Newnes workshop engineer’s pocket book

Newnes Workshop Engineer’s Pocket Book... No part of this publication may be reproduced in any material form including photocopying or storing in any medium by electronic means and wheth

Newnes Workshop Engineer’s Pocket Book

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OXFORD AUCKLAND BOSTON

JOHANNESBURG MELBOURNE NEW DELHI

An imprint of Butterworth-Heinemann

Linacre House, Jordan Hill, Oxford OX2 8DP

225 Wildwood Avenue, Woburn, MA 01801-2041

A division of Reed Educational and Professional Publishing Ltd

A member of the Reed Elsevier plc group

First published 2000

© Roger Timings 2000

All rights reserved No part of this publication may be

reproduced in any material form (including photocopying

or storing in any medium by electronic means and whether

or not transiently or incidentally to some other use of

this publication) without the written permission of the

copyright holder except in accordance with the provisions

of the Copyright, Designs and Patents Act 1988 or under

the terms of a licence issued by the Copyright Licensing

Agency Ltd, 90 Tottenham Court Rd, London, England W1P 9HE Applications for the copyright holder’s written permission

to reproduce any part of this publication should be

addressed to the publishers.

British Library Cataloguing in Publication Data

A catalogue record for this book is available from the British Library.

ISBN 0 7506 4719 1

Typeset by Laser Words, Madras, India

Printed in Great Britain by Antony Rowe Ltd, Reading, Berkshire

1.5 Twist drills: nearest equivalent sizes 61.6 Wire gauge equivalents 13

1.7 Mensuration of plane figures 14

1.12.1 Heights above keyways 26

1.12.2 Radii on bolt ends 26

1.12.3 Hexagon: distance across corners 261.12.4 Square: distance across corners 261.12.5 Helix angles 26

1.12.6 Cutting speeds (inch units) 271.12.7 Cutting speeds (metric units) 271.12.8 Typical cutting speeds for HSStools 27

1.18 Measurement of external tapers 57

1.18.1 To find the angle °(the semi-angle oftaper) 57

1.18.2 To find the major and minor

diameters 59

1.19 Measurement of internal tapers 62

1.19.1 To find the angleq° (the semi-angle

1.26 Belt drive (simple) 80

1.26.1 Open belt drive 80

1.26.2 Crossed belt drive 81

1.27 Belt drive (compound) 82

1.28 Typical belt tensioning devices 83

Part 2 Threaded Fasteners

2.1 Introduction to threaded fasteners 872.2 Threaded fasteners 90

2.2.1 Drawing proportions 90

2.2.2 Alternative screw heads 91

2.2.3 Alternative scew points 92

2.2.4 Hexagon socket cap head screw 922.2.5 Applications of screwed fasteners 922.2.6 Acme thread form 93

2.2.7 Square thread form 93

2.2.8 Buttress thread form 93

2.5 Hexagon head screws (coarse thread):

preferred sizes: product grade A and B 1052.6 Hexagon head screws (coarse

thread): preferred sizes: product grade C 1122.7 ISO metric tapping and clearance drills, coarsethread series 117

2.8 Hexagon nuts (coarse thread) style 1: productgrade A and B (preferred sizes) 117

2.9 Hexagon nuts (coarse thread) style 2: productgrade A and B (preferred sizes) 119

2.10 Hexagon nuts (coarse thread) style 1: productgrade C (preferred sizes) 121

2.11 Hexagon thin nuts (chamfered) – coarsethread – product grade A and B (also known

as lock-nuts) 122

2.12 ISO metric hexagon head bolts (fine thread):preferred sizes: product grade A and B 1232.13 Hexagon head screws (fine thread): preferredsizes: product grade A and B 126

