteners597 Machining Plastics600 Development of Prototypes601 Plastics Gearing

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DIMENSIONING, GAGING, AND MEASURING

DRAFTING PRACTICES

606 Drafting Practices606 Sizes of Drawing Sheets606 Symbols for Section Lining 606 Geometric Dimensioning609 ANSI and ISO Symbols610 Definitions614 Datum Referencing616 Positional Tolerance618 Checking Drawings

ALLOWANCES AND TOLERANCES FOR FITS

621 Limits and Fits621 Basic Dimensions621 Tolerances623 Force fits623 Pressure Factors624 Expansion and Shrinkage Fits627 Temperatures for Shrinkage Fits627 ANSI Standard Limits and Fits627 Definitions629 Preferred Basic Sizes629 Standard Tolerances631 ANSI Standard Fits632 Graphical Representation634 Running and Sliding Fits 636 Clearance Locational Fits638 Transition Locational Fits 642 Modified Standard Fits642 Definitions643 Tolerances Designation644 Preferred Metric Sizes645 Preferred Fits648 Hole Basis Metric Clearance Fits650 Hole Basis Metric Transition and

Interference Fits652 Shaft Basis Metric Clearance Fits654 Shaft Basis Metric Transition and

Interference Fits 656 Gagemakers Tolerances 657 ISO Metric Limits and Fits658 Definitions658 Calculated Limits of Tolerance660 Tolerance for Selected Holes 660 Tolerance for Selected Shafts 661 Clearances

ALLOWANCES AND TOLERANCES FOR FITS (Cont.)

663 Deviations for Shafts 665 Deviations for Holes 667 Preferred Sizes

MEASURING INSTRUMENTS AND INSPECTION METHODS

669 Verniers and Micrometers670 Dual Metric-Inch Vernier672 Metric Micrometer673 Sine-bar673 Types of Sine-bars675 Sine-bar Constants682 Measuring Tapers 682 Measuring Dovetail Slides683 Angles and Tapers684 Tapers per Foot 685 Figuring Tapers687 Measurement over Pins688 Compound Angles689 Formulas690 Measurement over Pins and Rolls690 Checking a V-shaped Groove691 Checking Radius of Arc693 Checking Shaft Conditions694 Lobing696 Measurements Using Light

SURFACE TEXTURE

699 Definitions701 Sampling Lengths701 Roughness Parameters702 Waviness Parameters702 Surface Roughness to Tolerances704 Instruments for Measurement704 Roughness Measurements705 Surface Texture Symbols708 Roughness Average Values708 Lay Symbols708 Surface Texture of Castings710 Metric Dimensions on Drawings711 ISO Surface Finish711 Surface Finish Symbology715 Compare Measured Values 716 Roughness Lengths717 Gage Blocks717 Precision Gage Blocks718 Gage Block Sets

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TOOLING AND TOOLMAKING

CUTTING TOOLS

723 Tool Contour723 Terms and Definitions726 Relief Angles727 Rake Angles728 Nose Radius729 Chipbreakers730 Planing Tools730 Indexable Inserts731 Identification System732 Indexable Insert Tool Holders733 Standard Shank Sizes734 Letter Symbols735 Indexable Insert Holders738 Sintered Carbide Blanks 739 Standard Sizes for Carbide Blanks 741 Style A Carbide Tipped Tools 741 Single-Point, Sintered-Carbide-

Tipped Tools742 Style B Carbide Tipped Tools743 Style C Carbide Tipped Tools743 Style D Carbide Tipped Tools744 Style E, Carbide Tipped Tools744 Standard Styles ER and EL

Carbide Tipped Tools 745 Style F Carbide Tipped Tools 745 Tool Nose Radii746 Tool Angle Tolerances746 Style G, Carbide Tipped Tools

CEMENTED CARBIDES

747 Cemented Carbide747 Carbides and Carbonitrides748 Properties of Tungsten-Carbide-

Based Cutting-Tool752 ISO Classifications of Hardmetals752 Ceramics755 Superhard Materials756 Machining Data757 Hardmetal Tooling757 Cutting Blades

FORMING TOOLS

758 Dovetail Forming Tools758 Straight Forming Tools761 Circular Forming Tools763 Formulas764 Circular Tools764 Circular Cut-Off Tools765 Constants for Diameters766 Corrected Diameters770 Arrangement of Circular Tools

MILLING CUTTERS

771 Selection of Milling Cutters771 Number of Teeth772 Hand of Milling Cutters773 Plain Milling Cutters774 Side Milling Cutters775 Staggered Teeth,T-Slot Milling

Cutters 776 Metal Slitting Saws776 Milling Cutter Terms778 Shell Mills779 Multiple- and Two-Flute Single-

End Helical End Mills 780 Regular-, Long-, and Extra Long-

Length, Mills 781 Two-Flute, High Helix, Regular-,

Long-, and Extra Long-Length, Mills

782 Roughing, Single-End End Mills790 Concave, Convex, and Corner-

Rounding Arbor-Type Cutters792 Roller Chain Sprocket794 Keys and Keyways795 Woodruff Keyseat Cutters799 Spline-Shaft Milling Cutter799 Cutter Grinding800 Wheel Speeds and Feeds800 Clearance Angles 801 Rake Angles for Milling Cutters801 Eccentric Type Radial Relief804 Indicator Drop Method806 Distance to Set Tooth

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REAMERS

807 Hand Reamers808 Irregular Tooth Spacing in

Reamers808 Threaded-end Hand Reamers808 Fluted and Rose Chucking

Reamers811 Vertical Adjustment of Tooth-rest812 Reamer Difficulties813 Dimensions of Centers 814 Expansion Chucking Reamers816 Hand Reamers817 Expansion Hand Reamers818 Driving Slots and Lugs819 Chucking Reamers 822 Shell Reamers825 Taper Pipe Reamers

TWIST DRILLS AND COUNTERBORES

827 Definitions of Twist Drill Terms828 Types of Drill848 British Standard Combined Drills 848 Split-Sleeve, Collet Type Drill

Drivers849 Three- and Four-Flute Straight

Shank Core Drills 850 Drill Drivers850 British Standard Metric Twist

Drills851 Gauge and Letter Sizes 852 Morse Taper Shank Twist Drills853 Tolerance on Diameter 854 Parallel Shank Jobber Series

Twist Drills856 Stub Drills856 Steels for Twist Drills856 Accuracy of Drilled Holes857 Counterboring858 Interchangeable Cutters 858 Three Piece Counterbores859 Style Designations 859 Square Boring Tools859 Sintered Carbide Boring Tools860 Carbide-Tipped Square Boring

Tools862 Solid Carbide Round Boring

Tools

TWIST DRILLS AND COUNTERBORES (Cont.)

865 Spade Drills and Drilling865 Spade Drill Geometry867 Spade Drilling869 Feed Rates 870 Power Consumption871 Trepanning

TAPS AND THREADING DIES

872 Types of Taps872 Definitions of Tap Terms876 Fraction-Size Taps878 Machine Screw Taps879 Ground Thread Limits880 Taper Pipe Taps881 Straight Pipe Taps883 Straight Fluted Taps885 Spiral-Pointed Taps890 ANSI Standard Taps 891 Pulley Taps891 Spark Plug Taps893 Spiral Pointed Ground Thread

Taps894 Taper and Straight Pipe Taps896 Thread Series Designations897 Pitch Diameter Tolerance897 Eccentricity Tolerances 899 Acme Threads Taps900 Acme and Square-Threaded Taps901 Proportions 901 Drill Hole Sizes902 Screwing Taps for ISO Metric

Threads905 Tapping Square Threads

STANDARD TAPERS

906 Standard Tapers906 Morse Taper906 Brown & Sharpe Taper906 Jarno Taper914 British Standard Tapers915 Morse Taper Sleeves916 Brown & Sharpe Taper Shank917 Jarno Taper Shanks917 Machine Tool Spindles918 Plug and Ring Gages919 Jacobs Tapers and Threads 920 Spindle Noses

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STANDARD TAPERS (Cont.)

