44543_fm_ptg01_hr_i-xxii.indd 22 17/01/14 11:55 PM Precision Machining Technology Second Edition Peter J. Hoffman Berks Career & Technology Center, West Campus, Leesport, PA Eric S. Hopewell Berks Career & Technology Center, West Campus, Leesport, PA Brian Janes Bowling Green Technical College, Bowling Green, KY Australia • Brazil • Japan • Korea • Mexico • Singapore • Spain • United Kingdom • United States Copyright 2015 Cengage Learning. All Rights Reserved. May not be copied, scanned, or duplicated, in whole or in part. Due to electronic rights, some third party content may be suppressed from the eBook and/or eChapter(s). Editorial review has deemed that any suppressed content does not materially affect the overall learning experience. Cengage Learning reserves the right to remove additional content at any time if subsequent rights restrictions require it. 44543_fm_ptg01_hr_i-xxii.indd 1 # 150505 Cust: Cengage Au: Hoffman Pg. No. i C / M / Y / K S4DcESIGaN SrERVlICiESS OlF e17/01/14 11:55 PM Title: Precision Machining Technology 2e Server: Short / Normal Publishing Services This is an electronic version of the print textbook. Due to electronic rights restrictions, some third party content may be suppressed. Editorial review has deemed that any suppressed content does not materially affect the overall learning experience. The publisher reserves the right to remove content from this title at any time if subsequent rights restrictions require it. For valuable information on pricing, previous editions, changes to current editions, and alternate formats, please visit www.cengage.com/highered to search by ISBN#, author, title, or keyword for materials in your areas of interest. Copyright 2015 Cengage Learning. All Rights Reserved. May not be copied, scanned, or duplicated, in whole or in part. Due to electronic rights, some third party content may be suppressed from the eBook and/or eChapter(s). 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The publisher shall not be liable for any special, consequential, or exemplary damages resulting, in whole or part, from the readers’ use of, or reliance upon, this material. Printed in the United States of America 1 2 3 4 5 6 7 18 17 16 15 14 Copyright 2015 Cengage Learning. All Rights Reserved. May not be copied, scanned, or duplicated, in whole or in part. Due to electronic rights, some third party content may be suppressed from the eBook and/or eChapter(s). Editorial review has deemed that any suppressed content does not materially affect the overall learning experience. Cengage Learning reserves the right to remove additional content at any time if subsequent rights restrictions require it. 44543_fm_ptg01_hr_i-x#x i1i.i5nd0d5 0 25 Cust: Cengage Au: Hoffman Pg. No. ii C / M / Y / K S4DcESIGaN SrERVlICiESS OlF e 17/01/14 11:55 PM Title: Precision Machining Technology 2e Server: Short / Normal Publishing Services Co n T E n TS Preface .......................................................................xv Conventional Machinist ........................................... 22 Acknowledgments .................................................xviii CNC Machinist ........................................................ 22 From the Authors ......................................................xx Programmer ........................................................... 24 Die Maker, Mold Maker, Toolmaker ............................ 24 About the Authors ...................................................xxi Supervisory Positions ............................................... 25 Related Careers ......................................................... 25 SECTION 1 Mechanical Designer ............................................... 25 Introduction to Machining .................3 Engineering Positions .............................................. 25 Machine Tool Service Technician ...............................26 Unit 1 Introduction to Machining ............4 Quality Control Technician/Inspector ........................26 Learning Objectives ....................................................4 Industrial Salesperson ...............................................27 Key Terms ....................................................................4 Summary ................................................................... 27 Introduction ................................................................5 Review Questions ..................................................... 27 Machining Defined .....................................................5 History of Machining ..................................................5 Simple Machine Tools ................................................5 Unit 3 Workplace Skills ............................. 28 Industrial Revolution .................................................6 Learning Objectives ..................................................28 20th-Century Machining ............................................ 7 Key Terms ..................................................................28 The Role of Machining in Society ..............................8 Introduction ..............................................................29 People, Manufacturing, and Machining .......................8 Personal Skills ............................................................29 Major Machine Tools .................................................. 11 Mechanical Aptitude ...............................................29 Sawing Machines ..................................................... 11 Manual Dexterity and Eye-Hand Coordination ...........29 Problem-Solving, Troubleshooting, The Drill Press ...........................................................13 and Decision-Making Skills .......................................29 The Lathe ................................................................13 Focus and Concentration with Attention to Detail .......29 The Milling Machine .................................................13 Persistence and Patience ..........................................30 Abrasive Machining ..................................................15 Personal Responsibility and Reliability .......................30 Electrical Discharge Machining ..................................16 Ability to Perform Multi-Step Processes ......................30 Laser Machining .......................................................16 Ability to Use Technical Reference Materials ...............30 Water Jet Machining .................................................17 Interpersonal Skills ..................................................30 Summary ....................................................................19 Review Questions ......................................................19 Significant Memory Use ...........................................30 Technical Skills ..........................................................30 Unit 2 Careers in Machining .................... 