Machine Tool Practices

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

• ISBN13: 9780130334473
• ISBN10: 0130334472
• Edition: 7th
• Format: Hardcover
• Copyright: 2002-01-01
• 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

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