Technology of machine tools / Steve F. Krar, Arthur R. Gill, Peter Smid, Jonathan A. Gill, Robert J. Gerritsen.

By: Krar, Stephen F [ author.]
Contributor(s): Gill, Arthur, 1930- [author.] | Smid, Peter [ author.] | Gill, Jonathan A [author.] | Gerritsen, Robert J [author.]
Language: English Publisher: New York, NY: McGraw Hill, [2024]Copyright date: ©2024Edition: Ninth edition, International student editionDescription: xi, 925 pages : illustrations (some color) ; 28 cmContent type: text Media type: unmediated Carrier type: volumeISBN: 9781266277474
Contents:
Contents Preface about the authors New to the Ninth Edition of Technology of Machine Tools acknowledgments Connect Unit 1: History of Machines Section 1: Introduction to Machine Tools Unit 1: Introduction Common Machine Tools Standard Machine Tools Drill Press Engine Lathe Metal Saw Milling Machine Grinder Special Machine Tools Computer Numerical Control Machines Major Developments in Metalworking over the Past Century Unit 1 Review Questions Unit 2: Careers in the Metalworking Industry Section 2: Machine Trade Opportunities Unit 2: Introduction New Technologies Technology Curriculums Technology Courses Modular Training System Apprenticeship Training Machine Operator Maintenance Machinist Machinist Types of Machine Shops Tool and Diemaker CNC Machine Operator/Programmer Technician Technologist Quality Control Inspector Instrument Makers Professions Trade Organizations AMT—The Association for Manufacturing Technology The Society of Manufacturing Engineers Unit 2 Review Questions Unit 3: Getting the Job Unit 3: Introduction Assess Your Abilities Explore Your Interests Writing a Résumé Facts About Interviews Arranging an Interview Questions Commonly Asked During an Interview The Interview After the Interview Points to Remember Unit 3 Review Questions Unit 4: Safety in the Machine Shop Section 3: Safety Unit 4: Introduction Safety on the Job Safety in the Shop Personal Grooming Housekeeping Safe Work Practices Fire Prevention Unit 4 Review Questions Unit 5: Engineering Drawings Section 4: Job Planning Unit 5: Introduction Types of Drawings and Lines Drafting Terms and Symbols Units of Measurement Manufacturing Methods Basic Dimensioning Dimensioning Tolerances Inch Dimensions Metric Dimensions Symbols Dimensioning Systems Workplace Communication Surface Symbols Unit 5 Review Questions Unit 6: Machining Procedures for Various Workpieces Unit 6: Introduction Machining Procedures for Round Work General Rules for Round Work Workpieces Requiring Center Holes Workpieces Held in a Chuck Machining External and Internal Diameters in a Chuck Machining Flat Workpieces Operations Sequence for a Sample Flat Part Unit 6 Review Questions Unit 7: Basic Measurement Section 5: Measurement ⊲⊲ Metric (Decimal) Systems ⊲⊲ The Changeover Period ⊲⊲ Inch/Metric Dimensioning Standards ⊲⊲ Symbols for Use with SI Unit 7: Introduction Inch System Metric System Fractional Measurement Steel Rules Metric Steel Rules Fractional Steel Rules Measuring Lengths The Rule as a Straightedge Outside Calipers Using Outside Calipers Inside Calipers Measuring an Inside Diameter Transferring Measurements Unit 7 Review Questions Unit 8: Squares and Surface Plates Unit 8: Introduction Machinist’s Combination Square Precision Squares Beveled-Edge Squares Toolmaker’s Surface Plate Square Cylindrical Squares Adjustable Squares Adjustable Micrometer Square Straightedges Surface Plates Care of Surface Plates Unit 8 Review Questions Unit 9: Micrometers Unit 9: Introduction Principle of the Inch Micrometer To Read a Standard Inch Micrometer Vernier Micrometer To Read a Vernier Micrometer Metric Micrometer To Read a Metric Micrometer Metric Vernier Micrometer To Read a Metric Vernier Micrometer Combination Inch–Metric Micrometer Micrometer Adjustments To Remove Play in the Micrometer Threads Testing the Accuracy of Micrometers To Adjust the Accuracy of a Micrometer Special-Purpose Micrometers Screw Thread Micrometers To Measure with a Thread Micrometer Unit 9 Review Questions Unit 10: Vernier Calipers Unit 10: Introduction Vernier Calipers Parts of the Vernier Caliper Measuring a Workpiece with a 25-Division Inch Vernier Caliper The 50-Division Inch Vernier Caliper The Metric Vernier Caliper To Read a Metric Vernier Caliper Direct-Reading Dial Caliper Unit 10 Review Questions Unit 11: Inside-, Depth-, and Height Measuring Instruments Unit 11: Introduction Inside-Measuring Instruments Direct-Reading Instruments Transfer-Type Instruments Depth Measurement Micrometer Depth Gage Vernier Depth Gage Height Measurement Vernier Height Gage Precision Height Gage Unit 11 Review Questions Unit 12: Gage Blocks Unit 12: Introduction Gage Block Manufacture Uses Gage Block Sets Inch Standard Gage Blocks Metric Gage Blocks Accuracy The Effect of Temperature Gage Block Buildups Unit 12 Review Questions Unit 13: Angular Measurement Unit 13: Introduction Universal Bevel Protractor To Read a Vernier Protractor Sine Bar Compound Sine Plate or Table Unit 13 Review Questions Unit 14: Gages Unit 14: Introduction Basic Terms Fixed Gages Cylindrical Plug Gages To Use a Cylindrical Plug Gage Plain Ring Gages Taper Plug Gages To Check an Internal Taper Using a Taper Plug Gage Taper Ring Gages Care of Plug and Ring Gages Thread Plug Gages Thread Ring Gages Snap Gages Using a Snap Gage to Check a Dimension Unit 14 Review Questions Unit 15: Comparison Measurement Unit 15: Introduction Comparators Dial Indicators To Measure with a Dial Test Indicator and Height Gage Mechanical and Electronic Comparators To Measure with a Mechanical Comparator Optical Comparators To Check the Angle of a 60° Thread Using an Optical Comparator Mechanical-Optical Comparators To Measure with a Reed Comparator Air Gages or Pneumatic Comparators Column-Type Air Gage Pressure-Type Air Gage Unit 15 Review Questions Unit 16: The Coordinate Measuring System Unit 16: Introduction Parts of the Measuring Unit Principle of the Moiré Fringe Operation of the Measuring Unit Advantages of the Coordinate Measuring System Unit 16 Review Questions Unit 17: Measuring with Light Waves Unit 17: Introduction Measuring with Optical Flats How to Interpret the Bands Measurement with Lasers The LaserMike Unit 17 Review Questions Unit 18: Surface Finish Measurement Unit 18: Introduction Surface Finish Definitions To Measure Surface Finish with a Surface Indicator Unit 18 Review Questions Unit 19: Basic Layout Materials, Tools, and Accessories Section 6: Layout Tools and Procedures Unit 19: Introduction Layout Solutions Layout Tables and Surface Plates Care of Surface Plates and Layout Tables Scribers Dividers and Trammels Hermaphrodite Calipers Squares The Combination Set Surface Gage Layout or Prick Punches and Center Punches Layout Accessories Unit 19 Review Questions Unit 20: Basic or Semiprecision Layout Unit 20: Introduction To Lay Out Hole Locations, Slots, and Radii To Lay Out a Casting Having a Cored Hole To Lay Out a Keyseat in a Shaft Unit 20 Review Questions Unit 21: Precision Layout Unit 21: Introduction The Vernier Height Gage To Make a Precision Layout Using a Vernier Height Gage To Make a Precision Layout Using a Sine Bar, Gage Blocks, and a Vernier Height Gage Unit 21 Review Questions Unit 22: Holding, Striking, and Assembling Tools Section 7: Hand Tools and Bench Work Unit 22: Introduction The Bench Vise Hammers Screwdrivers Care of a Screwdriver Regrinding a Standard Screwdriver Blade Wrenches Hints on Using Wrenches Pliers Hints on Using Pliers Unit 22 Review Questions Unit 23: Hand-Type Cutting Tools Unit 23: Introduction Sawing, Filing, and Scraping Hand Hacksaw To Use the Hand Hacksaw Files Degrees of Coarseness Machinist Files Filing Practice Draw Filing Polishing Special Files Precision Files Rotary Files and Burrs Using High-Speed Steel Rotary Files and Burrs Scrapers Unit 23 Review Questions Unit 24: Thread-Cutting Tools and Procedures Unit 24: Introduction Hand Taps Tap Drill Size Metric Taps Tap Drill Sizes for Metric Taps Tapping a Hole Removing Broken Taps Threading Dies To Thread with a Hand Die Unit 24 Review Questions Unit 25: Finishing Processes-Reaming, Broaching, and Lapping Unit 25: Introduction Hand Reamers Types of Hand Reamers Reaming Precautions To Ream a Hole with a Straight Hand Reamer Broaching Cutting a Keyway with a Broach Lapping Lapping Abrasives Types of Laps Unit 25 Review Questions Unit 26: Surface Finishing Processes Unit 26: Introduction Burnishing Electropolishing The Process Honing Types of Honing Processes Honing Stones Machine Requirements Honing Guidelines Tumbling Selecting the Equipment and Tumbling Media The Tumbling Process Black-Oxide Coatings Unit 26 Review Questions Unit 27: Physics of Metal Cutting Section 8: Metal-Cutting Technology Unit 27: Introduction Need for Metal-Cutting Research Metal-Cutting Terminology Plastic Flow of Metal Flat Punch Narrow-Faced Punch Knife-Edge Punch Chip Types Type 1—Discontinuous (Segmented) Chip Type 2—Continuous Chip Type 3—Continuous Chipwith a Built-Up Edge Unit 27 Review Questions Unit 28: Machinability of Metals Unit 28: Introduction Grain Structure Low-Carbon (Machine) Steel High-Carbon (Tool) Steel Alloy Steel Cast Iron Aluminum Copper The Effects of Temperature and Friction Friction Surface Finish Effects of Cutting Fluids Unit 28 Review Questions Unit 29: Cutting Tools Unit 29: Introduction Cutting-Tool Materials High-Speed Steel Cutting Tools Cast Alloy Cutting Tools Cemented-Carbide