Table Of Contentkra10831_fm_i-x_1.qxd 12/31/09 8:35 AM Page i
TECHNOLOGY of
MACHINE TOOLS
seventh edition
Steve F. Krar
Arthur R. Gill
Peter Smid
TM
kra10831_fm_i-x_1.qxd 1/14/10 12:10 PM Page ii
TM
TECHNOLOGY OF MACHINE TOOLS
Published by McGraw-Hill,a business unit of The McGraw-Hill Companies,Inc.,1221 Avenue of the
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1 2 3 4 5 6 7 8 9 0 DOW/DOW 1 0 9 8 7 6 5 4 3 2 1 0
ISBN 978-0-07-351083-5
MHID 0-07-351083-1
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Library of Congress Cataloging-in-Publication Data
Krar,Stephen F.
Technology of machine tools / Steve F. Krar,Arthur R. Gill,Peter Smid.—7th ed.
p. cm.
Includes index.
ISBN-13:978-0-07-351083-5 (alk. paper)
ISBN-10:0-07-351083-1 (alk. paper)
1. Machine-tools. 2. Machine-shop practice. I. Gill,Arthur,1930- II. Smid,Peter. III. Title.
TJ1185.K668 2011
621.9'02—dc22
2009051328
The Internet addresses listed in the text were accurate at the time of publication. The inclusion of a Web site
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
kra10831_fm_i-x_1.qxd 12/31/09 8:35 AM Page iii
contents
Preface vii SECTION 4
About the Authors viii
Job Planning 40
Acknowledgments ix
UNIT 5
Engineering Drawings 42
UNIT 6
SECTION 1
Machining Procedures for Various
Workpieces 50
Introduction to Machine Tools 2
UNIT 1
History of Machines 4 SECTION 5
Measurement 58
SECTION 2
UNIT 7
Basic Measurement 62
Machine Trade Opportunities 18
UNIT 8
UNIT 2 Squares and Surface Plates 68
Careers in the Metalworking Industry 20
UNIT 9
UNIT 3 Micrometers 73
Getting the Job 29
UNIT 10
Vernier Calipers 82
UNIT 11
SECTION 3
Inside-, Depth-, and Height-Measuring
Instruments 87
Safety 32
UNIT 12
Gage Blocks 98
UNIT 4
Safety in the Machine Shop 34 UNIT 13
Angular Measurement 104
iii
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UNIT 14 UNIT 28
Gages 110 Machinability of Metals 205
UNIT 15 UNIT 29
Comparison Measurement 117 Cutting Tools 210
UNIT 16 UNIT 30
The Coordinate Measuring System 128 Operating Conditions and Tool Life 221
UNIT 17 UNIT 31
Measuring with Light Waves 133 Carbide Cutting Tools 225
UNIT 32
UNIT 18
Diamond, Ceramic, and Cermet Cutting
Surface Finish Measurement 137
Tools 243
UNIT 33
SECTION 6
Polycrystalline Cutting Tools 254
Layout Tools and Procedures 142 UNIT 34
Cutting Fluids—Types and Applications 263
UNIT 19
Basic Layout Materials, Tools, and SECTION 9
Accessories 144
UNIT 20 Metal-Cutting Saws 274
Basic or Semiprecision Layout 152
UNIT 35
UNIT 21
Types of Metal Saws 276
Precision Layout 156
UNIT 36
Contour Bandsaw Parts and Accessories 281
SECTION 7
UNIT 37
Contour Bandsaw Operations 288
Hand Tools and Bench Work 162
UNIT 22 SECTION 10
Holding, Striking, and Assembling Tools 164
Drilling Machines 300
UNIT 23
Hand-Type Cutting Tools 170
UNIT 38
UNIT 24 Drill Presses 302
Thread-Cutting Tools and Procedures 177
UNIT 39
UNIT 25 Drilling Machine Accessories 307
Finishing Processes—Reaming, Broaching, and
UNIT 40
Lapping 183
Twist Drills 313
UNIT 26
UNIT 41
Surface Finishing Processes 190
Cutting Speeds and Feeds 322
UNIT 42
SECTION 8
Drilling Holes 326
UNIT 43
Metal-Cutting Technology 196
Reaming 334
UNIT 27 UNIT 44
Physics of Metal Cutting 198 Drill Press Operations 341
iv Contents
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SECTION 11 UNIT 62
Vertical Mill Operations 484
