Technology of Machine Tools provides state-of-the-art training for using machine tools in manufacturing technology, including up-to-date coverage of computer numerical control (CNC). It includes an overview of machine trades and career opportunities followed by theory and application. The text is structured to provide coverage of tools and measurement, machining tools and procedures, drilling and milling machines, computer-aided machining, and metallurgy.
This book is based on the authors’ many years of trade experience and experience as specialists in teaching. To keep up-to-date with technological change, the authors have researched the latest technical information available and have visited industries that are leaders in their field.
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Table of Contents:
Section 1: Introduction to Machine Tools
Unit 1: History of Machines
Section 2: Machine Trade Opportunities
Unit 2: Careers in the Metalworking Industry
Unit 3: Getting the Job
Section 3: Safety
Unit 4: Safety in the Machine Shop
Section 4: Job Planning
Unit 5: Engineering Drawings
Unit 6: Machining Procedures for Various Workpieces
Section 5: Measurement
Unit 7: Basic Measurement
Unit 8: Squares and Surface Plates
Unit 9: Micrometers
Unit 10: Vernier Calipers
Unit 11: Inside-, Depth-, and Height-Measuring Instruments
Unit 12: Gage Blocks
Unit 13: Angular Measurement
Unit 14: Gages
Unit 15: Comparison Measurement
Unit 16: The Coordinate Measuring System
Unit 17: Measuring with Light Waves
Unit 18: Surface Finish Measurement
Section 6: Layout Tools and Procedures
Unit 19: Basic Layout Materials, Tools, and Accessories
Unit 20: Basic or Semiprecision Layout
Unit 21: Precision Layout
Section 7: Hand Tools and Bench Work
Unit 22: Holding, Striking, and Assembling Tools
Unit 23: Hand-Type Cutting Tools
Unit 24: Thread-Cutting Tools and Procedures
Unit 25: Finishing Processes – Reaming, Broaching, and Lapping
Unit 26: Surface Finishing Processes
Section 8: Metal-Cutting Technology
Unit 27: Physics of Metal Cutting
Unit 28: Machinability of Metals
Unit 29: Cutting Tools
Unit 30: Operating Conditions and Tool Life
Unit 31: Carbide Cutting Tools
Unit 32: Diamond, Ceramic, and Cermet Cutting Tools
Unit 33: Polycrystalline Cutting Tools
Unit 34: Cutting Fluids – Types and Applications
Section 9: Metal-Cutting Saws
Unit 35: Types of Metal Saws
Unit 36: Contour Bandsaw Parts and Accessories
Unit 37: Contour Bandsaw Operations
Section 10: Drilling Machines
Unit 38: Drill Presses
Unit 39: Drilling Machine Accessories
Unit 40: Twist Drills
Unit 41: Cutting Speeds and Feeds
Unit 42: Drilling Holes
Unit 43: Reaming
Unit 44: Drill Press Operations
Section 11: The Lathe
Unit 45: Engine Lathe Parts
Unit 46: Lathe Accessories
Unit 47: Cutting Speed, Feed, and Depth of Cut
Unit 48: Lathe Safety
Unit 49: Mounting, Removing, and Aligning Lathe Centers
Unit 50: Grinding Lathe Cutting Tools
Unit 51: Facing Between Centers
Unit 52: Machining Between Centers
Unit 53: Knurling, Grooving, and Form Turning
Unit 54: Tapers and Taper Turning
Unit 55: Threads and Thread Cutting
Unit 56: Steady Rest, Follower Rests, and Mandrels
Unit 57: Machining in a Chuck
Unit 58: Drilling, Boring, Reaming, and Tapping
Section 12: Milling Machines
Unit 59: The Vertical Milling Machine
Unit 60: Cutting Speed, Feed, and Depth of Cut
Unit 61: End Mills
Unit 62: Vertical Mill Operations
Unit 63: Special Milling Operations
Unit 64: Horizontal Milling Machines and Accessories
Unit 65: Milling Cutters
Unit 66: Milling Machine Setups
Unit 67: Horizontal Milling Operations
Unit 68: The Indexing, or Dividing, Head
Unit 69: Helical Milling
Unit 70: Cam, Rack, Worm, and Clutch Milling
Section 13: Grinding
Unit 71: Types of Abrasives
Unit 72: Surface Grinders and Accessories
Unit 73: Surface Grinding Operations
Unit 74: Cylindrical Grinders
Unit 75: Universal Tool and Cutter Grinder
Section 14: Metallurgy
Unit 76: Manufacture and Properties of Steel
Unit 77: Heat Treatment of Steel
Unit 78: Testing of Metals and Nonferrous Metals
Section 15: Lean Manufacturing
Unit 79: Cellular Manufacturing
Unit 80: Continuous Improvement
Unit 81: Pull (Kanban) Systems