20 Ability to Interpret Engineering Drawings ...................30 Knowledge of English and Metric Learning Objectives ..................................................20 Systems of Measurement...........................................31 Key Terms ..................................................................20 Proficient Math Skills ................................................31 Introduction ...............................................................21 Use of Hand Tools, Measuring Tools, Modern Machining Careers ......................................21 and Machine and Cutting Tools .................................31 Operator .................................................................21 Understanding of Metals and Other Materials Set-up Technician .....................................................21 and Their Properties ..................................................31 iii Copyright 2015 Cengage Learning. 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No. iii C / M / Y / K S4DcESIGaN SrERVlICiESS OlF e17/01/14 11:55 PM Title: Precision Machining Technology 2e Server: Short / Normal Publishing Services iv Contents Knowledge and Skill in the Use of SDS .............................................................................56 Computer Technology ...............................................31 Fire Safety ..................................................................60 Training Opportunities/Methods .............................31 The Fire Triangle ......................................................60 Secondary School (High School) Programs ..................31 Fire Extinguishers ....................................................60 Post-Secondary Training .......................................... 32 Safety Documentation ..............................................61 Employer-Provided Training ..................................... 32 Summary ...................................................................62 Apprenticeships ...................................................... 32 Review Questions .....................................................63 NIMS ........................................................................... 33 Job Seeking ............................................................... 33 Unit 2 Measurement Systems Career Plan ............................................................. 33 Resume .................................................................. 33 and Machine Tool References ..............................................................36 Math overview ...............................64 Cover Letter ............................................................36 Learning Objectives ..................................................64 Career Portfolio .......................................................38 Key Terms ..................................................................65 Finding Opportunities ..............................................38 Introduction ..............................................................65 Interviewing ...........................................................38 Measurement Systems of the Summary ...................................................................40 Machining World ......................................................65 Review Questions .....................................................40 The English System (Inches) ......................................65 The Metric System or SI.............................................65 Machining Mathematic Concepts SECTION 2 and Operations .........................................................65 Fractional Operations ..............................................65 Measurement, Materials, Fractional/Decimal Conversion .................................68 and Safety ....................................................42 Basic Algebra ..........................................................68 Ratios and Proportions ............................................ 70 Unit 1 Introduction to Safety .................. 44 English/Metric and Metric/English Learning Objectives ..................................................44 Conversions ............................................................ 70 Key Terms ..................................................................44 Basic Geometry ........................................................71 Introduction ..............................................................45 Angles .....................................................................72 General Safety Guidelines ........................................45 Cartesian Coordinates ............................................. 76 OSHA and NIOSH ....................................................45 Basic Trigonometry ...................................................77 General Clothing Summary ....................................................................81 for a Machining Environment ..................................46 Review Questions .....................................................82 Personal Protective Equipment (PPE)......................46 Eye Protection ......................................................... 47 Hearing Protection .................................................. 47 Unit 3 Semi-Precision Respirators .............................................................48 Measurement .................................. 83 Gloves ....................................................................48 Learning Objectives ..................................................83 Hard Hats ...............................................................49 Key Terms ..................................................................83 Housekeeping ...........................................................49 Introduction ..............................................................84 Guards and Barriers ..................................................50 What Is Semi-Precision Handling and Lifting..................................................51 Measurement? ..........................................................84 Compressed Air Safety ..............................................51 Rules ..........................................................................84 Lockout/Tagout......................................................... 