The Lathe 348
UNIT 63
Special Milling Operations 500
UNIT 45
UNIT 64
Engine Lathe Parts 353
Horizontal Milling Machines and
UNIT 46
Accessories 508
Lathe Accessories 358
UNIT 65
UNIT 47
Milling Cutters 518
Cutting Speed, Feed, and Depth of Cut 370
UNIT 66
UNIT 48
Milling Machine Setups 525
Lathe Safety 376
UNIT 67
UNIT 49
Horizontal Milling Operations 532
Mounting, Removing, and Aligning Lathe
Centers 379 UNIT 68
The Indexing, or Dividing, Head 539
UNIT 50
Grinding Lathe Cutting Tools 383 UNIT 69
Helical Milling 548
UNIT 51
Facing Between Centers 386 UNIT 70
UNIT 52 Cam, Rack, Worm, and Clutch Milling 556
Machining Between Centers 391
UNIT 53
Knurling, Grooving, and Form Turning 399
SECTION 13
UNIT 54
Tapers and Taper Turning 407
Grinding 566
UNIT 55
Threads and Thread Cutting 419 UNIT 71
UNIT 56 Types of Abrasives 568
Steady Rests, Follower Rests,
UNIT 72
and Mandrels 440
Surface Grinders and Accessories 589
UNIT 57
UNIT 73
Machining in a Chuck 446
Surface Grinding Operations 601
UNIT 58
UNIT 74
Drilling, Boring, Reaming, and Tapping 457
Cylindrical Grinders 615
UNIT 75
SECTION 12
Universal Cutter and Tool Grinder 626
Milling Machines 464
UNIT 59
SECTION 14
The Vertical Milling Machine 466
UNIT 60
Metallurgy 640
Cutting Speed, Feed, and Depth of Cut 469
UNIT 61 UNIT 76
End Mills 476 Manufacture and Properties of Steel 642
Contents v
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UNIT 77 SECTION 17
Heat Treatment of Steel 656
Advanced Manufacturing
UNIT 78
Testing of Metals and Nonferrous Metals 672 Technology 794
UNIT 90
SECTION 15 Instant Digital Manufacturing 796
UNIT 91
Lean Manufacturing 684 Cryogenic Treatment/Tempering 801
UNIT 92
UNIT 79
QQC Diamond Coating 809
Cellular Manufacturing 693
UNIT 93
UNIT 80
Direct Metal Deposition 814
Continuous Improvement 697
UNIT 94
UNIT 81
e-Manufacturing 818
Pull (Kanban) Systems 702
UNIT 95
UNIT 82
STEP-NC and Internet Manufacturing 823
Total Productive Maintenance 707
UNIT 96
UNIT 83
Optical/Laser/Vision Measurement 830
Value-Stream Mapping 711
UNIT 97
UNIT 84
Electrical Discharge Machining 837
Workplace Organization 716
UNIT 98
Robotics 846
SECTION 16
UNIT 99
Manufacturing Intelligence: Can a Company
Computer-Age Machining 720 Survive Without Real-Time Knowledge? 852
UNIT 100
UNIT 85
Multi-Tasking Machines 857
The Computer 722
UNIT 86
Computer Numerical Control 725
UNIT 87
SECTION 18
CNC Turning Center 745
UNIT 88
CNC Machining Centers 766 GLOSSARY 864
APPENDIX OF TABLES 875
UNIT 89
CAD/CAM 786 INDEX 903
vi Contents
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preface
T
he use of computers continues to change how ma- The business and manufacturing world today is
chine tools are used to manufacture products. Com- very different from what it was as little as 5 or 10
puters have improved until there are now highly years ago. Ever more highly productive advanced
sophisticated units capable of controlling the opera- technology and global competition are the driving
tion of a single machine, a group of machines, or forces behind this never-ending change. It seems
even a complete manufacturing plant. Section 14, that new technological developments are occurring
“Computer-Age Machining,” now includes not only every month, and the days when we used to do the
computer numerical control machine tools, such as same thing month after month are gone.
