machining and cnc technology third edition pdf

Machining and CNC Technology, Third Edition, by Michael Fitzpatrick, is up to date and integrated with how-to-do-it CNC and CAD/CAM from the first chapter With many new features, it covers the trade from the basics to full CNC job readiness Part prepares students to enter the world of manufacturing Skills like measuring, reading drawings, bench work, and following a job plan are covered Part teaches basic machining setups, safety, and operations Manually operated machines are great places to learn drilling, turning, and milling—always with the focus on preparing for CNC experience ting offsets and reference points, tool loading, and setup alignments are covered here Part covers advanced and advancing technology Along with two new CAD and CAM lessons and free access to versions of Mastercam and SolidWorks, students are exposed to the new technologies such as lasers and water jets, additive manufacturing, and CMMs Part imparts skills in CNC setups, programs, and operations Students learn every aspect of using programmed machine tools Hand code compilation, setNew to this Edition New SolidWorks and Mastercam chapters Students can complete web-based activities on how part models are created then turned into toolpaths after completing Chapters 25 and 26 Indexed and mapped to work within any national machining standard Subjects have been completely indexed for programs needing to offer standard skills certificates Skill standards have been added to the text to make it easy for instructors to identify what can be learned and where to find it in the book New Chapter features Instructor Resources The Online Learning Center features: • Instructor’s Guide with tips on teaching the subject, resources and handouts • EZ Test computerized test bank makes it easy to customize your tests • Enhanced PowerPoint presentations, with video, for every chapter in the textbook Interactive and colorful, each set encourages students to dig into the chapter www.mhhe.com/fitzpatrick3e McGraw-Hill Create™ With McGraw-Hill Create™, you can easily rearrange chapters, combine material from other content sources, and quickly upload content you have written, like your course syllabus or teaching notes Find the content you need in Create by searching through thousands of leading McGraw-Hill textbooks Arrange your book to fit your teaching style Create even allows you to personalize your book’s appearance by selecting the cover and adding your name, school, and course information Order a Create book and you’ll receive a complimentary print review copy in 3–5 business days or a complimentary electronic review copy (eComp) via e-mail in minutes Go to ww.mcgrawhillcreate com today and register to experience how McGraw-Hill Create empowers you to teach your students your way www.mcgrawhillcreate.com ISBN 978-0-07-337378-2 MHID 0-07-337378-8 Part of ISBN 978-0-07-780541-8 MHID 0-07-780541-0 EAN www.mhhe.com www.EngineeringBooksPDF.com MD DALIM #1221806 01/08/13 CYAN MAG YELO BLK • Made Right Here highlights amazing companies and products to help your students understand that they made a great career choice with opportunities available in the industry • Xcursions are special codes students can scan using their mobile devices to view interesting videos, websites, and articles Xcursions are no-cost field trips from their seats • Terms Toolbox Challenge Terms matter in a trade! Using their mobile devices, students can scan a special code and review the terms they just read Machining and CNC Technology www.EngineeringBooksPDF.com fit73788_fm_i-xviii.indd i 11/01/13 5:52 PM www.EngineeringBooksPDF.com fit73788_fm_i-xviii.indd ii 11/01/13 5:52 PM Machining and CNC Technology Third Edition Michael Fitzpatrick www.EngineeringBooksPDF.com fit73788_fm_i-xviii.indd iii 11/01/13 5:52 PM TM MACHINING AND CNC TECHNOLOGY, THIRD EDITION Published by McGraw-Hill, a business unit of The McGraw-Hill Companies, Inc., 1221 Avenue of the Americas, New York, NY, 10020 Copyright © 2014 by The McGraw-Hill Companies, Inc All rights reserved Printed in the United States of America Previous editions © 2011 and 2005 No part of this publication may be reproduced or distributed in any form or by any means, or stored in a database or retrieval system, without the prior written consent of The McGraw-Hill Companies, Inc., including, but not limited to, in any network or other electronic storage or transmission, or broadcast for distance learning Some ancillaries, including electronic and print components, may not be available to customers outside the United States This book is printed on acid-free paper DOW/DOW ISBN MHID 978-0-07-337378-2 0-07-337378-8 Senior Vice President, Products & Markets: Kurt L Strand Vice President, General Manager, Products & Markets: Martin J Lange Vice President, Content Production & Technology Services: Kimberly Meriwether David Managing Director: Thomas Timp Director: Michael D Lange Global Publisher: Raghothaman Srinivasan Director of Development: Rose Koos Development Editor: Vincent Bradshaw Global Publisher: Curt Reynolds Project Manager: Jean R Starr Buyer II: Debra R Sylvester Designer: Matt Backhaus Cover/Interior Designer: Matt Backhaus Cover Image: Courtesy Haas Machine Tools USA Senior Content Licensing Specialist: Jeremy Cheshareck Manager, Digital Production: Janean A Utley Media Project Manager: Cathy L Tepper Typeface: 10.5/13 Times Compositor: MPS Limited Printer: R R Donnelley All credits appearing on page or at the end of the book are considered to be an extension of the copyright page Cataloging-in-Publication Data has been requested from the Library of Congress The Internet addresses listed in the text were accurate at the time of publication The inclusion of a website does