Table of Contents

Technology of Machine Tools 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 Cutter and Tool 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: Cellular 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: Instant Digital Manufacturing Unit 91: Cryogenic Treatment/Tempering Unit 92:QQC Diamond Coating Unit 93: Direct Metal Deposition Unit 94: e-Manufacturing Unit 95: STEP-NC and Internet Manufacturing 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 Unit 100: Multi-Tasking Machines Section 18 Glossary Appendix of Tables Index

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.