Machinery's Handbook Pocket Companion: Quick Access to Basic Data & More from the 31st Edition

By Richard Pohanish and Christopher McCauley

Machinery’s Handbook, Pocket Companion, is a concise yet authoritative, highly useful reference that draws its content from the Machinery’s Handbook. Designed as a time saver, the Pocket Companion is an ideal quick resource for anyone in manufacturing, metalworking, and related fields for whom convenient access to just the most basic data is essential. 
The Pocket Companion draws on the wealth of tables, charts, and text in the Machinery’s Handbook, 31st Edition. Much of the information has been reorganized, distilled, or simplified to increase the usefulness of this book, while keeping it compact. The Pocket Companion is not intended to replace the new Machinery’s Handbook, 31st Edition. Instead, it serves as a handy and more portable complement to the Handbook’s vast collection of text, data, and standards.
 
Features
 

• Serves as a handy and portable complement to the vastly larger compilation of data, standards, and text, in the Machinery’s Handbook.
• Revised to reflect numerous changes made in the new 31st edition, this second edition includes updated standards, key revisions, and added tables.
• The visual design and carefully organized presentation of fundamental and reliable data facilitates frequent and easy use, helping to save time and labor.
•  Practitioners and students will find the Pocket Companion to be a convenient ready-reference to keep nearby while working on engineering designs, on the shop or factory floor, or learning fundamentals in school and studies.
• The Pocket Companion also is sold as a standalone eBook. For information on this handy format, as well as the Machinery’s Handbook 31 Digital Edition, visit the Industrial Press eBookStore site at ebooks.industrialpress.com.

• Language: English
• Publisher: Industrial Press, Inc.
• Release date: Mar 1, 2020
• ISBN: 9780831195687

Book preview

Machinery’s

Handbook

Pocket

Companion

A REFERENCE BOOK

FOR THE MANUFACTURING AND MECHANICAL ENGINEER,

DESIGNER, DRAFTER, METALWORKER, TOOLMAKER,

MACHINIST, HOBBYIST, EDUCATOR, AND STUDENT

Machinery’s

Handbook

Pocket

Companion

Second Edition

RICHARD P. POHANISH AND CHRISTOPHER J. McCAULEY

LAURA BRENGELMAN, EDITOR

INDUSTRIAL PRESS, INC.

INDUSTRIAL PRESS, INC.

32 Haviland Street, Suite 3

South Norwalk, Connecticut 06854 U.S.A.

Phone: [phone]

Toll-Free: 888-528-7852

Fax: [phone]

Email: [e-mail]

Title: Machinery’s Handbook Pocket Companion, 2nd Edition

Authors and Compilers: Richard P. Pohanish and Christopher J. McCauley

Library of Congress Control Number: 2020931274

COPYRIGHT

© 2000, 2008, 2016, 2020 by Industrial Press, Inc.

ISBN PRINT: 978-0-8311-4431-9

ISBN ePDF: 978-0-8311-9567-0

ISBN ePub: 978-0-8311-9568-7

ISBN eMobi: 978-0-8311-9569-4

No part of this book may be reproduced or transmitted in any form or by any means, electronic or mechanical, including photocopying, recording, or by any information storage and retrieval system, without written permission from the publisher.

Limits of Liability and Disclaimer of Warranty

While every possible effort has been made to ensure the accuracy of all information presented herein, the publisher expresses no guarantee of the same, does not offer any warrant or guarantee that omissions or errors have not occurred, and may not be held liable for any damages resulting from use of this text. Readers accept full responsibility for their own safety and that of the equipment used in conjunction with this text.