922 Tool Shanks 923 Draw-in Bolt Ends924 Spindle Nose925 Twist Drills and Centering Tools

BROACHES AND BROACHING

926 The Broaching Process926 Types of Broaches927 Pitch of Broach Teeth928 Designing Data for Surface

Broaches928 Broaching Pressure929 Depth of Cut per Tooth930 Face Angle or Rake930 Clearance Angle930 Land Width930 Depth of Broach Teeth930 Radius of Tooth Fillet930 Total Length of Broach930 Chip Breakers931 Shear Angle931 Types of Broaching Machines931 Broaching Difficulties933 Tool Wear935 Sharpening Twist Drills935 Relief Grinding of the Tool Flanks936 Drill Point Thinning937 Sharpening Carbide Tools937 Silicon Carbide Wheels938 Diamond Wheels938 Diamond Wheel Grit Sizes938 Diamond Wheel Grades938 Diamond Concentration939 Dry Versus Wet Grinding of

Carbide Tools939 Coolants for Carbide Tool

Grinding939 Peripheral Versus Flat Side

Grinding940 Lapping Carbide Tools940 Chip Breaker Grinding940 Summary of Miscellaneous Points

JIGS AND FIXTURES

941 Jig Bushings941 Materials941 American National Standard942 Head Type Press Fit Wearing

Bushings945 Specifications for Press Fit

Wearing Bushings 945 Slip Type Renewable Wearing

Bushings947 Fixed Type Renewable Wearing

Bushings948 Headless Type Liner Bushings 950 Locking Mechanisms951 Jig Bushing Definitions951 Jig Plate Thickness951 Jig Bushing Designation System951 Definition of Jig and Fixture951 Jig Borers952 Jig-Boring Practice953 Transfer of Tolerances955 Lengths of Chords956 Hole Coordinate Dimension

Factors 957 Spacing Off the Circumferences

of Circles959 Hole Coordinate Dimension

Factors971 Collets971 Collets for Lathes, Mills,

Grinders, and Fixtures

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MACHNING OPERATIONS

CUTTING SPEEDS AND FEEDS

978 Cutting Tool Materials982 Cutting Speeds983 Cutting Conditions983 Selecting Cutting Conditions983 Tool Troubleshooting985 Cutting Speed Formulas987 RPM for Various Cutting Speeds

and Diameter

SPEED AND FEED TABLES

991 Introduction991 Feeds and Speeds Tables995 Speed and Feed Tables for Turning

1000 Tool Steels1001 Stainless Steels1002 Ferrous Cast Metals1004 Turning-Speed Adjustment

Factors1004 Tool Life Factors1005 Adjustment Factors for HSS

Tools1006 Copper Alloys1007 Titanium and Titanium Alloys1008 Superalloys1009 Speed and Feed Tables for Milling1012 Slit Milling1013 Aluminium Alloys1014 Plain Carbon and Alloy Steels1018 Tool Steels1019 Stainless Steels1021 Ferrous Cast Metals1023 High Speed Steel Cutters1025 Speed Adjustment Factors1026 Radial Depth of Cut1028 Tool Life1029 Drilling, Reaming, and Threading1030 Plain Carbon and Alloy Steels1035 Tool Steels1036 Stainless Steels1037 Ferrous Cast Metals1039 Light Metals1040 Adjustment Factors for HSS1041 Copper Alloys1041 Tapping and Threading1043 Cutting Speed for Broaching

ESTIMATING SPEEDS AND MACHINING POWER

1044 Planer Cutting Speeds1044 Cutting Speed and Time1044 Planing Time1044 Speeds for Metal-Cutting Saws1044 Turning Unusual Material1046 Estimating Machining Power1046 Power Constants1047 Feed Factors1048 Tool Wear Factors1050 Metal Removal Rates1051 Estimating Drilling Thrust,

Torque, and Power1053 Work Material Factor1053 Chisel Edge Factors1054 Feed Factors1055 Drill Diameter Factors

MACHINING ECONOMETRICS

1056 Tool Wear And Tool Life Relationships

1056 Equivalent Chip Thickness (ECT)1057 Tool-life Relationships1061 The G- and H-curves1062 Tool-life Envelope1065 Forces and Tool-life1067 Surface Finish and Tool-life1069 Shape of Tool-life Relationships1070 Minimum Cost1071 Production Rate1071 The Cost Function1072 Global Optimum1073 Economic Tool-life1076 Machine Settings and Cost

Calculations1076 Nomenclature1077 Cutting Formulas1081 Variation Of Tooling And Total

Cost1082 Optimized Data1085 High-speed Machining

Econometrics1086 Chip Geometry in Milling1088 Chip Thickness1090 Forces and Tool-life1091 High-speed Milling1092 Econometrics Comparison

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SCREW MACHINE FEEDS AND SPEEDS

1094 Automatic Screw Machine Tools1094 Knurling 1094 Revolution for Knurling1094 Cams for Threading1095 Cutting Speeds and Feeds1097 Spindle Revolutions1098 Practical Points on Cam1099 Stock for Screw Machine

Products1101 Band Saw Blade Selection1102 Tooth Forms1102 Types of Blades1103 Band Saw Speed and Feed Rate1104 Bimetal Band Saw Speeds1105 Band Saw Blade Break-In

CUTTING FLUIDS

1107 Types of Fluids1107 Cutting Oils1107 Water-Miscible Fluids1108 Selection of Cutting Fluids1109 Turning, Milling, Drilling and

Tapping1110 Machining 1111 Machining Magnesium1112 Metalworking Fluids1112 Classes of Metalworking fluids1112 Occupational Exposures 1113 Fluid Selection, Use, and

Application1114 Fluid Maintenance1115 Respiratory Protection for

Workers

MACHINING NONFERROUS METALS

1116 Machining1116 Aluminium1117 Magnesium1118 Zinc Alloy Die-Castings1118 Monel and Nickel Alloys1119 Copper Alloys1119 Hard Rubber

GRINDING FEEDS AND SPEEDS

1120 Basic Rules1120 Wheel life T and Grinding Ratio1121 ECT in Grinding1122 Optimum Grinding Data1124 Surface Finish, Ra1125 Spark-out Time1126 Grinding Cutting Forces1127 Grinding Data1128 Grindability Groups1128 Side Feed, Roughing and

Finishing1129 Relative Grindability1130 Grindability Overview1130 Procedure to Determine Data1136 Calibration of Recommendations1138 Optimization

GRINDING AND OTHER ABRASIVE PROCESSES

1139 Grinding Wheels1139 Abrasive Materials1140 Bond Properties1140 Structure1141 ANSI Markings1141 Sequence of Markings1142 ANSI Shapes and Sizes1142 Selection of Grinding Wheel1143 Standard Shapes Ranges1150 Grinding Wheel Faces 1151 Classification of Tool Steels1152 Hardened Tool Steels 1156 Constructional Steels1157 Cubic Boron Nitride 1158 Dressing and Truing1158 Tools and Methods for Dressing

and Truing1160 Guidelines for Truing and

Dressing1161 Diamond Truing and Crossfeeds1161 Size Selection Guide1162 Minimum Sizes for Single-Point

Truing Diamonds

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GRINDING AND OTHER ABRASIVE PROCESSES (Cont.)

1163 Diamond Wheels1163 Shapes1164 Core Shapes and Designations1164 Cross-sections and Designations1165 Designations for Location1166 Composition1167 Designation Letters1168 Selection of Diamond Wheels1168 Abrasive Specification1169 Handling and Operation 1169 Speeds and Feeds1170 Grinding Wheel Safety1170 Safety in Operating1170 Handling, Storage and Inspection1170 Machine Conditions1171 Grinding Wheel Mounting1171 Safe Operating Speeds1172 Portable Grinders1175 Cylindrical Grinding1175 Plain, Universal, and Limited-

Purpose Machines1175 Traverse or Plunge Grinding1175 Work Holding on Machines1176 Work-Holding Methods1176 Selection of Grinding Wheels1177 Wheel Recommendations1177 Operational Data1178 Basic Process Data1178 High-Speed1179 Areas and Degrees of Automation1179 Troubles and Their Correction1180 Chatter1180 Spirals on Work1180 Marks on Work1181 Burning and Discoloration of

Work1181 Thread on Work1182 Inaccuracies in Work1182 Inaccurate Work Sizing1182 Uneven Traverse or Infeed of

Wheel Head1183 Wheel Defects1183 Wheel Loading and Glazing1183 Wheel Breakage

GRINDING AND OTHER ABRASIVE PROCESSES (Cont.)

