Machining Fundamentals From Basic to Advanced Techniques by John R. Walker Publisher The Goodheart-Willcox Company, Inc. Tinley Park, MlinoisMachining Fundamencals Copyright 2000 by THE GOODHEART-WILLCOX COMPANY, INC, Previous Editions Copyright 1998, 1993, 1989, 1981, 1977, 1973 All rights reserved, No part of this book may be reproduced, stored in a retrieval system, or transmitted in any form or by any means, electronic, mechanical, photocopying, recording, or otherwise, without the prior written permission of The Goodheart-Willcox Company, Inc. Manufactured in the United States of America Library of Congress Card Catalog Number 99-1776 International Standard Book Number 1-56637-662-9 345678910 00 0302 0100 Cover photo OWestlight (K. Tiedge) Waker, John FL ‘Machining Fundamentals from basi to advanced techniques / by Jofn RWaiker pom. Includes indo. ISBN -56697-662.0 41, Macrine-shop paces, 2, Machining LTte soxrrs | op!Introduction Machinists are highly skilled men and women. They use drawings, hand tools, precision measuring tools, drilling machines, grinders, lathes, milling machines, and other specialized machine tools to shape and finish metal and nonmetal parts. Machinists must have a sound understanding of basic and advanced machining technology, which includes: ‘* Proficiency in safely operating machine tools of various types (manual, auto- matic, and computer controlled). « Knowledge of the working properties of metals and nonmetals. « The academic skills (math, science, English, print reading, metallurgy, etc) needed to make precision layouts and machine set-ups. Machining Fundamentals provides an introduction to this important area of manufacturing technology. The text explains the “how, why, and when” of numer- ous machining operations, set-ups, and procedures. Through it, you will learn how machine tools operate and when to use one particular machine instead of another. ‘The advantages and disadvantages of various machining techniques are discussed, along with their suitability for particular applications. Machining Fundamentals details the many common methods of machining and shaping parts to meet given specifications. It also covers newer processes such as laser machining and welding, water-jet cutting, high-energy-rate forming (HERP), cryogenics, chipless machining, electrical discharge machining (EDM), electro- chemical machining (ECM), robotics, and rapid prototyping. The importance of computer numerical control (CNC) in the operation of most machine tools, and its tole in automated manufacturing is explored thoroughly. This new edition of Machining Fundamentals has many features that make it easy to read and understand. A numbering system for headings has been adopted to make it casier to locate information in a chapter. Learning objectives are presented at the beginning of each chapter, along with a list of selected technical terms important to understanding the material in that chapter. Throughout the ‘book, technical terms are highlighted in bold italic type as they are introduced and defined. Several hundred of these terms are also listed and defined in a Glossary of ‘Technical Terms at the end of this text. Review questions covering the content taught are presented at the end of each chapter. Color is employed extensively in this new edition to enhance understanding and to emphasize safety precautions. A consistent color coding has been employed in the hundreds of line illustrations (most made especially for the text) to help you visualize more clearly the machining operations and procedures, Many of the black and white photographs in the text have been replaced with new, full-color photos showing the most current types of equipment and processes. Machining Fundamentals is a valuable guide to anyone interested in machining, since the procedures and techniques presented have been drawn from all areas of machining technology. John R. Walker