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Machine Tool Practices,9780130334473
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Machine Tool Practices

by ; ; ;
Edition:
7th
ISBN13:

9780130334473

ISBN10:
0130334472
Format:
Hardcover
Pub. Date:
1/1/2002
Publisher(s):
Prentice Hall

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Summary

This timely book covers the core subject areas essential toward building a basic foundation required to effectively work in the machining area of today's manufacturing technology.Each section begins with an introductory overview, followed by easy-to-read instructional units designed around specific projects that accurately reflect the state of the art in industrial machine shop environments. The book also includes an introduction to all common manual machine tool operations, with an introduction to computer numerical control operations.For budding computer numerical control (CNC) and conventional machine operators, general machinists or tool and die makers.

Table of Contents

Introduction
1(34)
Shop Safety
5(7)
Mechanical Hardware
12(14)
Reading Drawings
26(9)
Hand Tools
35(48)
Arbor and Shop Presses
36(7)
Work-Holding and Hand Tools
43(9)
Hacksaws
52(2)
Files
54(6)
Hand Reamers
60(4)
Identification and Uses of Taps
64(5)
Tapping Procedures
69(5)
Thread-Cutting Dies and Their Uses
74(4)
Off-Hand Grinding
78(5)
Dimensional Measurement
83(112)
Systems of Measurement
100(4)
Using Steel Rules
104(10)
Using Vernier, Dial, and Digital Instruments for Direct Measurements
114(10)
Using Micrometer Instruments
124(22)
Using Comparison Measuring Instruments
146(21)
Using Gage Blocks
167(8)
Using Angular Measuring Instruments
175(10)
Tolerances, Fits, Geometric Dimensions, and Statistical Process Control (SPC)
185(10)
Materials
195(42)
Selection and Identification of Steels
198(6)
Selection and Identification of Nonferrous Metals
204(6)
Hardening, Case Hardening, and Tempering
210(13)
Annealing, Normalizing, and Stress Relieving
223(3)
Rockwell and Brinell Hardness Testers
226(11)
Layout
237(32)
Basic Semiprecision Layout Practice
251(5)
Basic Precision Layout Practice
256(13)
Preparation for Machining Operations
269(36)
Machinability and Chip Formation
271(8)
Speeds and Feeds for Machine Tools
279(4)
Cutting Fluids
283(5)
Using Carbides and Other Tool Materials
288(17)
Sawing Machines
305(44)
Using Reciprocating and Horizontal Band Cutoff Machines
320(10)
Abrasive and Cold Saws
330(3)
Preparing to Use the Vertical Band Machine
333(9)
Using the Vertical Band Machine
342(7)
Drilling Machines
349(44)
The Drill Press
354(4)
Drilling Tools
358(10)
Hand Grinding of Drills on the Pedestal Grinder
368(4)
Operating Drilling Machines
372(12)
Countersinking and Counterboring
384(3)
Reaming in the Drill Press
387(6)
Turning Machines
393(128)
The Engine Lathe
402(8)
Toolholders and Toolholding for the Lathe
410(6)
Cutting Tools for the Lathe
416(8)
Lathe Spindle Tooling
424(6)
Operating the Machine Controls
430(5)
Facing and Center Drilling
435(9)
Turning Between Centers
444(12)
Alignment of the Lathe Centers
456(3)
Other Lathe Operations
459(15)
Sixty-Degree Thread Information and Calculations
474(5)
Cutting Unified External Threads
479(12)
Cutting Unified Internal Threads
491(3)
Cutting Tapers
494(12)
Using Steady and Follower Rests
506(5)
Additional Thread Forms
511(5)
Cutting Acme Threads on the Lathe
516(5)
Vertical Spindle Milling Machines
521(34)
Vertical Spindle Milling Machines
523(3)
Cutting Tools and Cutter Holders for the Vertical Milling Machine
526(6)
Setups on the Vertical Milling Machine
532(8)
Vertical Milling Machine Operations
540(10)
Using the Offset Boring Head
550(5)
Horizontal Spindle Milling Machines
555(42)
Horizontal Spindle Milling Machines
560(3)
Types of Spindles, Arbors, and Adapters
563(3)
Arbor-Driven Milling Cutters
566(5)
Work-Holding Methods and Standard Setups
571(5)
Machine Setup and Plain Milling
576(11)
Using Side Milling Cutters
587(4)
Using Face Milling Cutters on the Horizontal Milling Machine
591(6)
Grinding and Abrasive Machining Processes
597(78)
Selection and Identification of Grinding Wheels
613(8)
Truing, Dressing, and Balancing of Grinding Wheels
621(6)
Grinding Fluids
627(5)
Horizontal Spindle Reciprocating Table Surface Grinders
632(4)
Workholding on the Surface Grinder
636(4)
Using the Surface Grinder
640(7)
Problems and Solutions in Surface Grinding
647(3)
Center-Type Cylindrical Grinders
650(6)
Using the Cylindrical Grinder
656(4)
Universal Tool and Cutter Grinder
660(15)
Computer Numerical Control and Other Advanced Machining Processes
675(67)
CNC Machine Tool Programmable Axes and Position Dimensioning Systems
683(6)
CNC Programming
689(33)
CNC Tooling
722(13)
Other Advanced Machining Processes
735(7)
ANSWERS TO SELF-TESTS 742(30)
GENERAL TABLES 772(15)
Table 1 Decimal Equivalents of Fractional Inches
773(1)
Table 2 Inch/Metric Conversion Table
774(2)
Table 3 Tap Drill Sizes
776(1)
Table 4 Metric Tap Drill Sizes
777(1)
Table 5A Tapers
778(1)
Table 5B Tapers and Angles
779(1)
Table 6 General Measurements
780(2)
Table 7A Density or Specific Gravity of Metals and Alloys
782(1)
Table 7B Approximate Melting Points of Metals and Various Substances
783(1)
Table 8 Right-Triangle Solution Formulas
784(1)
Table 9 Wire Gages and Metric Equivalents
785(1)
Table 10 Cutting Speeds for Some Commonly Used Materials
786(1)
Table 10A Feeds for High-Speed End Mills
786(1)
Table 10B Coolants and Cutting Oils Used for General Machining
786(1)
APPENDIX 3 PRECISION VISE PROJECT DRAWINGS 787(4)
Glossary 791(10)
Index 801

