Machine Tool Practices

Machine Tool Practices

Hardcover

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Product Details

ISBN-13: 9780134893501
Publisher: Pearson
Publication date: 01/16/2019
Pages: 800
Product dimensions: 6.50(w) x 1.50(h) x 9.50(d)

About the Author

Jon Stenerson served an apprenticeship in toolmaking with Mercury Marine and was an instructor in the Machine Tool Program at Fox Valley Technical College (FVTC) in Appleton, WI. An industry consultant, Jon is the author of textbooks in the fields of machining, CNC programming, and industrial automation. He has a BBA from the University of Wisconsin Oshkosh and a master’s degree in vocational education from the University of Wisconsin-Stout.

Kelly S. Curran grew up in Michigan’s Upper Peninsula, where he started working in machine shops at a young age. Mr. Curran has considerable machine shop experience as well as industrial teaching experience. He is the author and co-author of several publications in the machine tool manufacturing field. Mr. Curran has spent many years developing a self-paced machine tool curriculum for the State of Wisconsin and Fox Valley Technical College. He holds a bachelor’s degree in career, technical education, and training from the University of Wisconsin-Stout, an associate of applied science degree with an emphasis in machine tool from Ferris State College, and an associate of applied science degree with an emphasis in business from Northern Michigan University.

Table of Contents

SECTION A
1. Careers and the Machinist’s Role in Process Plans
2. Manufacturing Competitiveness and Improvement
3. Shop Safety
4. Threads and Fasteners
5. Blueprint Reading Fundamentals
6. Views and Line Types
7. Dimensions, Tolerances, and Fits
8. Fundamentals of GD&T
9. Geometric Tolerancing

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. Measurement and Common Measuring Tools
2. Systems of Measurement
3. Using Steel Rules
4. Using Vernier, Dial, and Digital Instruments for Direct Measurements
5. Using Micrometers
6. Using Comparison Measuring Instruments
7. Using Gage Blocks
8. Using Angular Measuring Instruments
9. Quality in Manufacturing
10. Statistics in Manufacturing

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. Layout Tools
2. Basic Semiprecision Layout Practice
3. 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. Carbide Tooling Specification and Selection

SECTION G: SAWING MACHINES
1. Types of Cutoff Machines and Safety
2. Using Horizontal Cutoff Saws
3. Preparing a Vertical Band Machine for Use
4. Using a Vertical Band Saw

SECTION H: DRILLING MACHINES
1. Drill Press Fundamentals
2. Drilling Tools
3. Hand Grinding of Drills on the Pedestal Grinder
4. Operating Drilling Machines
5. Countersinking and Counterboring
6. Reaming in the Drill Press

SECTION I: TURNING MACHINES
1. Engine Lathe Fundamentals
2. Toolholders and Toolholding
3. Cutting Tools for the Lathe
4. Lathe Spindle Tooling
5. Operating Lathe Controls
6. Facing and Center Drilling
7. Turning between Centers
8. Alignment of 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 Milling Machines
2. Cutting Tools and Cutting Tool Holders for the Vertical Milling Machine
3. Setups on the Vertical Milling Machine
4. Vertical Milling Machine Operations
5. Using an 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

SECTION L: GRINDING AND ABRASIVE MACHINING PROCESSES
1. Types of Grinders
2. Selection and Use of Grinding Wheels
3. Setup of Surface Grinders
4. Using a Surface Grinder
5. Cylindrical Grinding
6. Using a Cylindrical Grinder
7. Universal Tool and Cutter Grinder

SECTION M: COMPUTER NUMERICAL CONTROL AND OTHER ADVANCED MACHINING PROCESSES
1. Fundamentals of Computer Numerical Control (CNC)
2. Fundamentals of Machining Centers
3. Fundamentals of Programming Machining Centers
4. Programming Examples
5. Programming Canned Cycles for Machining Centers
6. CNC Turning Machines
7. Programming CNC Turning Centers
8. Programming Canned Cycles for CNC Turning Centers
9. Advanced Machining Processes

Preface

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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