Machining for Dummies - Kip Hanson

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Résumé :

Introduction 1

About This Book 2

Foolish Assumptions 2

Icons Used in This Book 3

Beyond the Book 4

Where to Go from Here 4

Part 1: Turning Cranks and Pulling Handles 5

Chapter 1: Climbing the Manufacturing Ropes 7

Going Caveman: A World without Machining 8

Why it's called chipmaking 9

What's your job title? 11

Meeting Our Founding Fathers 11

Who got the machining ball rolling? 12

The other tools in the toolbox 15

Grappling with Machine Basics 16

Motoring about 17

Ways and means 19

Pulleys and gears 20

Turrets and tool changers 21

Spindle time 22

Bearing down 23

The nuts and bolts of motion 24

Chapter 2: Demystifying Machine Tools 25

Making Machine Tools Automatic 27

Screwing around with cam-operated machines 27

Multispindle madness 28

Mill-o-matic 28

The path to numerical control 28

Cutting through the red tape 29

Computer control 30

Halfway there 31

Milling About: Mills and Machining Centers 32

Taking the stand-up tour 33

Looking at it from all sides 35

Gantrification 37

Going horizontal 38

Sorry, this part's boring 39

Turning It Up: Exploring Lathes 39

Engine lathes 40

Turret lathes 41

Twice as nice 41

Looking up 42

Going gangsta' 43

Sliding about 43

It's a Mill, It's a Lathe It's Supermachine! 44

Mill turn, or turn mill 44

Multitaskers 45

Chapter 3: Rounding Out the Rest of the Machining Processes 47

Touring Toolmaking 47

Cutting without cutters: EDM 48

Grinding 51

Sawing 53

Honing 54

Hobbing, shaving, and milling gears 55

Gun drilling 55

Peering into the Niches 57

Electron beam machining 57

From ECM to PECM 57

Ultrasonics 58

Appreciating the Alternatives 58

When we were fab 59

Welding 101 61

Chapter 4: Being Materialistic 63

Grappling with the Elements 64

Meditating on Metal Removal 66

Machinability according to AISI 66

Like cutting sandpaper 66

Harder than the dickens 67

Stringy like spaghetti 67

Gummier than Juicy Fruit 68

Exploring Metals 68

Ironing things out 68

Segueing to steel 70

Surveying the superalloys 74

Wrapping It Up with the Easy Stuff 76

From superchargers to soda cans 76

Red metals 77

Magnesium and zinc 77

Peeking at the polymers 78

Part 2: TOOLING UP 81

Chapter 5: The Cutting Edge: Staying Sharp 83

Facing the Hard Facts 84

Getting Tough with High-Speed Steel 85

Going Fast and Furious: Carbide 87

Meet PEG 87

Micrograin marvels 88

Getting technical with ceramics 88

Coating conundrums 89

Round Tools: Notating on Rotating 90

Holemaking 101 90

All about drills 91

Selecting the right drill 92

Being productive 94

Holes need help, too 95

Tapping, tapping, at the door 96

Milling cutters 97

Staying put 100

Sticking with Stick Tools 100

The heavy lifters 101

Get in the groove 102

Nice threads 103

Not so boring 104

Cutting Advice 105

Chapter 6: Hanging on Tight with Workholding 107

Chucking Up on Lathes 108

Deciding how many and what type of jaws are needed 110

Collets, ho! 111

Making sense of shafts 113

It's Not Spelled Vice: Going Orthogonal with Workholding 114

Doubling down 116

Not so fast 117