Machine Tool Practices

by Kibbe, Richard R.; Neely, John E.; Meyer, Roland O.; White, Warren T.

• ISBN13: 9780132702324
• ISBN10: 0132702320
• Edition: 6th
• Format: Hardcover
• Copyright: 2002-04-01
• Publisher: Prentice Hall

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

Preface	v	(1)
Acknowledgments	vi
SECTION A INTRODUCTION	5	(31)
Unit 1 Shop Safety	5	(8)
Unit 2 Mechanical Hardware	13	(13)
Unit 3 Reading Drawings	26	(9)
SECTION B HAND TOOLS	35	(48)
Unit 1 Arbor and Shop Presses	36	(7)
Unit 2 Work-Holding and Hand Tools	43	(9)
Unit 3 Hacksaws	52	(2)
Unit 4 Files	54	(6)
Unit 5 Hand Reamers	60	(4)
Unit 6 Identification and Uses of Taps	64	(5)
Unit 7 Tapping Procedures	69	(5)
Unit 8 Thread-Cutting Dies and Their Uses	74	(4)
Unit 9 Off-Hand Grinding	78	(5)
SECTION C DIMENSIONAL MEASUREMENT	83	(111)
Unit 1 Systems of Measurement	100	(4)
Unit 2 Using Steel Rules	104	(9)
Unit 3 Using Vernier, Dial, and Digital Instruments for Direct Measurements	113	(11)
Unit 4 Using Micrometer Instruments	124	(22)
Unit 5 Using Comparison Measuring Instrument	146	(20)
Unit 6 Using Gage Blocks	166	(9)
Unit 7 Using Angular Measuring Instruments	175	(10)
Unit 8 Tolerances, Fits, Geometric Dimensions, and Statistical Process Control (SPC)	185	(9)
SECTION D MATERIALS	194	(40)
Unit 1 Selection and Identification of Steels	197	(6)
Unit 2 Selection and Identification of Nonferrous Metals	203	(6)
Unit 3 Hardening, Case Hardening, and Tempering	209	(13)
Unit 4 Annealing, Normalizing, and Stress Relieving	222	(3)
Unit 5 Rockwell and Brinell Hardness Testers	225	(9)
SECTION E LAYOUT	234	(31)
Unit 1 Basic Semiprecision Layout Practice	246	(5)
Unit 2 Basic Precision Layout Practice	251	(14)
SECTION F PREPARATION FOR MACHINING OPERATIONS	265	(37)
Unit 1 Machinability and Chip Formation	267	(9)
Unit 2 Speeds and Feeds for Machine Tools	276	(4)
Unit 3 Cutting Fluids	280	(5)
Unit 4 Using Carbides and Other Tool Materials	285	(17)
SECTION G SAWING MACHINES	302	(43)
Unit 1 Using Reciprocating and Horizontal Band Cutoff Machines	316	(10)
Unit 2 Abrasive and Cold Saws	326	(3)
Unit 3 Preparing to Use the Vertical Band Machine	329	(9)
Unit 4 Using the Vertical Band Machine	338	(7)
SECTION H DRILLING MACHINES	345	(44)
Unit 1 The Drill Press	350	(4)
Unit 2 Drilling Tools	354	(11)
Unit 3 Hand Grinding of Drills on the Pedestal Grinder	365	(4)
Unit 4 Operating Drilling Machines	369	(12)
Unit 5 Countersinking and Counterboring	381	(3)
Unit 6 Reaming in the Drill Press	384	(5)
SECTION I TURNING MACHINES	389	(127)
Unit 1 The Engine Lathe	398	(7)
Unit 2 Toolholders and Toolholding for the Lathe	405	(7)
Unit 3 Cutting Tools for the Lathe	412	(8)
Unit 4 Lathe Spindle Tooling	420	(7)
Unit 5 Operating the Machine Controls	427	(4)
Unit 6 Facing and Center Drilling	431	(9)
Unit 7 Turning Between Centers	440	(12)
Unit 8 Alignment of the Lathe Centers	452	(3)
Unit 9 Other Lathe Operations	455	(15)
Unit 10 Sixty-Degree Thread Information and Calculations	470	(6)