Cutting Tools Coated Carbide Cutting Tools Ceramic Cutting Tools Cermet Cutting Tools Diamond Cutting Tools Cubic Boron Nitride Cutting Tools Cutting-Tool Nomenclature Lathe Cutting Tools Angles and Clearances Positive Rake Angle Negative Rake Angle Cutting-Tool Shape Tool Life Principles of Machining Turning Planing Plain Milling End and Face Milling Drilling Unit 29 Review Questions Unit 30: Operating Conditionsand Tool Life Unit 30: Introduction Operating Conditions Depth of Cut, Feed Rate, and Cutting Speed Effects of Changing Operating Conditions General Operating Condition Rules Economic Performance Machining Cost Analysis Unit 30 Review Questions Unit 31: Carbide Cutting Tools Unit 31: Introduction Manufacture of Cemented Carbides Blending Compaction Presintering Sintering Cemented-Carbide Applications Types of Carbide Lathe Cutting Tools Cemented-Carbide Insert Identification Grades of Cemented Carbides Coated Carbide Inserts Tool Geometry Cutting-Tool Terms Cemented-Carbide Cutting-Tool Angles and Clearances Cutting Speeds and Feeds Machining with Carbide Tools Suggestions for Using Cemented-Carbide Cutting Tools Work Setup Tool Selection Tool Setup Machine Setup Cutting Operation Tool Selection and Application Guide Grinding Cemented-Carbide Tools Grinding Wheels Type of Grinder Tool Grinding Honing Cemented-Carbide Tool Problems Unit 31 Review Questions Unit 32: Diamond, Ceramic, and Cermet Cutting Tools Unit 32: Introduction Diamond Cutting Tools Manufactured Diamonds Advantages of Diamond Cutting Tools Use of Diamond Cutting Tools Cutting Speeds and Feeds Hints on the Use of Diamond Tools Ceramic Cutting Tools Manufacture of Ceramic Tools Ceramic Tool Applications Factors Affecting Ceramic Tool Performance Advantages and Disadvantages of Ceramic Tools Ceramic Tool Geometry Cutting Speeds Ceramic Tool Problems Grinding Ceramic Tools Cermet Cutting Tools Types of Cermet Tools Characteristics of Cermet Tools Advantages of Cermet Tools Use of Cermet Tools Unit 32 Review Questions Unit 33: Polycrystalline Cutting Tools Unit 33: Introduction Manufacture of Polycrystalline Cutting Tools Polycrystalline Cubic Boron Nitride (PCBN) Tools Properties of Polycrystalline Cubic Boron Nitride Types of PCBN Tools Types of Metal Cut Advantages of PCBN Cutting Tools Polycrystalline Diamond (PCD) Tools Types and Sizes of PCD Tools Properties of PCD Tools Advantages of PCD Tools Types of Material Cut Diamond-Coated Tools Unit 33 Review Questions Unit 34: Cutting Fluids-Types and Applications Unit 34: Introduction Heat Generated During Machining Characteristics of a Good Cutting Fluid Types of Cutting Fluids Cutting Oils Emulsifiable (Soluble) Oils Chemical Cutting Fluids Functions of a Cutting Fluid Cooling Lubrication Cutting-Tool Life Rust Control Rancidity Control Application of Cutting Fluids Lathe-Type Operations Drilling and Reaming Milling Grinding Unit 34 Review Questions Unit 35: Types of Metal Saws Section 9: Metal-Cutting Saws Unit 35: Introduction Methods of Cutting Off Material Horizontal Bandsaw Parts Saw Blades Installing a Blade Sawing Sawing Hints Unit 35 Review Questions Unit 36: Contour Bandsaw Parts and Accessories Unit 36: Introduction Contour Bandsaw Parts Base Column Head Bandsaw Applications Coolants Power Feed Bandsaw Blade Types and Applications Tooth Forms Pitch Set Width Gage Job Requirements Blade Length Unit 36 Review Questions Unit 37: Contour Bandsaw Operations Unit 37: Introduction Sawing External Sections To Mount a Saw Band To Cut an External Section Accuracy and Finish Sawing Internal Sections To Weld a Bandsaw Blade To Saw Internal Sections Trimming and Blanking Dies Friction Sawing High-Speed Sawing Band Filing To Set Up for Band Filing To File on a Contour Bandsaw Additional Band Tools Bandsaw Attachments Unit 37 Review Questions Unit 38: Drill Presses Section 10: Drilling Machines Unit 38: Introduction Standard Operations Principal Types of Drilling Machines Sensitive Drill Presses Upright Drilling Machine Radial Drilling Machine Unit 38 Review Questions Unit 39: Drilling Machine Accessories Unit 39: Introductin Tool-Holding Devices Drill Chucks Chucks Drill Sleeves and Sockets Work-Holding Devices Clamping Stresses Clamping Hints Unit 39 Review Questions Unit 40: Twist Drills Unit 40: Introduction Twist Drill Parts Shank Body Point Drill Point Characteristics Drill Point Angles and Clearances Systems of Drill Sizes Types of Drills Drilling Facts and Problems Drill Point Coatings Drill Grinding Causes of Drill Failure Web Thinning Unit 40 Review Questions Unit 41: Cutting Speeds and Feeds Unit 41: Introduction Cutting Speed Revolutions per Minute Feed Cutting Fluids Unit 41 Review Questions Unit 42: Drilling Holes Unit 42: Introduction Drill Press Safety Drilling Hints Measuring the Size of a Drill Lathe Center Holes Drilling Lathe Center Holes Spotting a Hole Location with a Center Drill Drilling Work Held in a Vise Drilling to an Accurate Layout Drilling Large Holes Drilling Round Work in a V-Block Unit 42 Review Questions Unit 43: Reaming Unit 43: Introduction Reamers Reamer Parts Types of Reamers Reamer Care Reaming Allowances Reaming Speeds and Feeds Speeds Feeds Reaming Hints Reaming a Straight Hole Hand Reaming a Straight Hole Machine Reaming a Straight Hole Reaming a Tapered Hole Unit 43 Review Questions Unit 44: Drill Press Operations Unit 44: Introduction Counterboring To Counterbore a Hole Countersinking To Countersink a Hole for a Machine Screw Tapping To Tap a Hole by Hand in a Drill Press Transferring Hole Locations To Spot with a Twist Drill To Use Transfer Punches To Use Transfer Screws Drill Jigs Unit 44 Review Questions Unit 45: Engine Lathe Parts Section 11: The Lathe Unit 45: Introduction Lathe Size and Capacity Parts of the Lathe Bed Headstock Quick-Change Gearbox Carriage Tailstock Setting Speeds on a Lathe Setting Feeds To Set the Feed for the Apron (Carriage Drive) Shear Pins and Slip Clutches Unit 45 Review Questions Unit 46: Lathe Accessories Unit 46: Introduction Work-Holding Devices Lathe Centers Chucks Lathe Dogs Cutting-Tool-Holding Devices Compound Rest Tooling Systems Modular, or Quick-Change, Tooling Unit 46 Review Questions Unit 47: Cutting Speed, Feed, and Depth of Cut Unit 47: Introduction Cutting Speed Inch Calculations Metric Calculations Lathe Feed Depth of Cut Graduated Micrometer Collars Hints on Graduated Collar Use Calculating Machining Time Unit 47 Review Questions Unit 48: Lathe Safety Unit 48: Introduction Safety Precautions Unit 48 Review Questions Unit 49: Mounting, Removing, and Aligning Lathe Centers Unit 49: Introductin To Mount Lathe Centers To Remove Lathe Centers Alignment of Lathe Centers To Align Centers by Adjusting the Tailstock To Align Centers by the Trial-Cut Method To Align Centers Using a Dial Indicator and Test Bar Unit 49 Review Questions Unit 50: Grinding Lathe Cutting Tools Unit 50: Introduction To Grind a General-Purpose Cutting Tool Unit 50 Review Questions Unit 51: Facing Between Centers Unit 51: Introduction To Set Up a Cutting Tool for Machining To Mount Work Between Centers Using a Revolving Tailstock Center Using a Dead Center Facing Between Centers To Face Work Between Centers Facing the Workpiece to an Accurate Length Unit 51 Review Questions Unit 52: Machining Between Centers Unit 52: Introduction Setting Up a Cutting Tool Mounting Work Between Centers Parallel Turning Setting an Accurate Depth of Cut Rough Turning Finish Turning Filing in a Lathe To File in a Lathe Polishing in a Lathe Turning to a Shoulder To Turn a Square Shoulder To Machine a Filleted Shoulder To Machine a Beveled (Angular) Shoulder Unit 52 Review Questions Unit 53: Knurling, Grooving, and Form Turning Unit 53: Introduction Knurling To Knurl in a Lathe Grooving To Cut a Groove Form Turning on a Lathe Turning a Freehand Form or Radius Form-Turning Tools Form Turning Using a Template and Follower Spherical Tool Hydraulic Tracer Attachment Unit 53 Review Questions Unit 54: Tapers and Taper Turning Unit 54: Introduction Self-Holding Tapers Steep Tapers Standard Tapers Lathe Spindle Nose Tapers Taper Calculations To Calculate the tpf To Calculate the Tailstock Offset Inch Taper Attachment Offset Calculations Metric Tapers Metric Tailstock Offset Calculations Metric Taper Attachment Offset Calculations Taper Turning Tailstock Offset Method Taper Turning Using the Compound Rest Checking a Taper To Fit an External Taper To Check a Metric Taper Unit 54 Review Questions Unit 55: Threads and Thread Cutting Unit 55: Introduction Threads Thread Terminology Thread Forms Thread Fits and Classifications Thread Calculations Thread-Chasing Dial Thread Cutting To Set Up a Lathe for Threading (60° Thread) Thread-Cutting Operation Thread Measurement Multiple Threads Square Threads Acme Thread Internal Threading Unit 55 Review Questions Unit 56: Steady Rests, Follower Rests, and Mandrels Unit 56: Introduction Steady Rest To Set Up a Steady Rest To True a Damaged Center Hole Follower Rest To Set Up a Follower Rest Mandrel Characteristics of a Standard Mandrel Types of Mandrels To Mount Work on a Plain Mandrel To Turn Work on a Mandrel Eccentrics To Turn an Eccentric With a .375-in. or 10-mm Throw To Cut an Eccentric With a Small Throw To Turn an Eccentric With a Large Throw Unit 56 Review Questions Unit 57: Machining in a Chuck Unit 57: Introduction Mounting and Removing Lathe Chucks To Mount a Chuck To Remove a Chuck Mounting Work in a Chuck To Mount Work