Customer Reviews

Machine Shop Essentials: Questions & Answers (Shop Essentials Series, 3)

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The author's stated purpose in writing this book was to provide a back to basics introduction to machining using small manual machines in a one-of-kind parts and prototyping environment. The author succeeds admirably in meeting his stated purpose. It should be noted that this is a practical treatment giving specific step-by-step procedures needed to create a particular feature using a particular machine tool. Furthermore, it must be kept in mind that what is cost-effective in an industrial setting when production runs are in the thousands or tens of thousands may not be so in a prototyping environment. Mr. Marlow does a great job of concentrating on procedures that can be cost-effective in a one-off environment.

Two notable features of the book in general merit special comment. First, the book is presented in a question and answer format. While this may seem unusual at first, it actually serves the very useful purpose of easily enabling the reader to locate and find information pertinent to a specific machining question. Second, the book uses plentiful line drawings that are absolutely superb. In comparison to the usual photographs, the line drawings used here have one gigantic advantage. Namely, photographs inevitably wind up blurring and obscuring details, some of which may be highly significant. In contrast, the line drawings in this book are models of clarity, usefully illustrating all relevant details. I frankly consider the line drawings in this book to be the best I have ever seen, and they are a major reason for the usefulness of the book.

The first four chapters of the book contain basic introductory material on measurement tools, basic hand tools, filing, sawing, grinding reaming, broaching, and lapping. This is all good, solid, useful stuff. The discussion on broaching, for example, is the best introductory treatment of this I have ever seen. Next, there is a chapter on drilling operations followed by a chapter on threads and threading using taps and dies. Although not encyclopedic in its coverage of various thread standards, the basics are covered thoroughly and again, it must be mentioned that the author uses superb line drawings to convey meaning.

Following the discussion of threading, there are chapters on turning and milling operations in which the author discusses a range of machines representative of those that might be found in a home workshop or a small prototyping operation. In the milling section, for example, Mr. Marlow discusses both the Sherline tabletop mini mill and the Bridgeport. A feature of interest is that the author does not discuss the ubiquitous (and to some, infamous!) mill/drill. I was particularly impressed with the thoroughness of his instructions for operating the Bridgeport mill, and I couldn't help but think that this chapter of the book would be invaluable to a home shop machinist purchasing a used Bridgeport. More than just an instruction manual for the Bridgeport, the book also provides general procedures for producing specific features that translate to any machine of a similar type. Mr. Marlow's discussion of how to mill dovetail slides, for example, is a model of thoroughness and clarity. Although Mr. Marlow does provide some introductory material, he wisely refers the reader to "Machinery's Handbook" and its voluminous tables for many specifics on "feeds and speeds".

The later chapters of the book cover such topics as fastening methods, basic metallurgy, and safety/shop practices. The section on metallurgy, while quite basic, I found particularly useful in helping me remember some of my college courses from long ago. Again, this is all good, solid, useful stuff, and presented at a level (neither too elementary nor too theoretical) that makes it extremely useful at the home machine shop level. I found the final chapter of the book in which Mr. Marlow presents a wide variety of "tricks of the trade" extremely interesting. It contains the sort of practical how-to information that almost never seems to be covered in print.

Finally, there are two appendices, one on sharpening lathe tools and the other providing a list of sources for tools, materials, and supplies. Although I do have two minor misgivings about the lathe tool sharpening appendix discussed in the paragraph immediately below this one, I must admit that Mr. Marlow's two page description of sharpening steel lathe tool bits is by far and away (again, because of the superb line drawings) the most easily understood of any I have ever encountered.

I do find a few minor flaws with the text. Table 8.5 on page 353, for example, has gotten the last two column-headings inverted. That is, the RPM figures listed under 5/8-inch cutters should actually be those listed under 3/8-inch cutters and vice versa. Mr. Marlow achieved near-perfection in his appendix on sharpening steel lathe tool bits, but there are two minor flaws.

The first flaw is as follows: In the line drawings at the top of page 483, he shows "side clearance angle" and "end clearance angle". In the subsequent table of sharpening angles, however, we find neither "side clearance" nor "end clearance". Instead, we find "side relief" and "front relief". Now it is true that the sentence immediately preceding the table: "What are typical rake and clearance (relief) angles for HSS tool bits?" does imply that clearance and relief are synonyms. But, aside from being (perhaps?) hard to catch, that still does not answer the problem. For if we understand that in referring from the table back to the preceding illustrations we are to substitute "clearance" wherever we see "relief" in the table, then we would wind up searching in vain through the illustrations for a depiction of what is meant by the "front clearance". Whilst the meaning may be clear to the experienced or well-read amongst us, this discrepancy is irritating and could be quite confusing to the novice.

