Handout 3

TOPICS: More measuring tools, Layout work, Fastener ID & recessing heads of fasteners , Dies,
Saws, Squaring stock, Clamping, Other lathe operations,

All reading and figure references are from Modern Metalworking by John Walker.

MORE MEASURING TOOLS

Telescoping gauge – used to measure internal dimensions (Refer to Fig. 5-63 p. 91).
These must be used with a micrometer (Refer to Fig. 5-64 p. 91). The gauge is set in
the dimension to be measure, the set screw is locked in place, and the distance is
measured with a micrometer. Always loosen the set screw b/f putting the tool away
Depth gauge – used to measure the depth of holes, slots, etc. It is the same as a
micrometer, but just different in its design (Refer to Fig. 5-13 p. 73).
Feeler gauge – used to measure the thickness of narrow slots, setting small gaps and
clearances, etc. (Refer to Fig. 5-59 p. 90).
Screw pitch gauge – measure the pitch of a screw (Refer to Fig. 5-60 p. 90). The
pitch of a screw is how many threads per inch there are.

LAYOUT WORK

Sometimes it is beneficial to layout, or draw directly onto the part, before machining.
There is a variety of different layout techniques that can be done. For example, using a
scribe to cut very light lines into the part. This is what is done for scribing out the circle
for the base plate. A center punch is used to put a small dimple in the middle of the part,
and with the divider set at the radius desired, a circle or arc can be laid out to help guide
you in the machining process. A divider (Fig. 6-6 p. 99)is used to scribe out smaller
circles/arc; a trammel (Fig. 6-7 p. 99) is used for larger circles/arcs.

Layout dye can be used to make the lines more visible (Fig. 6-2 p. 98).

A square, which is a tool w/ a perfect 90° angle, is used to make sure a part is square or to
make sure a part is clamped squared up with the spindle (Fig. 6-13 p. 101).

A protractor (Fig. 6-18 p. 102) can be used to measure or lay out angles.

A surface plate (Fig. 6-23 p. 103) is a granite block that has an extremely flat surface.
These are used for accurate layout work and are also used for sanding parts to give a nice
finish.

V-blocks (Fig. 6-26 p. 104) are used to support round stock during layout work or to hold
round part in a vice. Round parts need to have 3 points of contact in the vice when
machining on the mill.

Read pp. 104 – 105 – Making a Layout

Screws are identified by a numbering system:

¼-20 UNC-2A
Major ø of Class of Fit (i.e. thread
thread tolerance). Range: 1-4 where 1
is a loose fit and 4 is a tight fit

Thread Pitch (# of
threads/inch) Thread series
(Unified National
Coarse)

The major ø and the thread pitch of the screw are the information used to select the tap
drill. However, the class of fit (2A is the most common) is important as well. With a 2A
fit, there is approx. 75% thread contact b/t the screw and the threads in the part; this is
sufficient for most applications.

The two most common types of heads for screws used are a flat head and a socket head
(Refer to Fig. 10-7 on p. 153 and Fig. 10-9 on p. 154). The heads can be recessed into
the part making them flush w/ the top of the part by using a countersink and a
counterbore, respectively.

Countersink – a tool that cuts a chamfer above a hole to permit a flat head screw to sit
flush with the top of the part. These should be run at ~1/2 the RPM of a similar drill
size to prevent chatter (Refer to Figs. 24-51 and 24-52 on p. 383). Countersinks come
in a variety of angles; a 82° countersink should be used for most flat head screws.
Countersinks can also be used to debur holes.
Counterbore – a tool that cuts a square shoulder above a hole to permit a socket head
screw to sit flush with the top of the part. A counterbore has a pilot guide that helps
keep it aligned properly in the clearance hole (Refer to Fig. 24-54 on p. 384).

DIES

A die (Refer to Fig. 9-6 on p. 143) is used to cut external threads, for example the threads
on a screw. The ø of the stock should equal the major ø of the screw. A chamfer should
be machined onto the end of the part to make the die start easier. Dies have a taper on
one side to permit easier starting of the threads, and the threads should always be started
using this side. If threads are needed all the way to the bottom of a square shoulder then
cut the threads as far as possible with the taper side, back the die off, flip it around and
continue cutting the rest of the threads with the non-tapered side of the die.

Just as with tapping, always use a die ONLY BY HAND. A die handle is used to provide
the leverage needed to cut the threads (Fig. 9-17 on p. 148)

NMH; 9/09 2
SAWS

Hacksaws (Fig. 8-7 p. 126) are used to cut metal by hand. These only cut on the forward
stroke and the blade should be installed so the teeth point away from the handle. Pressure
should be relieved on the reverse stroke so the teeth do not get damaged. There is a 3-
teeth rule when cutting material: there needs to be at least 3 teeth contacting the part
during a cut. The set of the teeth provides the clearance for the blade and prevents the
blade from binding in the cut. There are 3 different kinds of sets: undulating, raker, and
alternate (Fig. 8-14 p. 130); the raker set is the most common.

If a blade dulls or breaks during a cut then replace the blade, however, do not start the
new blade in the same kerf, which is the groove that the blade makes in the part. Either
start the cut in a new spot or flip the part over and start from the other side. Cutting in the
same kerf made by the dull blade will dull the new blade in the first few strokes.

Know how to hold different shaped materials for sawing: Fig 25-18 p. 400.

Circular Saws:
Abrasive Saw – Uses a thin abrasive wheel to cut steel and hardened steel. DO NOT
cut aluminum with this saw; the aluminum will melt, damaging the saw and the part.
A face mask must be worn when using this machine b/c the chips are extremely hot.
Cold Circular Saw – Uses a circular blade to produce accurate cuts.
Friction Saw – Uses a blade that may or may not have teeth, normally a dull band saw
blade is used. The saw is run at a very high RPM and actually melts through the
material. This is good for cutting thicker pieces of stainless steel. A face mask,
gloves, and long sleeves or welding jacket must be worn b/c the chips are extremely
hot. This saw may not always be a circular saw; it could be a continuous saw like the
vertical bandsaw.

SQUARING STOCK

When facing a part with 4 nonparallel sides there is a sequence to cutting the sides to
make the part square:
A) Set the part in the vice so side 2 is on parallels. Face side 1
1 B) Flip the part over 180° so side 1 is on parallels and face
side 2, cutting the part to size for that dimension
4
3 C) Set the part in the vice so that sides 1 and 2 are against the
two jaws of the vice (i.e. flip the part 90°) and face side 3
2 D) Flip the part 180° (still with sides 1 and 2 against the jaws) and
face side 4, cutting the part to size for that dimension.

CLAMPING
Read pp. 370 – 373 for different ways to hold and machine parts.

OTHER LATHE OPERATIONS

NMH; 9/09 3