turning and machining centers, but also newer man- Globalization and the fierce competition it has
ufacturing technologies. To increase manufacturing brought have created a need for industry to produce
productivity, machine tools have been equipped with high-quality products quickly and at less cost. This is
modular tooling and work-holding systems, as well as a real challenge for some industries that have not
new cutting tools to produce accurate parts faster kept pace with the constant-changing technology and
and at competitive prices. that still hope 5- to 10-year-old technology will keep
Today’s industries are putting more emphasis on them in business. In order to survive, we must de-
using new manufacturing technologies and manufac- velop and use manufacturing systems that produce
turing intelligence systems to improve their produc- better products, faster, and at lower cost than our
tivity and remain competitive in the world. Section competitors. These highly productive systems are
14 gives an overview of 10 technologies or processes available to anyone in the world. Those companies
that are giving manufacturers an advantage over their that use them first are very likely to survive, while
competition. A few of these are Artificial Intelligence, those that do not will gradually fade away.
Open Architecture CNC, Step NC, Virtual Reality, e- The purposes of this text are to assist instructors
Manufacturing, Nanotechnology, and Cyber Manage- in providing the basic training on conventional ma-
ment Systems. Through the use of CDs and chine tools; to cover basic programming for CNC
videotapes, students can learn how the machine tool machines (such as turning and machining centers);
trade will be changing in the future. and to introduce new manufacturing technologies
This book is based on the authors’ many years and processes. To make this course interesting and
of trade experience and experience as specialists in challenging for students, videotapes can be used to
teaching. To keep up-to-date with technological cover new technologies. They are available on loan or
change, the authors have researched the latest tech- for a small fee from technical societies, manufactur-
nical information available and have visited indus- ers, and publishers. The instructor’s manual includes
tries that are leaders in their field. Key personnel in sources of videotapes, along with answers to the review
manufacturing firms and leading educators reviewed questions in the text. A student workbook is also
many sections of this book, so that accurate and up- available.
to-date information is presented. The authors are Steve F. Krar
grateful to the reviewers for the technical and practi- Arthur R. Gill
cal suggestions that were incorporated into the text. Peter Smid
vii
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about the authors
STEVE F. KRAR ARTHUR R. GILL
Steve F. Krar spent 15 years in the trade, first as a ma- Arthur R. Gill served an apprenticeship as a tool and die
chinist and finally as a tool and die maker. After this pe- maker. After 10 years in the trade, he entered the On-
riod, he entered Teachers’ College and graduated from tario Community College system. Mr. Gill served as a
the University of Toronto with a Specialist’s Certificate professor and coordinator of precision metal trades and
in Machine Shop Practice. During these 20 years of apprenticeship training for 30 years at Niagara College
teaching, Mr. Krar was active in vocational and techni- in St. Catharines. He was a member of the Ontario Pre-
cal education and served on the executive committee of cision Metal Trades college curriculum committee for
many educational organizations. For 10 years, he was apprenticeship training and Heads of Apprenticeship
on the summer staff of the College of Education, Uni- Training. Mr. Gill is a member of the Society of Manu-
versity of Toronto, involved in teacher training programs. facturing Engineers and worked closely with industry to
Active in machine tool associations, Steve Krar is a Life continually improve manufacturing technology.
Member of the Society of Manufacturing Engineers and Mr. Gill has coauthored a number of textbooks,
former associate director of the GE Superabrasives including CNC Technology and Programming, Com-
Partnership for Manufacturing Productivity. He was puter Numerical Control Simplified, and Exploring
inducted into the Canadian Manufacturers Hall of Fame Advanced Manufacturing Technologywith Steve Krar.
in March 2009. In 1991, he was invited by China to assist in devel-
Mr. Krar’s continual research over the past 50 oping a Precision Machining and Computer Numeri-
years in manufacturing technology has involved many cal Control (CNC) training facility at Yueyang
courses with leading world manufacturers and an op- University in Hunan Province.
portunity to study under Dr. W. Edwards Deming. Mr.
Krar spent a week researching Nanotechnology at Other Highlights (Krar and Gill)
leading research centers, universities, and industry
> Consulting editor, manufacturing technology,
in Switzerland. He is coauthor and consultant of over
for Industrial Press, New York, and
80 technical books, such as Machine Shop Train-
contributing editor, Advanced Manufacturing
ing, Machine Tool Operations, CNC Simplified,
Magazine,Burlington, Ontario
Superabrasives—Grinding and Machining, and
> Judge at the annual SkillsUSA competition for
Exploring Advanced Manufacturing Technologies,
CNC programming and machining, held in
some of which have been translated into 5 languages
Kansas City
and used throughout the world.