1183 Centerless Grinding1184 Through-feed Method of Grinding1184 In-feed Method 1184 End-feed Method1184 Automatic Centerless Method1184 Centerless Grinding 1185 Surface Grinding1186 Principal System1186 Grinding Wheel

Recommendations1188 Principal Systems1189 Process Data for Surface Grinding1190 Basic Process Data1190 Faults and Possible Causes1192 Offhand Grinding1192 Floor- and Bench-Stand Grinding1192 Portable Grinding1192 Swing-Frame Grinding1193 Mounted Wheels and Mounted

Points1193 Abrasive Belt Grinding1193 Application of Abrasive Belts1193 Selection Contact Wheels1195 Abrasive Cutting1196 Cutting-Off Difficulties1196 Honing Process1197 Rate of Stock Removal1197 Formula for Rotative Speeds1198 Factors in Rotative Speed

Formulas1198 Eliminating Undesirable Honing

Conditions1199 Tolerances1199 Laps and Lapping1199 Material for Laps1199 Laps for Flat Surfaces1200 Grading Abrasives 1200 Charging Laps1200 Rotary Diamond Lap1201 Grading Diamond Dust1201 Cutting Properties1201 Cutting Qualities1202 Wear of Laps1202 Lapping Abrasives1202 Effect on Lapping Lubricants1202 Lapping Pressures1202 Wet and Dry Lapping1203 Lapping Tests

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ARBORS, CHUCKS, AND SPINDLES

1203 Portable Grinding Tools1203 Circular Saw Arbors1203 Spindles for Geared Chucks1203 Spindle Sizes1204 Standard Shapes of Mounted

Wheels1207 Straight Grinding Wheel Spindles1207 Threaded and Tapered Spindles1208 Square Drives for Portable Air 1209 Abrasion Tool Spindles1210 Hexagonal Chucks for Portable

Air 1210 Hexagon Shanks for Portable Air

KNURLS AND KNURLING

1211 Knurls and Knurling1211 ANSI Standard1211 Preferred Sizes 1211 Specifications1212 Cylindrical Tools1213 Flat Tools1213 Specifications for Flat Dies1213 Formulas to Knurled Work1214 Tolerances 1215 Marking on Knurls and Dies1215 Concave Knurls

MACHINE TOOL ACCURACY

1219 Degrees of Accuracy Expected with NC Machine Tool

1220 Part Tolerances

NUMERICAL CONTROL

1225 Introduction1225 CNC Technology1225 Numerical Control vs. Manual

Operations1226 Numerical Control Standards1229 Programmable Controller1233 Closed-Loop System1233 Open-Loop System1233 Adaptive Control1234 Flexible Manufacturing Systems1235 Flexible Manufacturing Cell1235 Flexible Manufacturing Module1235 Axis Nomenclature1238 Total Indicator Reading

NUMERICAL CONTROL PROGRAMMING

1240 Programming1243 Postprocessors1243 G-Code Programming1243 Format Classification1243 Letter Addresses 1245 Sequence Number (N-Word)1245 Preparatory Word (G-Word)1249 Miscellaneous Functions1250 Feed Function (F-Word)1251 Spindle Function (S-Word)1251 Tool Function (T-Word)1253 Linear Interpolation1254 Circular Interpolation1255 Helical and Parabolic

Interpolation1256 Subroutine1258 Conditional Expressions1258 Fixed (Canned) Cycles1262 Turning Cycles1262 Thread Cutting1263 APT Programming1265 APT Computational Statements1265 APT Geometry Statements1266 Points, Lines and Circles1270 APT Motion Statements1271 Contouring Cutter Movements1272 Circles and Planes1274 3-D Geometry1275 APT Postprocessor Statements1277 APT Example Program1279 APT for Turning1280 Indexable Insert Holders for NC1281 Insert Radius Compensation1284 Threading Tool Insert Radius1284 V-Flange Tool Shanks 1286 Retention Knobs

CAD/CAM

1287 CAD/CAM1289 Drawing Projections1290 Drawing Tips and Traps1294 Sizes of Lettering on Drawing 1294 Drawing Exchange Standards1296 Rapid Automated Prototyping1296 DNC1297 Machinery Noise1297 Measuring Machinery Noise

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MANUFACTURING PROCESSES

PUNCHES, DIES, AND PRESS WORK

1301 Punches and Dies1301 Clearance1302 Lubricants for Press Work1302 Annealing Drawn Shells1302 Drawing Rectangular Shapes1302 Speeds and Pressures for Presses1303 Pressure Required for Punching1303 Shut Height of Press1303 Diameters of Shell Blanks1305 Drawn Cylindrical Shells1306 Depth and Diameter Reductions1307 Bending Sheet Metal1308 Lengths of Straight Stock 1311 Bending Allowance Formulas1311 Bending Sheet Metal1312 Fine Blanking1314 V-projections1315 Steel Rule Dies1316 Making Steel Rule Dies

ELECTRICAL DISCHARGE MACHINING

1319 EDM Terms1321 EDM Process1324 Electrical Control Adjustments1324 Workpiece Materials1324 Characteristics of Materials 1325 Electrode Materials1326 Types of Electrodes1327 Making Electrodes1328 Wire EDM

IRON AND STEEL CASTINGS

1330 Gray Cast Iron1330 White Cast Iron1330 Chilled Cast Iron1330 Alloy Cast Iron1331 Malleable-iron Castings1332 Ductile Cast Iron1332 Steel Castings1333 Carbon Steel Castings1334 Alloy Steel Castings1336 Casting of Metals1338 Removal of Gates and Risers1338 Blast Cleaning of Castings1339 Heat Treatment of Steel Castings1339 Estimating Casting Weight

IRON AND STEEL CASTINGS (Cont.)

1339 Woods for Patterns1339 Selection of Wood1340 Pattern Varnish1340 Shrinkage Allowances1340 Metal Patterns1340 Weight of Casting1341 Die Casting1342 Porosity1342 Designing Die Castings1342 Alloys Used for Die Casting1342 Aluminum-Base Alloys1343 Zinc-Base Alloys1343 Copper-Base Alloys1343 Magnesium-Base Alloys1343 Tin-Base Alloys1344 Lead-Base Alloys1344 Dies for Die-Casting Machines1344 Die-Casting Bearing Metal1344 Injection Molding of Metal1345 Precision Investment Casting1345 Casting Materials1345 General Procedure1346 Master Mold1346 Shrinkage Allowances1346 Casting Dimensions1346 Investment Materials1347 Casting Operations1347 Investment Removal1347 Investment Castings1347 Casting Weights and Sizes1347 Design for Investment Casting1347 Casting Milling Cutters 1348 Extrusion of Metals1348 Basic Process1350 Powder Metallurgy1350 Advantages of Powder Metallurgy1350 Limiting Factors1350 Design of Briquetting Tools1351 Flame Spraying Process

METAL JOINING, CUTTING, AND SURFACING

1352 Soldering1352 Forms Available1352 Fluxes for Soldering1352 Methods of Application1354 Ultrasonic Fluxless Soldering

TABLE OF CONTENTS

1299

METAL JOINING, CUTTING, AND SURFACING (Cont.)

1355 Brazing1355 Filler Metals1355 Fluxes for Brazing1356 Brazing Filler Metals1359 Selection of Filler Metals 1360 Steadying Work1360 Supplying Heat1360 Symbol Application

WELDING

1362 Welding Electrodes and Fluxes1362 Processes1363 Gas Metal Arc Welding (GMAW)1363 Electrode Diameters1364 Maximum Deposition Rates1364 GMAW Welding of Sheet Steel1364 Application of Shielding Gases1366 Welding Controls1368 GMAW Spray Transfer1368 Deposition Rates of Electrodes1370 Optimum Settings for GMAW1371 Spray Transfer Voltage1371 Flux-Cored Arc Welding1371 Flux-Cored Welding Electrodes1372 Gas-Shielded Electrodes1372 Settings for FCAW Electrodes1372 Weld Requirements1373 Selecting an FCAW Electrode1373 FCAW Electrodes1374 Contact Tip Recess1374 Porosity and Worm Tracks1374 Welding with Various Diameter 1375 High-Deposition Electrodes1376 Deposition Rates for Vertical Up

Welding1376 Deposition Rates of Flat and

Horizontal Welds1376 Electrode Diameters and

Deposition Rates1378 Shielding Gases and FCAW

Electrodes1378 Shielded Metal Arc Welding1379 ANSI/AWS Standard1380 AWS E60XX Electrodes1381 AWS E70XX Electrodes1382 Gas Tungsten Arc Welding1383 GTAW Welding Current

WELDING (Cont.)

1385 Tungsten Electrode Type1385 Selection of GTAW1385 Tungsten Electrode Compositions1386 Electrode and Current Selection1386 Current Ranges for GTAW

Electrodes1386 Current Ranges for EWP and

EWZ and GTAW Electrodes1387 Filler Metals1387 Shielding Gases1387 Plasma Arc Welding (PAW)1388 Welding Gases1388 Shielding Gases1389 PAW Welding Equipment1389 Applications1390 Welding Aluminum1390 Plasma Arc Surface Coating1391 Plasma Arc Cutting1391 Precision Plasma Arc Cutting1392 Electron-Beam (EB) Welding1393 Weld and Welding Symbols1393 ANSI Weld and Welding Symbols1394 Basic Weld Symbols1394 Supplementary Weld Symbols1395 Welding Codes, Rules,

Regulations, and Specifications1396 Letter Designations for Welding1397 ANSI Welding Symbols1402 Pipe Welding1404 Use of Flux-cored Electrodes1405 Complete Weld Fusion1405 Other Methods1405 Pipe Welding Procedure1405 Thick-walled, Carbon-steel Pipes,

Root Welding1407 Thin-walled Carbon Steel Pipes,

Root, Fill and Cover Pass1408 Nondestructive Testing1408 Symbols

TABLE OF CONTENTS

1300

LASERS

1410 Laser Light1410 Laser Beams1411 Beam Focusing1412 Types of Industrial Lasers1413 Industrial Laser Systems1413 Safety1413 Laser Beam/Material Interaction1414 Thermal Properties of Workpieces1415 Cutting Metal with Lasers1415 Beam Assistance Techniques1416 Cut Edge Roughness1416 Heat-Affected Zones1417 Cutting of Nonmetals1419 Welding with Lasers1419 Laser Welding Theory1420 Welded Joint Design1420 Welding Rates1420 Processing Gas1421 Drilling with Lasers1421 Laser Drilling Theory1421 Direct Drilling1421 Percussive Drilling1421 Trepanning1421 Drilling Rates1421 Heat Treatment with Lasers1422 Materials Applicability1422 Hardening Rates1422 Cladding with Lasers1422 Marking with Lasers1422 Mask Marking1423 Scanned-Beam Marking

HARD FACING

1423 Hard-Facing Materials1423 High-Speed Steels1424 Austenitic Manganese Steels1424 Austenitic High-Chromium Irons1425 Cobalt-Base Alloys1425 Copper-Base Alloys1426 Nickel-Chromium-Boron Alloys1427 Chromium Plating

CUTTING METALS

1428 The Cutting Torch1428 Adjustment of Cutting Torch1428 Metals That Can Be Cut1428 Cutting Stainless Steel1428 Cutting Cast Iron

CUTTING METALS (Cont.)