in a Three-Jaw Chuck Assembling Jaws in a Three-Jaw Universal Chuck To Mount Work in a Four-Jaw Chuck To True Work in a Four-Jaw Chuck Using a Dial Indicator To Face Work Held in a Chuck To Rough- and Finish-Turn Work in a Chuck Rough and Finish Turning Turning Hardened Steel with PCBN Tools Guidelines for PCBN Turning Turning the Part Cutting Off Work in a Chuck Unit 57 Review Questions Unit 58: Drilling, Boring, Reaming, and Tapping Unit 58: Introduction To Spot and Drill Work in a Chuck Boring To Bore Work in a Chuck Reaming To Ream Work in a Lathe Tapping To Tap a Hole in a Lathe Grinding on a Lathe To Grind a Lathe Center Unit 58 Review Questions Unit 59: The Vertical Milling Machine Section 12: Milling Machines Unit 59: Introduction Types of Vertical Milling Machines Heavy-Duty Vertical Milling Machine Parts of the Ram-Type Vertical Mill Unit 59 Review Questions Unit 60: Cutting Speed, Feed, and Depth of Cut Unit 60: Introduction Cutting Speed Inch Calculations Metric Calculations Milling Feed and Depth of Cut Feed Depth of Cut Unit 60 Review Questions Unit 61: End Mills Unit 61: Introduction High-Speed End Mills Coated End Mills Carbide End Mills Machining Operations End Mill Forms Types of End Mills Direction of Cut Milling Cutter Failure Excessive Heat Abrasion Chipping or Crumbling of Cutting Edges Clogging Built-Up Edges Work Hardening of the Workpiece Cratering Unit 61 Review Questions Unit 62: Vertical Mill Operations Unit 62: Introduction Aligning the Vertical Head Aligning the Vise Mounting and Removing Cutters To Mount a Cutter in a Spring Collet To Remove a Cutter from a Collet To Mount a Cutter in a Solid Collet To Machine a Flat Surface Machining a Block Square and Parallel Machining Side 1 Machining Side 2 Machining Side 3 Machining Side 4 Machining the Ends Square Procedure for Short Work To Machine an Angular Surface Milling Hardened Steel with PCBN Tools Machine Setup Producing and Finishing Holes To Drill Holes at 90° to the Work Surface To Drill Angular Holes To Ream on a Vertical Mill To Bore on a Vertical Mill To Tap a Hole on the Vertical Mill Cutting Slots and Keyseats Calculating the Depth of Keyseats Woodruff Keys Unit 62 Review Questions Unit 63: Special Milling Operations Unit 63: Introduction The Rotary Table Rotary Table Construction Radius Milling Milling a T-Slot Milling Dovetails Jig Boring on a Vertical Milling Machine To Position the Milling Machine Table Using Measuring Rods Digital Readout Boxes Vernier Scale Vertical Milling Machine Attachments Die Sinking Unit 63 Review Questions Unit 64: Horizontal Milling Machines and Accessories Unit 64: Introduction Horizontal Milling Machines Manufacturing-Type Milling Machines Special-Type Milling Machines Machining Centers Knee-and-Column-Type Milling Machines Parts of the Milling Machine Backlash Eliminator Milling Machine Accessories Fixtures Attachments Unit 64 Review Questions Unit 65: Milling Cutters Unit 65: Introduction Milling Cutter Materials Plain Milling Cutters Standard Shank-Type Helical Milling Cutters Side Milling Cutters Face Milling Cutters Angular Cutters Formed Cutters Metal-Slitting Saws End Mills T-Slot Cutter Dovetail Cutter Woodruff Keyseat Cutter Flycutters Unit 65 Review Questions Unit 66: Milling Machine Setups Unit 66: Introduction Milling Machine Safety Milling Machine Setups Milling Hints Mounting and Removing a Milling Machine Arbor The Arbor Assembly To Mount an Arbor To Remove an Arbor Mounting and Removing Milling Cutters To Mount a Milling Cutter To Remove a Milling Cutter Aligning the Table on a Universal Milling Machine Aligning the Milling Machine Vise To Align the Vise Parallel to the Table Travel Unit 66 Review Questions Unit 67: Horizontal Milling Operations Unit 67: Introduction Setting the Cutter to the Work Surface To Set the Cutter to the Work Surface Milling a Flat Surface Face Milling Side Milling Centering a Cutter to Mill a Slot Straddle Milling Gang Milling Sawing and Slitting Unit 67 Review Questions Unit 68: The Indexing, or Dividing, Head Unit 68: Introduction Index Head Parts Methods of Indexing Direct Indexing Simple Indexing Angular Indexing Differential Indexing The Wide-Range Dividing Head Indexing for Divisions Angular Indexing with the Wide-Range Divider Linear Graduating Unit 68 Review Questions Unit 69: Helical Milling Unit 69: Introduction Helical Terms Cutting a Helix Determining the Helix Angle Determining the Direction to Swing the Table Calculating the Change Gears to Produce the Required Lead Inch Calculations Metric Calculations Direction of Spindle Rotation Cutting Short Lead Helices Unit 69 Review Questions Unit 70: Cam, Rack, Worm, and Clutch Milling Unit 70: Introduction Cams and Cam Milling Cams Used to Impart Motion Cam Motions Radial Cam Terms Cam Milling Rack Milling Rack Indexing Attachment Worms and Worm Gears To Mill a Worm Clutches To Machine a Straight-Tooth Clutch Having Three Teeth To Machine a Straight-Tooth Clutch Having Four Teeth Unit 70 Review Questions Unit 71: Types of Abrasives Section 13: Grinding Unit 71: Introduction Aluminum Oxide Manufacture of Aluminum Oxide Silicon Carbide Manufacture of Silicon Carbide Zirconia-Aluminum Oxide Boron Carbide Manufacture of Boron Carbide Cubic Boron Nitride Manufactured Diamonds Diamond Types Ceramic Aluminum Oxide SG and CBN Abrasives Abrasive Products Grinding Wheels Abrasive Grain Bond Types Grade Structure Grinding Wheel Manufacture Standard Grinding Wheel Shapes Mounted Grinding Wheels Grinding Wheel Markings Selecting a Grinding Wheel for a Specific Job Handling and Storage of Grinding Wheels Wheel Grade Faults Soft Wheel Characteristics Hard Wheel Characteristics Inspection of Wheels Diamond Wheels Bonds Diamond Wheel Identification Cubic Boron Nitride Wheels Properties of Cubic Boron Nitride (CBN) Wheels Wheel Selection Coated Abrasives Selection of Coated Abrasives Coated Abrasive Machining Unit 71 Review Questions Unit 72: Surface Grinders and Accessories Unit 72: Introduction The Grinding Process Surface Grinding Types of Surface Grinders Grinding Wheel Care Mounting a Grinding Wheel Balancing a Grinding Wheel Grinder Safety Truing and Dressing a Grinding Wheel Work-Holding Devices Magnetic Chuck Permanent Magnetic Chuck Construction Magnetic Chuck Accessories Grinding Fluids Types of Grinding Fluids Methods of Applying Coolants Surface Finish Unit 72 Review Questions Unit 73: Surface Grinding Operations Unit 73: Introduction Mounting the Workpiece for Grinding Flat Work or Plates Thin Workpieces Short Workpieces Grinder Safety Grinding Operations To Grind a Flat (Horizontal) Surface To Grind the Edges of a Workpiece Setting Up the Workpiece Grinding a Flat Surface with a CBN Wheel Conditioning CBN Wheels Truing a CBN Wheel Dressing a CBN Wheel Grinding a Flat Surface To Grind a Vertical Surface To Grind an Angular Surface Form Grinding To Dress a Convex Radius On a Grinding Wheel Special Forms Creep Feed Grinding Grinding Wheels Advantages of Creep Feed Grinding Cutting-Off Operations Unit 73 Review Questions Unit 74: Cylindrical Grinders Unit 74: Introduction Center-Type Cylindrical Grinders Parts of the Universal Cylindrical Grinder Machine Preparation for Grinding Mounting the Wheel To Grind a Tapered Workpiece Plunge Grinding Internal Grinders Internal Grinding on a Universal Cylindrical Grinder To Grind a Tapered Hole Centerless Grinders Methods of Centerless Grinding Thru-Feed Centerless Grinding Infeed Centerless Grinding Endfeed Centerless Grinding Advantages of Centerless Grinding Unit 74 Review Questions Unit 75: Universal Tool and Cutter Grinder Unit 75: Introduction Parts of the Universal Tool and Cutter Grinder Accessories and Attachments Milling Cutter Nomenclature Cutter Clearance Angles Methods of Grinding Clearance on Cutters Clearance Grinding Hollow Grinding Circle Grinding Methods of Checking Cutter Clearance Angles To Check Cutter Clearance with a Dial Indicator To Check Cutter Clearance with a Brown & Sharpe Clearance Gage Checking the Cutter Clearance with a Starrett Cutter Clearance Gage Cutter Grinding Operations and Setups To Grind a Plain Helical Milling Cutter To Grind a Staggered Tooth Cutter To Grind a Form-Relieved Cutter Cylindrical Grinding Internal Grinding Unit 75 Review Questions Unit 76: Manufacture and Properties of Steel Section 14: Metallurgy Unit 76: Introduction Physical Properties of Metals Manufacture of Ferrous Metals Pig Iron Manufacture of Pig Iron Direct Ironmaking Manufacture of Cast Iron Manufacture of Steel Direct Steelmaking Steel Processing Strand, or Continuous, Casting Vacuum Processing of Molten Steel Minimills The Minimill Process HIsarna Steelmaking Process Chemical Composition of Steel Classification of Steel Plain Carbon Steels Alloy Steels Unit 76 Review Questions Unit 77: Heat Treatment of Steel Unit 77: Introduction Heat-Treating Equipment Types of Furnaces Heat-Treatment Terms Selection of Tool Steel Water-Hardening Tool Steels Oil-Hardening Steels Air-Hardening Steels High-Speed Steels Classification of Steel SAE-AISI Classification Systems Heat Treatment of Carbon Steel To Determine the Critical Points of 0.83% Carbon Steel Observations and Conclusions Hardening of 0.83% Carbon Steel Quenching Metcalf’s Experiment Tempering Annealing Normalizing Spheroidizing Case-Hardening Methods Carburizing Carbonitriding Processes Nitriding Processes Surface Hardening of Medium-Carbon Steels Induction Hardening Flame Hardening Unit 77 