Unit 82: Total Productive Maintenance
Unit 83: Value-Stream Mapping
Unit 84: Workplace Organization
Section 16: Computer-Age Machining
Unit 85: The Computer
Unit 86: Computer Numerical Control
Unit 87: CNC Turning Center
Unit 88: CNC Machining Centers
Unit 89: CAD/CAM
Section 17: Advanced Manufacturing Technology
Unit 90: Nanotechnology
Unit 91: Cryogenic Treatment/Tempering
Unit 92: Diamond Coating
Unit 93: Additive Manufacturing Technologies
Unit 94: Multi-Tasking Machines
Unit 95: Industry 4.0
Unit 96: Optical/Laser/Vision Measurement
Unit 97: Electrical Discharge Machining
Unit 98: Robotics
Unit 99: Manufacturing Intelligence: Can a Company Survive without Real-Time Knowledge
About the Author :
Steve F. Krar spent 15 years in the trade, first as a machinist and finally as a tool and die maker. After this period, he entered Teachers’ College and graduated from the University of Toronto with a Specialist’s Certificate in Machine Shop Practice. During these 20 years of teaching, Mr. Krar was active in vocational and technical education and served on the executive committee of many educational organizations. For 10 years, he was on the summer staff of the College of Education, University of Toronto, involved in teacher training programs. Active in machine tool associations, Steve Krar is a Life Member of the Society of Manufacturing Engineers and former associate director of the GE Superabrasives Partnership for Manufacturing Productivity. He was inducted into the Canadian Manufacturers Hall of Fame in March 2009. Mr. Krar’s continual research over the past 50 years in manufacturing technology has involved many courses with lead- ing world manufacturers and an opportunity to study under Dr. W. Edwards Deming. Mr. Krar spent a week researching Nano- technology at leading research centers, universities, and industry in Switzerland. He is coauthor and consultant of over 80 technical books, such as Machine Shop Training, Machine Tool Operations, CNC Simplified, Superabrasives—Grinding and Machining, Exploring Advanced Manufacturing Technologies, some of which have been translated into 5 languages and used throughout the world.
Jonathan A. Gill graduated from high school with an Ontario Secondary School Diploma. He entered Ryerson University in the industrial engineering program and then went into geographical analysis. Mr. Gill attended Humber College for electronics engineering and then spent 2 years at Mohawk College for computer networking and security analysis. Mr. Gill is currently an independent contractor employed by Nexas Networks Inc. as an Applications Engineer and Support Manager, providing factory floor networking and information technology for the aerospace and automotive industry, jobbing shops, and production discrete manufacturing facilities. Mr. Gill assisted the authors with the research, artwork, and final production of manuscript for the textbook Computer Numerical Control Simplified and is coauthor of the book Changing World of Manufacturing.
Peter Smid graduated from high school with a specialty in machine shop training. He then entered industry, completed an apprenticeship program, and gained valuable experience as a machinist skilled on all types of machine tools. Mr. Smid immigrated to Canada in 1968 and spent the next 26 years employed in the machine tool industry as a machinist and tool and die maker. In the early 1970s, he became involved in Computer Numerical Control (CNC) as a programmer/operator and devoted the next 18 years to becoming proficient in all aspects of computerized manufacturing. In 1989, he became an independent consultant, and hundreds of companies have used Mr. Smid’s CNC and CAD/CAM skills to improve their manufacturing operations. He also wrote a comprehensive, 500-page CNC programming handbook, which is rapidly becoming the Bible of the trade. In 1995, he became a consultant/professor of Advanced Manufacturing focusing on industrial and customized training in CNC, CAD/CAM, and Agile Manufacturing. His many years of teaching, training, lecturing, and designing curriculum give him the opportunity to pass along his vast knowledge of modern manufacturing technology to students of all ages.