1429 Mechanically Guided Torches1429 Cutting Steel Castings1429 Thickness of Metal 1429 Arc Cutting of Metals1429 Arc Cutting1429 Plasma Cutting of Metals

FILES AND BURS

1430 Definitions of File Terms1431 File Characteristics1431 Classes of Files1433 Effectiveness of Rotary Files and

Burs1434 Speeds of Rotary Files and Burs1435 Power Brush Finishing1435 Description of Brushes1435 Use of Brushes1435 Deburring and Producing a Radius1436 Eliminating Undesirable

Conditions1437 Characteristics in Power Brush 1439 Polishing and Buffing1439 Polishing Wheels1439 Polishing Operations and

Abrasives1440 Buffing Wheels1440 Speed of Polishing Wheels1440 Grain Numbers of Emery1440 Grades of Emery Cloth

SURFACE TREATMENTS FOR METALS

1440 Etching and Etching Fluids1440 Etching Fluids1441 Conversion Coatings and the

Coloring of Metals1441 Passivation of Copper1442 Coloring of Copper Alloys1442 Coloring of Iron and Steel1443 Anodizing Aluminum Alloys1443 Magnesium Alloys1443 Titanium Alloys1444 Plating1444 Surface Coatings

TABLE OF CONTENTS

1452

FASTENERS

NAILS, SPIKES AND WOOD SCREWS

1455 Wire Nails and Spikes1456 Wood Screws

RIVETS AND RIVETED JOINTS

1457 Riveted Joints1457 Classes and Types1458 Failure1459 Design of Riveted Joints1459 Allowable Stresses1459 Analysis of Joint Strength1463 Rivet Lengths1464 Standard Rivets1464 Rivet Length1464 Small Solid Rivet1464 Dimensions of Rivets1465 ANSI Large Rivets1467 ANSI Dimensions1468 ANSI Small Solid Rivets1471 Head Dimensions and Diameters 1473 Tentative Range of Length

TORQUE AND TENSION IN FASTENERS

1476 Wrench Torque1476 Preload in Loaded Joint1476 Preload In Shear1477 General Application of Preload1478 Preload Adjustments1478 Coefficients of Friction1479 Preload Relaxation1479 Measuring Preload1480 Bolt Preload Application Methods1480 Elongation Measurement1482 Tensile Stress Area1483 Torque and Clamping Force1485 Torque and Friction Coefficients1486 Torque-Tension Relationships1488 Grade Marks1488 Grade Identification Marks1489 Detecting Counterfeit Fasteners1489 Mechanical Properties of Nuts1489 Working Strength of Bolts1490 Lengths of Engagement1491 Breaking Force1491 Lock Wire Procedure Detail

BOLTS, SCREWS, NUTS, AND WASHERS

1492 Bolts, Screws, and Nuts1493 Square and Hex Bolts1494 ANSI Square Bolts1495 ANSI Hex and Heavy Hex Bolts1496 Heavy Hex Screws 1497 Square Lag Screws1498 Hex Lag Screws1499 Hex Nuts and Jam Nuts1500 Heavy Hex Flat Nuts 1501 Heavy Hex Slotted Nuts1502 Square Nuts1503 Low and High Crown Nuts1505 Round Head Square Neck Bolts 1505 T Head Bolts1506 Round Head Square Neck Bolts1506 Round Head Fin Neck Bolts1507 Round Head Ribbed Neck Bolts1508 Countersunk Square Neck Bolts 1509 Countersunk Bolts1510 Wrench Openings for Nuts1510 Wrench Clearance Dimensions1510 Box Wrench1512 Type A Plain Washer1513 ANSI Standard Plain Washers1514 Type B Plain Washers 1515 Helical Spring and Tooth Lock

Washers1516 Helical Spring Lock Washer1518 Tooth Lock Washers

METRIC FASTENERS

1520 Comparison with ISO Standards1521 Metric Hex Cap Screws1522 Metric Formed Hex Screws1523 Metric Heavy Hex Screws1523 Metric Screw and Bolt Diameters1524 Metric Hex Screws and Bolts1525 Metric Hex Lag Screws1526 Heavy Hex Flange Screws1527 Hex Flange Screws1527 Round Head Square Neck Bolts1529 Heavy Hex Bolts1529 Heavy Hex Structural Bolts1530 Hex Bolts1530 Mechanical Properties1531 Designation1532 Socket Head Cap Screws

TABLE OF CONTENTS

1453

METRIC FASTENERS (Cont.)

1532 Diameter-Length Combinations1532 Metric Hex Lag Screws1533 Cap Screws, Screws, Hex Flang1534 Heavy Hex Structural Bolts1534 Round Head Square Neck Bolts1535 Socket Head Cap Screws1536 Clearance Holes1537 Drill and Counterbore Sizes1538 Thread Series1538 Identification Symbols1539 Socket Head Cap Screws1540 Drilled Head Dimensions 1541 Metric Nuts1542 Comparison with ISO Standards1542 Tops and Bearing Surfaces1542 Mechanical Properties1543 Hex Nuts1544 Slotted Hex Nuts1544 Thread Series1545 Hex Flange Nuts1545 Prevailing-Torque Type Nuts1547 Metric Hex Flange Nuts1547 Metric Nut Identification Symbols1547 Metric Nut Designation1549 Metric Washers1549 Metric Plain Washers1549 Comparison with ISO Standards1549 Types of Metric Plain Washers1549 Materials and Finish1549 Metric Plain Washer Designation

BRITISH FASTENERS

1551 British Standard Bolts and Nuts1551 Square and Hexagon Bolts 1551 British Standard Screwed Studs1552 Whitworth and Fine Precision

Hexagon Bolts, Screws 1555 ISO Metric Precision Hexagon

Bolts, Screws and Nuts1556 Hexagon Bolts and Screws1557 Hexagon Nuts and Thin Nuts1558 Hexagon Slotted Nuts1559 Hexagon Bolts, Screws and Nuts1559 Nominal Lengths1561 Strength of Steel Bolts, Screws

and Nuts1561 Bolt and Nut Combinations1562 British Standard Studs

BRITISH FASTENERS (Cont.)

1563 British Standard Spring Washers1564 Double Coil Rectangular Section 1565 Square Section Spring Washers1565 British Standard for Metal

Washers1566 Bright Metal Washers1567 Black Metal Washers

MACHINE SCREWS

1568 Machine Screws and Nuts1568 Square and Hexagon Nuts1569 Slotted Flat Countersunk Head1571 Washer Head Machine Screws1572 Slotted Truss Head1573 Slotted Pan Head1574 Slotted Fillister1575 Slotted Oval Countersunk Head1576 Slotted Binding Head1577 Slotted Round Head1577 Machine Screw Cross Recesses1577 ANSI Metric Machine Screws1578 Thread Lengths1579 Square Recessed Flat

Countersunk Head1580 Oval Countersunk Head1581 Square Recessed Pan Head 1582 Header Points1583 Hex and Hex Flange Head1585 Nominal Screw Lengths1586 British Standard Machine Screws1586 Metric Series1588 Slotted Countersunk Head1589 Slotted Raised Countersunk Head1590 Machine Screw Nuts1592 Slotted Pan Head1593 Slotted Cheese Head1594 Machine Screws and Nuts1595 Unified Machine Screws and Nuts1595 Machine Screws and Nuts1597 Unified Machine Screws

TABLE OF CONTENTS

1454

CAP AND SET SCREWS

1599 Cap Screws1600 Slotted Round 1601 Hexagon and Spline Socket1602 Drill and Counterbore Size1603 Hexagon and Spline Socket1605 Socket Head Shoulder Screws1606 Slotted Headless Set Screws1607 Screw Optional Cup Points1608 Hexagon and Spline Sockets1609 Square Head Set Screws1611 Hexagon and Spline Keys and Bits1613 Hexagon Socket Screws1617 Button Head Screws1618 Hexagon Socket Set Screws1618 Holding Power of Set-screws1619 Bright Square Head Set-Screws