Printed and bound in the United States of America

MACHINERY’S HANDBOOK

POCKET COMPANION

2ND EDITION

First Printing

books.industrialpress.com

ebooks.industrialpress.com

TABLE OF CONTENTS

FOREWORD

MATHEMATICAL FORMULAS AND TABLES

Dimensions of Plane Figures

Square

Rectangle

Parallelogram

Triangle

Trapezoid and Trapezium

Regular Hexagon and Octagon

Circle

Cycloid

Circular Ring

Ellipse

Spandrel or Fillet

Parabola

Hyperbola

Regular Polygons

Segments of Circles

Diameters of Circles and Sides of Squares

Propositions of Geometry

Trigonometric Relationships and Functions

Useful Relationships Among Angles

Law of Sines

Law of Cosines

Trigonometric Functions and Identities

Solution of Triangles

Trigonometry Tables

Formulas for Compound Angles

Length of Chords for Spacing Off the Circumferences of Circles

Coordinates for Locating Equally-Spaced Holes

Decimal Equivalents, Squares, Cubes, Square Roots, Cube Roots, and Logarithms

Diameter, Circumference, and Area of Circles

MEASUREMENT AND INSPECTION

Sine-Bar

Calculations Using Sine-Bars

Measuring Tapers with V-Block and Sine-Bar

Using a Calculator to Determine Sine-Bar Constants

Setting a Sine-Bar

Measurement of Angles and Tapers

Rules for Figuring Tapers

Tapers per Foot and Corresponding Angles

Gage Block Sets—Inch Sizes

Measuring Dovetail Slides

Checking a V-Shaped Groove by Measurement Over Pins

Measuring American Standard and British Whitworth Screw Threads

Checking Pitch Diameters of Screw Threads by Three-Wire Method

Three-Wire Method Applied to Buttress Threads

Measuring Pitch Diameters of Inch and Metric Screws

STANDARD TAPERS

Morse Taper

Morse Standard Taper Shanks

Morse Stub Taper Shanks

Morse Taper Sleeves

Jarno Taper

Jarno Taper Shanks

Brown & Sharpe Taper

Brown & Sharpe Taper Shanks

Spindle Noses for Milling Machines

Spindle Nose with Large Flange

Tool Shanks for Milling Machines

V-Flange Tool Shanks

V-Flange Tool Shank Retention Knobs

THREADS

Thread Classes

Sharp V-Thread

Unified Internal and External Screw Thread Design Profiles

Fine-Thread Series

Unified Screw Threads—Standard Series and Selected Combinations

Unified Screw Thread Calculations

Taper Pipe Threads

Metric Screw Threads—M Profile

M Profile Screw Thread Limiting Dimensions

Metric Thread—M Profile Data

M Profile Internal Metric Thread

M Profile External Metric Thread

Metric Spark Plug Threads

British Standard for Spark Plugs

SAE Spark Plug Screw Threads

FASTENER INFORMATION

Grades and Mechanical Properties of Bolts and Screws

Hexagon and Spline Keys and Bits

Hexagon and Spline Socket Head Cap Screws

Socket Head Cap Screws—Metric Series

Hexagon and Spline Socket Set Screws

Drill and Counterbore Sizes for Socket Head Cap Screws

Drill and Counterbore Sizes for Metric Socket Head Cap Screws

Hexagon and Spline Socket Flat Countersunk Head Cap Screws

Slotted Flat Countersunk Head Cap Screws

Hardened Ground Machine Dowel Pins

Hardened Ground Production Dowel Pins

Chamfered and Square End Straight Pins

Straight Pins

Taper Pins

Parallel Steel Dowel Pins

Spring Pins

Slotted-Type Spring Pins

Coiled-Type Spring Pins

T-Nuts

Wrench Openings for Nuts

Open-End Engineers Wrenches

Single and Double Hexagon Socket Wrenches—Inch and Metric

Box Wrenches—Inch and Metric

Bolts and Screws Specification

British Unified Machine Screws and Nuts

British Whitworth and Fine Machine Screws

CUTTING FLUIDS

Recommendations for Machining, Turning, and Milling

Recommendations for Drilling and Tapping

DRILLING AND REAMING

Generally Used Drill Point Angles

US and Metric Size Commercial Drills

Common Drilling Difficulties

Combined Drills and Countersinks—Plain and Bell Types

Counterboring

Counterbores with Interchangeable Cutters and Guides

Length of Point on Twist Drills and Centering Tools

Solid Counterbores with Integral Pilot

Solid Carbide Square Boring Tools

Reamers

Common Reamer Difficulties

TAPPING

Tap Terms and Designs

Tap Dimensions, Inch and Metric

General Threading Formulas