not indicate an endorsement by the authors or McGraw-Hill, and McGraw-Hill does not guarantee the accuracy of the information presented at these sites www.mhhe.com www.EngineeringBooksPDF.com fit73788_fm_i-xviii.indd iv 18/01/13 3:53 PM While there were countless others along the way, these four made all the difference in my career and life Without them I question whether this book would have been To Linda, my wife for never complaining about the time taken from us to this, for believing, giving, and forgiving To Jan Carlson for demonstrating with acts, what a caring professional should be, and especially for the encouraging space to grow To Bill Simmons for trusting me with more than just your tool box, for your gentle guidance We all miss you, Uncle Bill To Bill Coberley for marketing me in the beginning and for being a lifelong friend www.EngineeringBooksPDF.com fit73788_fm_i-xviii.indd v 11/01/13 5:53 PM www.EngineeringBooksPDF.com fit73788_fm_i-xviii.indd vi 11/01/13 5:53 PM Contents About the Author ix Preface x Acknowledgements xii Walkthrough xiv PART Introduction to Manufacturing Chapter 17 Coordinates, Axes, and Motion 557 Chapter 18 CNC Systems 589 Chapter 19 CNC Controls 614 Chapter Professionalism in Manufacturing Chapter Math Skills Self-Review 26 Chapter 20 Operating a CNC Machine 629 Chapter Reading Technical Drawings 38 Chapter 21 Program Planning 655 Chapter Introduction to Geometrics 53 Chapter 22 Level-One Programming 674 Chapter Before and After Machining 79 Chapter 23 Level-Two Programming 699 Chapter The Science and Skill of Measuring—Five Basic Tools 145 Chapter Chapter Single-Purpose Measuring Tools, Gages, and Surface Roughness Layout Skills and Tools PART Introduction to Computer Numerical Control Machining Cutting Tool Geometry 182 218 237 Chapter 10 Drilling and Operations and Machines 260 Chapter 11 307 Turning Operations Chapter 12 Mills and Milling Operations 716 PART Advanced and Advancing Technology PART Introduction to Machining Chapter Chapter 24 Setting Up a CNC Machine Chapter 25 Design for CNC Manufacturing— Solid Modeling 752 Chapter 26 CAM Mill Programming for CNC Machinists 757 Chapter 27 Tool Life, Productivity, and Advancing Technology 768 Chapter 28 Statistical Process Control (SPC) 792 Chapter 29 Computer Coordinate Measuring 805 391 Chapter 13 Precision Grinding Operations and Machines 446 Chapter 14 Screw Thread Technology 489 Chapter 15 Metallurgy for Machinists—Heat Treating and Measuring Hardness 509 Chapter 16 Job Planning 539 Appendices 824 Credits 835 Index 839 vii www.EngineeringBooksPDF.com fit73788_fm_i-xviii.indd vii 11/01/13 5:53 PM www.EngineeringBooksPDF.com fit73788_fm_i-xviii.indd viii 11/01/13 5:53 PM About the Author As if it was yesterday, I remember carrying my new toolbox down the aisle at Kenworth Trucks of Seattle Scotty, the crusty drill press operator, stepped away from his machine and planted himself right in front of me Without a welcome, he raised his bushy eyebrows, poked two fingers into my chest, and said “You see all these men here?” He waited At eighteen, I recall only nodding, unable to speak He went on, “Each one of us will show you everything we know if you pay attention We’ll give you lifetimes of experience, but know this, lad, it comes with an obligation Someday you’ll pass it on.” Hello, I’m Mike Fitzpatrick, your machining instructor in print Since you’ve honored me by studying my book, I thought it might be a confidence builder to tell a little about why I’m qualified to pay forward to you what Scotty and countless other fine craftsmen taught me I began that apprenticeship on the first Monday after high school graduation, in 1964 A year or so later, I was given the life-altering opportunity to be their first employee to run the first Numerical Control (NC) machine brought to the Seattle area, other than the ones at the Boeing Aircraft Company Nothing like the computerized machines you’re about to learn, that NC machine was a turret head drill press, run by paper tapes Not far from a music box in its technology, it was primitive compared to the machines in your training lab Still, it was enough to hook me for life So, with a year of applications and interviews, I transferred to Boeing, where I completed my machining certificate There I learned to run programmed machines that had basements, and ladders to get up to the cutter head! Passing the tough final with a 100% score, I qualified to take the even tougher test to become a tool and die apprentice I made it and finished my training in 1971 That totaled 12,000 hours of rigorous on-the-job training under a whole army of skilled people It also came with many hours of technical classes Since then I’ve either been a machinist/tool maker or taught others for my entire adult life For the last 25 years I’ve taught manufacturing in technical schools, private industry, a highschool skills center, a junior high school, and in two foreign countries Today I can stand in front of anyone and say with pride, “I’m a journeyman tool and die maker and a master of my trade.” Nearing the end of my journey, Scotty’s imprint calls me to pass it forward But don’t forget, what we instructors and machinists give you comes with the same obligation One trait we clearly see you’ll need far more than we did is adaptability Beyond imparting skills and competencies, this book has a mission: to start its readers down the long, ever-accelerating technology path Clearly, the machinist of the future is one who can see and adapt to a changing future When you pass the baton forward, the trade won’t be anything like that found in this book But I’m confident it will be passed, because machinists have a long history of adaptation ix www.EngineeringBooksPDF.com fit73788_fm_i-xviii.indd ix 11/01/13 