Review Questions Unit 78: Testing of Metals and Nonferrous Metals Unit 78: Introduction Hardness Testing Rockwell Hardness Tester Brinell Hardness Tester Scleroscope Hardness Tester Destructive Testing Tensile Testing (Inch Equipment) To Determine the Tensile Strength of Steel Tensile Testing (Metric Equipment) Impact Tests Nondestructive Testing Scrap Metal Recycling Nonferrous Metals and Alloys Aluminum Copper Lead Magnesium Nickel Tin Zinc Bearing Metals Unit 78 Review Questions Unit 79: Cellular Manufacturing Section 15: Lean Manufacturing ⊲⊲ Lean Manufacturing ⊲⊲ Lean—Its Amazing Benefits ⊲⊲ Where Does Change Start? ⊲⊲ Lean Leadership ⊲⊲ Lean—Change or Perish Unit 79: Introduction Cellular Manufacturing One-Piece Flow Cellular Manufacturing Development Advantages of Cellular Manufacturing Production on Demand Productivity and Performance Improvement Teamwork Types of Cells Benefits of Cells Unit 79 Review Questions Unit 80: Continuous Improvement Unit 80: Introduction Introduction The Basic Principles of Kaizen The Reasons for Kaizen Kaizen’s Benefits Kaizen Events Keeping Everyone Aware The Four Stages of a Kaizen Event Choosing an Area for Improvement Unit 80 Review Questions Unit 81: Pull (Kanban) Systems Unit 81: Introduction Pull versus Push Production Pull Production Defined Pull Production Prerequisites How Inventory Accumulates Flow Requirements Kanban Card Information Advantages Unit 81 Review Questions Unit 82: Total Productive Maintenance Unit 82: Introduction Maintenance Types TPM Objectives Breakdowns Causes of Breakdowns Preparatory Stage The Value of Trained Personnel Train the Employees Clean the Equipment General Inspection The Future of Maintenance Unit 82 Review Questions Unit 83: Value-Stream Mapping Unit 83: Introduction Value-Stream Basics VSM as a Planning Tool Stairway to Success Waste Identification Four Stages in Value-Stream Mapping Stage 1: Product Development Stage 2: Process Design Stage 3: Preparation Stage 4: Planning Value-Stream Management The Purpose of Value-Stream Management Make the Commitment Sincere Map the Current State Mapping the Future State Beginning the Future-State Map Unit 83 Review Questions Unit 84: Workplace Organization Unit 84: Introduction Using the 5S System Creating Ideas From Ideas to Success Small Changes = Big Improvements Ergonomics Company Focus The Importance of Customer Care Points for Keeping Customers Unit 84 Review Questions Unit 85: The Computer Section 16: Computer-Age Machining Unit 85: Introduction History of the Computer The Role of the Computer Unit 85 Review Questions Unit 86: Computer Numerical Control Unit 86: Introduction Theory of CNC Role of a Computer in CNC Types of Computers Computer Functions CNC Performance Accuracy Reliability Repeatability Productivity Advantages of CNC Cartesian Coordinates Guidelines Machine Axes Machines Using CNC Programming Systems Incremental System Absolute System CNC Positioning Systems Point-to-Point Positioning Continuous-Path (Contouring) Control Systems Open Loop System Closed Loop System Input Media Types of Computer Control Computer Numerical Control Direct Numerical Control Programming Format Word Address Format Codes Block of Information Interpolation Linear Interpolation Circular Interpolation Program Planning Machining Procedures Tool List Manuscript Unit 86 Review Questions Unit 87: CNC Turning Center Unit 87: Introduction Types of Turning Centers CNC Chucking Center CNC Turning Center Combination Turning/Milling Center Programming Considerations Tooling Systems and Cutting Tools Diameter Versus Radius Programming Establish Part Zero Codes Programming Procedures Bench-Top Teaching Machines Standard-Size Turning Center Turning Center Setup Program Test Run Unit 87 Review Questions Unit 88: CNC Machining Centers Unit 88: Introduction Types of Machining Centers Horizontal Machining Center Vertical Machining Center Universal Machining Center Main Operative Parts Machining Center Accessories Adaptive Control Automatic Tool Changers Tools and Toolholders Combination Tools Toolholders Programming Procedures Bench-Top Teaching Machines Machining Center Setup Setting Part Zero Setting Tool Length Offset Program Test Run Standard-Size Machining Center Unit 88 Review Questions Unit 89: CAD/CAM Unit 89: Introduction The CAD Side of CAD/CAM CAD Development Systems Presently in Use Solids Solid Modeling and CAD/CAM How CAD/CAM Works Geometry Input Cadworthy Versus Camworthy Geometry Defining Where the Cut Takes Place How the Cut Takes Place Viewing and Verifying the Toolpath Converting the Toolpath toG- and M-Codes Downloading the Program to the Machine Setting Up the Machine Running the Part Toolpaths and Functions Toolpaths functions Unit 89 Review Questions Unit 90: Nanotechnology Section 17: Advanced Manufacturing Technology Unit 90: Introduction Micro-Nano Technology Nanotechnology in the Manufacturing Industry Nanorobots Nanomanufacturing Methods Approaches to Nanomanufacturing Automotive and Aerospace Nanotechnology in the Future Nanotechnology Health/Safety/Environment The Guidelines Investments in Nanotechnology Unit 90 Review Questions Unit 91: Cryogenic Treatment/Tempering Unit 91: Introduction Technical Data Cold Treatment Versus Cryogenics Cold Treatment Cryogenics Stress Relief Depth of Cryogenic Stress Relieving Carbide Increase Wear Resistance Metallurgy Changes kinetics of cryogenic treatment Advantages of Cryogenic Tempering Unit 91 Review Questions Unit 92: Diamond Coating Unit 92: Introduction Diamond Tool Development Manufactured Industrial Diamond Diamond Deposition Diamond Characteristics Previous Limitations A Diamond Coating Breakthrough Diamond Coating Diamond Thickness Types Of Diamond Coated Tooling Field Tests Benefits of Diamond Diamondlike Carbon Looking Ahead Cutting-Tool Technology Diamond Coating Technology Unit 92 Review Questions Unit 93: Additive Manufacturing Technologies Unit 93: Introduction Additive Manufacturing—Definition Additive vs. Subtractive Manufacturing Seven Primary 3D Printing Technologies Additive Manufacturing Process Chain 1. CAD 2. Build Setup 3. Slicing and Machine Control 4. Build 5. Removal 6. Post-Processing Additive Metal Processes Powder Bed Fusion with Metal Powder Directed Energy Deposition Binder Jetting—Metal Hybrid Systems New Emerging Technologies METAL MATERIALS-FEED STOCK Accuracy Surface Finish Metallurgy Post-Processing of Additive Metal Parts Unit 93 Review Questions Unit 94: Multi-Tasking Machines Unit 94: Introduction Cyber Management System Multi-Tasking Machining Defined Purpose of Multi-Tasking Machines Types of Multi-Tasking Machines Accessories Unit 94 Review Questions Unit 95: Industry 4.0 Unit 95: Introduction Industry 4.0 Internetworking Standard Connecting Machine Tools IoT IIoT Machine Tools as Smart Partners MT Connect® Theory of Constraints Ethernet Connectivity RFID Technology Cyber Security Summary Unit 95 Review Questions Unit 96: Optical/Laser/Vision Measurement Unit 96: Introduction Measurement: Contact or Noncontact Optical Comparators Laser Measurement Laser-Tool Measurement Laser Scan Micrometer Laser Scan Microscope Laser Surface-Finish Measurement Scanning Probes Reverse Engineering Video Measuring System Video Microscope Video Magnifiers Coordinate Measuring Machine Three Types of CMM Probes Scanning CMMs Inspection for the Future Unit 96 Review Questions Unit 97: Electrical Discharge Machining Unit 97: Introduction Use of EDM Principle of EDM Types of EDM Circuits The Electrode GRAPHITE VS COPPER The EDM Process Servo Mechanism Cutting Current (Amperage) The Discharge Process Dielectric Fluid Metal-Removal Rates Electrode (Tool) Wear Overcut Surface Finish Advantages of EDM Limitations of EDM Wire-Cut EDM Machine The Process Operating Systems EDM Micromachining Unit 97 Review Questions Unit 98: Robotics Unit 98: Introduction Robot Requirements Application Flexibility Robot Types Parts of a Robot Types of Sensors Vision-Based Robotics Intelligent Vision for Robots Vision System Development Artificial Intelligence Next-Generation Manufacturing Intelligent Vision Robotics and Vision Working Together Benefits of Next-Generation Systems COLLABORATIVE ROBOTS (Cobots) Advantages of Robots Preventive Maintenance Safety Precautio Unit 98 Review Questions Unit 99: Manufacturing Intelligence Unit 99: Introduction Manufacturing Intelligence Factors Information Sources Turning Data Into Knowledge Decreasing Downtime Protecting Manufacturing Investments Intelligent Manufacturing Systems Unit 99 Review Questions Glossary Section 18 Glossary Appendix of tables Appendix of Tables Index Index
Summary: "Today's modern machine shops and tool and die shops are now environmentally controlled with dedicated me-trology labs for quality control and inspection. They have integrated the use of more computer numerical control (CNC) machine tools, but they have still retained the ability to use conventional machines. A modern jobbing shop today will still have conventional machines such as mills, lathes, assorted drill presses, saws, and some of the pre-cision equipment used prior to CNC (such as surface grinders, jig borers, and cylindrical and tool and cutter grinders)"-- Provided by publisher.
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BOOK BOOK COLLEGE LIBRARY
COLLEGE LIBRARY
SUBJECT REFERENCE 		621.902 K8641 2024 (Browse shelf) Available CITU-CL-54184
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Includes index.