52 Reading English Rules ..............................................85 Tagout ................................................................... 52 Reading Metric Rules ...............................................86 Lockout .................................................................. 52 Calipers ......................................................................88 Hazardous Materials .................................................53 Adjustable Squares ....................................................91 Hazardous Material Labeling .................................... 53 The Combination Set ................................................91 Copyright 2015 Cengage Learning. 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No. iv C / M / Y / K S4DcESIGaN SrERVlICiESS OlF e 17/01/14 11:55 PM Title: Precision Machining Technology 2e Server: Short / Normal Publishing Services Contents v Angular Measurement .............................................92 Precision Transfer or Helper-Type Protractors ..............................................................92 Measuring Tools .......................................................133 Bevels .....................................................................92 Small Hole Gages ...................................................133 Die Maker’s Square ..................................................95 Telescoping Gages ..................................................134 Fixed Gages ...............................................................95 Adjustable Parallels ................................................134 Radius and Fillet Gages ............................................95 Dial and Digital Indicators .......................................135 Angle Gages ...........................................................96 Applications of Plunge-Type Indicators .....................136 Screw Pitch Gage .....................................................96 Applications of Test Indicators .................................136 Summary ...................................................................97 Sine Tools ..................................................................140 Review Questions .....................................................97 Sine Bars and Sine Blocks ........................................140 Sine Plates .............................................................140 Sine Vises ............................................................... 141 Unit 4 Precision Measurement ...............99 Surface Finish Measurement .................................. 141 Learning Objectives ..................................................99 Surface Roughness Comparator ...............................143 Key Terms ................................................................ 100 Profilometer ...........................................................143 Introduction ............................................................ 100 Optical Comparators ...............................................143 What is Precision Measurement? ........................... 100 Toolmaker’s Microscope ..........................................144 Care of Precision Tools ............................................ 100 Coordinate Measuring Machine .............................145 Straight Edges ..........................................................101 Summary ..................................................................145 Precision Fixed Gages ..............................................101 Review Questions ....................................................146 Thickness Gages ..................................................... 101 Pin or Plug Gages ................................................... 101 Unit 5 Quality Assurance, Ring Gages ............................................................103 Process Planning, Snap Gages ...........................................................105 Surface Plates .......................................................... 106 and Quality Control...................... 147 Solid Squares ............................................................107 Learning Objectives .................................................147 Gage Blocks ............................................................. 108 Key Terms .................................................................147 Selecting Gage Blocks for Builds ...............................109 Introduction .............................................................148 Vernier Measuring Tools ...........................................111 Quality Assurance ....................................................148 Vernier Calipers .......................................................111 The Process Plan ......................................................148 Vernier Height Gage.................................................111 Material Selection ..................................................148 Vernier Depth Gage .................................................112 Machine Selection and Workholding ........................148 Vernier Gear Tooth Caliper ........................................112 Tooling Selection ....................................................148 Vernier Protractor ....................................................112 Speed and Feed Calculation ....................................150 Reading Vernier Scales .............................................113 Other Information ..................................................150 Micrometers ..............................................................117 Quality Control .........................................................150 Outside Micrometer Caliper ......................................117 Sampling Plan .......................................................150 Reading Outside Micrometer Calipers ........................121 Inspection Plan ......................................................150 Calibration of the Outside Statistical Process Control (SPC) ...............................150 Micrometer Caliper .................................................122 Summary ..................................................................156 Inside Micrometers .................................................125 Review Questions ....................................................156 Depth Micrometers ................................................. 127 Dial and Digital Measuring Tools ............................128 Unit 6 Metal Composition Dial and Digital Calipers .........................................128 Dial and Digital Height Gages..................................130 and Classification ..........................157 Dial and Digital Depth Gages ..................................130 Learning Objectives .................................................157 Dial and Digital Bore Gages .....................................132 Key Terms .................................................................157 Copyright 2015 Cengage Learning. 