Table of Contents
(NOTE: Each number represents a Unit.)
SECTION A: INTRODUCTION.
1. Shop Safety.
2. Mechanical Hardware.
3. Reading Drawings.
SECTION B: HAND TOOLS.
1. Arbor and Shop Presses.
2. Work-Holding and Hand Tools.
3. Hacksaws.
4. Files.
5. Hand Reamers.
6. Identification and Uses of Taps.
7. Tapping Procedures.
8. Thread-Cutting Dies and Their Uses.
9. Off-Hand Grinding.
SECTION C: DIMENSIONAL MEASUREMENT.
1. Systems of Measurement.
2. Using Steel Rules.
3. Using Vernier, Dial, and Digital Instruments for Direct Measurements.
4. Using Micrometer Instruments.
5. Using Comparison Measuring Instruments.
6. Using Gage Blocks.
7. Using Angular Measuring Instruments.
8. Tolerances, Fits, Geometric Dimensions, and Statistical Process Control (SPC).
SECTION D: MATERIALS.
1. Selection and Identification of Steels.
2. Selection and Identification of Nonferrous Metals.
3. Hardening, Case Hardening, and Tempering.
4. Annealing, Normalizing, and Stress Relieving.
5. Rockwell and Brinell Hardness Testers.
SECTION E: LAYOUT.
1. Basic Semiprecision LayoutPractice.
2. Basic Precision Layout Practice.
SECTION F: PREPARATION FOR MACHINING OPERATIONS.
1. Machinability and Chip Formation.
2. Speeds and Feeds for Machine Tools.
3. Cutting Fluids.
4. Using Carbides and Other Tool Materials.
SECTION G: SAWING MACHINES.
1. Using Reciprocating and Horizontal Band Cutoff Machines.
2. Abrasive and Cold Saws.
3. Preparing to Use the Vertical Band Machine.
4. Using the Vertical Band Machine.
SECTION H: DRILLING MACHINES.
1. The Drill Press.
2. Drilling Tools.
3. Hand Grinding of Drills on the Pedestal Grinder.
4. Operation Drilling Machines.
5. Countersinking and Counterboring.
6. Reaming in the Drill Press.
SECTION I: TURNING MACHINES.
1. The Engine Lathe.
2. Toolholders and Toolholding for the Lathe.
3. Cutting Tools for the Lathe.
4. Lathe Spindle Tooling.
5. Operating the Machine Controls.
6. Facing and Center Drilling.
7. Turning between the Centers.
8. Alignment of the Lathe Centers.
9. Other Lathe Operations.
10. Sixty-Degree Thread Information and Calculations.
11. Cutting Unified External Threads.
12. Cutting Unified Internal Threads.
13. Cutting Tapers.
14. Using Steady and Follower Rests.
15. Additional Thread Forms.
16. Cutting Acme Threads on the Lathe.
SECTION J: VERTICAL MILLING MACHINES.
1. Vertical Spindle Milling Machines.
2. Cutting Tools and Cutter Holders for the Vertical Milling Machines.
3. Setups on the Vertical Milling Machine.
4. Vertical Milling Machine Operations.
5. Using the Offset Boring Head.
SECTION K: HORIZONTAL SPINDLE MILLING MACHINES.
1. Horizontal Spindle Milling Machines.
2. Types of Spindles, Arbors, and Adapters.
3. Arbor-Driven Milling Cutters.
4. Work-Holding Methods and Standard Setups.
5. Machine Setup and Plain Milling.
6. Using Side Milling Cutters.
7. Using Face Milling Cutters on the Horizontal Milling Machine.
SECTION L: GRINDING AND ABRASIVE MACHINING PROCESSES.
1. Selection and Identification of Grinding Wheels.
2. Truing, Dressing, and Balancing of Grinding Wheels.
3. Grinding Fluids.
4. Horizontal Spindle Reciprocating Table Surface Grinders.
5. Workholding on the Surface Grinder.
6. Using the Surface Grinder.
7. Problems and Solutions in Surface Grinding.
8. Center-Type Cylindrical Grinders.
9. Using the Cylindrical Grinder.
10. Universal Tool and Cutter Grinder.
SECTION M: COMPUTER NUMERICAL CONTROL AND OTHER ADVANCED MACHINE PROCESSES.
1. CNC Machine Tool Progammable Axes and Position Dimensioning Systems.
2. CNC Programming.
3. CNC Tooling.
4. Other Advanced Machining Processes.
Appendix 1: Answers to Self-Tests.
Appendix 2: General Tables.
1. Decimal Equivalents of Fractional Inches.
2. Inch/Metric Conversion Table.
3. Tap Drill Sizes.
4. Metric Tap Drill Sizes.
5A. Tapers.
5B. Tapers and Angles.
6. General Measurements.
7a. Density or Specific Gravity of Metals and Alloys.
7b. Approximate Melting Points of Metals and Various Substances.
8. Right-Triangle Solution Formulas.
9. Wire Gages and Metric Equivalents.
10. Cutting Speeds for Some Commonly Used Materials.
10A. Feeds for High-Speed End Mills.
10B. Coolants and Cutting Oils Used for General Machining.
Appendix 3: Precision Vise Project Drawings.
Glossary.
Index.
Forewords & Introductions
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 consultedand 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 throughout the text. The shop tips are designed to emphasize tricks of the trade and shortcuts that can be invaluable during a student's training. Safety tips emphasize shop and machine safety considerations. New technology and career tips are designed to stimulate a student's interest to pursue further information on the subject.
- Applications of trigonometry now appear in the text at appropriate points.
Although we have updated this edition to reflect current machining technology, we have preserved essential classical machine shop practice while deleting that which is truly not relevant or no longer used. We believe that the standard machine shop practices that make up the bulk of this edition are still very relevant to the machining technology field, even in this age of high-technology, computer-supported manufacturing. Students of modern machining technology will still require solid backgrounds in standard practice if they are to understand and appreciate computer-controlled and computer-supported machining as well as other high-technology manufacturing processes.
The following materials are available to supplement the textbook:
- An Instructor's Manual containing suggestions on how to use the textbook for conventional and competency-based education, post-tests, and answer keys. The post-tests can be freely reproduced by users of the book. All Instructor's Manual tests have been edited and reformatted so that test questions more closely correspond to the specific text passages.
- A workbook titled Workbook for Machine Tool Practices. This adjunct publication plays an extremely important part in maximizing use of the book. The workbook contains process worksheets with projects, alternative projects, and additional tables. These features are keyed to the text material and thus greatly enhance the use of the book as a complete instructional system.
The workbook is project oriented and not just a series of exercises in which the student has no real vested interest. The projects, when completed, are all useful devices and as such, help to motivate students. The workbook, together with Machine Tool Practices, provides an orderly, efficient, and complete teaching system that is quite flexible and easy to set up and use for any machine technology training program. Use of the student workbook is highly recommended.
Richard R. Kibbe
John E. Neely
Roland O. Meyer
Warren T. White
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