2.14 ISO metric tapping and clearance drills, finethread series 131

2.15 Hexagon nuts (fine thread) style 1: productgrade A and B (preferred sizes) 131

2.16 Hexagon thin nuts (chamfered) – fine

thread – product grade A and B (also known aslock-nuts) 133

2.17 Hexagon slotted nuts and castle nuts 1342.18 Marking threaded fasteners 136

2.23 ISO pipe thread forms 144

2.23.1 Basic Whitworth thread form: parallelthreads 144

2.23.2 Basic Whitworth thread form: taperthreads 145

2.23.3 Terms relating to taper pipe

threads 145

2.23.4 ISO pipe threads, parallel: basicsizes 146

2.23.5 ISO pipe threads, tapered: basicsizes 148

2.24 British Standard Whitworth (BSW) boltsand nuts 152

2.25 British Standard Whitworth (BSW) tappingand clearance drill sizes 154

2.26 British Standard Fine (BSF) bolts and

2.38 Friction locking devices 175

2.39 Positive locking devices 177

Part 3 Cutting Tools (HSS) and Abrasive Wheels

3.1 Twist drill sizes, metric 183

3.2 Gauge and letter size twist drills 1973.3 Hand reamer (normal lead) 200

3.4 Long flute machine reamers 202

3.5 Machine chucking reamers with Morse tapershanks 203

3.6 Shell reamers with taper bore 205

3.11 Countersinks with parallel shanks 2183.12 Countersinks with Morse taper shanks 2183.13 Single point cutting tools: butt weldedhigh-speed steel 219

3.14 Tool bits: ground high-speed steel 2243.15 Milling cutters 226

3.15.9 Convex milling cutters 237

3.15.10 Concave milling cutters 2383.15.11 Corner rounding concave millingcutters 239

3.15.12 Double equal angle milling

cutters 240

3.15.13 T-slot cutters with Morse tapershanks 241

3.15.14 Shell end mills 243

3.15.15 Arbors for shell end mills 2453.15.16 Screwed shank end mills: normalseries 247

3.15.17 Screwed shank slot drills: normalseries 249

3.15.18 Screwed shank slot drills, ball nosed:normal series 251

3.16 British Standard centre drill (60°) 2523.17 Engineers’ files – popular stock sizes 2533.18 Miscellaneous files 255

3.18.1 Needle (Swiss) files 255

3.18.2 Milled tooth files 255

3.19 Hacksaw blades (high-speed steel – allhard) 256

4.1.5 Double coil rectangular section springwashers: metric series, type D 2784.1.6 Toothed lock washers, metric 2794.1.7 Serrated lock washers, metric 2834.1.8 ISO metric crinkle washers: generalengineering 287

4.6 Circlips external: metric series 300

4.7 Circlips, internal: metric series 304

4.8 Toroidal sealing rings (O-rings) and theirhousings (inch series) 308

4.10 Riveted Joints 334

4.10.1 Typical rivet heads and shanks 3344.10.2 Typical riveted lap joints 3344.10.3 Typical riveted butt joints 3354.10.4 Proportions for hole diameter andrivet length 336

4.10.5 Cold forged snap head rivets 3374.10.6 Hot forged snap head rivets 3394.10.7 Tentative range of nominal lengthsassociated with shank diameters 3414.11 Self-secured joints 342

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This pocket book has been prepared as an aid topractising workshop engineers The tables have beenselected to provide a quick day-to-day reference foruseful workshop information For this reason many

of the highly prescriptive British and ISO Standards,necessary for design engineers and managers, havebeen abridged and simplified in this book However,wherever this has been done, the reference code forthe full Standard is included should this be required.For easy reference this book is divided into fourparts, namely:

1 workshop calculations and conversion tables;

2 threaded fastenings;

3 cutting tools;

4 miscellaneous

Within these parts, the material has been assembled in

a logical sequence for easy reference, and a hensive list of contents has been provided which leadsthe reader directly to the item required There is also

compre-a comprehensive compre-alphcompre-abeticcompre-al index

Currently, many revisions of the British Standards

is taking place These revisions range from tively minor amendments to complete withdrawal andreplacement This is necessary to reflect technologicalchanges and to ensure harmonization with international(ISO) requirements The currency and validity of anyStandard can be identified as set out in the followingnotes which preface the catalogue issued by the BritishStandards Institute (BSI)

rela-How to use the BSI catalogue basic details of entries

The list of BSI publications in their catalogue isarranged in numerical order, within each series Theseries can be identified from the alphabetical char-acters which precede the number of the Standard

For example: BS AU D automobile series, or BSEN DEuropean Standards adopted as British Standards.Current publications can be identified by the use

of bold type for the number of the publication andits title The revision of any publication automaticallysupersedes all previous editions of the publication.Only the current editions are listed

Withdrawn publications can be identified by the use

of light type for the number of the publication and itstitle, and the word ‘withdrawn’ in parentheses

Definitions of entries in the catalogue

An entry appears in the catalogue as in the examplebelow The various elements are labelled A – J Thekey explains each element

415 V and 60 A, 80 A or 100 A for use by the supplyauthority in the incoming unit of domestic and similarpremises

publication identical in everydetail with a correspondingEuropean and/or internationalStandard.