5:53 PM Paulson, D J., 145 Paulson, Dennis, 145 Paulson, Mike, 145 PC-based computers, 38–39 PD (pitch diameter), 380–382, 493 Peck drilling, 273, 278 Pedestal grinders, 116 Peening, 123, 125 PEP (predictable error point), 30 Perfect model, 64–65 Personal repeatability, 149 Perspective problem (parallax), 151 P/F assembly (see Press fit assembly) Physical characteristics of metals, 93–95 Pick feed (grinder down feed), 458, 461 Pilot point drills, 268 Pilot punch, 219, 220 Pipe threads, 493–494 National Pipe Thread designations, 494–496 NPSM (National Pipe Straight Mechanical), 494 NPT (National Pipe Tapered), 494 NPTF (National Pipe Dry-Seal), 494 nominal differences for, 494 Pitch, 127–128 Pitch diameter (PD), 380–382, 493 Plunge milling, 771–772 Plunge threading, 373, 375 Plunger safety switches, 619 midcycle stop techniques, 615, 619 multiple E-stop locations, 619 overt action, 615, 619 Points for geometry and/or reference, 568–569 (see also Coordinate systems and points) geometry points, 568–569 entities, 565, 568 identifying, 568 reference points, 565, 568–569 homing the CNC machine, 565, 568 local reference points, 568–569 machine home, 565, 568, 590 Polar coordinates, 579–581 absolute value polar coordinates, 579 bolt circle routines, 580 incremental polar coordinates, 579–581 following the rule of thumb, 580 positive and negative angles in, 580 polar reference line, 579 reading calculator manual, 580–581 reading machine control manual, 580–581 Positive rake, 243, 245 Precision gage blocks, 188–192 accessories, 190 caring for, 189–190 controlling inaccuracies, 188–190 keeping the box closed, 190 not touching gage surfaces, 189 preserving the surface, 190 radical care in using, 189 washing hands, 189 making up the gage block stack size, 191–192 target repeatability, 189 tolerance grades, 189 inspection shop, 189 master calibration, 189 shop grade, 189 uses of, 190–191 as an indicator comparison standard, 190 calibrating other tools, 190 as a gage measuring tool, 190 setting up other tools or processes, 190 wringing gage blocks, 188, 190 Precision grinding (see Grinding operations and machines) Predictable error point (PEP), 30 Press fit (P/F) assembly, 127, 139–141 calculating the press fit allowance, 139–140 class of press fit, 139–140 metal alloys involved, 140 nominal size of objects, 139–140, 146–147 permanency of the assembly, 139 heating and cooling metal for press fits, 140 shrink fitting, 127, 140 machines that perform press fits, 140 skill hints for, 140 Prick punch, 219, 220 Professionalism in manufacturing, 2–25 carrying materials, 8–9 crane carry, crane overswing, cutting fluids (coolants), 13–14 coolant ratios, 13 cutting oils and compounds, 13–14 organic coolants, 13 synthetic coolants, 13 dressing for career success, 3–6 environmental responsibility, 21 eye protection, 3–4 always wearing, 3–4 clear or yellow, extreme danger areas, prescription eyeware, fire safety, 21–22 5S process for leanness, 20–21 green manufacturing, 21 handling materials, 6–10 handling shop supplies, 10–14 kinds of shop chemicals, 12 knowing about shop chemicals, 11–12 MSDS sheets, 11–12 recycling and disposing of waste, 14 specific precautions, 11–12 hearing protection, hearing as your primary control, lean manufacturing, 20–21 lifting heavy materials, 7–8 disks in your back, 7–8 using a machine whenever possible, using your legs, not your back, lubricants getting exact oil for CNC machines, 12 identifying special oils and keeping them clean, 12 knowing which lube to use, 13 rolling action lubricants, 12–13 sliding lubricants, 12, 19 spindle oil, 12 using the right way, 12–13 way oil, 12 maintaining an efficient workspace, 15 maintaining the work area, 18–19 adjustments to equipment, 19 checking machine fluid levels, 18 lubrication flow glasses, 19 sight glass, 18 removing and handling chips, 15–18 chip breaking, 16 chip hazards, 15 clearing chips from operating machines, 16–17 compressed air, 17–18 coolant as a machine cleaner, 18 coolant as an air substitute, 18 first locking the machine, 16 machine safety, 18 personal danger, 17–18 using a chip hook or chip rake, 17, 368 safely storing machine accessories, 20 shop clothing, 4–6 aprons and shop coats, hair up, natural fibers, 4–5 no accessories, storing metals, 9–10 work shoes, link to work quality, steel toes, Profile, 55–56 Program creation and data management, 607–611 differences in software, 609–610 adding machining data before or after path selection, 609 geometry associative programs, 609 geometry drawing accuracy, 609–610 pre- or postcustomizing into codes for a given control, 609 flat pattern or wireframe element selection, 609 importing geometry, 607, 609 part geometries, 607–608 flat pattern line drawings, 608 solid model, 608 three-dimensional wireframe geometry, 608 two-dimensional wireframe line drawings, 608 program creation, 609–610 sending programs to the controller, 610–611 active or permanent memory, 610 data transfer (downloading), 607, 610–611 Program datum point (see Program reference zero) Program home (see Program reference zero) Program interrupt, 623 Program planning, 655–673 selecting the holding methods and cut sequences, 660–665 selecting the origin, quadrant, and axes, 656–660 Index 851 www.EngineeringBooksPDF.com fit73788_ind_839-862.indd 851 18/01/13 10:21 AM Program reference zero (PRZ), 427, 435, 565, 566, 815–816 Projection lines, 39, 41 Proving a program, tryout methods for, 733–739 PRZ (see Program reference zero) PTP (part-to-part) turnaround, 595–597 R R-8 machine taper, 416 Radial runout, 342 Radius lathes, 326 Ramps, 691–694 designing, 692 off ramps, 691, 694 on ramps, 691 ultrashort, 693 Rasp-cut files, 113 Rat’s nest, 368 Reading technical drawings, 38–52 Reamer float, 261, 271 Reamers, 137–138, 241, 270–271 