Tapping Specific Materials

Tap Drill Sizes for Threads

Tap Drills and Clearance Drills for Machine Screws

Tap Drills for Pipe Taps

Tap Drill or Core Hole Sizes for ISO Metric Threads

SPEEDS AND FEEDS

Cutting Speeds for Plain Carbon and Alloy Steels

Cutting Speeds for Ferrous Cast Metals

Cutting Speeds for Stainless Steels

Cutting Speeds for Tool Steels

Cutting Speeds for Light Metals

Cutting Speeds for Titanium and Titanium Alloys

Cutting Speeds for Superalloys

Cutting Speeds for Copper Alloys

Adjustment Factors for Turning with High-Speed Steel Tools

Feeds for Milling with High-Speed Steel Cutters

RPM for Drills of Number and Letter Sizes

RPM for Various Cutting Speeds and Diameters—Inch

RPM for Various Cutting Speeds and Diameters—Metric

Speeds and Feeds in Diamond Grinding

Speeds, Feeds, and Teeth for Drilling and Sawing Plastics

MILLING CUTTERS

Milling Cutter Terms and Parts

End Mill Terms and Parts

Wheels for Sharpening Milling Cutters

Wheel Speeds and Feeds for Sharpening Milling Cutters

Clearance Angles for Milling Cutter Teeth

Rake Angles for Milling Cutters

Set-Ups Used in Grinding Clearance Angle on Milling Cutter Teeth

Multiple- and Two-Flute Single-End Helical End Mills

Multiple-Flute Medium Helix Single-End End Mills

Form Relieved Corner Rounding Cutters

Two-Flute, High Helix Single-End End Mills

Two-Flute, Medium Helix, Plain- and Ball-End, Single-End End Mills

Three- and Four-Flute, Medium Helix, Center Cutting, Single-End End Mills

60-Degree Single-Angle Milling Cutters

Key Size Versus Shaft Diameter

Keys and Keyways for Milling Cutters and Arbors

Woodruff Keyseat Cutters

KEYS AND KEYSEATS

Depth Control Values for Shaft and Hub

Fits for Parallel and Taper Keys

Plain and Gib Head Keys

Depth of Keyseat

Woodruff Keys and Keyseats

Keyseat Dimensions for Woodruff Keys

BROACHING

Types of Broaches

Pitch of Broach Teeth

Data for Designing Surface Broaches

Broaching Pressure

Common Causes of Broaching Difficulties

CUTTING TOOLS FOR TURNING

Single-Point Turning Tools

Chipbreakers

Identification System for Indexable Inserts

Standard Shank Sizes for Indexable Insert Holders

Letter Symbols for Qualification of Tool Holders

Numerical Control Tooling

Insert-Radius Compensation

Threading Tool Insert-Radius Compensation

Cemented Carbides

ISO Classifications of Hardmetals

MACHINING OPERATIONS

Machining Aluminum

Machining Magnesium

Machining Zinc Alloy Die Castings

Machining Monel and Nickel Alloys

Machining Copper Alloys

Machining Hard Rubber

Tool Troubleshooting and Practical Tips

Tool Troubleshooting Checklist

Common Tool Faults, Failures, and Cures

COMPUTER NUMERICAL CONTROL

Format Classification

G-Code Addresses

Letter Addresses

Miscellaneous Function Words

GRINDING WHEELS

Grinding Wheel Safety

Handling, Storage, and Inspection

Machine Conditions

Grinding Wheel Mounting

Safe Operating Speeds

RPM for Various Grinding Speeds and Wheel Diameters

Portable Grinders

Maximum Peripheral Speeds for Grinding Wheels

Principal Systems of Surface Grinding

Periphery of Wheel

Face (Side) of Wheel

Wheel Recommendations for Surface Grinding

Data for Peripheral Surface Grinding

Common Faults and Possible Causes in Surface Grinding

Grinding Wheel Markings

Sequence of Markings

Composition of Diamond and Cubic Boron Nitride Wheels

Conventional Abrasives—Grinding Wheel Recommendations

Shapes and Sizes of Grinding Wheels

Shapes and Inch Size Ranges

Shapes and Metric Size Ranges

Shapes of Grinding Wheel Faces

Diamond Wheel Core Shapes and Designations

Diamond Wheel Cross Sections and Designations

Location of Diamond Section on Wheel

Letters for Diamond Wheel Modifications

Wheel Type Recommendations and Abrasive Specification

Standard Shapes and Inch Sizes of Mounted Wheels and Points

Standard Shapes and Metric Sizes of Mounted Wheels and Points

Lapping Lubricants

Sharpening Carbide Tools

Silicon Carbide Wheels

Diamond Wheel Grits and Grades

Diamond Concentration