Contents
Preface
about the authors
New to the Ninth Edition of Technology of Machine Tools
acknowledgments
Connect
Unit 1: History of Machines
Section 1: Introduction to Machine Tools
Unit 1: Introduction
Common Machine Tools
Standard Machine Tools
Drill Press
Engine Lathe
Metal Saw
Milling Machine
Grinder
Special Machine Tools
Computer Numerical Control Machines
Major Developments in Metalworking over the Past Century
Unit 1 Review Questions
Unit 2: Careers in the Metalworking Industry
Section 2: Machine Trade Opportunities
Unit 2: Introduction
New Technologies
Technology Curriculums
Technology Courses
Modular Training System
Apprenticeship Training
Machine Operator
Maintenance Machinist
Machinist
Types of Machine Shops
Tool and Diemaker
CNC Machine Operator/Programmer
Technician
Technologist
Quality Control Inspector
Instrument Makers
Professions
Trade Organizations
AMT—The Association for Manufacturing Technology
The Society of Manufacturing Engineers
Unit 2 Review Questions
Unit 3: Getting the Job
Unit 3: Introduction
Assess Your Abilities
Explore Your Interests
Writing a Résumé
Facts About Interviews
Arranging an Interview
Questions Commonly Asked During an Interview
The Interview
After the Interview
Points to Remember
Unit 3 Review Questions
Unit 4: Safety in the Machine Shop
Section 3: Safety
Unit 4: Introduction
Safety on the Job
Safety in the Shop
Personal Grooming
Housekeeping
Safe Work Practices
Fire Prevention
Unit 4 Review Questions
Unit 5: Engineering Drawings
Section 4: Job Planning
Unit 5: Introduction
Types of Drawings and Lines
Drafting Terms and Symbols
Units of Measurement
Manufacturing Methods
Basic Dimensioning
Dimensioning Tolerances
Inch Dimensions
Metric Dimensions
Symbols
Dimensioning Systems
Workplace Communication
Surface Symbols
Unit 5 Review Questions
Unit 6: Machining Procedures for Various Workpieces
Unit 6: Introduction
Machining Procedures for Round Work
General Rules for Round Work
Workpieces Requiring Center Holes
Workpieces Held in a Chuck
Machining External and Internal Diameters in a Chuck
Machining Flat Workpieces
Operations Sequence for a Sample Flat Part
Unit 6 Review Questions
Unit 7: Basic Measurement
Section 5: Measurement
⊲⊲ Metric (Decimal) Systems
⊲⊲ The Changeover Period
⊲⊲ Inch/Metric Dimensioning Standards
⊲⊲ Symbols for Use with SI
Unit 7: Introduction
Inch System
Metric System
Fractional Measurement
Steel Rules
Metric Steel Rules
Fractional Steel Rules
Measuring Lengths
The Rule as a Straightedge
Outside Calipers
Using Outside Calipers
Inside Calipers
Measuring an Inside Diameter
Transferring Measurements
Unit 7 Review Questions
Unit 8: Squares and Surface Plates
Unit 8: Introduction
Machinist’s Combination Square
Precision Squares
Beveled-Edge Squares
Toolmaker’s Surface Plate Square
Cylindrical Squares
Adjustable Squares
Adjustable Micrometer Square
Straightedges
Surface Plates
Care of Surface Plates
Unit 8 Review Questions
Unit 9: Micrometers
Unit 9: Introduction
Principle of the Inch Micrometer
To Read a Standard Inch Micrometer
Vernier Micrometer
To Read a Vernier Micrometer
Metric Micrometer
To Read a Metric Micrometer
Metric Vernier Micrometer
To Read a Metric Vernier Micrometer
Combination Inch–Metric Micrometer
Micrometer Adjustments
To Remove Play in the Micrometer Threads
Testing the Accuracy of Micrometers
To Adjust the Accuracy of a Micrometer
Special-Purpose Micrometers
Screw Thread Micrometers
To Measure with a Thread Micrometer
Unit 9 Review Questions
Unit 10: Vernier Calipers
Unit 10: Introduction
Vernier Calipers
Parts of the Vernier Caliper
Measuring a Workpiece with a 25-Division Inch Vernier Caliper
The 50-Division Inch Vernier Caliper
The Metric Vernier Caliper
To Read a Metric Vernier Caliper
Direct-Reading Dial Caliper
Unit 10 Review Questions
Unit 11: Inside-, Depth-, and Height Measuring Instruments
Unit 11: Introduction
Inside-Measuring Instruments
Direct-Reading Instruments
Transfer-Type Instruments
Depth Measurement
Micrometer Depth Gage
Vernier Depth Gage
Height Measurement
Vernier Height Gage
Precision Height Gage
Unit 11 Review Questions
Unit 12: Gage Blocks
Unit 12: Introduction
Gage Block Manufacture
Uses
Gage Block Sets
Inch Standard Gage Blocks
Metric Gage Blocks
Accuracy
The Effect of Temperature
Gage Block Buildups
Unit 12 Review Questions
Unit 13: Angular Measurement
Unit 13: Introduction
Universal Bevel Protractor
To Read a Vernier Protractor
Sine Bar
Compound Sine Plate or Table
Unit 13 Review Questions
Unit 14: Gages
Unit 14: Introduction
Basic Terms
Fixed Gages
Cylindrical Plug Gages
To Use a Cylindrical Plug Gage
Plain Ring Gages
Taper Plug Gages
To Check an Internal Taper Using a Taper Plug Gage
Taper Ring Gages
Care of Plug and Ring Gages
Thread Plug Gages
Thread Ring Gages
Snap Gages
Using a Snap Gage to Check a Dimension
Unit 14 Review Questions
Unit 15: Comparison Measurement
Unit 15: Introduction
Comparators
Dial Indicators
To Measure with a Dial Test Indicator and Height Gage
Mechanical and Electronic Comparators
To Measure with a Mechanical Comparator
Optical Comparators
To Check the Angle of a 60° Thread Using an Optical Comparator
Mechanical-Optical Comparators
To Measure with a Reed Comparator
Air Gages or Pneumatic Comparators
Column-Type Air Gage
Pressure-Type Air Gage
Unit 15 Review Questions
Unit 16: The Coordinate Measuring System
Unit 16: Introduction
Parts of the Measuring Unit
Principle of the Moiré Fringe
Operation of the Measuring Unit
Advantages of the Coordinate Measuring System
Unit 16 Review Questions
Unit 17: Measuring with Light Waves
Unit 17: Introduction
Measuring with Optical Flats
How to Interpret the Bands
Measurement with Lasers
The LaserMike
Unit 17 Review Questions
Unit 18: Surface Finish Measurement
Unit 18: Introduction
Surface Finish Definitions
To Measure Surface Finish with a Surface Indicator
Unit 18 Review Questions
Unit 19: Basic Layout Materials, Tools, and Accessories
Section 6: Layout Tools and Procedures
Unit 19: Introduction
Layout Solutions
Layout Tables and Surface Plates
Care of Surface Plates and Layout Tables
Scribers
Dividers and Trammels
Hermaphrodite Calipers
Squares
The Combination Set
Surface Gage
Layout or Prick Punches and Center Punches
Layout Accessories
Unit 19 Review Questions
Unit 20: Basic or Semiprecision Layout
Unit 20: Introduction
To Lay Out Hole Locations, Slots, and Radii
To Lay Out a Casting Having a Cored Hole
To Lay Out a Keyseat in a Shaft
Unit 20 Review Questions
Unit 21: Precision Layout
Unit 21: Introduction
The Vernier Height Gage
To Make a Precision Layout Using a Vernier Height Gage
To Make a Precision Layout Using a Sine Bar, Gage Blocks, and a Vernier Height Gage
Unit 21 Review Questions
Unit 22: Holding, Striking, and Assembling Tools
Section 7: Hand Tools and Bench Work
Unit 22: Introduction
The Bench Vise
Hammers
Screwdrivers
Care of a Screwdriver
Regrinding a Standard Screwdriver Blade
Wrenches
Hints on Using Wrenches
Pliers
Hints on Using Pliers
Unit 22 Review Questions
Unit 23: Hand-Type Cutting Tools
Unit 23: Introduction
Sawing, Filing, and Scraping
Hand Hacksaw
To Use the Hand Hacksaw
Files
Degrees of Coarseness
Machinist Files
Filing Practice
Draw Filing
Polishing
Special Files
Precision Files
Rotary Files and Burrs
Using High-Speed Steel Rotary Files and Burrs
Scrapers
Unit 23 Review Questions
Unit 24: Thread-Cutting Tools and Procedures
Unit 24: Introduction
Hand Taps
Tap Drill Size
Metric Taps
Tap Drill Sizes for Metric Taps
Tapping a Hole
Removing Broken Taps
Threading Dies
To Thread with a Hand Die
Unit 24 Review Questions
Unit 25: Finishing Processes-Reaming, Broaching, and Lapping
Unit 25: Introduction
Hand Reamers
Types of Hand Reamers
Reaming Precautions
To Ream a Hole with a Straight Hand Reamer
Broaching
Cutting a Keyway with a Broach
Lapping
Lapping Abrasives
Types of Laps
Unit 25 Review Questions
Unit 26: Surface Finishing Processes
Unit 26: Introduction
Burnishing
Electropolishing
The Process
Honing
Types of Honing Processes
Honing Stones
Machine Requirements
Honing Guidelines
Tumbling
Selecting the Equipment and Tumbling Media
The Tumbling Process
Black-Oxide Coatings
Unit 26 Review Questions
Unit 27: Physics of Metal Cutting
Section 8: Metal-Cutting Technology
Unit 27: Introduction
Need for Metal-Cutting Research
Metal-Cutting Terminology
Plastic Flow of Metal
Flat Punch
Narrow-Faced Punch
Knife-Edge Punch
Chip Types
Type 1—Discontinuous (Segmented) Chip
Type 2—Continuous Chip
Type 3—Continuous Chipwith a Built-Up Edge
Unit 27 Review Questions
Unit 28: Machinability of Metals
Unit 28: Introduction
Grain Structure
Low-Carbon (Machine) Steel
High-Carbon (Tool) Steel
Alloy Steel
Cast Iron
Aluminum
Copper
The Effects of Temperature and Friction
Friction
Surface Finish
Effects of Cutting Fluids
Unit 28 Review Questions
Unit 29: Cutting Tools
Unit 29: Introduction
Cutting-Tool Materials
High-Speed Steel Cutting Tools
Cast Alloy Cutting Tools
Cemented-Carbide Cutting Tools
Coated Carbide Cutting Tools
Ceramic Cutting Tools
Cermet Cutting Tools
Diamond Cutting Tools
Cubic Boron Nitride Cutting Tools
Cutting-Tool Nomenclature
Lathe Cutting Tools Angles and Clearances
Positive Rake Angle
Negative Rake Angle
Cutting-Tool Shape
Tool Life
Principles of Machining
Turning
Planing
Plain Milling
End and Face Milling
Drilling
Unit 29 Review Questions
Unit 30: Operating Conditionsand Tool Life
Unit 30: Introduction
Operating Conditions
Depth of Cut, Feed Rate, and Cutting Speed
Effects of Changing Operating Conditions
General Operating Condition Rules