The second flaw, and here I realize I am opening up a can of worms, is Mr. Marlow's advice to "dip the tool in coolant frequently to keep it from overheating and annealing".
Now I freely admit that I am not a metallurgical scientist, but I have had opportunity to talk to a number of folks who are. And here is what I have been told. Dipping the tool in coolant is a holdover from the days of sharpening carbon steel tools which do have an annealing temperature low enough to be easily reached in tool grinding. And of course, once the tool is annealed, its hardness is gone, and it is useless for cutting. I am told, however, that the annealing temperature of virtually all HSS alloys is sufficiently high that it will not be approached during a tool grinding operation. So annealing of HSS is not the problem. Apparently what IS the problem is that the HSS tool may develop a series of micro-fractures or cracks when shocked by the sudden dip in coolant from a heated state. Now I have also been told that HSS may develop the micro-fractures from overly aggressive grinding as well, but that this is less likely to occur. So if what I have been told by some folks I know to be quite reputable metallurgical scientists is true, it seems to me that it would make sense to grind less aggressively (this is not an industrial production job, after all) to help avoid unnecessary heat build up and to eschew the use of a coolant dip. Note that if facilities are available to have constant coolant flow over the tip of the tool, the sudden shocking issue would not arise---but such facilities are probably not available to the average reader of this book.

I wish Mr. Marlow had covered two additional topics. First, drilling flat-bottomed holes is a subject that continues to vex. Some sage advice here would have been much appreciated. Second, a chapter on shapers, analogous to that on milling machines, would have been of interest to me. Admittedly, I have not seen a shaper in industrial use for years, but there are many of them still in use in home machining operations, and for those folks who have them, a good modern text would be useful.

I cannot help but comment on the one reviewer who was disappointed that Mr. Marlow did not recommend specific machines. First, I suppose Mr. Marlow's inclusion of Clausing drill presses and lathes as well as Bridgeport milling machines may constitute a recommendation of sorts. Secondly, given the wide variety of new (not to say used!) machine tools available, I don't see how it would be feasible for anyone to review them all and make specific recommendations. Finally, which machine tool is best depends upon a number of factors: budget, space available, intended use, etc. So Mr. Marlow was, in my opinion, wise to adopt the approach he did.

While this book would probably not be of much use to an experienced machinist, it certainly is the best single introduction to manual machine operations for the home shop machinist I have ever seen. It would be nice to see Mr. Marlow turn his attention to two additional topics: motors/variable frequency drives and CNC machining. With regards to the former, I understand that one can do wonders nowadays with VFD's and that the price has come down to make them truly affordable. Yet specific information useable by the non-specialist is hard to come by. Second CNC systems and conversion kits seem to be coming down in price and bringing CNC machining into reach of the small prototype shop/home workshop. If Mr. Marlow could address these two topics with the same precision and clarity he did for manual machine tools with this volume, he would provide a valuable service.

"Machine Shop Essentials" is an absolute must for the manual machining newbie, or CNC people wanting to
delve into the manual world. The common sense in-depth information, 
coupled with the remarkable illustrations by Pamela Tallman, 
give the reader a really big heads up. Particularly those interested in doing 
machining operations for prototype developments, industrial model making, 
instrument making, custom motorcycle or car building and the like.
But having said that, there's also plenty of good information, resources and tips
for the machinist who's been "over, under, around and thru the chips".
The "Machine Shop Essentials" book is a great tool to add to your necessary collection
of machinists tools."

This book is well written, beautifully illustrated and extremely helpful. Although not my profession, some machine shop work has been a serious hobby for me and I found Machine Shop Essentials to help fill in gaps in my knowledge resulting from a lack of formal training. This book should appeal to enthusiasts and beginning professionals alike. It was a breath of fresh air after having looked at either dated references with photographs of industrial machines or at home shop manuals with very limited information. Having done mostly lathework, I was most interested in learning more about milling and the book "asked" questions that I had in mind and "answered" them, including specific issues regarding the availability and proper use of various cutting bits. The coverage of both lathe and milling basics is far superior to that in three other manuals I purchased (unfortunately) before this one. The diagrams provide a lot of exquisite detail and really compliment the text.

