Machining Fundamentals From Basic to Advanced Techniques by John R. Walker Publisher The Goodheart-Willcox Company, Inc. Tinley Park, MlinoisMachining Fundarencals 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Machining Fundamentals Color Key Colors are used throughout Machining Fundamentals to indicate various materials or equipment features. The following key shows what each color represents. E| Metals (surfaces) Rulers and measuring devices | Metals (in section) Direction or force arrows, — dimensional information Bw Machines/machine parts || Fasteners B Tools ial Abrasives Be Cutting edges LI Fluids fo Work-holding and tool-holding devices ga Miscellaneous IMPORTANT SAFETY NOTICE Work procedures and shop practices described in this book are effective, but general, methods of performing given operations. Always use special tools and equipment as recommended. Carefully follow all safety warnings and cautions (\hey are printed in red type for greater legibility). Note that these warnings are not exhaustive. Proceed with care and under proper supervision to minimize the risk of personal injury or injury to others. Also follow specific equipment operating instructions. This book contains the most complete and accurate information that could be obtained from various authoritative sources at the time of publication. Goodheart-Willcox Publisher cannot assume respon- sibility for any changes, errors, or omissions.Contents Chapter |. An Introduction to Machining Technology .. 1.1 The Evolution of Machine Tools. .... : 1.2. Basic Machine Tool Operation . ... 13 Nontraditional Machining Processes 14 Automating the Machining Process. 15 The Evolving Role of the Machinist Chapter 2. Shop Safety... . 2.1 Safety in the Shop . . 22 General Machine Safety 23 General Tool Safety . 24 Fire Safety Chapter 3. Understanding Drawings 3.1 Dimensions. . 32 Information Included on Drawings 3.3. Types of Prints..... 344 Types of Drawings Used in the Shop 35. Parts List... 36 Drawing Sizes . 37 Geometric Dimensioning and Tolerancing . Chapter 4. Measurement 4.1 TheRule. . : 42 The Micrometer Caliper . 43. Vernier Measuring Tools. 44 Gages .... 45 Dial Indicators . 4.6 Other Gaging Tools .....-- 47 Helper Measuring Tools . . Chapter 5. Layout Work .. 5.1 Making Lines on Metal 52 Squares... : 5.3 Measuring Angles a 54 Simple Layout Steps -....... 55 Layout SafetyMachining Fundan Chapter 6. Hand Tools ........+.+seceeeee ee IE 6.1 Clamping Devices . 1 62 Pliers... 63 Wrenches ..... 64 Screwdrivers... 6.5 Striking Tools 69 6.10 6.11 Hand Polishing ........... Chapter 7. Fasteners . 7.1 Threaded Fasteners . cee 72 Nonthreaded Fastening Devices, 73 Adhesives. 74 Fastener Safety. Chapter 8. Jigs and Fixtures 143 B81 Jigs... : 143 82 Fixtures. 115 83 Jig and Fixture Construction, 146 Chapter 9. Cutting Fluids. . 149 9.1. Types of Cutting Fluids : 2149 9.2 Application of Cutting Fluids. -150 Chapter 10. Drills and Drilling | Macl 153 10.1 Drilling Machines coset evteeeees eee 138 10.2 Drill Press Safety . fesse BT 103. Drills. 104 Drill-holding Devices - 105° Work-holding Devices. ..... 10.6 Cutting Speeds and Feeds. 107 Cutting Compounds ..... 108 Sharpening Drills. 10.9. Drilling . : 10.10 Countersinking 10.11 Counterboring 10.12 Spotfacing. 10.13 Tapping. . 10.14 Reaming . Chapter 11. Offhand Grinding . ‘11.1 Abrasive Belt Grinders ....... M2 Bench and Pedestal Grinders . 11.3. Grinding Wheels . 114 Abrasive Belt and Grinder Safety 11.5 Using a Dry-type Grinder IL6 Using a Wet-type Grinder. 11.7 Portable Hand Grinders . 183 = 183 + 183 2185 - 186 187 «188 188table of Contents Chapter 12. Sawing and Cutoff Machines ....... 191 12.1. Metal-cutting Saws .. ee er 122. Reciprocating Power Hacksaw. 123 Power Band Saw . 124 Using Reciprocating and Band Saws 125 Circular Metal-cutting Saws . 12.6 Power Saw Safety ... Chapter 13. The Lathe 13.1 LatheSize.... 13.2 Major Parts of a Lathe 133 Preparing Lathe for Operation. 13.4 Cleaning the Lathe. ....... 13.5. Lathe Safety .... 136 Cutting Tools and Tool Holders - 13,7 Cutting Speeds and Feeds. 13.8 Workholding Attachments... 139 Turning Work Between Centers 13.10 Using Lathe Chucks. 13.11 Facing Stock Held in Chuck... : 13.12 Plain Turning and Turning to a Shoulder 13.13 Parting Operations. . Chapter 14. Cutting Tapers and Screw Threads on the Lathe ... 14.1 Taper Turning 142 Calculating 143 Measuring TTilstock Setover. 144 Cutting a Taper 14.3. Measuring Tapers . . 14.6 Cutting Screw Threads on the Lathe . Chapter 15. Other Lathe Operations .........- 261 15.1 Boring on a Lathe. ..... a --261 152 Drilling and Reaming on a Lathe +263 153 Knurling on a Lathe. : = 265 154 Filing and Polishing on a Lathe . -267 155. Steady and Follower Rests . = 268 15.6 Mandrels. . wee -.270 15.7 Grinding on v the Lathe. 270 158 Milling ona Lathe . 272 159. Special Lathe Attachments . 122 15.10 Industrial Applications of the Lathe . 274 Chapter 16. Broaching Operations. cence ee eee se 281 16.1 Advantages of Broaching -....... 283 16.2 Keyway Broaching. = 283