Economic Performance
Machining Cost Analysis
Unit 30 Review Questions
Unit 31: Carbide Cutting Tools
Unit 31: Introduction
Manufacture of Cemented Carbides
Blending
Compaction
Presintering
Sintering
Cemented-Carbide Applications
Types of Carbide Lathe Cutting Tools
Cemented-Carbide Insert Identification
Grades of Cemented Carbides
Coated Carbide Inserts
Tool Geometry
Cutting-Tool Terms
Cemented-Carbide Cutting-Tool Angles and Clearances
Cutting Speeds and Feeds
Machining with Carbide Tools
Suggestions for Using Cemented-Carbide Cutting Tools
Work Setup
Tool Selection
Tool Setup
Machine Setup
Cutting Operation
Tool Selection and Application Guide
Grinding Cemented-Carbide Tools
Grinding Wheels
Type of Grinder
Tool Grinding
Honing
Cemented-Carbide Tool Problems
Unit 31 Review Questions
Unit 32: Diamond, Ceramic, and Cermet Cutting Tools
Unit 32: Introduction
Diamond Cutting Tools
Manufactured Diamonds
Advantages of Diamond Cutting Tools
Use of Diamond Cutting Tools
Cutting Speeds and Feeds
Hints on the Use of Diamond Tools
Ceramic Cutting Tools
Manufacture of Ceramic Tools
Ceramic Tool Applications
Factors Affecting Ceramic Tool Performance
Advantages and Disadvantages of Ceramic Tools
Ceramic Tool Geometry
Cutting Speeds
Ceramic Tool Problems
Grinding Ceramic Tools
Cermet Cutting Tools
Types of Cermet Tools
Characteristics of Cermet Tools
Advantages of Cermet Tools
Use of Cermet Tools
Unit 32 Review Questions
Unit 33: Polycrystalline Cutting Tools
Unit 33: Introduction
Manufacture of Polycrystalline Cutting Tools
Polycrystalline Cubic Boron Nitride (PCBN) Tools
Properties of Polycrystalline Cubic Boron Nitride
Types of PCBN Tools
Types of Metal Cut
Advantages of PCBN Cutting Tools
Polycrystalline Diamond (PCD) Tools
Types and Sizes of PCD Tools
Properties of PCD Tools
Advantages of PCD Tools
Types of Material Cut
Diamond-Coated Tools
Unit 33 Review Questions
Unit 34: Cutting Fluids-Types and Applications
Unit 34: Introduction
Heat Generated During Machining
Characteristics of a Good Cutting Fluid
Types of Cutting Fluids
Cutting Oils
Emulsifiable (Soluble) Oils
Chemical Cutting Fluids
Functions of a Cutting Fluid
Cooling
Lubrication
Cutting-Tool Life
Rust Control
Rancidity Control
Application of Cutting Fluids
Lathe-Type Operations
Drilling and Reaming
Milling
Grinding
Unit 34 Review Questions
Unit 35: Types of Metal Saws
Section 9: Metal-Cutting Saws
Unit 35: Introduction
Methods of Cutting Off Material
Horizontal Bandsaw Parts
Saw Blades
Installing a Blade
Sawing
Sawing Hints
Unit 35 Review Questions
Unit 36: Contour Bandsaw Parts and Accessories
Unit 36: Introduction
Contour Bandsaw Parts
Base
Column
Head
Bandsaw Applications
Coolants
Power Feed
Bandsaw Blade Types and Applications
Tooth Forms
Pitch
Set
Width
Gage
Job Requirements
Blade Length
Unit 36 Review Questions
Unit 37: Contour Bandsaw Operations
Unit 37: Introduction
Sawing External Sections
To Mount a Saw Band
To Cut an External Section
Accuracy and Finish
Sawing Internal Sections
To Weld a Bandsaw Blade
To Saw Internal Sections
Trimming and Blanking Dies
Friction Sawing
High-Speed Sawing
Band Filing
To Set Up for Band Filing
To File on a Contour Bandsaw
Additional Band Tools
Bandsaw Attachments
Unit 37 Review Questions
Unit 38: Drill Presses
Section 10: Drilling Machines
Unit 38: Introduction
Standard Operations
Principal Types of Drilling Machines
Sensitive Drill Presses
Upright Drilling Machine
Radial Drilling Machine
Unit 38 Review Questions
Unit 39: Drilling Machine Accessories
Unit 39: Introductin
Tool-Holding Devices
Drill Chucks
Chucks
Drill Sleeves and Sockets
Work-Holding Devices
Clamping Stresses
Clamping Hints
Unit 39 Review Questions
Unit 40: Twist Drills
Unit 40: Introduction
Twist Drill Parts
Shank
Body
Point
Drill Point Characteristics
Drill Point Angles and Clearances
Systems of Drill Sizes
Types of Drills
Drilling Facts and Problems
Drill Point Coatings
Drill Grinding
Causes of Drill Failure
Web Thinning
Unit 40 Review Questions
Unit 41: Cutting Speeds and Feeds
Unit 41: Introduction
Cutting Speed
Revolutions per Minute
Feed
Cutting Fluids
Unit 41 Review Questions
Unit 42: Drilling Holes
Unit 42: Introduction
Drill Press Safety
Drilling Hints
Measuring the Size of a Drill
Lathe Center Holes
Drilling Lathe Center Holes
Spotting a Hole Location with a Center Drill
Drilling Work Held in a Vise
Drilling to an Accurate Layout
Drilling Large Holes
Drilling Round Work in a V-Block
Unit 42 Review Questions
Unit 43: Reaming
Unit 43: Introduction
Reamers
Reamer Parts
Types of Reamers
Reamer Care
Reaming Allowances
Reaming Speeds and Feeds
Speeds
Feeds
Reaming Hints
Reaming a Straight Hole
Hand Reaming a Straight Hole
Machine Reaming a Straight Hole
Reaming a Tapered Hole
Unit 43 Review Questions
Unit 44: Drill Press Operations
Unit 44: Introduction
Counterboring
To Counterbore a Hole
Countersinking
To Countersink a Hole for a Machine Screw
Tapping
To Tap a Hole by Hand in a Drill Press
Transferring Hole Locations
To Spot with a Twist Drill
To Use Transfer Punches
To Use Transfer Screws
Drill Jigs
Unit 44 Review Questions
Unit 45: Engine Lathe Parts
Section 11: The Lathe
Unit 45: Introduction
Lathe Size and Capacity
Parts of the Lathe
Bed
Headstock
Quick-Change Gearbox
Carriage
Tailstock
Setting Speeds on a Lathe
Setting Feeds
To Set the Feed for the Apron (Carriage Drive)
Shear Pins and Slip Clutches
Unit 45 Review Questions
Unit 46: Lathe Accessories
Unit 46: Introduction
Work-Holding Devices
Lathe Centers
Chucks
Lathe Dogs
Cutting-Tool-Holding Devices
Compound Rest Tooling Systems
Modular, or Quick-Change, Tooling
Unit 46 Review Questions
Unit 47: Cutting Speed, Feed, and Depth of Cut
Unit 47: Introduction
Cutting Speed
Inch Calculations
Metric Calculations
Lathe Feed
Depth of Cut
Graduated Micrometer Collars
Hints on Graduated Collar Use
Calculating Machining Time
Unit 47 Review Questions
Unit 48: Lathe Safety
Unit 48: Introduction
Safety Precautions
Unit 48 Review Questions
Unit 49: Mounting, Removing, and Aligning Lathe Centers
Unit 49: Introductin
To Mount Lathe Centers
To Remove Lathe Centers
Alignment of Lathe Centers
To Align Centers by Adjusting the Tailstock
To Align Centers by the Trial-Cut Method
To Align Centers Using a Dial Indicator and Test Bar
Unit 49 Review Questions
Unit 50: Grinding Lathe Cutting Tools
Unit 50: Introduction
To Grind a General-Purpose Cutting Tool
Unit 50 Review Questions
Unit 51: Facing Between Centers
Unit 51: Introduction
To Set Up a Cutting Tool for Machining
To Mount Work Between Centers
Using a Revolving Tailstock Center
Using a Dead Center
Facing Between Centers
To Face Work Between Centers
Facing the Workpiece to an Accurate Length
Unit 51 Review Questions
Unit 52: Machining Between Centers
Unit 52: Introduction
Setting Up a Cutting Tool
Mounting Work Between Centers
Parallel Turning
Setting an Accurate Depth of Cut
Rough Turning
Finish Turning
Filing in a Lathe
To File in a Lathe
Polishing in a Lathe
Turning to a Shoulder
To Turn a Square Shoulder
To Machine a Filleted Shoulder
To Machine a Beveled (Angular) Shoulder
Unit 52 Review Questions
Unit 53: Knurling, Grooving, and Form Turning
Unit 53: Introduction
Knurling
To Knurl in a Lathe
Grooving
To Cut a Groove
Form Turning on a Lathe
Turning a Freehand Form or Radius
Form-Turning Tools
Form Turning Using a Template and Follower
Spherical Tool
Hydraulic Tracer Attachment
Unit 53 Review Questions
Unit 54: Tapers and Taper Turning
Unit 54: Introduction
Self-Holding Tapers
Steep Tapers
Standard Tapers
Lathe Spindle Nose Tapers
Taper Calculations
To Calculate the tpf
To Calculate the Tailstock Offset
Inch Taper Attachment Offset Calculations
Metric Tapers
Metric Tailstock Offset Calculations
Metric Taper Attachment Offset Calculations
Taper Turning
Tailstock Offset Method
Taper Turning Using the Compound Rest
Checking a Taper
To Fit an External Taper
To Check a Metric Taper
Unit 54 Review Questions
Unit 55: Threads and Thread Cutting
Unit 55: Introduction
Threads
Thread Terminology
Thread Forms
Thread Fits and Classifications
Thread Calculations
Thread-Chasing Dial
Thread Cutting
To Set Up a Lathe for Threading (60° Thread)
Thread-Cutting Operation
Thread Measurement
Multiple Threads
Square Threads
Acme Thread
Internal Threading
Unit 55 Review Questions
Unit 56: Steady Rests, Follower Rests, and Mandrels
Unit 56: Introduction
Steady Rest
To Set Up a Steady Rest
To True a Damaged Center Hole
Follower Rest
To Set Up a Follower Rest
Mandrel
Characteristics of a Standard Mandrel
Types of Mandrels
To Mount Work on a Plain Mandrel
To Turn Work on a Mandrel
Eccentrics
To Turn an Eccentric With a .375-in. or 10-mm Throw
To Cut an Eccentric With a Small Throw
To Turn an Eccentric With a Large Throw
Unit 56 Review Questions
Unit 57: Machining in a Chuck
Unit 57: Introduction
Mounting and Removing Lathe Chucks
To Mount a Chuck
To Remove a Chuck
Mounting Work in a Chuck
To Mount Work in a Three-Jaw Chuck
Assembling Jaws in a Three-Jaw Universal Chuck
To Mount Work in a Four-Jaw Chuck
To True Work in a Four-Jaw Chuck Using a Dial Indicator
To Face Work Held in a Chuck
To Rough- and Finish-Turn Work in a Chuck
Rough and Finish Turning
Turning Hardened Steel with PCBN Tools
Guidelines for PCBN Turning
Turning the Part
Cutting Off Work in a Chuck
Unit 57 Review Questions
Unit 58: Drilling, Boring, Reaming, and Tapping
Unit 58: Introduction
To Spot and Drill Work in a Chuck
Boring
To Bore Work in a Chuck
Reaming
To Ream Work in a Lathe
Tapping
To Tap a Hole in a Lathe
Grinding on a Lathe
