Machining, Metallurgy, and Metalworking Books
Reviewed by: T.J. Nelson
achining is the technology of using tools to make functional parts out of
metal. Metalsmithing is the art of manipulating and shaping metal for
decorative purposes. Metallurgy is the science of metals. Excellent books
are available on all three of these overlapping topics. Any of these books
would be great summer reading on the beach.
Machine Shop Essentials, 2nd ed.
by Frank Marlow
his is an outstanding introduction to lathes, milling machines, and
fundamental techniques in making metal parts, oriented toward R&D
and prototype labs and home machinists. For these users, the economics
of running a machine shop are different than for a production environment,
where economic considerations may make it cheaper to burn up a tool than
to run it at a slower speed. Although there's no information on CNCs, other
machine tools are discussed in detail.
Of particular note are the two sections on using a lathe and using a milling machine. Marlow provides enough detail that with a little practice, a reader could go into a machine shop and produce an intricate metal part of their own. The section on milling machines emphasizes the well-regarded small Sherlines and the larger Bridgeport milling machines, and describes the benefits and quirks of each. Each section is prefaced by a question, but this is really just a gimmick; the writing would be just as clear and organized without the questions. Although there are no photographs, the book is full of excellent diagrams. This is the best book I have seen for the small lab or individual who needs to learn how to make metal parts. The writing style is so clear and readable I couldn't put it down. Read this book before you make the mistake of running down to Harbor Freight to buy that cheap made in China lathe. Oh, I know you were going to.
Machine Shop Practice
by K.H. Moltrecht
lthough this two-volume set was published in 1981 (and much of the
equipment pictured in it appears much older), most of the techniques
described in this book are still in use today. Back in those days,
there were no calculators, and "small" computers cost a hundred
thousand dollars and were as big as a closet. So people had to use
tables to perform basic calculations like converting centimeters to
inches or using trigonometric functions. Many of those tables are
included here. There's also a detailed tutorial on Vernier gages,
micrometers, and similar analog measuring tools.
With about 1000 pages in total, this book has enough detail to bring you up to a professional level (as of 1980). For example, there are 40 pages on how to cut screw threads on a lathe. There are 56 pages devoted to a problem that's faced by everyone on their first day in the shop: how to drill a hole in a precise location. Fully half of Volume 2 is devoted to milling machines and milling. The emphasis is on a large-scale production environment. Some of the photographs depict machine operators dwarfed by the 15-foot high pieces of metal they are machining. Of course, there is almost no discussion of computers, which have since revolutionized the machining industry. But a chapter on early CNC machines would be interesting for readers nostalgic for the days of paper tape and Nixie tubes.
I recommend reading this book after Machine Shop Essentials in order to understand which techniques have become obsolete since this book was written. If it weren't for its age (at one point the author feels the need to state the advantages of electricity over the steam engine), I would say this is one of the best books ever written on the subject. It's still useful and highly readable. One minor drawback is a somewhat inadequate index.
Machine Shop Trade Secrets
by James A. Harvey
ostly common sense tips like, "Be aware that the head of your mill
might not be trammed in" and "make a shallow cut first when using thin
slitting saws." But there are also a few useful tricks such as a
clever way to remove bushings that have been pressed into blind
holes. The main value of this book is the numerous grayscale
photos that show the novice how things are supposed to be set up.
These photos take up about half the space in the book.
Metals Handbook, 2nd ed.
ASM Handbook, edited by J.R. Davis
here's a lot to know about the properties of metals, and even this
encyclopedic 1500-page reference work on metallurgy can't cover it all.
Of particular interest is the chapter on special purpose materials,
which includes magnetically soft materials, electrical resistance
alloys, and metal-matrix composites. Numerous tables, diagrams, and
black/white photographs. Also has several chapters on materials
testing. (Disclaimer: I did not read this book in its entirety.)
Metalworking: Tools and Techniques
by Stan Bray
he author of this thin book has provided a gentle introduction to time-tested
methods for machining metal in a hobbyist environment, learned from decades
of hands-on experience building and repairing models and mechanical clocks.
This book is characterized by high-quality color photographs of tools and by
an emphasis on safety. Topics include measuring, cutting, tapping, threading,
drilling, and use of the lathe and milling machine. Although not as detailed
as Machine Shop Practice or Machine Shop Essentials, it's full
of useful tips for beginners, without bogging them down with talk about collets,
quill stops, and feet per second calculations.
Metalworking: Sink or Swim
Tips and tricks for machinists, welders, and fabricators
by Tom Lipton
ometimes the best way to learn stuff is by getting advice from the old guys
like Tom Lipton, who not only gives us technical tips and career advice, but
also, as all us old geezers love to do, tells stories. Your skills must not
stay static, says Lipton. Learn everything you can about everything. This
book shows that he followed his own advice: there are tips on manual lathes, CNC
mills, welding, abrasion, shop math, sheet metal, and dealing with engineers.
Despite the informal style and the hundreds of color pictures, it's oriented to
professionals in industry. Beginners unfamiliar with the equipment may find they
have no idea what he's talking about. For instance, on page 165 he says,
"You can use G41/G42 tool compensation if you like to adjust the diameter, but
this can be a little tricky sometimes down the hole of an internal thread." If
you've never programmed a CNC, that sentence is gibberish. The advice might
not be systematic, but it includes insights that might not have
occurred even to professional machinists.
Complete Metalsmith, Professional ed.
by Tim McCreight
his spiral-bound book describes the use of hand tools to bend and shape
metals, including gold, silver, bronze, and aluminum, to make jewelry and
other decorative objects. Other techniques, such as setting stones, enameling,
casting, and finishing, are also covered. There are sections on gemstones
and on making small decorative chains. The level is appropriate for an amateur
or a small-time handicrafter. A cheaper student edition is also available.
Machinery's Handbook, 28th ed.
by Oberg, Jones, Horton, and Ryffel
his 2600-page reference book is essential for every machinist. It comes
in two sizes: the Toolbox Edition and the Large Print Edition. Although
the Toolbox Edition is cheaper, the pages are only 0.001486 inches thick
and the printing is small--capital letters are just a tad over 1/16 of an
inch high. Those in the figures and tables are even smaller: about
one millimeter high. Anyone over forty--maybe even thirty--will need the
large print version. There is also a CD-ROM version that contains material
not found in the books. There are much more than tables and formulas in
this book. There's also a lot of text describing the professional way of
doing things. For example, on page 1035, an entire page is devoted to
drilling holes in glass. Useful information indeed. (Disclaimer: I
did not read this book in its entirety.)
Tabletop Machining
by Joe Martin
his book is basically an applications guide for Sherline, a well-known
manufacturer of miniature aluminum lathes and milling machines. It is
printed on heavy, slick paper with lavish color photographs of the
company's tools and accessories, along with useful general information
for novice home machinists. Martin's goal is to teach craftsmanship as
well as to sell tools. Martin asks: Do you need to buy the Sherline
mill or the Sherline lathe? The answer is: yes, of course you do, and
don't forget the accessories. A free catalog is included to help you
with that task.
