Machining Fundamentals

by Walker, John R.

• ISBN13: 9781566376624
• ISBN10: 1566376629
• Edition: 7th
• Format: Hardcover
• Copyright: 1999-08-01
• Publisher: GOODHEART WILCOX COMPANY

Summary

Provides an introduction to this area of manufacturing technology explaining the how, why, and when of numerous machining operations, set-ups and procedures. Discusses how machine tools operate and when to use one particular machine instead of another. DLC: Machine-shop practice.

Table of Contents

Chapter 1. An Introduction to Machining Technology	11	(12)
1.1 The Evolution of Machine Tools	12	(2)
1.2 Basic Machine Tool Operation	14	(3)
1.3 Nontraditional Machining Processes	17	(1)
1.4 Automating the Machining Process	17	(3)
1.5 The Evolving Role of the Machinist	20	(3)
Chapter 2. Shop Safety	23	(6)
2.1 Safety in the Shop	23	(3)
2.2 General Machine Safety	26	(1)
2.3 General Tool Safety	27	(1)
2.4 Fire Safety	27	(2)
Chapter 3. Understanding Drawings	29	(26)
3.1 Dimensions	31	(1)
3.2 Information Included on Drawings	32	(5)
3.3 Types of Prints	37	(1)
3.4 Types of Drawings Used in the Shop	38	(1)
3.5 Parts List	38	(1)
3.6 Drawing Sizes	38	(3)
3.7 Geometric Dimensioning and Tolerancing	41	(14)
Chapter 4. Measurement	55	(26)
4.1 The Rule	55	(2)
4.2 The Micrometer Caliper	57	(6)
4.3 Vernier Measuring Tools	63	(4)
4.4 Gages	67	(3)
4.5 Dial Indicators	70	(1)
4.6 Other Gaging Tools	71	(4)
4.7 Helper Measuring Tools	75	(6)
Chapter 5. Layout Work	81	(10)
5.1 Making Lines on Metal	81	(4)
5.2 Squares	85	(1)
5.3 Measuring Angles	85	(2)
5.4 Simple Layout Steps	87	(2)
5.5 Layout Safety	89	(2)
Chapter 6. Hand Tools	91	(36)
6.1 Clamping Devices	91	(1)
6.2 Pliers	92	(3)
6.3 Wrenches	95	(4)
6.4 Screwdrivers	99	(2)
6.5 Striking Tools	101	(1)
6.6 Chisels	102	(2)
6.7 Hacksaw	104	(3)
6.8 Files	107	(5)
6.9 Reamers	112	(2)
6.10 Hand Threading	114	(8)
6.11 Hand Polishing	122	(5)
Chapter 7. Fasteners	127	(16)
7.1 Threaded Fasteners	127	(8)
7.2 Nonthreaded Fastening Devices	135	(3)
7.3 Adhesives	138	(2)
7.4 Fastener Safety	140	(3)
Chapter 8. Jigs and Fixtures	143	(6)
8.1 Jigs	143	(2)
8.2 Fixtures	145	(1)
8.3 Jig and Fixture Construction	146	(3)
Chapter 9. Cutting Fluids	149	(4)
9.1 Types of Cutting Fluids	149	(1)
9.2 Application of Cutting Fluids	150	(3)
Chapter 10. Drills and Drilling Machines	153	(30)
10.1 Drilling Machines	153	(4)
10.2 Drill Press Safety	157	(1)
10.3 Drills	158	(5)
10.4 Drill-holding Devices	163	(1)
10.5 Work-holding Devices	164	(3)
10.6 Cutting Speeds and Feeds	167	(1)
10.7 Cutting Compounds	168	(2)
10.8 Sharpening Drills	170	(3)
10.9 Drilling	173	(3)
10.10 Countersinking	176	(1)
10.11 Counterboring	177	(1)
10.12 Spotfacing	178	(1)
10.13 Tapping	178	(2)
10.14 Reaming	180	(3)
Chapter 11. Offhand Grinding	183	(8)
11.1 Abrasive Belt Grinders	183	(1)
11.2 Bench and Pedestal Grinders	183	(2)
11.3 Grinding Wheels	185	(1)
11.4 Abrasive Belt and Grinder Safety	186	(1)
11.5 Using a Dry-type Grinder	187	(1)
11.6 Using a Wet-type Grinder	188	(1)
