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Automated Machines and Toolmaking All New 5th Edition
Auteur : Rex Miller Mark Richard Miller Edition : Wiley Pages:503 Format: pdf
Contents
Acknowledgments xv
About the Authors xvii
Introduction xix
Chapter 1: Jigs and Fixtures 1
Jigs 1
Clamp Jig 1
Box Jig 6
Fixtures 11
Summary 13
Review Questions 14
Chapter 2: Helix and Spiral Calculations 15
Milling a Helix 15
Angle of Table Swivel 17
Lead of the Machine 19
Change Gears 20
Change-Gear Train 20
Change-Gear Ratio 22
Change-Gear Calculations 22
Milling a Spiral 25
Summary 28
Review Questions 28
Chapter 3: Spur Gear Computations 31
Evolution of Gears 31
Gear Teeth 33
Gear Tooth Terms 34
Spur Gear Computations 36
Involute Gears 48Summary 50
Review Questions 51
Chapter 4: Gears and Gear Cutting 53
Development of Gear Teeth 53
Diametral and Circular Pitch Systems 54
American Standard Spur Gear Tooth Forms 55
Gear-Cutting Operations 59
Cutting Spur Gears 59
Cutting Bevel Gears 66
Cutting Helical Gears 82
Cutting Rack Teeth 86
Cutting Worm and Worm Wheel Teeth 89
Summary 93
Review Questions 94
Chapter 5: Cams and Cam Design 97
Cam Principles 97
Uniform Motion Cams 98
Uniformly Accelerated Motion Cams 99
How a Cam Operates 100
Cam Design 101
Displacement Diagrams 101
Design for Gas Engines 105
Design for Automatic Screw
Machines 107
Drawing the Cams 124
How to Machine Cams 137
Transferring the Cam Outline 137
Machining the Cam Outline 137
Summary 141
Review Questions 141
Chapter 6: Dies and Diemaking 143
Cutting or Punching Dies 143
Plain Die 143Self-Centering Die 144Shaping Dies 147
Plain Bending Die 147
Curling Die 148
Wiring Die 149
Bulging Die 150
Combination Punching and
Shaping Dies 151
Double-Action Dies 152
Plain Drawing Die 153
Redrawing Die 153
Gang and Follow Dies 155
Compound Die 156
Miscellaneous Dies 157
Diemaking Operations 160
Lubricants 160
Materials for Making Dies 161
Laying Out Dies 161
Laying Out the Design on the Die 165
Making the Die 166
Hardening and Tempering 168
Summary 169
Review Questions 170
Chapter 7: Grinding 173
Cylindrical Grinders 173
Centerless Grinders 179
Basic Principles 180
Abrasive-Belt Centerless Grinding 190
Advantages of Centerless Grinding 190
Internal Grinding 191
Rotating-Work Machine 191
Internal Centerless Grinding Machine 192
Cylinder Grinding Machine—StationaryCutter and Tool Grinding 197
Grinding Cemented Carbide Tools 198
Cutter Sharpening Machines 198
Barrel Finishing (Abrasive Tumbling) 199
Summary 204
Review Questions 205
Chapter 8: Laps and Lapping 207
Laps 207
Classification 207
Materials 207
Lapping Powders 210
Lapping Operations 210
Hand Lapping 211
Machine Lapping 212
Lapping a Cylinder 213
Lapping a Tapered Hole 214
Rotary Disc Lap 214
Honing 215
Summary 218
Review Questions 218
Chapter 9: Toolmaking Operations 221
Introduction 221
Allowances and Tolerances 223
Precision Measurements 224
Tolerance Limits 224
Fits and Fitting 226
Limits of Fits 227
Layout 229
Laying Out the Workpiece 253
Drilling Center Holes 256
Locating Center Points with Precision 256
Checking the Square 275
Sine Bar for Measuring Angles 275
Summary 284
Review Questions 285Chapter 10: Heat-Treating Furnaces 287
Classification 287
Types of Furnaces 287
Gas-Fired Oven Furnaces 288
Electrically Heated Furnaces 289
Pit Furnaces 290
Pot-Hardening Furnaces 291
Recuperative Furnaces 297
Controlled Atmosphere 300
Scale 300
Decarburization 300
Carburization 301
Controlled-Atmosphere Furnaces 301
Temperature Control of Heat-Treating
Furnaces 303
Results Are Important 305
Response 305
Measuring Temperature 305