SELF-THREADING SCREWS

1620 Sheet Metal, Self-Tapping, and Metallic Drive Screws

1621 Method of Designation1622 Self-Tapping Screws1623 Threads and Points1623 Cross Recesses1624 Forming Tapping Screws1625 B and BP Thread 1626 Thread and Point Dimensions1627 D, F, G, and T Thread1628 Hole Sizes1629 Types A, B, and BP Screws 1631 Types D, F, G, and T Screws1634 Types BF and BT Screws1635 Type U Hardened Screw1635 Torsional Strength1635 Self-tapping Thread Inserts1635 Screw Thread Inserts1635 Thread Cutting Tapping Screws1636 Threads and Points1637 Method of Designation1638 Nominal Screw Lengths 1639 Types BF, BT, D, F, and T Screws1639 Material and Heat Treatment1640 Clearance Holes1641 Clean-Punched Hole Sizes1644 BF and BT Metric Thread

T-SLOTS, BOLTS, AND NUTS

1645 T-Slots1646 T-Bolts1647 T-Nuts

PINS AND STUDS

1648 Dowel & Cotter Pins1649 Clevis Pins1649 Metric Series Dowel Pins1650 Steel Dowel Pins1651 Hardened Ground Machine1653 Unhardened Ground Dowel Pin1654 ANSI Straight Pins1655 ANSI Taper Pins1656 Drilling Specifications1658 ANSI Grooved Pins1659 T-Head Cotter Pins and Round

Head Grooved Drive Studs1662 Grooved T-Head Cotter Pins1662 Grooved Drive Studs1663 Slotted Type Spring Pins1663 Spring Pins1664 Coiled Type Spring Pins

RETAINING RINGS

1665 Retaining Rings1666 Tapered Retaining Rings1668 Reduced Cross Section1671 Basic Internal Series 1673 E-Type External Series 1678 Heavy Duty Internal Spiral1680 Heavy Duty External Spiral1682 Dimensions of Retaining Rings1688 Inch Series Self-Locking 1690 Retaining Ring Failure1691 Retaining Ring Standards

WING NUTS, WING SCREWS AND THUMB SCREWS

1693 Wing Nuts1696 Specification of Wing Nuts1696 Threads for Wing Nuts1697 Materials and Finish1697 Wing Screws1698 Types A and B 1699 Types C and D1700 Types A and B Thumb Screws1701 Threads for Wing Screws1701 Points for Wing Screws

TABLE OF CONTENTS

1702

THREADS AND THREADING

SCREW THREAD SYSTEMS

1706 Screw Thread Forms1706 Sharp V-thread1706 Unified Screw Thread Forms1707 Definitions of Screw Threads

UNIFIED SCREW THREADS

1712 Unified Screw Threads1712 Thread Form1713 Internal and External Screw

Thread Design Profile1714 Inch Screw Thread1715 Diameter-Pitch Combination1716 Standard Series Combinations1740 Basic Dimensions1740 Coarse-Thread Series1741 Fine-Thread Series1742 Extra-Fine-Thread Series1743 4-Thread Series1744 6-Thread Series1745 8-Thread Series1746 12-Thread Series1747 16-Thread Series1748 20-Thread Series1749 28-Thread Series1750 Thread Classes1751 Coated 60-deg. Threads1753 Screw Thread Selection1753 Pitch Diameter Tolerance1753 Screw Thread Designation1754 Designating Coated Threads1754 Designating UNS Threads1754 Hole Sizes for Tapping1754 Minor Diameter Tolerance

METRIC SCREW THREADS

1755 Metric Screw Threads M Profile 1755 Comparison with Inch Threads1755 Interchangeability1755 Definitions1756 Basic M Profile1756 M Crest and Root Form1756 General Symbols1757 M Profile Screw Thread Series1757 Mechanical Fastener Coarse Pitch1758 M Profile Data1759 Limits and Fits1765 Dimensional Effect of Coating1765 Formulas for M Profile

METRIC SCREW THREADS (Cont.)

1769 Tolerance Grade Comparisons1769 M Profile Limiting Dimension1769 Internal Metric Thread 1771 External Metric Thread 1774 Designations1777 MJ Profile1777 Diameter-Pitch Combinations1779 Trapezoidal Metric Thread1780 Comparison of Maximum Metal

Dimension

MINIATURE AND INTERFERENCE FIT THREADS

1781 Unified Miniature Screw Thread1781 Basic Thread Form1782 Design Thread Form1783 Design Form Dimensions1783 Formulas for Basic Dimensions 1784 Limits of Size and Tolerances1785 Minimum Root Flats 1786 Interference-Fit Threads1787 Design and Application Data1788 External Thread Dimension1788 Internal Thread Dimension1789 Engagement Lengths1790 Allowances for Coarse Thread1790 Tolerances for Coarse Thread1791 Variations in Lead and Diameter

ACME SCREW THREADS

1792 Acme Screw Threads1792 General Purpose Acme Threads1793 Acme Thread Form1795 Acme Thread Abbreviations1795 Designation1796 Basic Dimensions1796 Formulas for Diameters 1797 Limiting Dimensions1799 Single-Start Screw Thread Data1800 Pitch Diameter Allowances1800 Multiple Start Acme Threads1801 Pitch Diameter Tolerances1802 Centralizing Acme Threads1803 Basic Dimensions 1804 Formulas for Diameters1805 Limiting Dimensions1807 Screw Thread Data

TABLE OF CONTENTS

1703

ACME SCREW THREADS (Cont.)

1808 Pitch Diameter Allowances1809 Pitch Diameter Tolerances 1810 Tolerances and Allowances1811 Designation1811 Stub Acme Threads1812 Basic Dimensions 1812 Formulas for Diameters 1813 Limiting Dimensions1814 Stub Acme Thread Designations1814 Alternative Stub Acme Threads1816 Acme Centralizing Thread1816 60-Degree Stub Thread

BUTTRESS THREADS

1817 10-Degree Square Thread1817 Threads of Buttress Form1818 Buttress Inch Screw Threads1818 Basic Dimensions 1818 Pitch Combinations1819 Buttress Thread1820 Symbols and Form1821 Buttress Thread Tolerances1822 Class 2 Tolerances1822 Class 3 Tolerances1823 Allowances for Easy Assembly1823 External Thread Allowances1823 Example 1824 Buttress Thread Designations1824 Designation Sequence

BRITISH THREADS

1825 British Standard Buttress Threads1825 Löwenherz Thread1825 International Metric Thread1825 Unified Screw Threads1826 ISO Metric Screw Threads1826 Basic Profile Dimensions1827 Fundamental Deviations1828 Tolerance Classes for Nuts1828 Tolerance Classes for Bolts1829 Lengths of Thread Engagements1831 Limits and Tolerances1834 Diameter/Pitch Combinations1836 British Standard Whitworth (BSW)

and Fine (BSF) Threads1836 Standard Thread Form1836 Whitworth Standard Thread Form1836 Tolerance Formulas

BRITISH THREADS (Cont.)

1837 Basic Dimensions1839 British Association Standard

Thread1839 Basic Dimensions1839 Tolerance Formulas

OTHER THREADS

1840 BS Spark Plugs 1840 SAE Standards Threads1841 Hose Coupling Threads1842 Screw Thread Length1842 ANSI Standard1843 Fire Hose Connection1844 Basic Dimensions1845 Limits of Size1846 Rolled Threads1846 Instrument Makers' System1846 Pipe Threads1847 Taper Pipe Thread1847 Limits on Crest and Root1848 Tolerances on Thread Elements1848 Pipe Couplings1849 Basic Dimensions1850 Engagement 1850 Railing Joint 1851 Straight Pipe Threads1851 Mechanical Joints1852 Thread Designation and Notation1852 Dryseal Pipe Thread1853 Limits on Crest and Root1853 Types of Dryseal Pipe Thread1854 Limitation of Assembly 1855 Tap Drill Sizes1855 Special Dryseal Threads1856 Limitations for Combinations1856 Non-pressure-tight Joints1857 Basic Sizes1858 Limits of Size

MEASURING SCREW THREADS

1859 Measuring Screw Threads1859 Pitch and Lead of Screw Threads1859 Thread Micrometers1860 Ball-point Micrometers1860 Three-wire Method1861 Classes of Formulas1861 Screw Thread Profiles1861 Checking Pitch Diameters

TABLE OF CONTENTS

1704

MEASURING SCREW THREADS (Cont.)