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No. v C / M / Y / K S4DcESIGaN SrERVlICiESS OlF e17/01/14 11:55 PM Title: Precision Machining Technology 2e Server: Short / Normal Publishing Services vi Contents Introduction .............................................................158 Unit 8 Maintenance, Lubrication, Ferrous Metals ..........................................................158 and Cutting Fluid Wrought Iron .........................................................158 overview .........................................190 Plain Carbon Steels .................................................158 Learning Objectives ................................................ 190 Alloy Steels ............................................................159 Key Terms ................................................................ 190 Tool Steels..............................................................160 Maintenance ............................................................191 Cast Iron ................................................................164 Lubrication ............................................................ 191 Stainless Steels .......................................................164 Moving Parts and Wear Surfaces ..............................193 Nonferrous Metals ...................................................167 Cutting Fluids ...........................................................193 Aluminum Alloys ....................................................167 Oil-Based Cutting Fluids ..........................................194 Magnesium Alloys ..................................................168 Chemical-Based Cutting Fluids ................................195 Copper Alloys .........................................................169 Measuring Cutting Fluid Mixtures.............................196 Titanium Alloys ......................................................170 Refractometer ........................................................196 Superalloys ............................................................170 Cold Air Guns .........................................................196 Summary ..................................................................174 Solid and Semi-Solid Cutting Compounds .................196 Review Questions ....................................................174 Methods of Application ...........................................197 Summary ................................................................. 198 Unit 7 Heat Treatment of Metals ............175 Review Questions ................................................... 199 Learning Objectives .................................................175 Key Terms .................................................................175 SECTION 3 Introduction .............................................................176 Hardening ................................................................176 Job Planning, Benchwork, Direct Hardening ....................................................176 Surface Hardening..................................................176 and Layout .............................................. 200 Case Hardening ......................................................176 Unit 1 Understanding Drawings ...........202 Tempering ................................................................179 Annealing .................................................................179 Learning Objectives ................................................202 Normalizing ..............................................................179 Key Terms ................................................................202 Heat Treatment of Nonferrous Metals ....................179 Importance of Engineering Drawings ...................203 Aluminum Alloys ....................................................179 Components of Engineering Drawings ................203 Heat-Treating Furnaces .......................................... 180 Title Block ............................................................. 203 Box Furnaces ..........................................................180 Orthographic Projection ........................................ 203 Production and Specialty Furnaces ...........................180 Line Types ..............................................................207 Atmospheric Furnaces ............................................ 181 Basic Symbols and Notation ................................... 211 Furnace Controls ....................................................182 Tolerance .................................................................. 211 Bilateral Tolerances..................................................211 Heat-Treatment Safety.............................................182 Hardness Scales and Testing ...................................182 Unilateral Tolerances ...............................................211 Rockwell Hardness Scales ........................................182 Limit Tolerances .....................................................213 Brinell Hardness Scale .............................................186 MMC and LMC .......................................................213 Cross-Reference of Brinell and Rockwell Tolerance Specifications ..........................................214 Hardness Values .....................................................188 Classes of Fit .............................................................214 Summary ................................................................. 188 Allowances ............................................................214 Review Questions ................................................... 189 Classifications of Fits ............................................... 217 Copyright 2015 Cengage Learning. 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No. vi C / M / Y / K S4DcESIGaN SrERVlICiESS OlF e 17/01/14 11:55 PM Title: Precision Machining Technology 2e Server: Short / Normal Publishing Services Contents vii Geometric Dimensioning Tongue-and-Groove Pliers .......................................252 and Tolerancing (GD&T) .........................................220 Side Cutting Pliers ...................................................252 Datum ................................................................. 220 Diagonal Cutters ....................................................252 Feature Control Frame ........................................... 