Dry versus Wet Grinding of Carbide Tools

Coolants for Carbide Tool Grinding

Peripheral versus Flat Side Grinding

Lapping Carbide Tools

Chipbreaker Grinding

GEARING

Gear Teeth Nomenclature and Comparative Size

Gear Tooth Forms

Formulas for Standard Spur Gears

Circular Pitch in Gears

Chordal Thicknesses and Addenda of Gear Teeth and Milling Cutters

Series of Involute, Finishing Gear Milling Cutters

Gear Design Based upon Module System

Tooth Form for Spur and Bevel Gears

Tooth Dimensions Based Upon Module System

Rules for Module System of Gearing

Equivalent Diametral Pitches, Circular Pitches, and Metric Modules

Caliper Measurement of Gear Tooth

Checking Spur Gear Size by Chordal Measurement

Chordal Dimensions over Spur Gear Teeth

Number of Teeth Included in Chordal Measurement

Formulas for Chordal Dimension

PROPERTIES OF MATERIALS

Standard Steel Classification

Classification of Tool Steels

System of Designating Carbon and Alloy Steels

Classification, Compositions, and Properties of Tool and Die Steels

Quick Reference Guide for Tool Steel Selection

Molybdenum High-Speed Steels

Hot-Work Tool Steels

Tungsten High-Speed Tool Steel

Cold-Work Tool Steels

Shock-Resisting, Mold, and Special-Purpose Tool Steels

Phase Diagram of Carbon Steel

Temperature of Steel as Indicated by Color

Comparative Hardness Scales for Steel

Weights of Various Metals and Shapes

Aluminum Alloy Properties and Designations

Typical Thermal Properties of Various Metals

Characteristics of Plastics

Working with Plastics

STANDARDS FOR DRAWINGS

Shop Prints, Reading and Interpreting

Symbols for Section Lining

ASME Geometric Symbols

ISO Geometric Symbols

Symbols for Datum Referencing

SURFACE TEXTURE

Surface Texture Symbols

Applying Surface Texture Symbols

Roughness Sampling Length

Roughness Average (Ra) Values

Waviness Height Values

Lay Symbols

Example Designations

Surface Characteristics

Surface Roughness Produced by Common Production Methods

CORROSION

Types of Corrosion

Methods of Protection

Galvanic Compatibility of Metals in Select Environments

Sample Galvanic Series

Anodic Index

ALLOWANCES AND TOLERANCES

Limits and Fits

Preferred Basic Sizes

Tolerances and Allowances

Standard Tolerances

Relation of Machining Processes to Tolerance Grades

Designation of Standard Fits

Graphical Representation of Limits and Fits

Running and Sliding Fits

Clearance Locational Fits

Transition Locational Fits

Interference Locational Fits

Force and Shrink Fits

Preferred Metric Limits and Fits

Preferred Metric Sizes

Preferred Fits

Description of Preferred Fits

Preferred Hole Basis Metric Clearance Fits

Hole Basis Metric Transition and Interference Fits

Preferred Shaft Basis Metric Clearance Fits

Preferred Shaft Basis Metric Transition and Interference Fits

Gagemakers Tolerances

Relation of Machining Processes to IT Tolerance Grades

Usage of International Tolerance Grades

CONVERSION FACTORS

Metric Conversion Factors

Factors and Prefixes of SI Units

Inch to Millimeter and Inch to Centimeter

Decimals of an Inch to Millimeters

Millimeters to Inches

Fractional Inch to Millimeter and Feet to Millimeter

Thousandths of an Inch to Millimeters

Rounding Off Numbers

Fundamental Constants

Function of π

Functions of g and e

Weights and Volumes

Roman Numerals

Greek Letters and Standard Abbreviations

Conversion Factors

Temperature Conversion

USEFUL ONLINE RESOURCES

INDEX

FOREWORD

Twenty years ago, the first edition of the Machinery’s Handbook Pocket Companion was developed for users of the Machinery’s Handbook who could benefit by having a smaller, more convenient volume for bench- or desk-side quick reference. Containing key content from the Machinery’s Handbook, it has evolved into a handy timesaver for anyone in manufacturing, metalworking, and related fields for whom convenient access to fundamental and reliable data is essential. Over the years, the Pocket Companion has been perennially popular with practitioners, educators, and students of the machine trades.