drilling the reamer pilot hole, 271–272 expansion reamers, 270 feed rates, 284 machine reamers, 270 reverse helix reamers, 271 selecting drills for reamers, 271–272 selecting for size, 262–265 diameter markings, 262 measuring on the margins, 262 oversize reamers, 264 resharpening reducing size, 264 special undersized reamers, 262, 264 standard and nonstandard diameters, 262, 264 selecting the holding method, 265–267 shell reamers, 270 specialty reamers, 270–271 taper reamers, 271 Reboundless hammers, 126 Recast layer, 773, 782 Reciprocal surface grinding, 458–465 alternatives for machines without coolant, 462–463 choosing a cooler grinding wheel, 462 creating a cooler setup or operation, 462–463 cut material removal rate, 462 providing mist coolant, 462 chip ejection, 462 coolant injection, 462 for chip ejection, 462 lubing chip deformation, 462 coolant-to-water ratios, 463 coolants for grinding operations, 462–463 extending wheel life, 462 hydraulic production grinders, 460 hydrostatic bearings, 458, 460 warming up, 460 low-pressure flood versus high-pressure injection, 462 manual or tool room surface grinders, 458–460 reducing heat production, 462 852 removing heat from the work and holding accessories, 462 setting up, 460–462 correct stroke length and width, 460–461 guidelines for setup and operation, 461 Z axis steps and limits, 461 work-holding methods, 463–465 electromagnetic chucks, 458, 464 ensuring a safe setup, 464–465 magnetic chucks, 464–465 permanent magnetic chucks, 458, 464–465 precision grinding vises, 463–464 Reference zero (RZ), 427, 435 Relief (thread), 373, 379 Removal rate, 243, 462 Resinoid wheels, 108, 117 Rest milling, 764–766 Reverse helix reamers, 271 Ring test, 118 Robot burring and part finishing, 120 Rockwell hardness test, 527–528 calibrating load, 528 Rockwell numbers, 528 testing load, 528 Root diameter (see Pitch diameter) Rough alignment, 720 Rule of ten, 184 Rulers (see Machinist’s rules) Runout, 55–56 RZ (reference zero), 427, 435 S Saddle (lathe), 322–323 SAE (see Society of Automotive Engineers) SAE threads, 127 Sample part template (SPT), 47 Sandvik Coromant, 768 Saw blade set, 95, 97–98 Sawing material, 94–111 abrasive sawing, 95, 107–109 band saw blade welding, 109–110 annealing the weld, 95, 110 final shaping, 110 band saws, 96 friction sawing, 95, 105 safety precautions, 105 supersonic tooth stripping, 106 hacksawing, 96–97 applying pressure on forward stroke, 98 not forcing the cut, 97 in parting, 318 selecting blade pitch, 95–97 slowing stroke rate for hard materials, 98 teeth facing away from handle, 97 watching for blade shattering, 98 hand sawing, 96 horizontal power sawing, 106–107 any length workpiece, 106 coolant systems, 106 horizontal saw safety, 107 self-feeding, 106 vise-held work, 106 industry methods, 96 high-energy laser cutting, 96 high-pressure waterjet cutting, 96 plasma cutting, 96 reciprocal sawing, 96 rigid sawing, 96 oxygen-acetylene flame cutting, 96 planning excess material, 95 allowing for saw kerf thickness, 96 amount of excess, 95 power sawing, 98–99 bi-metal blades, 99 blade alloys, 99 high-speed steel blades, 99 saw blade selection, 98–99 sawing internal features, 99 tooth pattern and set, 98–99 using bulk blades, 99 scroll sawing, 95, 103–106 adjusting blade guides, 104 shearing, 96 vertical band sawing, 99–103 Scatter shield, 297, 298 Scheduled tooling, 597 Scratch awl, 219–220 Screw pitch gage, 131 Screw threading (see Technical screw threads; Threading) Second tap, 134 Secondary offload operations and assembly, 127–141 avoiding offload-machining, 127 finishing holes, 137–141 press fit assembly, 127, 139–141 threading, 127–137 Section views, 39, 42–43 Selecting the holding methods and cut sequences, 660–665 Selecting the origin, quadrant, and axes, 656–660 Serial number (S/N), 10 Set (of saw blade), 95, 98 Shank, 261, 262, 265 Sharpening drill bits, 297–300 checking and correcting the shape, 300 checking the dead center, 297, 300 keeping the bit cool, 300 long dead center on short drills, 300 wrong angle, 300 recognizing a dull bit, 297 inspection before mounting, 297 observation while drilling, 297 regrinding the bit, 298–299 clearance angle, 298 control by reading the sparks, 299 holding the bit for sharpening, 298 point angle (lead angle), 298 safety check list, 298 “Shear line,” 246, 300, 301 Shell end mills, 414, 416 Shell reamers, 270 Shore hardness test, 527, 529–530 horizontal, flat test surface, 530 scleroscope, 527, 530 solid sample, 530 Index www.EngineeringBooksPDF.com fit73788_ind_839-862.indd 852 18/01/13 10:21 AM Shoulder thread, 373 Shrink fitting, 127, 140 SI—International System of Units, 27, 29 Sight glass, 15, 18 Silicon carbide, 95, 108, 117 Sine ratio, 199, 204 Single-cut files, 113 Single-point threading, 315–316, 373–380 cutting the thread, 376–377 coordinating thread depth, 378 crash procedures, 377 engaging the chasing dial, 377–378 first pass, positioning the tool and axes, 376–377 half nut lever engagement, 373, 376–377 making threading passes, 377 thread stops, 379 internal threading, 378–379 bit on far side right side up, 379 bit upside down, 378 progressing inward, 378 threading outward, 378 metric threading, 378 positioning the bit, 375 setting the cutting angle, 375 vertical height centering, 375 setting gear selections for threading, 376 chasing dial, 373, 376 right-hand spiral, 376 RPM, 376 thread drive, 376 thread pitch levers, 376 setting the compound, 374–375 setting up for threading, 373–376 coordinating the X axis and compound micrometer dials, 375 grinding the thread bit, 374 holding method, 373 part prep, 373–374 Single-purpose measuring tools, 182–217 choosing the right measuring tool, 211–212 gage measuring, 192–198 measuring angles, 199–205 measuring surface roughness, 