Standard: a BSI publication inall technical respects the same

as a corresponding Europeanand/or international Standard,though the wording andpresentation may differ quiteextensively

Standard: a BSI publicationthat covers subject matterssimilar to that covered by aEuropean and/or internationalStandard The content however

is short of complete identity ortechnical equivalence

E 00000833 Unique product code for the

amendment

responsible for this publication

reprinted text No ‘R’ meansthe amendment is not part ofthe text

flap on the inside back cover ofthe catalogue

I 00000818 Unique product code.

J A5, 44 pages Most new and revised

Standards are published in A4size Sizes other than A4 arelisted

Amendments

All separate amendments to date of despatch areincluded with any main publication ordered Pricesare available on application With the next reprint ofthe publication the amendment is incorporated into thetext which then carries a statement drawing attention

to this and includes an indication in the margin at theappropriate places on the amended pages

Review

The policy of BSI is for every Standard to be reviewed

by the technical committee responsible not more thanfive years after publication, to establish whether it isstill current and, if it is not, to identify and set inhand appropriate action Circumstances may lead to

Declaration of obsolescence: indicting by amendment

that the Standard is not recommended for use in newequipment, but needs to be retained to provide for theservicing of existing equipment that is expected to have

a long working life

Revision: involving the procedure for new projects Confirmation: indicating the continuing currency of

many products are still being manufactured to cent and obsolete Standards to satisfy a still buoyantdemand This is not only for maintenance purposes butalso for current manufacture where market forces havenot yet demanded an update in design This is partic-ularly true of screwed fasteners For this reason thetraditional screw thread tables have been retained andstand alongside the new BS EN requirements.This pocket book is not a textbook but is a compila-tion of useful data The author is indebted to the BritishStandards Institution for their cooperation in providingup-to-date data in so many technical areas Unfortu-nately, limitations of space have allowed only abstracts

obsoles-to be included from the wealth of material provided.The tables in this pocket book should be adequate forday-to-day workshop use However, where additionalinformation is required, the reader is strongly recom-mended to consult the complete Standard, industrialmanuals or catalogues after an initial perusal of thetables of data found in this book To this end, anappendix is provided listing the names and addresses ofthe libraries and institutions where the complete Stan-dards may be consulted or purchased Many industrialmanuals are available free of charge to bona fide users.Within the restraints of commercial viability, it isstill the intention of the author and the publisher toupdate this book from time to time Therefore, theauthor would appreciate (via the publishers) sugges-tions from the users of this book for additions and/ordeletions to be taken into account when producing neweditions

Roger Timings

Part 1

Conversion Tables and

Workshop Calculations

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1.1 Conversion table: fractions to decimals

Fraction Decimal Fraction Decimal Fraction Decimal

1/64 0.015 625 11/32 0.343 750 43/64 0.671 875 1/32 0.031 250 23/64 0.359 375 11/16 0.687 500 3/64 0.046 875 3/8 0.375 000 45/64 0.703 125 1/16 0.062 500 25/64 0.390 625 23/32 0.718 750 5/64 0.078 125 13/32 0.406 250 47/64 0.734 375 3/32 0.093 750 27/64 0.421 875 3/4 0.750 000 7/64 0.109 375 7/16 0.437 500 49/64 0.765 625 1/8 0.125 000 29/64 0.453 125 25/32 0.781 250 9/64 0.140 625 15/32 0.468 750 51/64 0.796 875 5/32 0.156 250 31/64 0.484 375 13/16 0.812 500 11/64 0.171 875 1/2 0.500 000 53/64 0.828 125 3/16 0.187 500 33/64 0.515 625 27/32 0.843 750 13/64 0.203 125 17/32 0.531 250 55/64 0.859 375 7/32 0.218 750 35/64 0.546 875 7/8 0.875 000 15/64 0.234 375 9/16 0.562 500 57/64 0.890 625 1/4 0.250 000 37/64 0.578 125 29/32 0.906 250 17/64 0.265 625 19/32 0.593 750 59/64 0.921 875 9/32 0.281 250 39/64 0.609 375 15/16 0.937 500 19/64 0.296 875 5/8 0.625 000 61/64 0.953 125 5/16 0.312 500 41/64 0.640 625 31/32 0.968 750 21/64 0.328 125 21/32 0.656 250 63/64 0.984 375