Thermocouples 309
Automatic Controls 313
Recording Pyrometers 314
Summary 314
Review Questions 316
Chapter 11: Annealing, Hardening, and Tempering 317
Annealing 317
Methods of Annealing 318
Temperature for Annealing 318
Effects of Forging 320
Hardening 321
Heating Process 321
Heating Baths 323
Quenching or Cooling Baths 324
Tempering 324
Color Indications 325
Case-Hardening 326
Variations on Case-Hardening Methods 328Summary 328
Review Questions 329
Chapter 12: Principles of Induction Heating 331
Adjustable Induction Heating Coil 336
Summary 338
Review Questions 339
Chapter 13: High-Frequency Induction Heating 341
Producing Heat by Resistance 341
Heating Units 342
High-Frequency Applications 343
Summary 347
Review Questions 348
Chapter 14: Furnace Brazing 349
Basic Process 349
Holding Assemblies Together 351
Laying and Pressing Parts Together 352
Summary 360
Review Questions 360
Chapter 15: Cold-Treating Process 363
Fundamental Principle of
Cold Treating 363
Decalescence 363
Cold-Treating Temperatures 364
Convection Fluid 365
Calculating Rate of Production 365
Cold-Treating Procedures 366
High-Speed Tool Steel 366
High-Carbon Steel 368
Stabilizing Dimensions 369
Subzero Chilling 369Chapter 16: Automatic Lathes 373
Automatic Turret Lathes 373
Automatic Threading Lathes 374
Summary 378
Review Questions 378
Chapter 17: The Automatic Screw Machine 381
Classification 381
Operating Principles 382
Selection and Use of Tools 383
Types of Tools 384
General Suggestions for Tool Selection 386
Setting Up an Automatic Screw
Machine 388
Arrangement of Belts for Correct
Spindle Speed 391
Indexing the Turret 392
Changing from Double to Single Index 393
Setting Cross-Slide Tools 393
Adjusting the Cutting Tool to
Proper Distance
from Chuck 393
Adjust the Form Tool to Line
Up with the Cutoff Tool 395
Placing the Cams 396
Adjusting the Cutoff Tool to the
Cam Lobe 396
Adjusting the Turret to the
Correct Distance
from the Chuck 396
Setting the Stock for Length 396
Setting the Chuck and Feed Trip Dog 396
Setting Turret Indexing Trip Dogs 397
Setting the Spindle Reverse Trip Dog 398
Setting the Indexing Trip Dogs 398
Adjusting the Feed Slide for
Length of Stock 398Placing and Adjusting the First
Turret Tool 399
Adjusting the Form Tool 399
Adjusting the Threading Tool 400
Setting the Deflector 400
Setting the Automatic Stock 400
Measuring the Work 400
Renewing Stock 400
Dial-Controlled Machines 401
Summary 402
Review Questions 402
Chapter 18: Automated Machine Tools 405
Basic Principles of Numerical Control 407
Preparation for Numerical Control 409
Electronic Control of Machine Tools 413
Tape Preparation 419
Control 420
Transducers 421
Summary 426
Review Questions 427
Chapter 19: Computerized Machining 429
Numerical Controls 431
Computer-Operated Machine Tools 432
CNC Components and Control
System 433
Positioning Formats 434
Advantages of CNC over NC 437
CNC Programming 437
Machining Centers 441
CAD/CAM 441
Computer-Integrated Manufacturing
(CIM) 443
Summary 445
Review Questions 447Appendix: Reference Materials 449
Colors and Approximate Temperatures
for Carbon Steel 449
Nominal Dimensions of Hex Bolts and
Hex Cap Screws 450
Nominal Dimensions of Heavy Hex
Bolts and Heavy Hex Cap Screws 450
Nominal Dimensions of Heavy Hex
Structural Bolts 451
Nominal Dimensions of Hex Nuts,
Hex Thick Nuts, and Hex Jam Nuts 452
Nominal Dimensions of Square-Head
Bolts 452
Nominal Dimensions of Heavy Hex
Nuts and Heavy Hex Jam Nuts 453
Nominal Dimensions of Square Nuts
and Heavy Square Nuts 454
Nominal Dimensions of Lag Screws 455
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