206–210 measuring with depth micrometers, 186–188 measuring with inside micrometers, 183–185 precision gage blocks, 188–192 Sintering, 349, 354 Skip tooth blades, 95, 98–99 Slant bed lathe, 559–560 Slitting wheels, 117 SME (Society of Mechanical Engineers), 127 SME Education Foundation, 629 Smelter, 90 S/N (serial number), 10 Society of Automotive Engineers (SAE), 127, 497, 511 Society of Mechanical Engineers (SME), 127 Soft-faced hammers, 126 Solid modeling, 752–756 advantage of, 753–755 creating MC-X solid with CAM, 767 creating/testing assemblies, 753–754 downloading SolidWorks, 755 drawing solid models, 755 end user advantages of, 754 SolidWorks: downloading, 755 Mastercam in, 758 SPC (see Statistical process control) Special CNC programming tools, 709–712 Spindle oil, 11, 12 Splitting the line, 219–220 Sprayed coatings, expected surface finish for, 833 SPT (sample part template), 47 Spur-pointed drills, 268 Stamping, 124–126 erasing, 124 machine shop hammers, 125–126 noting grooves for orientation, 124 striking stamp once, 124 Standard (gage), 150 Standard dimensioning, 54 Statistical process control (SPC), 792–804 bell curve distribution, 793, 796–797 centering, 793, 797 spread, 793, 796 capability showing on histograms, 795 control during production, 798 real-time control, 794, 798 trends, 793, 798 control limits, 795–796 Cp ratio describing capability, 797–798 Cpk ratio, 799–802 detection of assignable cause, 801–802 common, 801 exceptional nonrepeating, 801 exceptional repeating, 801 trend, 801 finding normal variation, 795–798 global oversight, 793 and kinds of variation, 793 making a histogram, 799–802 dipstick, 800 process capability, 800 setting control limits, 794 common cause variation, 793, 794 key dimension feature, 794 lower control limits, 793, 794 providing real-time comparison to normal, 794 real-time control charts, 794 upper control limits, 793, 794 SPC experiment, 799–802 training for, 793 using software, 799 a visual data tool, 793 what and why of SPC, 793–798 Steel alloys, 89–92 alloy steels, 89 free cutting steel, 90 low-carbon steel, 90 mild steel, 90 forming methods, 89–91 cold rolled steel, 91 hot rolled steel, 91 stainless steels, 91–92 corrosion resistant steels, 91–92 and rust, 92 tool steels, 89 Steel glow, 519 Steel stamping, 124–126 Straight-line probe, 176–177 Straightline Precision Industries, Inc., 145 Strap clamps (magnetic chuck), 466, 473–474 Stringers, 93 Stripping, 95, 97 of blade teeth, 95, 97 resistance to, 128 of threads, 490, 492 Superabrasives, 451, 830–831 Supplementary angles, 199, 203 Surface cutting speeds, 95, 101–102, 282–283 in feet per minute, 828 Surface evaluation computer, 207–208 Surface finish, 155 by grit size, 833 Surface speeds, recommended, 828 Symbolic language, 54–55 Symbols, 836 Synthetic fibers, 3, T Tang, 261, 266 Tangential cutting, 421, 425 Tap alignment, 135 drill press guidance, 135 tap blocks, 135 Tap drill holes, 137 Tap drill sizes, 824–825 Tap wrench nuts project, 525, 551–552 Taper angles, 312 Taper reamers, 271 Tapping fluids, custom-designed, 291 Taps for internal threads, 127, 133–137 bottom taps, 127, 134 cold-formed threads, 136–137 keeping lubricated, 135 keeping sharp, 134 plug taps, 127, 134 removing broken taps, 134 roll form tapping, 136–137 spiral or gun pointed taps, 134 starting taps, 133–134 tap alignment, 135 tap burners, 134 tap drill holes, 137 tap flutes, 134 tap handles, 136 TCT (tool-to-tool) cycle time, 597–598 TecEast, Inc., 53 Index 853 www.EngineeringBooksPDF.com fit73788_ind_839-862.indd 853 18/01/13 10:21 AM Technical drawings, 38–52 alphabet of lines, 45 break lines, 45 centerlines, 44–45 dimension lines, 45 extension lines, 45 hidden lines, 44 leader lines, 45 object lines, 44 phantom lines, 44 symmetrical features, 44–45 visualization, 44–45 challenge problems, 46–47 orthographic projection, 39–44 paperless trend for, 38–39 special situations, 47 asking your foreman, 47 digital images, 47 following the work order, 47 sample parts, 47 trade tip for forming the 3-D picture, 46–47 choosing details not seen clearly in front view, 46 choosing one major/obvious front view feature, 46–47 mentally summing up a more detailed overall image, 46 nicknaming the object, 46 repeating the V-T-V process, 46 studying front view first, 46 Technical screw threads, 489–507 canned (fixed) cycles, 490 galling, 491 getting and using thread data from references, 501 left-hand thread setups, 502–503 dropping chasing dial rules, 503 inverted tool method, 502–503 left-hand threading tool, 503 reverse tool travel method, 502–503 tool compound angle, 503 manual lathe setups for technical threads, 502–505 multiple-start thread setups, 503–504 holding between centers, 503–504 indexing the whole chuck, 504 producing tapered threads, 504 offset tailstock method, 504 taper attachment method, 504 stripping, 491 task families, 490–491 fastening and assembling, 490–491 forming a seal and joining, 491 imparting motion and/or thrust (translation), 491 technical thread variations, 490–501 tripping die, 502 Technology, 751–823 advancing technology, 768–791 computer coordinate measuring, 805–823 statistical process control, 792–804 Tenth (of a thousandth), 27–28 Tesla Motors, 716 Third-angle projection, 39, 40 854 Thread forms, 127, 129–131, 491–496 Acme threads, 490–492 axial thrust, 490, 491 backlash control threads, 499–500 ball-screws (continuous feed, recirculating), 490, 500, 592 multiple start ball-screws, 500 single start ball-screws, 500 buttress threads, 490, 492–493 classes of threads, 127, 130 controlled radius root threads, 495–496 critical application threads and fasteners, 495–496 fastener grades, 496–497 left-handed threads, 497–498 multiple-start threads, 490, 498–500 lead distance, 490, 498–499 pitch distance, 498 