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Tables of Contents for Machining Fundamentals
Chapter/Section Title
Page #
Page Count
Chapter 1. An Introduction to Machining Technology
11
12
1.1 The Evolution of Machine Tools
12
2
1.2 Basic Machine Tool Operation
14
3
1.3 Nontraditional Machining Processes
17
1
1.4 Automating the Machining Process
17
3
1.5 The Evolving Role of the Machinist
20
3
Chapter 2. Shop Safety
23
6
2.1 Safety in the Shop
23
3
2.2 General Machine Safety
26
1
2.3 General Tool Safety
27
1
2.4 Fire Safety
27
2
Chapter 3. Understanding Drawings
29
26
3.1 Dimensions
31
1
3.2 Information Included on Drawings
32
5
3.3 Types of Prints
37
1
3.4 Types of Drawings Used in the Shop
38
1
3.5 Parts List
38
1
3.6 Drawing Sizes
38
3
3.7 Geometric Dimensioning and Tolerancing
41
14
Chapter 4. Measurement
55
26
4.1 The Rule
55
2
4.2 The Micrometer Caliper
57
6
4.3 Vernier Measuring Tools
63
4
4.4 Gages
67
3
4.5 Dial Indicators
70
1
4.6 Other Gaging Tools
71
4
4.7 Helper Measuring Tools
75
6
Chapter 5. Layout Work
81
10
5.1 Making Lines on Metal
81
4
5.2 Squares
85
1
5.3 Measuring Angles
85
2
5.4 Simple Layout Steps
87
2
5.5 Layout Safety
89
2
Chapter 6. Hand Tools
91
36
6.1 Clamping Devices
91
1
6.2 Pliers
92
3
6.3 Wrenches
95
4
6.4 Screwdrivers
99
2
6.5 Striking Tools
101
1
6.6 Chisels
102
2
6.7 Hacksaw
104
3
6.8 Files
107
5
6.9 Reamers
112
2
6.10 Hand Threading
114
8
6.11 Hand Polishing
122
5
Chapter 7. Fasteners
127
16
7.1 Threaded Fasteners
127
8
7.2 Nonthreaded Fastening Devices
135
3
7.3 Adhesives
138
2
7.4 Fastener Safety
140
3
Chapter 8. Jigs and Fixtures
143
6
8.1 Jigs
143
2
8.2 Fixtures
145
1
8.3 Jig and Fixture Construction
146
3
Chapter 9. Cutting Fluids
149
4
9.1 Types of Cutting Fluids
149
1
9.2 Application of Cutting Fluids
150
3
Chapter 10. Drills and Drilling Machines
153
30
10.1 Drilling Machines
153
4
10.2 Drill Press Safety
157
1
10.3 Drills
158
5
10.4 Drill-holding Devices
163
1
10.5 Work-holding Devices
164
3
10.6 Cutting Speeds and Feeds
167
1
10.7 Cutting Compounds
168
2
10.8 Sharpening Drills
170
3
10.9 Drilling
173
3
10.10 Countersinking
176
1
10.11 Counterboring
177
1
10.12 Spotfacing
178
1
10.13 Tapping
178
2
10.14 Reaming
180
3
Chapter 11. Offhand Grinding
183
8
11.1 Abrasive Belt Grinders
183
1
11.2 Bench and Pedestal Grinders
183
2
11.3 Grinding Wheels
185
1
11.4 Abrasive Belt and Grinder Safety
186
1
11.5 Using a Dry-type Grinder
187
1
11.6 Using a Wet-type Grinder
188
1
11.7 Portable Hand Grinders
188
3
Chapter 12. Sawing and Cutoff Machines
191
10
12.1 Metal-cutting Saws
191
1
12.2 Reciprocating Power Hacksaw
191
3
12.3 Power Band Saw
194
2
12.4 Using Reciprocating and Band Saws
196
1
12.5 Circular Metal-cutting Saws
197
1
12.6 Power Saw Safety
197
4
Chapter 13. The Lathe
201
40
13.1 Lathe Size
201
1
13.2 Major Parts of a Lathe
202
6
13.3 Preparing Lathe for Operation
208
1
13.4 Cleaning the Lathe
209
1
13.5 Lathe Safety
209
2
13.6 Cutting Tools and Tool Holders
211
9
13.7 Cutting Speeds and Feeds
220
2
13.8 Work-holding Attachments
222
1
13.9 Turning Work Between Centers
223
8
13.10 Using Lathe Chucks
231
5
13.11 Facing Stock Held in Chuck
236
1
13.12 Plain Turning and Turning to a Shoulder
237
1
13.13 Parting Operations
237
4
Chapter 14. Cutting Tapers and Screw Threads on the Lathe
241
20
14.1 Taper Turning
241
3
14.2 Calculating Tailstock Setover
244
1
14.3 Measuring Tailstock Setover
245
1
14.4 Cutting a Taper
246
2
14.5 Measuring Tapers
248
2
14.6 Cutting Screw Threads on the Lathe
250
11
Chapter 15. Other Lathe Operations
261
20
15.1 Boring on a Lathe
261
2
15.2 Drilling and Reaming on a Lathe
263
2
15.3 Knurling on a Lathe
265
2
15.4 Filing and Polishing on a Lathe
267
1
15.5 Steady and Follower Rests
268
2
15.6 Mandrels
270
1
15.7 Grinding on the Lathe
270
2
15.8 Milling on a Lathe
272
1
15.9 Special Lathe Attachments
272
2
15.10 Industrial Applications of the Lathe
274
7
Chapter 16. Broaching Operations
281
4
16.1 Advantages of Broaching
283
1
16.2 Keyway Broaching
283
2
Chapter 17. The Milling Machine
285
32
17.1 Types of Milling Machines