1862 Wire Sizes1862 Diameters of Wires 1863 Measuring Wire Accuracy1863 Measuring or Contact Pressure1863 Three-Wire Formulas 1864 General Formula1864 Notation1865 Formulas for Checking Pitch

Diameters1866 Values of Constants1866 Small Thread Angle Affects1867 Dimensions Over Wires1867 Buckingham Simplified Formula1868 Measuring Whitworth Standard1869 Buckingham Exact Formula1870 Accuracy of Formulas1871 Acme and Stub Acme Thread1871 Thickness of Threads1871 Checking Thickness1872 Wire Sizes1872 Testing Angle of Thread1873 Best Wire Diameters1875 Taper Screw Threads1876 Buttress Threads1877 Measurement of Pitch Diameter 1877 Thread Gage Classification1877 Screw Thread Gage Classification1877 Unified Inch Screw Threads1880 Thread Forms of Gages1880 Thread Gage Tolerances1882 Tolerance1883 Tolerances for Cylindrical Gages1883 Constants for Thread Gage1884 Formulas for Limits

TAPPING AND THREAD CUTTING

1885 Selection of Taps1887 Tap Rake Angles1887 Cutting Speed1887 Tapping Specific Materials1890 Diameter of Tap Drill1891 Hole Size Limits1899 Tap Drill Sizes1900 Tap Drills and Clearance Drills1900 Tolerances of Tapped Holes1901 Hole Sizes before Tapping

TAPPING AND THREAD CUTTING (Cont.)

1902 Miniature Screw Threads1903 Tapping Drill Sizes1903 ISO Metric Threads 1904 Clearance Holes1905 Cold Form Tapping1906 Core Hole Sizes1907 Tap Drill Sizes1907 Removing a Broken Tap1907 Tap Drills for Pipe Taps1907 Power for Pipe Taps1908 High-Speed CNC Tapping1909 Coolant for Tapping1909 Combined Drilling and Tapping1910 Relief Angles for Cutting Tools1912 Lathe Change Gears1912 Change Gears for Thread Cutting1912 Compound Gearing1912 Fractional Threads1913 Change Gears for Metric Pitches1913 Threads per Inch 1913 Change Gears for Fractional

Ratios1914 Quick-Change Gearbox Output1916 Finding Accurate Gear Ratios1916 Lathe Change-gears1917 Relieving Helical-Fluted Hobs

THREAD ROLLING

1918 Thread-Rolling Machine 1918 Flat-Die Type1918 Cylindrical-Die Type1918 Rate of Production1919 Precision Thread Rolling1919 Steels for Thread Rolling1919 Diameter of Blank1919 Automatic Screw Machines1920 Factors Governing the Diameter1920 Diameter of Threading Roll1920 Kind of Thread on Roll1921 Application of Thread Roll1921 Speeds and Feeds for Thread

Rolling

TABLE OF CONTENTS

1705

THREAD GRINDING

1923 Thread Grinding1923 Wheels for Thread Grinding1923 Single-Edge Wheel1924 Edges for Roughing and Finishing1924 Multi-ribbed Wheels1925 Ribbed Wheel for Fine Pitches1925 Solid Grinding Threads 1925 Number of Wheel Passes1925 Wheel and Work Rotation1926 Wheel Speeds1926 Work Speeds1926 Truing Grinding Wheels1927 Wheel Hardness or Grade1927 Grain Size1927 Grinding by Centerless Method

THREAD MILLING

1928 Thread Milling Machine1928 Single-cutter Method1928 Multiple-cutter Method1929 Planetary Method1930 Classes of Work 1930 Pitches of Die-cut Threads 1930 Changing Pitch of Screw1931 Helical Milling1931 Lead of a Milling Machine1931 Change Gears for Helical Milling1931 Short-lead Milling1932 Helix1932 Helix Angles1933 Change Gears for Different Leads1943 Lead of Helix1946 Change Gears and Angles1947 Helix Angle for Given Lead and

Diameter1948 Helix Angle for Given Lead 1948 Lead of Tooth 1948 Helix Angle and Lead

SIMPLE, COMPOUND, DIFFERENTIAL, AND

BLOCK INDEXING

1949 Milling Machine Indexing1949 Hole Circles1949 Holes in Brown & Sharpe1949 Holes in Cincinnati1949 Simple Indexing1950 Compound Indexing1951 Simple and Compound Indexing1956 Angular Indexing1956 Tables for Angular Indexing1957 Angular Values of Cincinnati

Index1958 Accurate Angular Indexing 1976 Indexing for Small Angles1976 Differential Indexing1977 Ratio of Gearing1977 Determining Gear Ratio1977 To Find the Indexing Movement1977 Use of Idler Gears1978 Compound Gearing1978 Check Number of Divisions1979 Simple and Different Indexing1986 Indexing Movements of Plate1987 Indexing Movements for High

Numbers1990 Indexing Tables1990 Block or Multiple Indexing1992 Indexing Movements for 60-

Tooth1993 Linear Indexing for Rack Cutting1993 Linear Indexing Movements 1994 Contour Milling

TABLE OF CONTENTS

1995

GEARS, SPLINES, AND CAMS

GEARS AND GEARING

1998 Definitions of Gear Terms2002 Sizes and Shape of Gear Teeth2002 Nomenclature of Gear Teeth2002 Properties of the Involute Curve2003 Diametral and Circular Pitch

Systems2004 Formulas for Spur Gear2005 Gear Tooth Forms and Parts2007 Gear Tooth Parts2008 Tooth Proportions2009 Fine Pitch Tooth Parts2009 American Spur Gear Standards2010 Formulas for Tooth Parts2010 Fellows Stub Tooth2010 Basic Gear Dimensions2011 Formulas for Outside and Root

Diameters 2013 Tooth Thickness Allowance2014 Circular Pitch for Given Center

Distance2014 Circular Thickness of Tooth2018 Chordal Addendum2019 Addendums and Tooth

Thicknesses2019 Enlarged Pinion2020 Caliper Measurement of Gear

Tooth2021 Involute Gear Milling Cutter2022 Circular Pitch in Gears2022 Increasing Pinion Diameter2023 Finishing Gear Milling Cutters2024 Increase in Dedendum2024 Dimensions Required2025 Tooth Proportions for Pinions 2027 Minimum Number of Teeth 2027 Gear to Mesh with Enlarged

Pinion2027 Standard Center-distance 2027 Enlarged Center-distance 2028 Contact Diameter2029 Contact Ratio2029 Lowest Point of Single Tooth

Contact2030 Maximum Hob Tip Radius2030 Undercut Limit2030 Highest Point of Single Tooth

Contact

GEARS AND GEARING (Cont.)

2030 True Involute Form Diameter2031 Profile Checker Settings2033 Gear Blanks2034 Spur and Helical Gear Data2036 Backlash2036 Determining Amount of Backlash2037 Helical and Herringbone Gearing2038 Bevel and Hypoid Gears2039 Providing Backlash2039 Excess Depth of Cut2039 Control of Backlash Allowances2040 Measurement of Backlash2041 Control of Backlash2041 Allowance and Tolerance 2042 Angular Backlash in Gears2042 Inspection of Gears2042 Pressure for Fine-Pitch Gears2042 British Standard for Spur and

Helical Gears2044 Addendum Modification

INTERNAL GEARING

2047 Internal Spur Gears2047 Methods of Cutting Internal Gears2047 Formed Cutters for Internal Gears2047 Arc Thickness of Gear Tooth2047 Arc Thickness of Pinion Tooth2047 Relative Sizes of Internal Gear2048 Rules for Internal Gears

HYPOID AND BEVEL GEARING

2049 Hypoid Gears2050 Bevel Gearing2050 Types of Bevel Gears2051 Applications of Bevel and Hypoid

Gears2052 Design of Bevel Gear Blanks2053 Mountings for Bevel Gears2053 Cutting Bevel Gear Teeth2054 Nomenclature for Bevel Gears2054 Formulas for Dimensions 2058 Numbers of Formed Cutters2060 Selecting Formed Cutters2061 Offset of Cutter2062 Adjusting the Gear Blank 2063 Steels Used for Bevel Gear2064 Circular Thickness, Chordal

Thickness

TABLE OF CONTENTS

1996

WORM GEARING

2064 Standard Design for Fine-pitch2065 Formulas for Proportions of

Wormgears2067 Materials for Worm Gearing2067 Single-thread Worms2067 Multi-thread Worms

HELICAL GEARING

2068 Helical Gear Calculations2068 Rules and Formulas 2068 Determining Direction of Thrust2069 Determining Helix Angles2069 Pitch of Cutter to be Used2072 Shafts at Right Angles, Center

Distance approx2073 Shafts at Right Angles, Center

Distance Exact2076 Shafts at Any Angle, Center

Distance Exact2077 Selecting Cutter for Milling

Helical Gears2078 Factors for Selecting Cutters2078 Outside and Pitch Diameters2079 Milling the Helical Teeth2079 Fine-Pitch Teeth For Helical

Gears2080 Center Distance with no Backlash2081 Change-gears for Hobbing2083 Helical Gear Hobbing2083 Herringbone Gears2084 General Classes of Problems2084 Causes of Failures