steeper helix angle, 490, 498 trading mechanical advantage, 499 pipe threads, 130–131, 494 different pitches, 130–131 tapered threads, 130 preload split nuts (self-adjusting), 499–500, 592 radial thrust, 490, 492 split nuts (adjustable), 499 square threads, 490, 493–494 threaded inserts, 496 truncation in, 127, 129–130 to avoid jamming, 130 for mechanical strength, 128–129 Unified threads, 491 variations for any thread form, 497–499 Thread relief, 373, 379 Thread stops, 379 Threading, 127–137, 315–317 (see also Drilling operations and machines; Technical screw threads) bolt nominal diameter, 127, 128 determining thread pitch, 131 handheld dies and taps, 316 pitch, 127–128 pitch distance, 127–129 production dies and taps, 316–317 standard sizes, 128 coarse threads, 127–128 fine threads, 127–128 taps for internal threads, 127, 133–137 bottom taps, 127, 134 cold-formed threads, 136–137 keeping lubricated, 135 keeping sharp, 134 plug taps, 127, 134 removing broken taps, 134 roll form tapping, 136–137 spiral or gun pointed taps, 134 starting taps, 133–134 tap alignment, 135 tap burners, 134 tap drill holes, 137 tap flutes, 134 tap handles, 136 taps in the tailstock, 316 thread forms, 127, 129–131 threading with a die, 127, 131–133 chasing dies, 131–132 fixed size dies, 133 insert jaw dies, 133 threading dies, 132–133 Three-tooth pitch rule, 97 TMI sources, 127 Tolerances, 146–148 angular dimensioning and tolerancing, 148 geometric angular tolerance, 146, 148 protracted angles, 146, 148 feature tolerances, 33–34 bilateral, 34 limits, 34 nominal dimensions, 33 unilateral, 34 kinds of measuring in machining, 146–147 form, 146–147 orientation, 147 position, 146 size, 146 surface finish, 147 linear tolerances, 147 bilateral tolerance, 146–147 general tolerances, 147 tolerance expressed as limits, 146, 147 unilateral tolerance, 147 tolerances on drawings, 147–148 Tool drum, 598 Tool float, 261 Tool number, 598 Tool position number, 598 Tool shapes, 349–352 boring bars, 351–352 with carbide inserts, 352 preshaped, 350 form tools, 350 parting and grooving tools, 349–350 setting up, 351–352 clearances, 351 depth control and overhang, 351–352 vertical axis alignment, 352 threading tools, 350 turning tools, 349 universal, 350 Toolholder Identification System, 356 Toolpaths: advancing technology for, 769–772 chip thinning, 769–770 modifying Mastercam toolpath, 770–771 plunge milling, 771–772 dynamic, 758, 761–763 benefits of, 764 compensating for chip thinning, 763 feature-based machining, 764 for optimized roughing and peel milling, 764–766 protecting cutters with, 761–762 protecting machines with, 761 radial engagement, 762 standard, 758–760 billet definition, 760 contour, 760 pockets, 759 Index www.EngineeringBooksPDF.com fit73788_ind_839-862.indd 854 18/01/13 10:21 AM toolpath utility software, 735–736 trochoidial, 758 Tool-to-tool (TCT) cycle time, 597–598 Traceability, 7, 10 Transitions, tapers for, 312 Translation, 127–128 Translation screws, 490–491 Trochoidial toolpaths, 758 Tryout methods for proving a program, 733–739 comparing the methods, 739 halt run, 739 prerun tests, 739 test runs, 739 dry run, 733, 737–738 axis disable, 733, 737 cutting tool withheld, 737 missing material, 737 oversize radius offsets, 738 single-step tryout, 733, 738 tryout material, 733, 737–738 history of the program and programmer, 733 nature of the object, 733 number and cost of parts to be run, 733 program tests, 734–739 in run, 738–739 optional stops (optstop), 733, 738–739 safest testing, 734–736 graphic evaluations, 734–735 reading programs, 734 toolpath utility software, 735–736 total screen associativity and surface analysis, 733, 736–737 CNC controller toolpath graphics, 737 machine motion tests, 737 Turning Insert Identification System, 358–359 Turning operations, 307–390 basic lathe operations, 308–321 lathe components, 321–334 lathe safety, 366–369 measuring threads, 380–383 motion and positioning, 326–330 adjusting for backlash, 326–327 single-point threading, 373–380 troubleshooting lathe setups, 369–373 work-holding methods, 334–348 Turning tool basics, 348–365 cutting tool material, 353–359 direction of tool cut, 352–353 compound rake, 352–353 side rake, 349, 352–353 manual lathe tool posts, 360–363 indexing, 362–363 industrial varieties, 360 quick change tool posts, 361–363 rocker tool posts and tool holders, 360–361 solid tool posts, 361 standard load tools, 361 tool post strength, 360 turret tool holder, 362–363 positioning turning tools on vertical center, 364–365 captured flat object method, 364–365 dedicated height gage method, 364 tailstock center method, 364 tool shapes, 349–352 Twist drills, 261 Vises (see Floating vise setup; Machiningcenter vise alignment) Visible lines, 44 Visual test, 118 Vitrified wheels, 111, 117 Volts, 773, 781 W U UNC (Unified National Coarse) threads, 128 Uncertainty principal, 160 UNF (Unified National Fine) threads, 128 Unified Numbering System (UNS), 511–512 Unified Screw Thread System, 127 Uptime, 596 V V-T-V (view-to-view), 46 Valve domes project, 544, 549–551 Variation, 146–147 direct reading of, 156 Vertical band sawing, 99–103 checkoff guide for setting up, 102 horizontal and vertical blade types, 99–100 saw accessories, 103 saw vises, 103 setting saw at right blade speed, 101–102 vertical saw safety, 100–101 adjusting the guard, 100 bracing your hands, 101 bracing yourself, 100–101 keeping hands clear, 101 nonskid flooring, 101 not wearing gloves, 101 securing workpiece, 101 setting guides correctly, 101 watching for broken blades, 101 Vertical machining centers, 597–599 chip-to-chip time, 597–598 CNC cutter holders, 599 automatic draw studs, 599 robot grip slots, 599 spindle orientation coding, 599 CNC tool management, 598 random tool storage, 595, 598 tech-specs for