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
Five ways better 117
Holding horizontally 118
Hanging on to the Weird Ones 119
Chapter 7: Entering the Toolholding No Spin Zone 123
Hanging around with Rotary Tools 124
It’s taper time 125
Why 7/24 isn’t a date in the calendar 126
Faster, faster! 127
Cruising through the Toolholding Catalog 128
Hit me sideways 129
Meet Chuck’s little brother 129
Preventing pullout 130
The incredible shrinking toolholder 132
A few toolholding odds and ends 133
Turning about Is Fair Play 135
Giving lathe tools a wedgie 136
A bit about bushings and sleeves 137
Going Faster with Quick-Change 138
Chapter 8: Accessorizing for Success 141
Palletizing Your Parts 142
Buying a pallet changer–equipped machining center 142
Adding a pallet changer to an existing machine 143
Putting pallets on pallets 143
Giving Rotary Tables a Whirl 144
Viva, la difference 145
Round and round we go 146
Trunnion time 146
Raising the Bar with Bar Feeders 147
Step on up to the bar 148
Rattling about 149
Happiness through hydraulics 149
Collaborating with R2D2 151
Measuring Up 152
Touching off 153
Finding home 154
Taking It Offline 155
Presetting particulars 155
Achieving a nice balance 157
Going soft 158
Vending machines 158
Choosing the Right Machine Options 159
Cooling Down with High Pressure 161
Making Your Job Easier (and Safer) 162
Chip conveyors 162
It’s called smog for a reason 163
Part 3: PUTTING IT ALL TOGETHER: MAKING PartS 165
Chapter 9: Succeeding with Software 167
Deciphering Software Acronyms 168
Here’s to Being a CAD 170
Playing with Models 171
Wondrous wireframes 172
Doing me a solid 172
CAMming It Up 173
Simulating Reality 175
Having Meaningful Conversations 176
Exploring File Formats 177
Making It Manufacturable 178
DFM and DFMA 179
FEA 180
Managing the Shop Floor 180
MES 181
TMS 181
Chapter 10: Measuring Up 183
Drawing Pretty Pictures 185
Tolerance is a good thing 185
Enter GD&T 186
Characterizing characteristics 188
Blocking and Tackling: Hard Gages 189
Playing with your blocks 190
Pinned down 191
Gages, gages, everywhere 192
Meeting Mic(rometer) 192
Filling the Shopping Cart 194
Touching the surface 195
Checking holes 196
Jumping at shadows 197
Checking around 198
Measuring with Machines 199
Hitting the Quality Road 200
Chapter 11: Demystifying G-Code 203
Eating the CNC Alphabet Soup 204
Moving along with G-Codes 206
Giddyup! 207
Straightening out 207
Round the clock 208
Coordinating Coordinates 209
Homing the machine 210
Thinking in absolutes 211
Compensating for Size (and Location) 212
Offset success 212
Go left, or right? 213
Cycling About: Canned and Multiple Repetitive Cycles 215
One line, or two 215
Best of both worlds 215
Don’t forget to cancel 216
Switching On with M-Codes 217
Making It with Macros 219
Chapter 12: Touring Some Machining Operations 221
Happy Holemaking 223
Threading the Needle 224
Internal threads 224
External threads 226
Taking the Right Turn 227
Facing About 228
Milling Madness 229
Face milling 229
Pocket milling 230
Surfacing 230
Slotting 231
Boring Better 232
Taming Interpolation 233
Getting the Burrs Off 234
Bouncing about 234
A charged situation 235
Chapter 13: Looking toward Tomorrow 237
Turning Out the Lights 238
Embracing an FMS 239
Getting cellular 241
Monitoring machines remotely 241
Unplugging Along 243
Staying Bug-Free 243
Making Tools Smarter 245
Busting chatter 246
Tagging along 247
Part 4: THE Part OF TENS 249
Chapter 14: Ten Ways to Make Processes Predictable 251
Thinking Scientifically 252
Learning Your Feeds and Speeds 253
Cutting speeds 254
Feed rates 256
Depth of cut 256
Watching for Tool Wear 257
Writing It Down 259
Staying Cool 259
Keeping Machines Healthy 260
Getting Torqued 261
Poka-yoking 262
Buying Right 262
Standardizing Everything 263
Chapter 15: Ten Terrific Tools, Tips, and Technologies 265
Adding It Up with Additive 266
Surfing the Internet of Things 267
Looking to the Cloud 269
Automating Everything 270
Riding Virtual Rollercoasters 271
Becoming Sustainable 272
Lightweighting the World 273
Losing the Paper Trail 274
Having Fun with Hybrids 275
Getting Small: MEMS Devices and Other Lilliputian Parts 277
Chapter 16: Ten Tips for Successful Machining 279
Machining Is Not a Dirty Word 280
Returning to School: Certification 281
Staying Lean 282
Developing Vertical Markets 283
Taking Tools Faster and Farther 284
Keeping Parts and Tools Put 285
Keeping Things (and People) Cool, Clean, and Safe 287
Setting Up Successfully 289
Taking Off the Gloves (and Putting On the Safety Glasses) 290
Embracing Change 292
Index 293