PLANETARY GEARING

2084 Direction of Rotation2084 Compound Drive2084 Planetary Bevel Gears2085 Ratios of Epicyclic Gearing

RATCHET GEARING

2088 Types of Ratchet Gearing2089 Shape of Ratchet Wheel Teeth2089 Pitch of Ratchet Wheel Teeth

MODULE SYSTEM

2090 Module System Gear Design 2090 German Standard Tooth Form2091 Tooth Dimensions 2092 Rules for Module System of

Gearing2093 Equivalent Diametral Pitches,

Circular Pitches

CHECKING GEAR SIZES

2094 Checking Externall Spur Gear Sizes2095 Measurement Over ires2099 Checking Internal Spur Gear 2108 Measurements for Checking

Helical Gears using Wires 2109 Checking Spur Gear Size2111 Formula for Chordal Dimension

GEAR MATERIALS

2113 Gearing Material2113 Classification of Gear Steels2113 Use of Casehardening Steels2113 Use of “Thru-Hardening” Steels2113 Heat-Treatment for Machining2114 Making Pinion Harder2114 Forged and Rolled Carbon Steels2114 Compositions 2114 Forged and Rolled Alloy Steels2115 Compositions 2115 Steel Castings for Gears2115 Compositions 2115 Effect of Alloying Metals2116 Sintered Materials2117 Steels for Industrial Gearing2117 Bronze and Brass Gear Castings2118 Materials for Worm Gearing2119 Non-metallic Gears2119 Power-Transmitting Capacity2120 Safe Working Stresses2120 Preferred Pitch 2120 Bore Sizes2121 Preferred Pitches2121 Keyway Stresses 2122 Invention of Gear Teeth2122 Calculating Replacement2123 Spur Gears2125 Helical Gears

TABLE OF CONTENTS

1997

SPLINES AND SERRATIONS

2126 Involute Splines2126 American National Standard2127 Terms2128 Types of involute spline2130 Tooth Proportions2130 Symbols2131 Formulas for Basic Dimensions 2133 Basic Dimensions2133 Tooth Numbers2133 Types and Classes of Fits2133 Classes of Tolerances2134 Maximum Tolerances2135 Fillets and Chamfers2135 Spline Variations2136 Effect of Spline Variations2136 Effective and Actual Dimensions2137 Space Width and Tooth Thickness

Limits2137 Effective and Actual Dimensions2138 Combinations of Spline Types2138 Interchangeability2139 Drawing Data2140 Spline Data and Reference

Dimensions2140 Estimating Key and Spline Sizes2141 Formulas for Torque Capacity2141 Spline Application Factors2142 Load Distribution Factors2142 Fatigue-Life Factors2142 Wear Life Factors2144 Allowable Shear Stresses2145 Allowable Compressive Stresses2145 Allowable Tensile Stresses 2145 Crowned Splines for Large

Misalignments2146 Fretting Damage to Splines 2146 Inspection Methods2147 Inspection with Gages2147 Measurements with Pins2148 Metric Module Splines2150 Comparison of Symbols

SPLINES AND SERRATIONS (Cont.)

2151 Formulas for Dimensions and Tolerances

2153 Tooth Thickness Modification2153 Machining Tolerances2153 Tooth Thickness Total Tolerance2154 Selected Fit Classes Data2156 British Standard Striaght Splines2157 Standard Splined Fittings2160 Dimensions of Standard Splines2160 Splines Fittings2160 Polygon-type Shaft Connections

CAMS AND CAM DESIGN

2163 Classes of Cams2163 Cam Follower Systems2164 Displacement Diagrams2169 Cam Profile Determination2170 Modified Constant Velocity Cam2172 Pressure Angle and Radius of

Curvature2173 Cam Size for a Radial Follower2175 Cam Size for Swinging Roller

Follower2176 Formulas for Calculating Pressure

Angles2178 Radius of Curvature2180 Cam Forces, Contact Stresses, and

Materials2184 Calculation of Contact Stresses2186 Layout of Cylinder Cams2186 Shape of Rolls for Cylinder Cams2187 Cam Milling2188 Cutting Uniform Motion Cams

TABLE OF CONTENTS

2189

MACHINE ELEMENTS

PLAIN BEARINGS

2193 Classes of Plain Bearings2193 Types of Journal Bearings2195 Hydrostatic Bearings2196 Modes of Bearing Operation2197 Methods of Retaining Bearings2198 Methods of Bearing Retention2198 Methods of Sealing2199 Hardness and Surface Finish2200 Machining2201 Methods of Lubrication2203 Lubricant Selection2205 Greases and Solid Lubricants2206 Journal or Sleeve Bearings2206 Grooving and Oil Feeding2206 Heat Radiating Capacity2207 Journal Bearing Design Notation2209 Journal Bearing Lubrication2215 Sleeve Bearing Pressure2216 Use of Lubrication Analysis

THRUST BEARINGS

2219 Thrust Bearing2219 Design Notation2220 Flat Plate Design2225 Step Design2227 Tapered Land Design2232 Tilting Pad Thrust Bearing Design2236 Guide Bearings

PLAIN BEARING MATERIALS

2237 Properties of Bearing Materials2237 Babbitt or White Metal Alloys2238 Bearing and Bushing Alloys2239 White Metal Bearing Alloys2240 Copper-Lead2241 Leaded Bronze and Tin-Bronze2241 Aluminum2241 Silver2241 Cast Iron2241 Porous Metals2242 Sintered Metal and Nonmetallic

Bearings2242 Plastics Bearings2243 Copper- and Iron-Base Sintered

Bearings2245 Carbon-Graphite

BALL, ROLLER, AND NEEDLE BEARINGS

2246 Types of Anti-friction Bearings2246 Types of Ball Bearings2247 Types of Rolling Element

Bearings2251 Types of Roller Bearings2252 Types of Ball and Roller Thrust

Bearings2253 Types of Needle Bearings2254 Plastics Bearings2254 Flanged Housing Bearings2254 Conventional Bearing Materials2255 Cage Materials2255 Method of Bearing Designation2261 Bearing Tolerances2262 Cylindrical Roller Thrust

Bearings2263 Needle Roller Bearings2269 Design and Installation2269 Needle Roller Bearing Fitting2271 Bearing Mounting Practice2273 Alignment Tolerances2273 Squareness and Alignment2274 Soft Metal and Resilient Housings2274 Quiet or Vibration-free Mountings2275 General Mounting Precautions2275 Seating Fits for Bearings2275 Clamping and Retaining Methods2280 Bearing Closures2280 Bearing Fits2281 Selection of Ball and Roller

Bearings2282 Method of Lubrication2283 Type of Mounting2283 Radial and Axial Clearance2284 Bearing Handling Precautions2285 Bearing Failures and Deficiencies2285 Load Ratings and Fatigue Life2285 Ball and Roller Bearing Life2286 Ball Bearing Types Covered2286 Limitations for Ball Bearings2287 Ball Bearing Rating Life2291 Roller Bearing Types Covered2293 Roller Bearing Rating Life2296 Life Adjustment Factors2297 Ball Bearing Static Load Rating2300 Equivalent Load

TABLE OF CONTENTS

2190

STANDARD METAL BALLS

2303 Standard Metal Balls2303 Definitions and Symbols2304 Preferred Ball Gages2307 Preferred Ball Sizes2309 Number of Metal Balls per Pound2310 Number of Metal Balls per Kg

LUBRICANTS AND LUBRICATION

2311 Lubricating Oils2312 Types of Oils2312 Viscosity2313 Specific Gravity of Oils2313 Application of Lubricating Oils2314 Lubrication Systems2315 Oil Mist Systems2316 Lubricating Greases2316 Grease Classifications2316 Types of Grease2317 Temperature Effects on Grease

Life2317 Relubricating with Grease2318 Solid Film Lubricants2318 Anti-friction Bearing Lubrication2321 Aerodynamic Lubrication2321 Elastohydrodynamic Lubrication2324 Viscosity-pressure relationship

COUPLINGS AND CLUTCHES

2325 Connecting Shafts2325 Safety Flange Coupling2326 Interference Fits2326 Double-cone Clamping Couplings2327 Flexible Couplings2327 The Universal Joint2328 Knuckle Joints2328 Friction Clutches2329 Proportions of Knuckle Joints2330 Cast-iron Friction Clutches2330 Formulas for Cone Clutches2331 Magnetic Clutches2332 Slipping Clutch/Couplings2332 Wrapped-spring Clutches2333 Positive Clutches2334 Cutting Clutch Teeth

FRICTION BRAKES

2337 Formulas for Band Brakes2339 Coefficient of Friction in Brakes2340 Formulas for Block Brakes

KEYS AND KEYSEATS

2342 Keys and Keyseats2342 Key Size Versus Shaft Diameter2345 Plain and Gib Head Keys2346 Fits for Parallel and Taper Keys2347 Key Chamfer 2347 Keyseat Tolerances for Electric

Motor2347 Set Screws for Use Over Keys2347 Woodruff Keys and Keyseats2348 Woodruff Keys2350 Keyseat Dimensions 2353 Depth of Keyseat2354 Depths for Milling Keyseats2354 Cotters2354 British Keys and Keyways2354 Metric Keys and Keyways2360 Preferred Lengths of Metric Keys 2361 Parallel Keys, Keyways, and

Keybars2363 Taper Keys and Keyways2365 Dimensions and Tolerances 2365 Woodruff Keys and Keyways2367 Preferred Lengths of Plain and

Gib-head Keys2368 Flat Belting2370 Pulley Diameters and Speeds2371 Pulley Speed in Compound Drive2371 Belt Length in Three Pulleys

FLEXIBLE BELTS AND SHEAVES

2372 Power Transmitted By Belts2372 Measuring the Effective Length2373 Narrow V-Belts 2374 Standard Effective Lengths2375 Sheave and Groove Dimensions2377 Sheave Outside Diameters 2378 Length Correction Factors2379 Cross Section Correction Factors2379 Classical V-Belts 2380 Standard Datum Length2381 Sheave and Groove Dimensions2385 Length Correction Factors2386 Double V-Belts

TABLE OF CONTENTS

2191

FLEXIBLE BELTS AND SHEAVES (Cont.)