11.7 Portable Hand Grinders	188	(3)
Chapter 12. Sawing and Cutoff Machines	191	(10)
12.1 Metal-cutting Saws	191	(1)
12.2 Reciprocating Power Hacksaw	191	(3)
12.3 Power Band Saw	194	(2)
12.4 Using Reciprocating and Band Saws	196	(1)
12.5 Circular Metal-cutting Saws	197	(1)
12.6 Power Saw Safety	197	(4)
Chapter 13. The Lathe	201	(40)
13.1 Lathe Size	201	(1)
13.2 Major Parts of a Lathe	202	(6)
13.3 Preparing Lathe for Operation	208	(1)
13.4 Cleaning the Lathe	209	(1)
13.5 Lathe Safety	209	(2)
13.6 Cutting Tools and Tool Holders	211	(9)
13.7 Cutting Speeds and Feeds	220	(2)
13.8 Work-holding Attachments	222	(1)
13.9 Turning Work Between Centers	223	(8)
13.10 Using Lathe Chucks	231	(5)
13.11 Facing Stock Held in Chuck	236	(1)
13.12 Plain Turning and Turning to a Shoulder	237	(1)
13.13 Parting Operations	237	(4)
Chapter 14. Cutting Tapers and Screw Threads on the Lathe	241	(20)
14.1 Taper Turning	241	(3)
14.2 Calculating Tailstock Setover	244	(1)
14.3 Measuring Tailstock Setover	245	(1)
14.4 Cutting a Taper	246	(2)
14.5 Measuring Tapers	248	(2)
14.6 Cutting Screw Threads on the Lathe	250	(11)
Chapter 15. Other Lathe Operations	261	(20)
15.1 Boring on a Lathe	261	(2)
15.2 Drilling and Reaming on a Lathe	263	(2)
15.3 Knurling on a Lathe	265	(2)
15.4 Filing and Polishing on a Lathe	267	(1)
15.5 Steady and Follower Rests	268	(2)
15.6 Mandrels	270	(1)
15.7 Grinding on the Lathe	270	(2)
15.8 Milling on a Lathe	272	(1)
15.9 Special Lathe Attachments	272	(2)
15.10 Industrial Applications of the Lathe	274	(7)
Chapter 16. Broaching Operations	281	(4)
16.1 Advantages of Broaching	283	(1)
16.2 Keyway Broaching	283	(2)
Chapter 17. The Milling Machine	285	(32)
17.1 Types of Milling Machines	286	(6)
17.2 Milling Safety Practices	292	(1)
17.3 Milling Operations	293	(1)
17.4 Milling Cutters	293	(3)
17.5 Types and Uses of Milling Cutters	296	(8)
17.6 Methods of Milling	304	(1)
17.7 Holding and Driving Cutters	304	(4)
17.8 Milling Cutting Speeds and Feeds	308	(2)
17.9 Cutting Fluids	310	(1)
17.10 Milling Work-holding Attachments	310	(7)
Chapter 18. Milling Machine Operations	317	(36)
18.1 Milling Operations	317	(1)
18.2 Vertical Milling Machine	317	(1)
18.3 Vertical Milling Machine Operations	317	(9)
18.4 Milling Machine Care	326	(2)
18.5 Horizontal Milling Machine Operations	328	(9)
18.6 Slitting	337	(2)
18.7 Slotting	339	(1)
18.8 Drilling and Boring on a Horizontal Milling Machine	339	(1)
18.9 Cutting a Spur Gear	340	(6)
18.10 Cutting a Bevel Gear	346	(3)
18.11 Precautions When Operating a Milling Machine	349	(1)
18.12 Industrial Applications	349	(4)
Chapter 19. Precision Grinding	353	(30)
19.1 Types of Surface Grinders	353	(3)
19.2 Work-holding Devices	356	(2)
19.3 Grinding Wheels	358	(4)
19.4 Cutting Fluids (Coolants)	362	(2)
19.5 Grinding Applications	364	(2)
19.6 Grinding Problems	366	(1)
19.7 Grinding Safety	367	(1)
19.8 Universal Tool and Cutter Grinder	368	(1)
19.9 Tool and Cutter Grinding Wheels	368	(5)
19.10 Cylindrical Grinding	373	(2)