220 Hammers ................................................................. 252 Interpretation of Geometric Tolerances .................... 220 Ball Peen................................................................252 Summary .................................................................229 Soft Face ................................................................252 Review Questions ...................................................230 Wrenches ................................................................. 253 Open-End Wrench ................................................. 254 Unit 2 Layout ...............................................232 Box-End Wrench .................................................... 254 Learning Objectives ................................................ 232 Double-Ended Wrench ........................................... 254 Key Terms ................................................................ 232 Adjustable Wrench ................................................ 254 Introduction ............................................................ 233 Socket Wrench .......................................................255 Layout Fluid (Layout Dye) ...................................... 233 Spanner Wrench .....................................................255 Layout Fluid Remover .............................................233 Hex Key Wrench .....................................................255 Semi-Precision Layout ............................................234 Bench Vise ...............................................................256 Scribers ................................................................ 234 Bases ................................................................... 256 Layout with a Combination Set ................................235 Jaws .....................................................................257 Divider ..................................................................235 Clamps .....................................................................258 Trammel ............................................................... 236 C-Clamp ............................................................... 258 Prick and Center Punches ....................................... 236 Parallel Clamp....................................................... 258 Hermaphrodite Caliper .......................................... 238 Hinged Clamp ....................................................... 258 Plain Protractor ..................................................... 238 Hacksaws .................................................................258 Surface Plate ......................................................... 238 Hacksaw Blades .................................................... 258 Surface Gage ........................................................ 238 Hacksaw Use ........................................................ 258 Workholding Accessories ........................................ 240 Files ..........................................................................259 Precision Layout .......................................................241 File Classification ................................................... 259 Height Gage ..........................................................241 Special Files ..........................................................260 Precision Angular Layout ........................................241 File Selection ..........................................................261 Basic Layout Construction and Math .................... 242 General File Use ......................................................261 The Layout of Square Shapes ...................................245 Filing Tips ............................................................. 263 Layout Procedure Guidelines .................................248 Deburring ................................................................263 Summary .................................................................248 Abrasives .................................................................263 Review Questions ...................................................249 Summary .................................................................264 Review Questions ...................................................265 Unit 3 Hand Tools .......................................250 Learning Objectives ................................................250 Unit 4 Saws and Cutoff Machines ....... 266 Key Terms ................................................................250 Learning Objectives ................................................266 Introduction .............................................................251 Key Terms ................................................................266 Screwdrivers .............................................................251 Introduction ............................................................ 267 Phillips ..................................................................251 Power Hacksaws ..................................................... 267 Straight .................................................................251 Band Sawing Machines .......................................... 267 Offset ....................................................................251 Horizontal Band Saws .............................................267 Torx ......................................................................251 Vertical Band Saws ................................................269 Pliers .........................................................................251 Saw Blade Characteristics and Applications ..........271 Slip Joint Pliers .......................................................251 Blade Material........................................................ 