A tool designed to provide years of use, this book provides detailed information in a concise package. The presented material has been carefully selected from current and former editions of Machinery’s Handbook. Some of the subject matter has been reorganized, distilled, or simplified to increase the usefulness of this book without adding to its bulk—though this edition has grown, with replaced and extended material from the 31st edition and a new list of useful online resources (see page 345).

The intention has been to provide information of technical value where only a brief or no introduction and essential data are needed to save time and labor. To obtain the full value of this small handbook, the user must have sufficient knowledge about the subject to apply the tables, formulas, and other data where such information can be used with efficiency. The Machinery’s Handbook Pocket Companion minimizes explanations of the various subjects, based on the assumption that its users are acquainted with information and procedures necessary for the safe operation and manipulation of machines and tools.

The Pocket Companion does not replace the Machinery’s Handbook, 31st Edition, but instead serves as a handy and more portable distillation of just some of the Handbook’s vastly larger collection of invaluable text, data, and standards. Readers who require in-depth information, background on manufacturing operations, and theory should refer to discussions in the 31st edition.

This book, like all of the Machinery’s Handbook product family, is the result of collaborative efforts. Among those credited with the Pocket Companion becoming the valuable tool it is today are authors and compilers Richard P. Pohanish and Christopher J. McCauley, as well as Arief Era, John Carleo, Cara Chamberlain, Ken Evans, Robert Green, Steve Heather, Jason Hughes, Kathy McKenzie, Gerald Murray, Julia Phelps, Henry Ryffel, Industrial Press owner Alex Luchars, and the rest of the Machinery’s Handbook, 31st Edition team.

Many of the American National Standards Institute (ANSI) standards that deal with mechanical engineering, extracts from which are included in the Pocket Companion, are published by the American Society of Mechanical Engineers (ASME). The editors thank ASME for its exceptional collaboration in helping to identify and bring essential data up to date, in both the Machinery’s Handbook, 31st Edition, and this companion volume, according to the latest, definitive industry standards. Information concerning other standards and nomenclature also is included in this book. Official standards and related publications are copyrighted by the issuing organizations; contact them directly for further information regarding standards and to purchase copies. We also thank Carr-Lane Manufacturing, the Norton Company, Sandvik Coromant, and other referenced firms for permission to use their material.

Finally, we wish to thank all of the associations, societies, companies, professionals, hobbyists, scholars, educators, students, and other individuals who have provided invaluable material and input for this book and the 31st edition.

We encourage readers with suggestions for improving or adding to the Pocket Companion to send us your thoughts and feedback. We also encourage you to share with us how the Machinery’s Handbook product family supports and enhances your involvement in this endlessly fascinating field.

Laura Brengelman

Editor

MATHEMATICAL FORMULAS AND TABLES

Dimensions of Plane Figures

Square:

Rectangle:

Parallelogram:

Right Triangle (one angle is a 90-degree angle):

Acute Triangle (all three angles measure less than 90 degrees):

Obtuse Triangle (one angle measures greater than 90 degrees):

Trapezoid:

Trapezium:

Regular Hexagon:

Regular Octagon:

Circle:

Sector of a Circle:

Segment of a Circle:

Cycloid:

Circular Ring (Annulus):

Sector of Circular Ring:

Ellipse:

Spandrel or Fillet:

Parabola:

Parabola:

Hyperbola:

Formulas and Table for Regular Polygons.—The following formulas and table can be used to calculate the area, length of side, and radii of the inscribed and circumscribed circles gf regular polygons (equal sided).

Area, Length of Side, and Inscribed and Circumscribed Radii of Regular Polygons

Segments of Circles for Radius = 1 (US Customary or Metric Units)

Diameters of Circles and Sides of Squares of Equal Area

(US Customary or Metric Units)

Propositions of Geometry