machining centers, 597–599 tool changing, 597 Video screen selections, 623–624 coordinate position screens, 624 distance to go screen, 620, 624 machine coordinates screen, 624 work coordinate position screen, 624 split and combined screens, 624 toolpath graphics screens, 623 graphic programming, 623 program dry run, 623 program monitoring, 623 View-to-view (V-T-V), 46 Viking Yacht Company, 260 Vise jaw datums, 61 Viscosity, 11 Waterjet cutting, 773–776 adding abrasives to increase cutting power, 774–775 environmental issues, 776 industrial applications, 776 intensifier pumps, 772, 775 positive displacement gear pumps, 775–776 pressure pumps, 775 safety issues, 776 Way oil, 11, 12 Welding, of chip to bit, 243 Wet grinding, troubleshooting guide, 830 Wheel dressing tools, 469–470 diamond chip dressers, 470 nibs, 466, 469 Wiggler, 286, 289, 427, 437 WIP (work in progress), 596 Wire wheels, 120 contamination caused by, 120 safety in, 120 Wireframe, 608, 609 Witness mark, 219, 221 Work axes, 813, 815 Work hardening, 88, 93 Work-holding methods, 334–348 cam lock chucks, 334, 344–346 assembling, 345–346 reading the cam lock indicators, 346 removing, 345 collet chucks, 334, 339–340 collet closer, 340 draw bar, 340 setting up, 339–340 soft and custom shapes, 339 spindle collet adapter, 340 decision factors, 334–335 grip, 334, 339 runout, 335 turnaround time, 335 work/operation requirements, 334–335 flying wrench rule for chucks, 337 four-jaw chucks, 337–338 holding work between precision centers, 342–343 dead centers, 334, 343 drive plate, 343 lathe dog, 343 live centers, 334, 343 independent jaw chucks, 334, 337–338 lathe fixtures, 334, 341–342 face plates, 341–342 potential dangers of, 341–342 RPM limits with, 343 wood block support for, 342 Index 855 www.EngineeringBooksPDF.com fit73788_ind_839-862.indd 855 18/01/13 10:21 AM Work-holding methods–Cont mandrels, 340–341 precision expanding, 340–341 tailstock support, 340 threaded, 340 using a bolt, 340 mounting chucks and other accessories on the lathe, 344–346 soft jaw work holding, 334, 346–347 ensuring chuck grip bias, 347 equal thickness, 346 machined, 346–347 protectors, 346 spider for, 347 three-jaw universal chucks, 335–336 reversing chuck jaws, 336 scroll plate, 334–336 Work in progress (WIP), 596 Work orders (WOs), 38, 80–84 job sequence planning, 80–81 multiple sheet drawings, 83 part numbers, 81–83 Work reversal, 657–660 coordinate shift, 656–658 machined temporary datum, 657–660 mill program reference zeros, 658–659 top surface, lower-left corner, 658–659 touch-off method for setting tool reference, 656, 659 856 spindle work stop, 656, 657 tooling references, with PRZ not on the workpiece, 656, 659–660 set (fixture reference) points, 659–660 soft jaw vises and chucks, 660 World axis standards, 558–564 orthogonal axis sets, 558 primary linear axes X, Y, and Z, 558–560 axis ID on a CNC machine, 559–560 right-hand rule, 558–559 three primary planes, 558–559 world orientation, 558–559 primary rotary axes A, B, and C, 560–562 articulating mill heads, 558, 561 five-axis mills, 558, 561 mill rotary axes, 561 part rotating and indexing, 562 plus or minus rotary motion, 561 rotary axis sign value, 561 rule of thumb, 558, 561 tombstone table, 562 warped surfaces, 562 secondary linear axes U, V, and W, 562–563 multitasking, 558 warped surfaces, 563 WOs (see Work orders) Writing arc commands, 687–690 arc facts, 687–688 current tool position, 688 default facts, 687–688 center point arc method (IJK), 687, 689 polar arc method, 687 radius arc method, 687–689 arcs larger than 180°, 688 controller differences for greater arcs, 688 curvature code, 687 Writing compensated programs, 690–694 preparing a program for compensation, 691–694 current program plane on mills, 692 dummy moves, 691, 693 ending compensation, 692–694 lock on distance, 691, 693 radius offset, 691 ramps, 691–694 rapid lock, 693 X X-Y-Z digital position readouts (DROs), 410–411 Xcursion, 762, 765 Z Z87, Z87.1, Index www.EngineeringBooksPDF.com fit73788_ind_839-862.indd 856 18/01/13 10:21 AM www.EngineeringBooksPDF.com fit73788_ind_839-862.indd 857 18/01/13 10:21 AM www.EngineeringBooksPDF.com fit73788_ind_839-862.indd 858 18/01/13 10:21 AM www.EngineeringBooksPDF.com fit73788_ind_839-862.indd 859 18/01/13 10:21 AM www.EngineeringBooksPDF.com fit73788_ind_839-862.indd 860 18/01/13 10:21 AM www.EngineeringBooksPDF.com fit73788_ind_839-862.indd 861 18/01/13 10:21 AM www.EngineeringBooksPDF.com fit73788_ind_839-862.indd 862 18/01/13 10:21 AM Dear Student, Why did you buy this textbook? Because your teacher required it? Probably Because you need it to complete your assignments? Most likely How about: because this textbook will give you the information you need to get a higher grade Sounds good, doesn’t it? What exactly did you buy? A textbook? Well, yes But did you know that by purchasing this book you also purchased: The Student DVD for Machining and CNC Technology This disc is bound in the back of the textbook and contains programs and files that can be used as you read the chapters • A demo version of Mastercam Version X6 and student data files that will be used to complete many of the CAM/CAD drawings in the textbook • SolidWorks student files that will help you learn how to design in this widelyused program A demo version of Solidworks is available on the instructor’s side of the OLC Now what? It’s pretty simple By reading this book and taking advantage of all the materials that come with it, a higher grade is in your future We want to see you learn, get a good grade, and master the concepts of this course Together, our materials and your hard work will make the right combination for a good grade and help you begin a long, challenging, and rewarding career in the field Let’s get started