To Grind a Lathe Center
Unit 58 Review Questions
Unit 59: The Vertical Milling Machine
Section 12: Milling Machines
Unit 59: Introduction
Types of Vertical Milling Machines
Heavy-Duty Vertical Milling Machine
Parts of the Ram-Type Vertical Mill
Unit 59 Review Questions
Unit 60: Cutting Speed, Feed, and Depth of Cut
Unit 60: Introduction
Cutting Speed
Inch Calculations
Metric Calculations
Milling Feed and Depth of Cut
Feed
Depth of Cut
Unit 60 Review Questions
Unit 61: End Mills
Unit 61: Introduction
High-Speed End Mills
Coated End Mills
Carbide End Mills
Machining Operations
End Mill Forms
Types of End Mills
Direction of Cut
Milling Cutter Failure
Excessive Heat
Abrasion
Chipping or Crumbling of Cutting Edges
Clogging
Built-Up Edges
Work Hardening of the Workpiece
Cratering
Unit 61 Review Questions
Unit 62: Vertical Mill Operations
Unit 62: Introduction
Aligning the Vertical Head
Aligning the Vise
Mounting and Removing Cutters
To Mount a Cutter in a Spring Collet
To Remove a Cutter from a Collet
To Mount a Cutter in a Solid Collet
To Machine a Flat Surface
Machining a Block Square and Parallel
Machining Side 1
Machining Side 2
Machining Side 3
Machining Side 4
Machining the Ends Square
Procedure for Short Work
To Machine an Angular Surface
Milling Hardened Steel with PCBN Tools
Machine Setup
Producing and Finishing Holes
To Drill Holes at 90° to the Work Surface
To Drill Angular Holes
To Ream on a Vertical Mill
To Bore on a Vertical Mill
To Tap a Hole on the Vertical Mill
Cutting Slots and Keyseats
Calculating the Depth of Keyseats
Woodruff Keys
Unit 62 Review Questions
Unit 63: Special Milling Operations
Unit 63: Introduction
The Rotary Table
Rotary Table Construction
Radius Milling
Milling a T-Slot
Milling Dovetails
Jig Boring on a Vertical Milling Machine
To Position the Milling Machine Table Using Measuring Rods
Digital Readout Boxes
Vernier Scale
Vertical Milling Machine Attachments
Die Sinking
Unit 63 Review Questions
Unit 64: Horizontal Milling Machines and Accessories
Unit 64: Introduction
Horizontal Milling Machines
Manufacturing-Type Milling Machines
Special-Type Milling Machines
Machining Centers
Knee-and-Column-Type Milling Machines
Parts of the Milling Machine
Backlash Eliminator
Milling Machine Accessories
Fixtures
Attachments
Unit 64 Review Questions
Unit 65: Milling Cutters
Unit 65: Introduction
Milling Cutter Materials
Plain Milling Cutters
Standard Shank-Type Helical Milling Cutters
Side Milling Cutters
Face Milling Cutters
Angular Cutters
Formed Cutters
Metal-Slitting Saws
End Mills
T-Slot Cutter
Dovetail Cutter
Woodruff Keyseat Cutter
Flycutters
Unit 65 Review Questions
Unit 66: Milling Machine Setups
Unit 66: Introduction
Milling Machine Safety
Milling Machine Setups
Milling Hints
Mounting and Removing a Milling Machine Arbor
The Arbor Assembly
To Mount an Arbor
To Remove an Arbor
Mounting and Removing Milling Cutters
To Mount a Milling Cutter
To Remove a Milling Cutter
Aligning the Table on a Universal Milling Machine
Aligning the Milling Machine Vise
To Align the Vise Parallel to the Table Travel
Unit 66 Review Questions
Unit 67: Horizontal Milling Operations
Unit 67: Introduction
Setting the Cutter to the Work Surface
To Set the Cutter to the Work Surface
Milling a Flat Surface
Face Milling
Side Milling
Centering a Cutter to Mill a Slot
Straddle Milling
Gang Milling
Sawing and Slitting
Unit 67 Review Questions
Unit 68: The Indexing, or Dividing, Head
Unit 68: Introduction
Index Head Parts
Methods of Indexing
Direct Indexing
Simple Indexing
Angular Indexing
Differential Indexing
The Wide-Range Dividing Head
Indexing for Divisions
Angular Indexing with the Wide-Range Divider
Linear Graduating
Unit 68 Review Questions
Unit 69: Helical Milling
Unit 69: Introduction
Helical Terms
Cutting a Helix
Determining the Helix Angle
Determining the Direction to Swing the Table
Calculating the Change Gears to Produce the Required Lead
Inch Calculations
Metric Calculations
Direction of Spindle Rotation
Cutting Short Lead Helices
Unit 69 Review Questions
Unit 70: Cam, Rack, Worm, and Clutch Milling
Unit 70: Introduction
Cams and Cam Milling
Cams Used to Impart Motion
Cam Motions
Radial Cam Terms
Cam Milling
Rack Milling
Rack Indexing Attachment
Worms and Worm Gears
To Mill a Worm
Clutches
To Machine a Straight-Tooth Clutch Having Three Teeth
To Machine a Straight-Tooth Clutch Having Four Teeth
Unit 70 Review Questions
Unit 71: Types of Abrasives
Section 13: Grinding
Unit 71: Introduction
Aluminum Oxide
Manufacture of Aluminum Oxide
Silicon Carbide
Manufacture of Silicon Carbide
Zirconia-Aluminum Oxide
Boron Carbide
Manufacture of Boron Carbide
Cubic Boron Nitride
Manufactured Diamonds
Diamond Types
Ceramic Aluminum Oxide
SG and CBN Abrasives
Abrasive Products
Grinding Wheels
Abrasive Grain
Bond Types
Grade
Structure
Grinding Wheel Manufacture
Standard Grinding Wheel Shapes
Mounted Grinding Wheels
Grinding Wheel Markings
Selecting a Grinding Wheel for a Specific Job
Handling and Storage of Grinding Wheels
Wheel Grade Faults
Soft Wheel Characteristics
Hard Wheel Characteristics
Inspection of Wheels
Diamond Wheels
Bonds
Diamond Wheel Identification
Cubic Boron Nitride Wheels
Properties of Cubic Boron Nitride (CBN) Wheels
Wheel Selection
Coated Abrasives
Selection of Coated Abrasives
Coated Abrasive Machining
Unit 71 Review Questions
Unit 72: Surface Grinders and Accessories
Unit 72: Introduction
The Grinding Process
Surface Grinding
Types of Surface Grinders
Grinding Wheel Care
Mounting a Grinding Wheel
Balancing a Grinding Wheel
Grinder Safety
Truing and Dressing a Grinding Wheel
Work-Holding Devices
Magnetic Chuck
Permanent Magnetic Chuck Construction
Magnetic Chuck Accessories
Grinding Fluids
Types of Grinding Fluids
Methods of Applying Coolants
Surface Finish
Unit 72 Review Questions
Unit 73: Surface Grinding Operations
Unit 73: Introduction
Mounting the Workpiece for Grinding
Flat Work or Plates
Thin Workpieces
Short Workpieces
Grinder Safety
Grinding Operations
To Grind a Flat (Horizontal) Surface
To Grind the Edges of a Workpiece
Setting Up the Workpiece
Grinding a Flat Surface with a CBN Wheel
Conditioning CBN Wheels
Truing a CBN Wheel
Dressing a CBN Wheel
Grinding a Flat Surface
To Grind a Vertical Surface
To Grind an Angular Surface
Form Grinding
To Dress a Convex Radius On a Grinding Wheel
Special Forms
Creep Feed Grinding
Grinding Wheels
Advantages of Creep Feed Grinding
Cutting-Off Operations
Unit 73 Review Questions
Unit 74: Cylindrical Grinders
Unit 74: Introduction
Center-Type Cylindrical Grinders
Parts of the Universal Cylindrical Grinder
Machine Preparation for Grinding
Mounting the Wheel
To Grind a Tapered Workpiece
Plunge Grinding
Internal Grinders
Internal Grinding on a Universal Cylindrical Grinder
To Grind a Tapered Hole
Centerless Grinders
Methods of Centerless Grinding
Thru-Feed Centerless Grinding
Infeed Centerless Grinding
Endfeed Centerless Grinding
Advantages of Centerless Grinding
Unit 74 Review Questions
Unit 75: Universal Tool and Cutter Grinder
Unit 75: Introduction
Parts of the Universal Tool and Cutter Grinder
Accessories and Attachments
Milling Cutter Nomenclature
Cutter Clearance Angles
Methods of Grinding Clearance on Cutters
Clearance Grinding
Hollow Grinding
Circle Grinding
Methods of Checking Cutter Clearance Angles
To Check Cutter Clearance with a Dial Indicator
To Check Cutter Clearance with a Brown & Sharpe Clearance Gage
Checking the Cutter Clearance with a Starrett Cutter Clearance Gage
Cutter Grinding Operations and Setups
To Grind a Plain Helical Milling Cutter
To Grind a Staggered Tooth Cutter
To Grind a Form-Relieved Cutter
Cylindrical Grinding
Internal Grinding
Unit 75 Review Questions
Unit 76: Manufacture and Properties of Steel
Section 14: Metallurgy
Unit 76: Introduction
Physical Properties of Metals
Manufacture of Ferrous Metals
Pig Iron
Manufacture of Pig Iron
Direct Ironmaking
Manufacture of Cast Iron
Manufacture of Steel
Direct Steelmaking
Steel Processing
Strand, or Continuous, Casting
Vacuum Processing of Molten Steel
Minimills
The Minimill Process
HIsarna Steelmaking Process
Chemical Composition of Steel
Classification of Steel
Plain Carbon Steels
Alloy Steels
Unit 76 Review Questions
Unit 77: Heat Treatment of Steel
Unit 77: Introduction
Heat-Treating Equipment
Types of Furnaces
Heat-Treatment Terms
Selection of Tool Steel
Water-Hardening Tool Steels
Oil-Hardening Steels
Air-Hardening Steels
High-Speed Steels
Classification of Steel
SAE-AISI Classification Systems
Heat Treatment of Carbon Steel
To Determine the Critical Points of 0.83% Carbon Steel
Observations and Conclusions
Hardening of 0.83% Carbon Steel
Quenching
Metcalf’s Experiment
Tempering
Annealing
Normalizing
Spheroidizing
Case-Hardening Methods
Carburizing
Carbonitriding Processes
Nitriding Processes
Surface Hardening of Medium-Carbon Steels
Induction Hardening
Flame Hardening
Unit 77 Review Questions
Unit 78: Testing of Metals and Nonferrous Metals
Unit 78: Introduction
Hardness Testing
Rockwell Hardness Tester
Brinell Hardness Tester
Scleroscope Hardness Tester
Destructive Testing
Tensile Testing (Inch Equipment)
To Determine the Tensile Strength of Steel
Tensile Testing (Metric Equipment)
Impact Tests
Nondestructive Testing
Scrap Metal Recycling
Nonferrous Metals and Alloys
Aluminum
Copper
Lead
Magnesium
Nickel
Tin
Zinc
Bearing Metals
Unit 78 Review Questions
Unit 79: Cellular Manufacturing
Section 15: Lean Manufacturing
⊲⊲ Lean Manufacturing
⊲⊲ Lean—Its Amazing Benefits
⊲⊲ Where Does Change Start?