This is an excellent book for beginner to intermediate machinists. The question and answer format and the index allow you to find specific topics of interest very quickly. The amount of detail is just right-not too little and not too much. Covers most of the topics a beginner or intermediate machinist will need. I strongly recommend this book.

I have owned a fairly nice Atlas 12" lathe for several years and recently purchased a Bridgeport milling machine to replace an old Jet 16 vertical mill. I also bought a copy of "Machine Shop Essentials" to help fill in a few "knowledge gaps." The book came highly recommended on the CAMS (Capitol Area Machinist listserv)so I knew it would be better than most machine shop books but I was absolutely delighted when I received my copy.

This book is terrific for those of us who enjoy working in a home shop to build models and to generally make repairs on things that are broken. The author has prepared this book to be easy to understand and simple to reference. The many drawings and diagrams are clear and concise so I can quickly understand what is being explained. Whether I'm lookin for a refresher on using a rotary table and dividing heads or how to cut threads on my lathe, I can quickly find what I need to know.

Machine Shop Essentials is not full of fluff or huge charts of numbers that only a seasoned tool and die maker will understand. It is jammed with easy-to-understand explanations and diagrams of how to properly use common and some not-so-common tools and procedures in your shop. I have already dog-eared my copy and keep it handy in the shop while other books remain in the bookshelf for those times when I have plenty of time to absorb a more complex and in-depth treatment of a subject.

Machine shop Essentials will become your favorite reference for quick tips and easy-to-understand explanations of how you can use a wide range of machine tools to make your workshop jobs easier and fun--while getting the results you expect without a hassle.

I highly recommend this book to anyone that likes to work with metal and especially to thos of you who are thinking about pruchasing a lathe or milling machine for your home shop.

And if you're wondering...no I was not paid for this review...I simply think this book is excellent and think you'll love it too.

"Machine Shop Essentials" is an excellent reference for the metal-working novice and professional alike. Geared towards small prototype R&D shops that mostly rely on manual machine tools, this book describes the basics and some of the more advanced concepts in the field.

Done in a "question and answer format," the questions answer everything from basic to more advanced topics. This book covers many of the essentials needed for skillfully operating basic machine tools and also includes hand tool basics, measurement & layout, fastening methods, some steel metallurgy, safety and other shop "know how."

Additionally, many entries serve as a good reminder & overview covering those practices that we've learned, but may forget over time. So, this book is definitely an excellent addition to any metalworking library.

It's kinda like having an eye to eye contact with a teacher. You are not talked down to. Topics are discussed like the author is talking to you. The book is easy to read and understand. I am a beginning machinist, so I needed that edge. The problem area's I had were covered just like I had asked to author to write it for me.
I would recommend this book for anyone with a machine in their shop.

I am new in machining field, and quite honestly without anyone that could help me or to occasionally answer my questions. After reading this book I got many of my questions answered. What I like the most, is that the book is written in the way that is easy for reading yet with enough technical details. The space is given to the topics that are really important for anyone starting in this field as a hobby or as profession. It is clear that Mr. Frank Marlow surly has full knowledge and a lots of experience with a talent of transferring it to the reader.
Now after I am done reading, I keep the book in my shop to occasionally remind myself on how something is done. The feature found in the book - all important tasks are explained and listed in numbered and consecutive order just like user manual for treading, turning, milling... It is what you would expect in the user manual that come with your milling machine or lathe, but you never find it there.
After reading the book I was so excited to test my new acquired knowledge and I did a few projects. Not just that I succeeded in my projects, but also I had a pleasure doing it just as explained in the book - step by step and it it all worked.
If you are new in this field, like myself, this book would be the best tool that you could buy for your shop. I am strongly recommending it.

Good coverage of a broad range of topics. Very easy to understand and perfectly illustrated. Many handy tips that an experienced machinist would already know, but are invaluable for a newbie. Terms not introduced in the text are covered in an extensive glossary. Lathe cutting is more thoroughly covered than milling, but the two are complimentary. I have only two complaints. There is no discussion of gear cutting. Although this might be considered an advanced topic, I think it should have been discussed at least generally. My other issue is with the index, which I found confusing. For example, if you want to know about threading, you need to look under "threading" and also under "lathe, threading". All in all, I found it well worth the price.

This book has literally everything I need on working a lathe. Even the harder questions like cutting curves without a CNC machine are covered. And as a bonus it covers everything else that a home machinist would want to know about mills, grinding, polishing, threads, metallurgy, etc. I am seriously considering returning all my other books on the topic.