www.mhhe.com/fitzpatrick3e Machining and CNC Technology, 3e website www.EngineeringBooksPDF.com ISBN: 9780073373782/0073373788 Author: Fitzpatrick Title: Machining and CNC Technology 3e Front endsheets Color: color Pages: 2,3 Dear Student, Why did you buy this textbook? Because your teacher required it? Probably Because you need it to complete your assignments? Most likely How about: because this textbook will give you the information you need to get a higher grade Sounds good, doesn’t it? What exactly did you buy? A textbook? Well, yes But did you know that by purchasing this book you also purchased: The Student DVD for Machining and CNC Technology This disc is bound in the back of the textbook and contains programs and files that can be used as you read the chapters • A demo version of Mastercam Version X6 and student data files that will be used to complete many of the CAM/CAD drawings in the textbook • SolidWorks student files that will help you learn how to design in this widelyused program A demo version of Solidworks is available on the instructor’s side of the OLC Now what? It’s pretty simple By reading this book and taking advantage of all the materials that come with it, a higher grade is in your future We want to see you learn, get a good grade, and master the concepts of this course Together, our materials and your hard work will make the right combination for a good grade and help you begin a long, challenging, and rewarding career in the field Let’s get started www.mhhe.com/fitzpatrick3e Machining and CNC Technology, 3e website www.EngineeringBooksPDF.com ISBN: 9780073373782/0073373788 Author: Fitzpatrick Title: Machining and CNC Technology 3e Front endsheets Color: color Pages: 2,3 Machining and CNC Technology, Third Edition, by Michael Fitzpatrick, is up to date and integrated with how-to-do-it CNC and CAD/CAM from the first chapter With many new features, it covers the trade from the basics to full CNC job readiness Part prepares students to enter the world of manufacturing Skills like measuring, reading drawings, bench work, and following a job plan are covered Part teaches basic machining setups, safety, and operations Manually operated machines are great places to learn drilling, turning, and milling—always with the focus on preparing for CNC experience ting offsets and reference points, tool loading, and setup alignments are covered here Part covers advanced and advancing technology Along with two new CAD and CAM lessons and free access to versions of Mastercam and SolidWorks, students are exposed to the new technologies such as lasers and water jets, additive manufacturing, and CMMs Part imparts skills in CNC setups, programs, and operations Students learn every aspect of using programmed machine tools Hand code compilation, setNew to this Edition New SolidWorks and Mastercam chapters Students can complete web-based activities on how part models are created then turned into toolpaths after completing Chapters 25 and 26 Indexed and mapped to work within any national machining standard Subjects have been completely indexed for programs needing to offer standard skills certificates Skill standards have been added to the text to make it easy for instructors to identify what can be learned and where to find it in the book New Chapter features Instructor Resources The Online Learning Center features: • Instructor’s Guide with tips on teaching the subject, resources and handouts • EZ Test computerized test bank makes it easy to customize your tests • Enhanced PowerPoint presentations, with video, for every chapter in the textbook Interactive and colorful, each set encourages students to dig into the chapter www.mhhe.com/fitzpatrick3e McGraw-Hill Create™ With McGraw-Hill Create™, you can easily rearrange chapters, combine material from other content sources, and quickly upload content you have written, like your course syllabus or teaching notes Find the content you need in Create by searching through thousands of leading McGraw-Hill textbooks Arrange your book to fit your teaching style Create even allows you to personalize your book’s appearance by selecting the cover and adding your name, school, and course information Order a Create book and you’ll receive a complimentary print review copy in 3–5 business days or a complimentary electronic review copy (eComp) via e-mail in minutes Go to ww.mcgrawhillcreate com today and register to experience how McGraw-Hill Create empowers you to teach your students your way www.mcgrawhillcreate.com ISBN 978-0-07-337378-2 MHID 0-07-337378-8 Part of ISBN 978-0-07-780541-8 MHID 0-07-780541-0 EAN www.mhhe.com www.EngineeringBooksPDF.com MD DALIM #1221806 01/08/13 CYAN MAG YELO BLK • Made Right Here highlights amazing companies and products to help your students understand that they made a great career choice with opportunities available in the industry • Xcursions are special codes students can scan using their mobile devices to view interesting videos, websites, and articles Xcursions are no-cost field trips from their seats • Terms Toolbox Challenge Terms matter in a trade! Using their mobile devices, students can scan a special code and review the terms they just read ... Machining and CNC Technology Third Edition Michael Fitzpatrick www.EngineeringBooksPDF.com fit73788_fm_i-xviii.indd iii 11/01/13 5:52 PM TM MACHINING AND CNC TECHNOLOGY, THIRD EDITION Published.. .Machining and CNC Technology www.EngineeringBooksPDF.com fit73788_fm_i-xviii.indd i 11/01/13 5:52 PM www.EngineeringBooksPDF.com fit73788_fm_i-xviii.indd ii 11/01/13 5:52 PM Machining and CNC. .. thousandths C Nine hundred ninety-nine and nine tenths thousandths, or nine hundred ninety-nine and nine tenths D Eighty-seven thousandths and eight tenths E Eight and seven tenths thousandths