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Choosing & Using the Right Metal Shop Lathe
Investing in a new metalworking lathe is a big step for any shop (especially home shops), where there's usually no one around to help. Once the lathe is up and running, you should theoretically be able to make the special items you previously did without (or paid through the nose for), such as shafts, plain, tapered or threaded discs, bearings, and so on. But if you are new to this, you'll want to know a lot more than you can learn from the salesman or the manual. Does the lathe really match your needs, and if so, how much? Choosing & Using the Right Metal Shop Lathe is an essential source of information for lathe buyers and users at every level, from mini-size tabletops up to industrial machines weighing half a ton or more. It answers the question of what else you will need to get useful work from the machine. For instance, what comes as "standard equipment" with the lathe? Most include a chuck (usually a 4-jaw independent, not the self-centering 3-jaw you'll want to use most of the time), maybe a faceplate (rarely used), and a 4-way toolholder you will probably swap right away for a more sensible design. Never included is a tailstock drill chuck, an essential accessory you will need from day one--and the same goes for actual cutting tools. Almost certainly, there won't be a digital readout (DRO), which used to be regarded as a "maybe-someday" luxury--but not anymore. The work talks about cutting oils, cutting speeds and easier-to-machine materials, and it cautions against buying sets of anything, vs. buying the one accessory you'll truly need. Finally, there are chapters on building a tailstock drill press, a special toolpost for easy screw cutting, and a precision grinder for lathe tools that can be made from oddments of material in a couple of days or less. Features Differentiates between the truly essential features (screw-cutting) and the nice-to-have (power feeding), spindle speed selection from a gearbox (typical) or continuously variable (more convenient). Offers advice on screw-cutting US and metric threads, and handling the machinist's most trouble-prone actions, such as knurling and parting off. Provides a workpiece tutorial that demonstrates many of the commonplace lathe routines--ideal for first-time users.
Cover (Choosing & Using The Right Metal Shop Lathe) -- Front Matter -- Title Page -- Copyright -- Table of Contents -- Acknowledgments -- Note from the Author -- Chapter 1 -- Choosing a Lathe -- A Selection of Metal Shop Lathes -- Mini Lathes -- Larger-Model Shop Lathes -- Lathe Size -- How Big a Lathe Do You Need? -- Weight -- Bench or Stand Mounting -- Handling the Lathe -- Spindle Bearings -- Spindle Bore -- Spindle Speed -- Power Requirement -- Cross-Slide and Compound Dials -- Chucks -- What Size of Chuck? -- Faceplates -- How Do Chucks/Faceplates Attach to Spindles?
Steady Rest and Follower Rest -- Lathe Centers -- Other Workpiece Holding Accessories -- Taper Turning -- Screw Cutting and Power Feeding -- Gearbox or External Gears? -- Everyday Power Feeding Versus Screw Cutting -- Saddle Controls -- Power-Feed Direction and Left-Hand Threads -- Power-Feed Key Facts -- The Main Power-Feed Question to Ask -- Lathe Refinements -- Tailstock Chuck -- QCTP Instead of a 4-Way Turret -- Tailstock Digital Readout (DRO) -- Saddle and Cross-Slide DRO -- Installing a DRO -- Saddle Stop -- What Do You Intend to Do With Your Lathe? -- Chapter 2 -- Turning Tool Basics
Cutting Fluids and Surface Finish Questions -- Basic Terminology of Lathe Tools -- Lathe Tool Materials -- HSS Specifics -- Shaping a Lathe Tool -- End Relief -- Side Relief -- Don't Worry About Back Rake -- Tool Angle Nomenclature -- Tool Height -- Think Small -- Hone Those Edges -- Tuning Up the Grinding Wheel -- Tungsten Carbide -- Grades of Carbide -- Tungsten Carbide Tool Formats -- Carbide-Tipped Tools -- Indexable Carbide Tools -- Screw Cutting Tools -- Internal Cutting Tools -- Are There Carbide Inserts for Internal Cutting? -- Is the Hole the Right Size? -- Grinding Internal Tools
Cut-Off Tools -- Grooving Tools -- Drill Bits -- Drill Length -- Drill Geometry -- Split-Point Geometry -- Drilling Small Holes -- Controlling Drill Depth -- Deburring a Drilled Hole -- Drilling Large Holes -- Working with Oversize Drills -- Drilling Deep Holes -- Drilling a Flat-Bottomed Hole -- Screw Cutting Basics -- Taps -- Hole Sizes for Tapping -- Tapping Techniques -- Dies -- Reamers -- Cutting Speeds for Knife Tools -- Speeds for Drilling -- Cutting Speed and Tool Life -- Chapter 3 -- Add-Ons to Make Life Easier -- Is the Compound Really Necessary? -- Add Guidelines for Specific Jobs
A New Way of Screw Cutting -- Rough-Cutting Metal with a Bandsaw -- Block Squaring the Easy Way -- Spindle Indexing -- Filing Flats on a Workpiece -- Drilling from the Tool Post -- Tool-Post Grinder -- Tailstock Drill Press -- Center Height Gauge -- An Indispensable Finishing Tool -- Workpiece Clean-Up -- General Clean-Up in the Shop -- Two More Must-Haves -- Chapter 4 -- Things I Wish Someone Had Told Me -- How to Level the Lathe -- How to Deal With Unexpected Tapers -- Aligning the Tailstock -- Tailstock Alignment-Quick Method -- Tailstock Alignment-Precise Method
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