Machine Tool Practices

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

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ISBN: 9780132702324 | 0132702320
Cover: Hardcover
Copyright: 4/1/2002

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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.

Preface

(1)

Acknowledgments

SECTION A INTRODUCTION

(31)

Unit 1 Shop Safety

(8)

Unit 2 Mechanical Hardware

(13)

Unit 3 Reading Drawings

(9)

SECTION B HAND TOOLS

(48)

Unit 1 Arbor and Shop Presses

(7)

Unit 2 Work-Holding and Hand Tools

(9)

Unit 3 Hacksaws

(2)

Unit 4 Files

(6)

Unit 5 Hand Reamers

(4)

Unit 6 Identification and Uses of Taps

(5)

Unit 7 Tapping Procedures

(5)

Unit 8 Thread-Cutting Dies and Their Uses

(4)

Unit 9 Off-Hand Grinding

(5)

SECTION C DIMENSIONAL MEASUREMENT

(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

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Machine Tool Practices

Summary

Table of Contents

Supplemental Materials