19.11 Internal Grinding	375	(1)
19.12 Centerless Grinding	376	(1)
19.13 Form Grinding	377	(1)
19.14 Other Grinding Techniques	378	(5)
Chapter 20. Band Machining	383	(16)
20.1 Band Machining Advantages	383	(1)
20.2 Band Blade Selection	384	(3)
20.3 Welding Blades	387	(1)
20.4 Band Machine Preparation	388	(2)
20.5 Band Machining Operations	390	(3)
20.6 Band Machine Power Feed	393	(1)
20.7 Other Band Machining Applications	393	(3)
20.8 Troubleshooting Band Machines	396	(1)
20.9 Band Machining Safety	397	(2)
Chapter 21. Computer Numerical Control	399	(24)
21.1 Computer-aided Machining Technology	399	(2)
21.2 Positioning with Numerical Control	401	(3)
21.3 NC Movement Systems	404	(4)
21.4 Programming NC Machines	408	(4)
21.5 Computer Languages	412	(1)
21.6 Adaptive Control	413	(1)
21.7 NC and the Future	413	(2)
21.8 Advantages and Disadvantages of NC	415	(8)
Chapter 22. Automated Manufacturing	423	(12)
22.1 Flexible Manufacturing System	424	(1)
22.2 Robotics	424	(4)
22.3 Safety In Automated Manufacturing	428	(1)
22.4 Rapid Prototyping Techniques	428	(5)
22.5 The Future of Automated Manufacturing	433	(2)
Chapter 23. Quality Control	435	(16)
23.1 The History of Quality Control	435	(1)
23.2 Classifications of Quality Control	436	(1)
23.3 Nondestructive Testing Techniques	437	(11)
23.4 Other Quality Control Techniques	448	(3)
Chapter 24. Metal Characteristics	451	(16)
24.1 Classifying Metals	451	(1)
24.2 Ferrous Metals	452	(6)
24.3 Nonferrous Metals	458	(3)
24.4 Copper-based Alloys	461	(1)
24.5 High-temperature Metals	462	(1)
24.6 Rare Metals	463	(4)
Chapter 25. Heat Treatment of Metals	467	(22)
25.1 Heat-treatable Metals	467	(1)
25.2 Types of Heat Treatment	467	(5)
25.3 Heat Treatment of Other Metals	472	(1)
25.4 Heat-treating Equipment	473	(2)
25.5 Hardening Carbon Steel	475	(2)
25.6 Tempering Carbon Steel	477	(1)
25.7 Case Hardening Low-carbon Steel	478	(1)
25.8 Hardness Testing	479	(7)
25.9 Heat-treating Safety	486	(3)
Chapter 26. Metal Finishing	489	(14)
26.1 Quality of Machined Surfaces	489	(3)
26.2 Other Metal Finishing Techniques	492	(11)
Chapter 27. Electromachining Processes	503	(8)
27.1 Electrical Discharge Machining (EDM)	503	(3)
27.2 Electrical Discharge Wire Cutting (EDWC)	506	(1)
27.3 Electrochemical Machining (ECM)	507	(4)
Chapter 28. Nontraditional Machining Techniques	511	(14)
28.1 Chemical Machining	511	(5)
28.2 Hydrodynamic Machining (HDM)	516	(1)
28.3 Ultrasonic Machining	517	(2)
28.4 Electron Beam Machining (EBM)	519	(2)
28.5 Laser Beam Machining	521	(4)
Chapter 29. Other Processes	525	(22)
29.1 Machining Plastics	525	(6)
29.2 Chipless Machining	531	(1)
29.3 Powder Metallurgy	532	(5)
29.4 High-energy-rate Forming (HERF)	537	(6)
29.5 Cryogenic Applications	543	(4)
Chapter 30. Occupations in Machining Technology	547	(10)
30.1 Machining Job Categories	547	(6)
30.2 Preparing to Find a Job in Machining Technology	553	(1)
30.3 How to Get a Job	554	(3)
Reference Section	557	(36)
Glossary of Technical Terms	593	(22)
Index	615