> Research in new developments in Manufac-
turing Technology in North America and
Nanotechnology at universities, industries, and
the IBM Research Lab in Switzerland
viii
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PETER SMID turing. In 1989, he became an independent consult-
ant, and hundreds of companies have used Mr. Smid’s
Peter Smid graduated from high school with a spe- CNC and CAD/CAM skills to improve their manufac-
cialty in machine shop training. He then entered turing operations. He also wrote a comprehensive,
industry, completed an apprenticeship program, and 500-page CNC programming handbook, which is rap-
gained valuable experience as a machinist skilled on idly becoming the Bible of the trade.
all types of machine tools. Mr. Smid immigrated to In 1995, he became a consultant/professor of
Canada in 1968 and spent the next 26 years em- Advanced Manufacturing focusing on industrial
ployed in the machine tool industry as a machinist and customized training in CNC, CAD/CAM, and
and tool and die maker. Agile Manufacturing. His many years of teaching,
In the early 1970s, he became involved in Com- training, lecturing, and designing curriculum give
puter Numerical Control (CNC) as a programmer/ him the opportunity to pass along his vast knowl-
operator and devoted the next 18 years to becoming edge of modern manufacturing technology to stu-
proficient in all aspects of computerized manufac- dents of all ages.
ACKNOWLEDGMENTS
T
he authors wish to express their sincere thanks Electric Co.; Cincinnati Machine, a UNOVA Co.; Do-
and appreciation to Alice H. Krar for her untiring de- rian Tool International; GE Superabrasives; Moore Tool
votion in reading, typing, and checking the manu- Co.; Norton Co.; Nucor Corporation; and Stelco, Inc.
script for this text. Without her supreme effort, this We also extend our thanks to the team at
text could not have been produced. McGraw-Hill: Sarah Wood, Director of Development;
The authors wish to thank all the teachers and Vincent Bradshaw, Editorial Coordinator; Jeremy
industrial reviewers who took their valuable time to Cheshareck, Senior Photo Research Coordinator;
offer concrete suggestions for the manuscript, which Kevin White, Digital Developmental Editor; Kelly
we were happy to include. Their suggestions will Curran, Marketing Manager; Theodore Knight, Free-
make this book, which is considered to be a world lance Development Editor; Srdjan Savanovic, Senior
leader, even more valuable as an educational tool. Designer; Janean Utley, Production Supervisor,
Our sincere thanks go to the following firms that Kathryn Mikulic, Project Manager; and all the rest
reviewed sections of the manuscript and offered sug- who assisted in getting this revision published.
gestions that were incorporated to make this text as We are grateful to the following firms, which
accurate and up-to-date as possible: ABB Robotics; assisted in the preparation of this text by supplying
American Iron & Steel Institute; American Superior illustrations and technical information:
3D Systems Armstrong Bros. Tool Co. Carpenter Technology Corp.
300 Below, Inc. Ash Precision Equipment Inc. Carr Lane Manufacturing Co.
ABB Robotics, Inc. Automatic Electric Co. Charmilles Technologies Corp.
Able Corporation Avco-Bay State Abrasive Company Cincinnati Gilbert Co.
Allen Bradley Co. Bausch & Lomb Cincinnati Machine, a UNOVA Co.
Allen, Chas. G. & Co. Bethlehem Steel Corporation Clausing Industrial, Inc.
American Chain & Cable Co. Inc., Blanchette Tool and Gage Cleveland Taping Machine Co.
Wilson Instrument Division Boston Gear Works Cleveland Twist Drill Ltd.
American Iron & Steel Institute Bridgeport Machines, Inc. CNC Technologies
American Machinist Ametek Testing Brown & Sharpe Manufacturing Co. Cogsdill Tool Products, Inc.
Equipment Carboloy, Inc. Colchester Lathe Co.
AMT—The Association for Carborundum Co. Div. Saint Gobain Concentric Tool Corp.
Manufacturing Technology Abrasives Criterion Machine Works
About the Authors ix