2387 Sheave and Groove Dimensions2390 Terms for Calculations2391 Allowable Tight Side Tension2394 Tension Ratio/Arc of Contact

Factors2394 Light Duty V-Belts 2394 Belt Cross Sections2394 Belt Size Designation2395 V-Belt Standard Dimensions2396 Sheave and Groove Dimensions2397 Combined Correction Factors2397 V-Ribbed Belts 2397 Nominal Dimensions2398 Sheave and Groove Dimensions2400 Standard Effective Lengths2401 Length Correction Factors2401 Arc of Contact Correction Factors2402 Speed Ratio Correction Factors2402 Variable Speed Belts 2402 Normal Dimensions2403 Standard Belt Lengths2404 Sheave and Groove Dimensions2407 Arc of Contact Correction Factors2408 Length Correction Factors2409 60 Degree V-Belts2409 Speed Ratio Correction Factors2409 Synchronous Belts2411 Standard Pulley and Flange

Dimensions2411 Nominal Tooth and Section

Dimensions2412 Pitch Lengths and Tolerances2413 Widths and Tolerances2414 Pulley Diameters 2415 Pulley Tolerances 2416 Teeth in Mesh Factor2417 Torque Rating2417 Belt Width Factor2417 Belt Storage and Handling2418 Service Factors2420 SAE Standard V-Belts2420 Pulley Dimensions

TRANSMISSION CHAINS

2421 Types of Chains2421 Types of roller chains2422 Roller Chain Parts2423 Transmission Roller Chain2423 Dimensions and Loads2423 ANSI Dimensions2424 Roller Chain Numbers2424 Types of Sprockets2425 Attachments2425 Straight and Bent Link Plate2426 Sprocket Classes2426 Keys, Keyways, and Set Screws2426 Sprocket Diameters2428 Tolerances on the Caliper

Diameter2429 Profile Dimension2430 Proportions of Sprockets2430 Proportions of Single-Strand2430 Bar-steel Sprockets2431 Chain and Sprockets2431 Selection of Chain and Sprockets2431 Power Ratings for Roller Chain2436 Maximum Bore and Hub

Diameter2436 Center Distance between

Sprockets2437 Center Distance of Chain Length2437 Idler Sprockets2437 Length of Driving Chain2438 Tooth Form for Roller Chain2439 Standard Hob Design2440 Cutting Sprocket Tooth Form2440 Standard Space Cutters2441 Space Cutter Sizes2441 Sprocket Materials2442 Roller Chain Drive Ratings2442 Service Factors2443 Lubrication2443 Installation and Alignment2444 Design Procedure

STANDARDS FOR ELECTRIC MOTORS

2445 Classes of NEMA Standards2445 Mounting Dimensions 2445 Integral-horsepower Motors2446 Locked-rotor Torque2447 Torque and Current Definitions

TABLE OF CONTENTS

2192

STANDARDS FOR ELECTRIC MOTORS (Cont.)

2447 Direction of Motor Rotation2448 Pull-up Torque2448 Types of Motors2449 Shunt-wound Motor Drive2450 Compound-wound Motors2450 Types of Polyphase AC Motors2450 Squirrel-cage Induction Motor2451 Multiple-Speed Induction Motors2451 Wound-Rotor Induction Motors2451 High-Frequency Induction Motors2451 Synchronous Motors2452 Alternating-Current Motors2453 Speed Reducers2453 Factors Governing Motor Selection2453 Speed, Horsepower, Torque and

Inertia Requirements2454 Space Limitations in Motor

Selection2456 Applications of DC Motors2457 Polyphase AC Motors2458 Electric Motor Maintenance2458 Electric Motor Inspection

Schedule

ADHESIVES AND SEALANTS

2460 Bonding Adhesives2461 Two-Component Mix Adhesives2463 Retaining Compounds2464 Threadlocking2464 Sealants2465 Tapered Pipe-thread Sealing2466 Anaerobic Pipe Sealants

MOTION CONTROL

2467 Control Systems2468 Control Motor Types2470 Controllers2470 Control Function2471 Electromechanical Control Systems2471 Mechanical Stiffness2472 Torsional Vibration2472 Electric Motors2473 Stepper Motors2473 Gearing2474 Feedback Transducers2475 Analog Transducers2475 Synchros and Resolvers

MOTION CONTROL (Cont.)

2475 Hydraulic and Pneumatic Systems2476 Hydraulic Pumps2476 Hydraulic Fluids2479 Proportional Control Systems2480 Electronic Controls2481 Pneumatic Systems

O-RINGS

2483 Gland Depth 2485 Clearances and Groove Sizes2486 Typical O-Ring Compounds2487 Ring Materials

ROLLED STEEL SECTIONS, WIRE AND SHEET-METAL

GAGES

2488 Rolled Steel Sections2488 Angles Bent to Circular Shape2488 Hot-Rolled Structural Steel2489 Steel Wide-Flange2493 Steel S Sections2494 Steel Channels2495 Steel Angles with Equal Legs2496 Angles with Unequal Legs2498 Aluminum Structural Shapes2499 Wire and Sheet-metal Gages2499 Wire Gages2499 Wall Thicknesses of Tubing2501 Sheet-Metal Gages2503 Flat Metal Products2503 Preferred Metric Thicknesses

PIPE AND PIPE FITTINGS

2504 Wrought Steel Pipe2505 Weights and Dimensions2507 Properties of Schedule Pipe2509 Volume of Flow2510 Plastics Pipe2510 Dimensions and Weights 2511 Properties and Uses2512 Temperature-Correction Factors

TABLE OF CONTENTS

2513

MEASURING UNITS

THERMAL ENERGY OR HEAT

2514 Thermometer Scales2514 Absolute Temperature and

Absolute Zero2514 Thermal Energy2514 Fahrenheit-Celsius Conversion2515 Interpolation Factors

WEIGHTS AND MEASURES

2517 Measures of Length2517 Surveyor's Measure2517 Nautical Measure2517 Square Measure2517 Cubic Measure2518 Shipping Measure2518 Dry Measure2518 Liquid Measure2518 Old Liquid Measure2518 Apothecaries' Fluid Measure2518 Avoirdupois or Commercial Weight2518 Troy Weight, used for Weighing

Gold and Silver2519 Apothecaries' Weight2519 Measures of Pressure2519 Miscellaneous

METRIC SYSTEMS OF MEASUREMENT

2520 International System of Units2522 Factors and Prefixes2522 Standard of Length2522 Measures of Length2523 Square Measure2523 Surveyor's Square Measure2523 Cubic Measure2523 Dry and Liquid Measure2523 Measures of Weight

METRIC SYSTEMS OF MEASUREMENT (Cont.)

2525 Metric System2525 Metric Conversion Factors2531 Metric and English Equivalents2531 Use of Conversion Tables2532 Ohm’s Law2533 Binary Multiples2533 Linear Measure2534 Decimals of an Inch to

Millimeters2536 Millimeters to Inches 2538 Fractional Inch2539 Microinches to Micrometers2540 Micrometers to Microinches2541 Foot Meter and Mile Kilometer

Conversion2541 Square Measure2542 Square Inch Square Centimeter

Conversion2542 Cubic Measure2543 Cubic Foot Cubic Meter

Conversion2544 Acre Hectare Conversion2545 Gallon Liter Conversion 2546 Weight2546 Pound Kilogram Conversion 2548 Pounds per Square Inch

Kilopscals Conversion2549 Pounds per Cubic Inch Grams per

Cubic Centimeter2550 Pounds-force to Newtons

Conversion2551 Power and Heat Equivalents2553 British Thermal Unit Joule

Conversion2554 Greek Letters and Standard

Abbreviations2554 Abbreviations for Scientific and

Engineering Terms