Machine tool practices [Novena edición] 9780135015087, 0135015081

Table of contents :
Cover......Page 1
Contents......Page 4
Preface......Page 7
Guided Tour......Page 9
Acknowledgments......Page 12
About the Authors......Page 14
SECTION A: Introduction......Page 16
Unit 1 Shop Safety......Page 21
Unit 2 Mechanical Hardware......Page 29
Unit 3 Reading Drawings......Page 41
SECTION B: Hand Tools......Page 50
Unit 1 Arbor and Shop Presses......Page 52
Unit 2 Work-Holding and Hand Tools......Page 60
Unit 3 Hacksaws......Page 69
Unit 4 Files......Page 72
Unit 5 Hand Reamers......Page 78
Unit 6 Identification and Uses of Taps......Page 82
Unit 7 Tapping Procedures......Page 87
Unit 8 Thread-Cutting Dies and Their Uses......Page 92
Unit 9 Off-Hand Grinding......Page 96
SECTION C: Dimensional Measurement......Page 102
Unit 1 Systems of Measurement......Page 118
Unit 2 Using Steel Rules......Page 122
Unit 3 Using Vernier, Dial, and Digital Instruments for Direct Measurements......Page 131
Unit 4 Using Micrometer Instruments......Page 140
Unit 5 Using Comparison Measuring Instruments......Page 161
Unit 6 Using Gage Blocks......Page 181
Unit 7 Using Angular Measuring Instruments......Page 189
Unit 8 Tolerances, Fits, Geometric Dimensions, and Statistical Process Control (SPC)......Page 198
SECTION D: Materials......Page 208
Unit 1 Selection and Identification of Steels......Page 212
Unit 2 Selection and Identification of Nonferrous Metals......Page 218
Unit 3 Hardening, Case Hardening, and Tempering......Page 224
Unit 4 Annealing, Normalizing, and Stress Relieving......Page 236
Unit 5 Rockwell and Brinell Hardness Testers......Page 240
SECTION E: Layout......Page 250
Unit 1 Basic Semiprecision Layout Practice......Page 259
Unit 2 Basic Precision Layout Practice......Page 265
SECTION F: Preparation for Machining Operations......Page 278
Unit 1 Machinability and Chip Formation......Page 281
Unit 2 Speeds and Feeds for Machine Tools......Page 290
Unit 3 Cutting Fluids......Page 294
Unit 4 Using Carbides and Other Tool Materials......Page 299
SECTION G: Sawing Machines......Page 316
Unit 1 Using Reciprocating and Horizontal Band Cutoff Machines......Page 328
Unit 2 Abrasive and Cold Saws......Page 338
Unit 3 Preparing to Use the Vertical Band Machine......Page 341
Unit 4 Using the Vertical Band Machine......Page 350
SECTION H: Drilling Machines......Page 356
Unit 1 The Drill Press......Page 361
Unit 2 Drilling Tools......Page 364
Unit 3 Hand Grinding of Drills on the Pedestal Grinder......Page 373
Unit 4 Operating Drilling Machines......Page 377
Unit 5 Countersinking and Counterboring......Page 389
Unit 6 Reaming in the Drill Press......Page 392
SECTION I: Turning Machines......Page 398
Unit 1 The Engine Lathe......Page 406
Unit 2 Toolholders and Toolholding for the Lathe......Page 414
Unit 3 Cutting Tools for the Lathe......Page 420
Unit 4 Lathe Spindle Tooling......Page 428
Unit 5 Operating the Machine Controls......Page 435
Unit 6 Facing and Center Drilling......Page 440
Unit 7 Turning between Centers......Page 450
Unit 8 Alignment of the Lathe Centers......Page 463
Unit 9 Other Lathe Operations......Page 466
Unit 10 Sixty-Degree Thread Information and Calculations......Page 480
Unit 11 Cutting Unified External Threads......Page 485
Unit 12 Cutting Unified Internal Threads......Page 496
Unit 13 Cutting Tapers......Page 500
Unit 14 Using Steady and Follower Rests......Page 511
Unit 15 Additional Thread Forms......Page 517
Unit 16 Cutting Acme Threads on the Lathe......Page 522
SECTION J: Vertical Milling Machines......Page 526
Unit 1 Vertical Spindle Milling Machines......Page 529
Unit 2 Cutting Tools and Cutter Holders for the Vertical Milling Machine......Page 532
Unit 3 Setups on the Vertical Milling Machine......Page 538
Unit 4 Vertical Milling Machine Operations......Page 545
Unit 5 Using the Offset Boring Head......Page 555
SECTION K: Horizontal Spindle Milling Machines......Page 560
Unit 1 Horizontal Spindle Milling Machines......Page 564
Unit 2 Types of Spindles, Arbors, and Adapters......Page 568
Unit 3 Arbor-Driven Milling Cutters......Page 571
Unit 4 Work-Holding Methods and Standard Setups......Page 577
Unit 5 Machine Setup and Plain Milling......Page 582
Unit 6 Using Side Milling Cutters......Page 592
Unit 7 Using Face Milling Cutters on the Horizontal Milling Machine......Page 596
SECTION L: Grinding and Abrasive Machining Processes......Page 600
Unit 1 Selection and Identification of Grinding Wheels......Page 613
Unit 2 Truing, Dressing, and Balancing of Grinding Wheels......Page 621
Unit 3 Grinding Fluids......Page 627
Unit 4 Horizontal Spindle Reciprocating Table Surface Grinders......Page 632
Unit 5 Work Holding on the Surface Grinder......Page 636
Unit 6 Using the Surface Grinder......Page 640
Unit 7 Problems and Solutions in Surface Grinding......Page 647
Unit 8 Center-Type Cylindrical Grinders......Page 650
Unit 9 Using the Cylindrical Grinder......Page 656
Unit 10 Universal Tool and Cutter Grinder......Page 660
SECTION M: Computer Numerical Control and Other Advanced Machining Processes......Page 674
Unit 1 CNC Machine Tool Programmable Axes and Position Dimensioning Systems......Page 683
Unit 2 CNC Programming......Page 688
Unit 3 CNC Tooling......Page 720
Unit 4 Other Advanced Machining Processes......Page 733
APPENDIX 1 Answers to Self-Tests......Page 741
APPENDIX 2 General Tables......Page 766
Table 1 Decimal Equivalents of Fractional Inches......Page 767
Table 2 Inch/Metric Conversion Table......Page 768
Table 3 Tap Drill Sizes......Page 770
Table 4 Metric Tap Drill Sizes......Page 771
Table 5A: Tapers......Page 772
Table 5B: Tapers and Angles......Page 773
Table 6 General Measurements......Page 774
Table 7A: Density or Specific Gravity of Metals and Alloys......Page 776
Table 7B: Approximate Melting Points of Metals and Various Substances......Page 777
Table 8 Right-Triangle Solution Formulas......Page 778
Table 9 Wire Gages and Metric Equivalents......Page 779
Table 10B: Coolants and Cutting Oils Used for General Machining......Page 780
APPENDIX 3 Precision Vise Project Drawings......Page 781
B......Page 786
C......Page 787
E......Page 788
H......Page 789
M......Page 790
P......Page 791
S......Page 792
T......Page 793
Z......Page 794
B......Page 796
C......Page 797
D......Page 800
F......Page 802
G......Page 803
H......Page 804
L......Page 805
M......Page 806
N......Page 807
P......Page 808
S......Page 809
T......Page 811
V......Page 813
W......Page 814
Z......Page 815