286
6
17.2 Milling Safety Practices
292
1
17.3 Milling Operations
293
1
17.4 Milling Cutters
293
3
17.5 Types and Uses of Milling Cutters
296
8
17.6 Methods of Milling
304
1
17.7 Holding and Driving Cutters
304
4
17.8 Milling Cutting Speeds and Feeds
308
2
17.9 Cutting Fluids
310
1
17.10 Milling Work-holding Attachments
310
7
Chapter 18. Milling Machine Operations
317
36
18.1 Milling Operations
317
1
18.2 Vertical Milling Machine
317
1
18.3 Vertical Milling Machine Operations
317
9
18.4 Milling Machine Care
326
2
18.5 Horizontal Milling Machine Operations
328
9
18.6 Slitting
337
2
18.7 Slotting
339
1
18.8 Drilling and Boring on a Horizontal Milling Machine
339
1
18.9 Cutting a Spur Gear
340
6
18.10 Cutting a Bevel Gear
346
3
18.11 Precautions When Operating a Milling Machine
349
1
18.12 Industrial Applications
349
4
Chapter 19. Precision Grinding
353
30
19.1 Types of Surface Grinders
353
3
19.2 Work-holding Devices
356
2
19.3 Grinding Wheels
358
4
19.4 Cutting Fluids (Coolants)
362
2
19.5 Grinding Applications
364
2
19.6 Grinding Problems
366
1
19.7 Grinding Safety
367
1
19.8 Universal Tool and Cutter Grinder
368
1
19.9 Tool and Cutter Grinding Wheels
368
5
19.10 Cylindrical Grinding
373
2
19.11 Internal Grinding
375
1
19.12 Centerless Grinding
376
1
19.13 Form Grinding
377
1
19.14 Other Grinding Techniques
378
5
Chapter 20. Band Machining
383
16
20.1 Band Machining Advantages
383
1
20.2 Band Blade Selection
384
3
20.3 Welding Blades
387
1
20.4 Band Machine Preparation
388
2
20.5 Band Machining Operations
390
3
20.6 Band Machine Power Feed
393
1
20.7 Other Band Machining Applications
393
3
20.8 Troubleshooting Band Machines
396
1
20.9 Band Machining Safety
397
2
Chapter 21. Computer Numerical Control
399
24
21.1 Computer-aided Machining Technology
399
2
21.2 Positioning with Numerical Control
401
3
21.3 NC Movement Systems
404
4
21.4 Programming NC Machines
408
4
21.5 Computer Languages
412
1
21.6 Adaptive Control
413
1
21.7 NC and the Future
413
2
21.8 Advantages and Disadvantages of NC
415
8
Chapter 22. Automated Manufacturing
423
12
22.1 Flexible Manufacturing System
424
1
22.2 Robotics
424
4
22.3 Safety In Automated Manufacturing
428
1
22.4 Rapid Prototyping Techniques
428
5
22.5 The Future of Automated Manufacturing
433
2
Chapter 23. Quality Control
435
16
23.1 The History of Quality Control
435
1
23.2 Classifications of Quality Control
436
1
23.3 Nondestructive Testing Techniques
437
11
23.4 Other Quality Control Techniques
448
3
Chapter 24. Metal Characteristics
451
16
24.1 Classifying Metals
451
1
24.2 Ferrous Metals
452
6
24.3 Nonferrous Metals
458
3
24.4 Copper-based Alloys
461
1
24.5 High-temperature Metals
462
1
24.6 Rare Metals
463
4
Chapter 25. Heat Treatment of Metals
467
22
25.1 Heat-treatable Metals
467
1
25.2 Types of Heat Treatment
467
5
25.3 Heat Treatment of Other Metals
472
1
25.4 Heat-treating Equipment
473
2
25.5 Hardening Carbon Steel
475
2
25.6 Tempering Carbon Steel
477
1
25.7 Case Hardening Low-carbon Steel
478
1
25.8 Hardness Testing
479
7
25.9 Heat-treating Safety
486
3
Chapter 26. Metal Finishing
489
14
26.1 Quality of Machined Surfaces
489
3
26.2 Other Metal Finishing Techniques
492
11
Chapter 27. Electromachining Processes
503
8
27.1 Electrical Discharge Machining (EDM)
503
3
27.2 Electrical Discharge Wire Cutting (EDWC)
506
1
27.3 Electrochemical Machining (ECM)
507
4
Chapter 28. Nontraditional Machining Techniques
511
14
28.1 Chemical Machining
511
5
28.2 Hydrodynamic Machining (HDM)
516
1
28.3 Ultrasonic Machining
517
2
28.4 Electron Beam Machining (EBM)
519
2
28.5 Laser Beam Machining
521
4
Chapter 29. Other Processes
525
22
29.1 Machining Plastics
525
6
29.2 Chipless Machining
531
1
29.3 Powder Metallurgy
532
5
29.4 High-energy-rate Forming (HERF)
537
6
29.5 Cryogenic Applications
543
4
Chapter 30. Occupations in Machining Technology
547
10
30.1 Machining Job Categories
547
6
30.2 Preparing to Find a Job in Machining Technology
553
1
30.3 How to Get a Job
554
3
Reference Section
557
36
Glossary of Technical Terms
593
22
Index
615