This classic book features a richly illustrated, intensely visual treatment of basic machine tool technology and related subjects, including measurement and tools, reading drawings, mechanical hardware, hand tools, metallurgy, and the essentials of CNC. Covering introductory through advanced topics, Machine Tool Practices is formatted so that it may be used in a traditional lab-lecture program or a self-paced program. The book is divided into major sections that contain many instructional units. Each unit contains listed objectives, self tests with answers, and boxed material covering shop tips, safety, and new technologies. In this updated edition there are over 600 new photos and 1,500 revised line drawings!
Table of Contents:
SECTION A
Introduction
Unit 1 Shop Safety
Unit 2 Mechanical Hardware
Unit 3 Reading Drawings
SECTION B
Hand Tools
Unit 1 Arbor and Shop Presses
Unit 2 Work-Holding and Hand Tools
Unit 3 Hacksaws
Unit 4 Files
Unit 5 Hand Reamers
Unit 6 Identification and Uses of Taps
Unit 7 Tapping Procedures
Unit 8 Thread-Cutting Dies and Their Uses
Unit 9 Off-Hand Grinding
SECTION C
Dimensional Measurement
Unit 1 Systems of Measurement
Unit 2 Using Steel Rules
Unit 3 Using Vernier, Dial, and Digital Instruments for Direct Measurements
Unit 4 Using Micrometer Instruments
Unit 5 Using Comparison Measuring Instruments
Unit 6 Using Gage Blocks
Unit 7 Using Angular Measuring Instruments
Unit 8 Tolerances, Fits, Geometric Dimensions, and Statistical Process Control
SECTION D
Materials
Unit 1 Selection and Identification of Steels
Unit 2 Selection and Identification of Nonferrous Metals
Unit 3 Hardening, Case Hardening, and Tempering
Unit 4 Annealing, Normalizing, and Stress Relieving
Unit 5 Rockwell and Brinell Hardness Testers
SECTION E
Layout
Unit 1 Basic Semiprecision Layout Practice
Unit 2 Basic Precision Layout Practice
SECTION F
Preparation for Machining Operations
Unit 1 Machinability and Chip Formation
Unit 2 Speeds and Feeds for Machine Tools
Unit 3 Cutting Fluids
Unit 4 Using Carbides and Other Tool Materials>
SECTION G
Sawing Machines
Unit 1 Using Reciprocating and Horizontal Band Cutoff Machines
Unit 2 Abrasive and Cold Saws
Unit 3 Preparing to Use the Vertical Band Machine
Unit 4 Using the Vertical Band Machine
SECTION H
Drilling Machines
Unit 1 The Drill Press
Unit 2 Drilling Tools
Unit 3 Hand Grinding of Drills on the Pedestal Grinder
Unit 4 Operating Drilling Machines
Unit 5 Countersinking and Counterboring
Unit 6 Reaming in the Drill Press
SECTION I
Turning Machines
Unit 1 The Engine Lathe
Unit 2 Toolholders and Toolholding for the Lathe
Unit 3 Cutting Tools for the Lathe
Unit 4 Lathe Spindle Tooling
Unit 5 Operating the Machine Controls
Unit 6 Facing and Center Drilling
Unit 7 Turning between Centers
Unit 8 Alignment of the Lathe Centers
Unit 9 Other Lathe Operations
Unit 10 Sixty-Degree Thread Information and Calculations
Unit 11 Cutting Unified External Threads
Unit 12 Cutting Unified Internal Threads
Unit 13 Cutting Tapers
Unit 14 Using Steady and Follower Rests
Unit 15 Additional Thread Forms
Unit 16 Cutting Acme Threads on the Lathe
SECTION J
Vertical Milling Machines
Unit 1 Vertical Spindle Milling Machines
Unit 2 Cutting Tools and Cutter Holders for the Vertical Milling Machine
Unit 3 Setups on the Vertical Milling Machine
Unit 4 Vertical Milling Machine Operations
Unit 5 Using the Offset Boring Head
SECTION K
Horizontal Spindle Milling Machines
Unit 1 Horizontal Spindle Milling Machines
Unit 2 Types of Spindles, Arbors, and Adapters
Unit 3 Arbor-Driven Milling Cutters
Unit 4 Work-Holding Methods and Standard Setups
Unit 5 Machine Setup and Plain Milling
Unit 6 Using Side Milling Cutters
Unit 7 Using Face Milling Cutters on the Horizontal Milling Machine
SECTION L
Grinding and Abrasive Machining Processes
Unit 1 Selection and Identification of Grinding Wheels
Unit 2 Truing, Dressing, and Balancing of Grinding Wheels
Unit 3 Grinding Fluids
Unit 4 Horizontal Spindle Reciprocating Table Surface Grinders
Unit 5 Work Holding on the Surface Grinder
Unit 6 Using the Surface Grinder
Unit 7 Problems and Solutions in Surface Grinding
Unit 8 Center-Type Cylindrical Grinders
Unit 9 Using the Cylindrical Grinder
Unit 10 Universal Tool and Cutter Grinder
SECTION M
Computer Numerical Control and Other Advanced Machining Processes
Unit 1 CNC Machine Tool Programmable Axes and Position Dimensioning Systems
Unit 2 CNC Programming
Unit 3 CNC Tooling
Unit 4 Other Advanced Machining Processes
Appendix 1 Answers to Self-Tests
Appendix 2 General Tables
Table 1 Decimal Equivalents of Fractional Inches
Table 2 Inch/Metric Conversion Table
Table 3 Tap Drill Sizes
Table 4 Metric Tap Drill Sizes
Table 5A Tapers
Table 5B Tapers and Angles
Table 6 General Measurements