⊲⊲ Lean Leadership
⊲⊲ Lean—Change or Perish
Unit 79: Introduction
Cellular Manufacturing
One-Piece Flow
Cellular Manufacturing Development
Advantages of Cellular Manufacturing
Production on Demand
Productivity and Performance Improvement
Teamwork
Types of Cells
Benefits of Cells
Unit 79 Review Questions
Unit 80: Continuous Improvement
Unit 80: Introduction
Introduction
The Basic Principles of Kaizen
The Reasons for Kaizen
Kaizen’s Benefits
Kaizen Events
Keeping Everyone Aware
The Four Stages of a Kaizen Event
Choosing an Area for Improvement
Unit 80 Review Questions
Unit 81: Pull (Kanban) Systems
Unit 81: Introduction
Pull versus Push Production
Pull Production Defined
Pull Production Prerequisites
How Inventory Accumulates
Flow Requirements
Kanban Card Information
Advantages
Unit 81 Review Questions
Unit 82: Total Productive Maintenance
Unit 82: Introduction
Maintenance Types
TPM Objectives
Breakdowns
Causes of Breakdowns
Preparatory Stage
The Value of Trained Personnel
Train the Employees
Clean the Equipment
General Inspection
The Future of Maintenance
Unit 82 Review Questions
Unit 83: Value-Stream Mapping
Unit 83: Introduction
Value-Stream Basics
VSM as a Planning Tool
Stairway to Success
Waste Identification
Four Stages in Value-Stream Mapping
Stage 1: Product Development
Stage 2: Process Design
Stage 3: Preparation
Stage 4: Planning
Value-Stream Management
The Purpose of Value-Stream Management
Make the Commitment Sincere
Map the Current State
Mapping the Future State
Beginning the Future-State Map
Unit 83 Review Questions
Unit 84: Workplace Organization
Unit 84: Introduction
Using the 5S System
Creating Ideas
From Ideas to Success
Small Changes = Big Improvements
Ergonomics
Company Focus
The Importance of Customer Care
Points for Keeping Customers
Unit 84 Review Questions
Unit 85: The Computer
Section 16: Computer-Age Machining
Unit 85: Introduction
History of the Computer
The Role of the Computer
Unit 85 Review Questions
Unit 86: Computer Numerical Control
Unit 86: Introduction
Theory of CNC
Role of a Computer in CNC
Types of Computers
Computer Functions
CNC Performance
Accuracy
Reliability
Repeatability
Productivity
Advantages of CNC
Cartesian Coordinates
Guidelines
Machine Axes
Machines Using CNC
Programming Systems
Incremental System
Absolute System
CNC Positioning Systems
Point-to-Point Positioning
Continuous-Path (Contouring)
Control Systems
Open Loop System
Closed Loop System
Input Media
Types of Computer Control
Computer Numerical Control
Direct Numerical Control
Programming Format
Word Address Format
Codes
Block of Information
Interpolation
Linear Interpolation
Circular Interpolation
Program Planning
Machining Procedures
Tool List
Manuscript
Unit 86 Review Questions
Unit 87: CNC Turning Center
Unit 87: Introduction
Types of Turning Centers
CNC Chucking Center
CNC Turning Center
Combination Turning/Milling Center
Programming Considerations
Tooling Systems and Cutting Tools
Diameter Versus Radius Programming
Establish Part Zero
Codes
Programming Procedures
Bench-Top Teaching Machines
Standard-Size Turning Center
Turning Center Setup
Program Test Run
Unit 87 Review Questions
Unit 88: CNC Machining Centers
Unit 88: Introduction
Types of Machining Centers
Horizontal Machining Center
Vertical Machining Center
Universal Machining Center
Main Operative Parts
Machining Center Accessories
Adaptive Control
Automatic Tool Changers
Tools and Toolholders
Combination Tools
Toolholders
Programming Procedures
Bench-Top Teaching Machines
Machining Center Setup
Setting Part Zero
Setting Tool Length Offset
Program Test Run
Standard-Size Machining Center
Unit 88 Review Questions
Unit 89: CAD/CAM
Unit 89: Introduction
The CAD Side of CAD/CAM
CAD Development
Systems Presently in Use
Solids
Solid Modeling and CAD/CAM
How CAD/CAM Works
Geometry Input
Cadworthy Versus Camworthy Geometry
Defining Where the Cut Takes Place
How the Cut Takes Place
Viewing and Verifying the Toolpath
Converting the Toolpath toG- and M-Codes
Downloading the Program to the Machine
Setting Up the Machine
Running the Part
Toolpaths and Functions
Toolpaths
functions
Unit 89 Review Questions
Unit 90: Nanotechnology
Section 17: Advanced Manufacturing Technology
Unit 90: Introduction
Micro-Nano Technology
Nanotechnology in the Manufacturing Industry
Nanorobots
Nanomanufacturing Methods
Approaches to Nanomanufacturing
Automotive and Aerospace
Nanotechnology in the Future
Nanotechnology Health/Safety/Environment
The Guidelines
Investments in Nanotechnology
Unit 90 Review Questions
Unit 91: Cryogenic Treatment/Tempering
Unit 91: Introduction
Technical Data
Cold Treatment Versus Cryogenics
Cold Treatment
Cryogenics
Stress Relief
Depth of Cryogenic Stress Relieving
Carbide Increase
Wear Resistance
Metallurgy Changes
kinetics of cryogenic treatment
Advantages of Cryogenic Tempering
Unit 91 Review Questions
Unit 92: Diamond Coating
Unit 92: Introduction
Diamond Tool Development
Manufactured Industrial Diamond
Diamond Deposition
Diamond Characteristics
Previous Limitations
A Diamond Coating Breakthrough
Diamond Coating
Diamond Thickness
Types Of Diamond Coated Tooling
Field Tests
Benefits of Diamond
Diamondlike Carbon
Looking Ahead
Cutting-Tool Technology
Diamond Coating Technology
Unit 92 Review Questions
Unit 93: Additive Manufacturing Technologies
Unit 93: Introduction
Additive Manufacturing—Definition
Additive vs. Subtractive Manufacturing
Seven Primary 3D Printing Technologies
Additive Manufacturing Process Chain
1. CAD
2. Build Setup
3. Slicing and Machine Control
4. Build
5. Removal
6. Post-Processing
Additive Metal Processes
Powder Bed Fusion with Metal Powder
Directed Energy Deposition
Binder Jetting—Metal
Hybrid Systems
New Emerging Technologies
METAL MATERIALS-FEED STOCK
Accuracy
Surface Finish
Metallurgy
Post-Processing of Additive Metal Parts
Unit 93 Review Questions
Unit 94: Multi-Tasking Machines
Unit 94: Introduction
Cyber Management System
Multi-Tasking Machining Defined
Purpose of Multi-Tasking Machines
Types of Multi-Tasking Machines
Accessories
Unit 94 Review Questions
Unit 95: Industry 4.0
Unit 95: Introduction
Industry 4.0
Internetworking Standard
Connecting Machine Tools
IoT
IIoT
Machine Tools as Smart Partners
MT Connect®
Theory of Constraints
Ethernet Connectivity
RFID Technology
Cyber Security
Summary
Unit 95 Review Questions
Unit 96: Optical/Laser/Vision Measurement
Unit 96: Introduction
Measurement: Contact or Noncontact
Optical Comparators
Laser Measurement
Laser-Tool Measurement
Laser Scan Micrometer
Laser Scan Microscope
Laser Surface-Finish Measurement
Scanning Probes
Reverse Engineering
Video Measuring System
Video Microscope
Video Magnifiers
Coordinate Measuring Machine
Three Types of CMM Probes
Scanning CMMs
Inspection for the Future
Unit 96 Review Questions
Unit 97: Electrical Discharge Machining
Unit 97: Introduction
Use of EDM
Principle of EDM
Types of EDM Circuits
The Electrode
GRAPHITE VS COPPER
The EDM Process
Servo Mechanism
Cutting Current (Amperage)
The Discharge Process
Dielectric Fluid
Metal-Removal Rates
Electrode (Tool) Wear
Overcut
Surface Finish
Advantages of EDM
Limitations of EDM
Wire-Cut EDM Machine
The Process
Operating Systems
EDM Micromachining
Unit 97 Review Questions
Unit 98: Robotics
Unit 98: Introduction
Robot Requirements
Application Flexibility
Robot Types
Parts of a Robot
Types of Sensors
Vision-Based Robotics
Intelligent Vision for Robots
Vision System Development
Artificial Intelligence
Next-Generation Manufacturing
Intelligent Vision
Robotics and Vision Working Together
Benefits of Next-Generation Systems
COLLABORATIVE ROBOTS (Cobots)
Advantages of Robots
Preventive Maintenance
Safety Precautio
Unit 98 Review Questions
Unit 99: Manufacturing Intelligence
Unit 99: Introduction
Manufacturing Intelligence Factors
Information Sources
Turning Data Into Knowledge
Decreasing Downtime
Protecting Manufacturing Investments
Intelligent Manufacturing Systems
Unit 99 Review Questions
Glossary
Section 18
Glossary
Appendix of tables
Appendix of Tables
Index
Index

"Today's modern machine shops and tool and die shops are now environmentally controlled with dedicated me-trology labs for quality control and inspection. They have integrated the use of more computer numerical control (CNC) machine tools, but they have still retained the ability to use conventional machines. A modern jobbing shop today will still have conventional machines such as mills, lathes, assorted drill presses, saws, and some of the pre-cision equipment used prior to CNC (such as surface grinders, jig borers, and cylindrical and tool and cutter grinders)"-- Provided by publisher.

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