Unit 11 Cutting Unified External Threads	476	(11)
Unit 12 Cutting Unified Internal Threads	487	(4)
Unit 13 Cutting Tapers	491	(11)
Unit 14 Using Steady and Follower Rests	502	(5)
Unit 15 Additional Thread Forms	507	(5)
Unit 16 Cutting Acme Threads on the Lathe	512	(4)
SECTION J VERTICAL MILLING MACHINES	516	(33)
Unit 1 Vertical Spindle Milling Machines	518	(3)
Unit 2 Cutting Tools and Cutter Holders for the Vertical Milling Machines	521	(6)
Unit 3 Setups on the Vertical Milling Machine	527	(8)
Unit 4 Vertical Milling Machine Operations	535	(10)
Unit 5 Using the Offset Boring Head	545	(4)
SECTION K HORIZONTAL MILLING MACHINES	549	(47)
Unit 1 Plain and Universal Horizontal Milling Machines	556	(4)
Unit 2 Types of Spindles, Arbors, and Adapters	560	(3)
Unit 3 Arbor-Driven Milling Cutters	563	(6)
Unit 4 Work-Holding Methods and Standard Setups	569	(5)
Unit 5 Machine Setup and Plain Milling	574	(11)
Unit 6 Using Side Milling Cutters	585	(6)
Unit 7 Using Face Milling Cutters on the Horizontal Milling Machine	591	(5)
SECTION L ROTARY TABLES AND INDEXING DEVICES	596	(13)
Unit 1 Setup and Operation of Indexing Heads and Rotary Tables	601	(3)
Unit 2 Direct and Simple Indexing	604	(3)
Unit 3 Angular Indexing	607	(2)
SECTION M GEARS AND GEAR CUTTING	609	(22)
Unit 1 Introduction to Gears	616	(4)
Unit 2 Spur Gear Terms and Calculations	620	(4)
Unit 3 Cutting a Spur Gear	624	(3)
Unit 4 Gear Inspection and Measurement	627	(4)
SECTION N GRINDING AND ABRASIVE MACHINING PROCESSES	631	(76)
Unit 1 Selection and Identification of Grinding Wheels	646	(8)
Unit 2 Truing, Dressing, and Balancing of Grinding Wheels	654	(6)
Unit 3 Grinding Fluids	660	(5)
Unit 4 Horizontal Spindle Reciprocating Table Surface Grinders	665	(3)
Unit 5 Work Holding on the Surface Grinder	668	(4)
Unit 6 Using the Surface Grinder	672	(8)
Unit 7 Problems and Solutions in Surface Grinding	680	(3)
Unit 8 Center-Type Cylindrical Grinders	683	(6)
Unit 9 Using the Cylindrical Grinder	689	(4)
Unit 10 Universal Tool and Cutter Grinder	693	(14)
SECTION O ADVANCED MACHINING PROCESSES	707	(47)
Unit 1 CNC Machine Tools	712	(9)
Unit 2 CNC Positioning and Input	721	(6)
Unit 3 CNC Tooling	727	(11)
Unit 4 CNC Applications	738	(10)
Unit 5 Nontraditional Machining Processes	748	(6)
APPENDIX 1 ANSWERS TO SELF-TESTS	754	(32)
APPENDIX 2 GENERAL TABLES	786	(15)
Table 1 Decimal Equivalents of Fractional Inches	787	(1)
Table 2 Inch/Metric Conversion Table	788	(2)
Table 3 Tap Drill Sizes	790	(1)
Table 4 Metric Tap Drill Sizes	791	(1)
Table 5A Tapers	792	(1)
Table 5B Tapers and Angles	793	(1)
Table 6 General Measurements	794	(2)
Table 7 Density and Melting Points for Metals and Other Materials	796	(2)
Table 8 Right-Triangle Solution Formulas	798	(1)
Table 9 Wire Gages and Metric Equivalents	799	(1)
Table 10 Cutting Speeds for Some Commonly Used Materials	800	(1)
Table 10A Feeds for High-Speed End Mills	800	(1)
Table 10B Coolants and Cutting Oils Used for General Machining	800	(1)
GLOSSARY	801	(8)
INDEX	809