Table 7A Density or Specific Gravity of Metals and Alloys
Table 7B Approximate Melting Points of Metals and Various Substances
Table 8 Right-Triangle Solution Formulas
Table 9 Wire Gages and Metric Equivalents
Table 10 Cutting Speeds for Commonly Used Materials
Table 10A Feeds for High-Speed Steel End Mills
Table 10B Coolants and Cutting Oils Used for General Machining
About the Author :
Richard R. Kibbe served his apprenticeship in the shipbuilding industry and was graduated as a journeyman marine machinist. He holds an Associate in Arts degree in applied arts from Yuba Community College with an emphasis in machine tool technology. He also holds Bachelor’s and Master’s degrees from the California State University with an emphasis in machine tool manufacturing technology.
Mr. Kibbe has considerable job machine shop experience as well as community college and industrial teaching experience and is the author and co-author of several publications in the chain tool manufacturing field.
Roland O. Meyer spent the first 20 years of his career in the metal-working industry as a tool and die maker, machinist and worked in machine design and manufacturing. He completed his apprenticeship as a tool and die maker at Siemens in Germany and continued there as a journeyman building progressive punching dies.
He then worked in die shops in Toronto and Windsor, Canada before moving to Chicago employed as a gage maker at Ford Motor Company. Following this stint, he was in charge of the US army machine shops in Korea and Italy for five years. When he returned to the US, he worked in a manufacturing company designing and building experimental machines used in the timber and plywood industry. He next entered academia and became the lead instructor at Lane Community College’s Manufacturing Technology program in Eugene, Oregon, where he taught for 25 years. As CNC became the new method in machining, he developed a CNC curriculum and program. When CAM (Computer Aided Machining) became available he also developed a state of the art CAM program with the assistance of a local software company.
John E. Neely grew up in the Pacific Northwest and entered the Army to serve in World War II. The life John E. Neely is characterized by hard work, a variety of successes, and mentoring many others who became a part of his life.
Over the years Mr. Neely provided himself with a broad education and professional training through reading, a correspondence course in mechanical engineering, and good use of opportunities throughout his career. He became a master machinist, a mechanical engineer, a hydraulic engineer, and eventually an instructor at Lane Community College in Eugene, Oregon.
During his time as instructor he collaborated with others to develop highly successful course materials based on the individualized instruction approach. He and his collaborators wrote and had published several textbooks based on those materials. Those books continue to be in use nationally and internationally. After the death of his wife, he moved to Colorado Springs, Colorado, in April 2000 to be with his son and his family. There, for the three years until his death, he enjoyed the company of family and friends.
Warren White apprenticed as an Optical Instrument Maker with Land-Air, Inc. After military service with the Army Air Defense Board he obtained a graduate degree in Psychology at Clark University. His interest in both learning theory and machine tools led to employment at Foothill College in the Engineering Department.
Warren White initiated the Machine Tool Technology program at De Anza College after an extensive survey of Silicon Valley manufacturing firms. He was the Director of a California State-funded program to develop an Individualized Machinist Curriculum in conjunction with several California Community Colleges and Lane Community College in Oregon. He also initiated the California Community Colleges’ Multimediamobile which operated between several California Community Colleges to develop individualized instructional media in several technical disciplines.
He was the lead author and editor forMachine Tools and Machining Practices Volumes I and II published by John Wiley and Sons. He later taught Industrial Engineering classes at San Jose State University. He is certified by the Society of Manufacturing Engineers as a Manufacturing Engineer. After retiring from teaching he did voluntary Assistive Technology work with the Easter Seal Society in Santa Cruz, California, in a special program sponsored by IBM. He returned to work as a Quality Engineer for Seagate Technology, and obtained certification as a Quality Auditor. He started Seagate Technology on the path to achieving ISO 9001 certification.