1.2 Conversion table: millimetres to inches

0.01 0.000 394 36 1.417 323 89 3.503 9370.02 0.000 787 37 1.456 693 90 3.543 3070.03 0.001 181 38 1.496 063 91 3.582 6770.04 0.001 575 39 1.535 433 92 3.622 0470.05 0.001 969 40 1.574 803 93 3.661 4170.06 0.002 362 41 1.614 173 94 3.700 7880.07 0.002 756 42 1.653 543 95 3.740 1580.08 0.003 150 43 1.692 913 96 3.779 5280.09 0.003 543 44 1.732 283 97 3.818 8980.10 0.003 937 45 1.771 654 98 3.858 2680.20 0.007 874 46 1.811 024 99 3.897 6380.30 0.011 810 47 1.850 394 100 3.937 0080.40 0.015 748 48 1.889 764 200 7.874 0160.50 0.019 685 49 1.929 134 300 11.811 020.60 0.023 622 50 1.968 504 400 15.748 03

1.4 Circles: areas and circumferences

Dia Area Cir Dia Area Cir Dia Area Cir.

Dia Area Cir Dia Area Cir Dia Area Cir.

where: r D radius of the circle

d D diameter of the circle

1.5 Twist drills: nearest equivalent sizes

1.5 (continued )

1.5 (continued )

1.5 (continued )

1.6 Wire gauge equivalents

Standard Wire Gauge (SWG) for sheet metal, wire androds

1.7 Mensuration of plane figures

Square

area D b2length of diagonal Dp

2 ð bRectangle

area D b ð hlength of diagonal D

b2C h2Parallelogram

area D b ð h

area D  ð r2perimeter D 2 ð  ð r

Simpon’s rule As an example of these, Simpson’s rule

is as shown Divide x1x2into an even number of equalparts of width d Let p, q, r, be the lengths ofvertical lines measured from some datum, and let A

be the approximate area of the irregular plane, shownshaded Then

of evens C 2 ð sum of odds]

where first, last, evens, odds refer to ordinate lengthsand d is the width of the equal parts of the datum line

1.8 Mensuration of solids

Rectangular prism

volume D bhltotal surface area D 2bh C hl C lb

Cylinder

volume D 1/3r2htotal surface area D rl C r

Frustrum of cone

volume D 1/3hR2C Rr C r2

total surface area D lR C r C R2C r2

Sphere

volume D 4/3r3total surface area D 4r2

Zone of sphere

volume D h/6h2C 3R2C 3r2

total surface area D 2rh C R2C r2

where r is the radius of the sphere

Pyramid

volume D 1/3Ahwhere A is the area

of the base and h

is the perpendicularheight

Regular solids

The volume of any regular solid can be found by usingthe prismoidal rule Three parallel planes of areas A1,

A3, A2, are considered to be at the ends and at thecentre of the solid respectively Then

volume D l/6A1C 4A2C A3

where l is the length of the solid

Irregular solids

Various methods can be used to determine volumes

of irregular solids; one of these is by applying theprinciples of Simpson’s rule (see Section 1.7) Thesolid is considered to be divided into an even number

of sections by equally spaced, parallel planes, distance

d apart and having areas of A1, A2, A3, Assuming,say, seven such planes, then approximate volume D

d/3[A1C A7 C 4A2C A4C A6 C 2A3C A5]

1.9 Taper systems (metric units)

ΙνχλυδεδανγλεΠλυγ δεπτη

designation angle of taper at gauge plane depth plug line

1.9.2 Quick-release tapers (milling machine tapers for spindle nozes)

Taper Taper Included Diameter Plug Diameter at designation ratio angle of at gauge depth plug