Excerpts

The major objective of this edition, like that of previous editions, is to provide a current and richly illustrated text for those students training to become computer numerical control (CNC) and conventional machine operators, general machinists, or tool and die makers, either through apprenticeship training or community college and vocational programs. The content deals with topics usually presented in a combined lecture/laboratory program. However, the text is designed such that it may also be used in a self-paced instructional environment.The authors fully realize that the field of machine tools and machining practices has changed greatly over the past few years. Many of the classical processes heretofore considered to be an important component of machinist training are no longer taught or even done in manufacturing, especially in the age of CNC. However, we feel that the content of this edition continues to verbalize and illustrate the major core subject areas of the machinist's education, even though the major thrust of a student's employment may be more oriented toward CNC production machine operation than toward the more general job shop or prototype manufacturing environment.No matter what directions the field of machine tools and machining practices may take in future years, we remain steadfast in our belief that the content of this edition is both timely and essential to the basic foundation that a student needs to participate effectively in the machining area of manufacturing technology.To better meet the needs of users of this book, the authors have made a careful study of the entire contents. Many users of previous editions were consulted and their comments incorporated so that this seventh edition could be updated to meet the present-day needs of students and instructors, and current industry training standards. Following are some of the special features included in this textbook: Each section begins with an introductory over-view, followed by instructional units with clearly stated objectives. Instructional units in each section contain easy-to-read information and instructions that accurately reflect the state of the art in industrial machine shop environments. The book is illustrated extensively with many photographs of actual machining operations. We have also taken several major steps in this new edition to improve the quality of the art throughout the text. Graphic explanations are used to highlight important concepts and common errors and difficulties encountered by machinists. Many units are designed around specific projects that provide much of the performance experience for the student. The structure of the book makes it easy for instructors to insert projects that are more applicable to specific individual programs. Self-tests at the end of most units enable students to evaluate their own progress and understanding of the text material. Self-test answers are given in Appendix 1.Additions and new features in the seventh edition include: New and updated illustrations are included where appropriate. The seventh edition reflects the ever-increasing importance of CNC. This section has been extensively revised and now contains much more material specific to industry-standard conventional code CNC programming, patterned after the most common numerical control formats presently used in the industry. The section has also been reorganized in order to present a more logical topic development. Many new drawings and more detailed explanations of specific programming sequences have been included. Although the coverage is not intended to be as extensive as a dedicated text on CNC, we feel that it is sufficient to give the student a solid start in learning the basics of this popular and growing technology. Shop tips, safety tips, career tips, and new or developing technology are emphasized in color boxes through


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