271 Needle Nose Pliers ..................................................251 Tooth Set ...............................................................273 Locking Pliers .........................................................252 Blade Pitch or TPI ....................................................273 Copyright 2015 Cengage Learning. All Rights Reserved. May not be copied, scanned, or duplicated, in whole or in part. Due to electronic rights, some third party content may be suppressed from the eBook and/or eChapter(s). Editorial review has deemed that any suppressed content does not materially affect the overall learning experience. Cengage Learning reserves the right to remove additional content at any time if subsequent rights restrictions require it. 44543_fm_ptg01_hr_i-xxii.indd 7 # 150505 Cust: Cengage Au: Hoffman Pg. No. vii C / M / Y / K S4DcESIGaN SrERVlICiESS OlF e17/01/14 11:55 PM Title: Precision Machining Technology 2e Server: Short / Normal Publishing Services viii Contents Blade Width ...........................................................274 Threading and Tapping ..........................................298 Blade Thickness or Gauge ........................................274 Basic Thread Terminology ......................................298 Rake ......................................................................274 Thread Designations...............................................301 Gullet ....................................................................275 Tap Drills ...............................................................301 Tooth Patterns........................................................275 Tapered Pipe Threads ............................................. 302 Band Saw Blade Welding .........................................275 Tap Styles ............................................................. 302 Band Length ..........................................................275 Tap Use .................................................................307 Band Welding ........................................................276 Die Use .................................................................309 Band Saw Blade Mounting/Removal..................... 278 Summary ..................................................................310 Blade Speed ............................................................ 279 Review Questions .................................................... 311 The Abrasive Cutoff Saw ........................................ 279 Metal Cutting Circular (Cold) Saws .........................281 Summary ..................................................................281 SECTION 4 Review Questions ...................................................282 Drill Press ................................................. 313 Unit 5 offhand Grinding .........................283 Unit 1 Introduction to Learning Objectives ................................................283 the Drill Press .................................. 314 Key Terms ................................................................283 Learning Objectives .................................................314 Introduction ............................................................284 Key Terms .................................................................314 Grinder Uses ............................................................284 Introduction .............................................................315 Abrasive Belt and Disc Machine Uses ....................285 Upright Drill Press ....................................................316 Grinding Wheels .....................................................285 Drill Press Controls .................................................. 317 Abrasive Type ........................................................ 285 Gang Drill Press ......................................................318 Wheel Grit (Abrasive Grain Size) ..............................286 Radial-Arm Drill Press ..............................................319 Wheel Size ............................................................286 Micro Drill Press ......................................................319 Maximum Wheel Speed .........................................286 Summary .................................................................320 Grinding Wheel Storage ..........................................287 Review Questions ...................................................320 Pedestal Grinder Setup .......................................... 287 Grinding Wheel Ring Testing ....................................287 Grinding Wheel Mounting ......................................288 Unit 2 Tools, Toolholding, Tool Rest and Adjustment .......................................288 and Workholding Spark Breaker and Adjustment ................................289 for the Drill Press ........................... 321 Grinding Wheel Dressing ........................................289 Learning Objectives .................................................321 Grinding Procedures ................................................291 Key Terms .................................................................321 Summary ..................................................................291 Introduction ............................................................ 322 Review Questions ...................................................292 Types Of Cutting-Tool Materials ............................ 322 Drill Bits .................................................................... 322 Unit 6 Drilling, Threading, Twist Drills .............................................................322 Tapping, and Reaming ................293 Spotting and Center Drills .......................................325 Learning Objectives ................................................293 Reamers ...................................................................326 Key Terms ................................................................293 Reamer Parts ........................................................ 326 Introduction ............................................................294 Reamer Sizes ..........................................................327 Benchwork Holemaking Operations .....................294 Countersinks and Counterbores .............................327 Twist Drilling .........................................................294 Toolholding .............................................................329 Counterboring, Countersinking, and Spotfacing ....... 295 Morse Taper-Shank Toolholding .............................. 329 Reaming ...............................................................296 Straight-Shank Toolholding .....................................331 Copyright 2015 Cengage Learning. All Rights Reserved. May not be copied, scanned, or duplicated, in whole or in part. Due to electronic rights, some third party content may be suppressed from the eBook and/or eChapter(s). Editorial review has deemed that any suppressed content does not materially affect the overall learning experience. Cengage Learning reserves the right to remove additional content at any time if subsequent rights restrictions require it. 44543_fm_ptg01_hr_i-x#x i1i.i5nd0d5 0 85 Cust: Cengage Au: Hoffman Pg. No. viii C / M / Y / K S4DcESIGaN SrERVlICiESS OlF e 17/01/14 11:55 PM Title: Precision Machining Technology 2e Server: Short / Normal Publishing Services