OER Textbook Index

This page contains links to the chapters, sections, and nested sub-sections of the OER textbook Introduction to Machining. Numerical hierarchy reflects the structure the book's URL and hash-fragment scheme: I have flattened the structure in a few places (with notes) where that seemed reasonable. This indexing should be largely complete, less author's tips and attribution sections, however there are likely gaps and other errors: your mileage may vary.

  1. Front Cover

  2. Introduction to the Machining Industry

    1. What Is Machining?

    2. What Do We Call Ourselves?

    3. What Do Machinists Do?

    4. What Qualifications Does a Machinist Need?

    5. How Much Training Do Machinists Need?

    6. Do Machinists Do Math?

    7. Where Do You Find Machinists?

    8. What Industries Do Machinists Support?

    9. Chapter Conclusion

  3. General Machine Shop Safety

    1. Federal Government Safety Agencies

      1. The Occupational Safety and Health Act of 1970 (OSH Act)

    2. Hazardous Materials (HAZMAT)

      1. Safety Data Sheets (SDS)

      2. Hazardous Material Labeling

      3. Personal Protection

      4. Hazardous Waste (HAZWASTE)

      5. Hazard Communication Standard

    3. Fires In The Workplace

      1. The Chemistry of Fire

      2. Classifications of Fire

    4. Fire Extinguishers

      1. When to Use a Fire Extinguisher

      2. How to Operate a Fire Extinguisher

    5. Personal Protective Equipment

      1. Clothing and Accessories

      2. Hearing Protection

      3. Health Effects of Excessive Noise Exposure

      4. Respirator Protection

      5. Dust Mask Respirator

      6. Health Effects of Respiratory Hazards

      7. Eye Protection

      8. American National Standard for Occupational and Educational Personal Eye and Face Protection Devices

      9. Health Effects of Eye Hazards

    6. Common Machine Shop Hazards

      1. Receiving

      2. Cutting

      3. Chips, Chips, Chips

      4. Slip, Trip and Fall

    7. Chapter Conclusion

  4. Technical Drawings

    1. Industry Drawing Standards

    2. Sheet Size and Format

      1. The Sheet

      2. Title Block

      3. Drawing Area

    3. Drawing Views

      1. Assembly Drawing

      2. Detail Drawings

      3. Part Views

      4. Orthographic Projected View

      5. Front View

      6. Detail View

    4. Lines

      1. Solid Lines

      2. Hidden Lines

      3. Leader Lines

      4. Center Lines

      5. Cutting Plane Lines

      6. Section View

    5. Dimensions, Tolerances, and Allowance

      1. Overall Dimensions (OD)

      2. Diameter (Ø) Dimensions

      3. Radial Dimensions

      4. Angular Dimensions

      5. Center-to-Center Dimensions

      6. Chamfer Dimensions

      7. Hole Patterns and Spacing Dimensions

      8. Counterbore Dimension (⌴)

      9. Countersink Dimension (⌵)

      10. Threaded Hole Callout

    6. Surface Texture/Finish

      1. Units of Measure

      2. Roughness Average (Ra)

      3. Symbols

    7. Chapter Conclusion

  5. Metrology

    1. Decimal Numbers

      1. Decimal Theory

      2. Talk Like a Machinist

    2. Measuring Equipment and Decimals

    3. Direct Read Measuring Equipment

      1. Slide Calipers

        1. Caring for Slide Calipersh3 without element id; nesting is inferred

      2. Using Incremental on Digital Equipment

      3. Outside Micrometers

      4. Operation of a Micrometer

        1. Preoperational Inspection
        2. Zero the Indicator
        3. Measuring with a micrometer.
          1. Micrometer Accessories
        4. Reading a vernier micrometer
        5. Reading in thousandths of an inch, .001
        6. Reading in the ten-thousandths of an inch, .0001
        7. Reading in hundredths of a millimeter, 0.01mm
        8. Reading in thousandths of a millimeter, 0.001mm Labeled in text as 4.3.4.8, but h3 does not have id.

      5. Blade Micrometers

      6. Disc Micrometer

      7. Thread Micrometer

        1. Thread Micrometer Operation

      8. Inside Micrometers

      9. Depth Micrometers

    4. Height Gages

      1. Height Gage Attachments

      2. Scribe

      3. Depth Gage Attachment

      4. Test Indicator

      5. Cleaning a Height Gage

    5. Measuring Diameters

    6. Snap Gages

    7. Bore Gages

    8. Pin Gages

    9. Gage Blocks

    10. Radius Gages

    11. Thread Plug Gages

    12. Indicators

    13. Dial Indicators

    14. Test Indicator

  6. Benchwork

    1. What is a Layout and Benchwork?

    2. Stock Preparation

    3. Layout Dye

    4. Layout: Straight Lines

      1. Steel Rules

      2. Firm Joint Caliper

      3. Squares

      4. Slide Caliper

    5. Layout: Arcs

      1. Divider

      2. Trammel

      3. Gage Pins

      4. Radius Gages

    6. Scribes

    7. Punches

      1. Punch Tips

      2. How to Center Punch

      3. Automatic Center Punch

    8. Files

    9. Tap and Dies

      1. Tapping Threads

      2. Layout and Punch

      3. Tap Drills

      4. Tap Drilling Operation

      5. Choose a Tap

      6. Hand Taps

      7. Hand Tap Chamfers

      8. Tapping Operation

      9. Thread Dies

      10. Die Threading Operation

    10. Workholding

      1. Bench Vise

      2. Clamps

    11. Off-Hand-Grinding

    12. Bench Grinders

      1. Grinding Wheels

      2. Tool Rests

      3. Bench Grinder Operation

        1. ON/OFF switch
        2. Dress for success!
        3. Position the tool rest
        4. Roughing and finishing
        5. Controlling heat
        6. Sparks
        7. You can't grind that!

    13. Chapter Conclusion

  7. Job Planning

    1. Introduction

      1. The Role of Job Planning in Machining

    2. Technical Drawings

      1. A picture is Worth a Thousand Words

    3. Tool Selection

      1. Mill tools

      2. Lathe Tools

    4. Material Selection

    5. Choosing a Machine

    6. Work Holding

      1. Mill workholding

      2. Lathe workholding

    7. Documentation

      1. Keep notes

    8. Application

      1. Reading the drawing

      2. Find the Tools

      3. Material

      4. Machines and Workholding

    9. Chapter Conclusion

  8. Saws

    1. Introduction

      1. Keep your fingers away from anything moving...

      2. Housekeeping and Preventative Maintenance

      3. Workholding

    2. Types of Saws

      1. Horizontal Saws

      2. Vertical Saws

      3. Abrasive Saws

    3. Blade Characteristics

      1. Important characteristics of a band saw blade

      2. Choosing an abrasive blade

    4. Saw Operations and Handling

      1. Horizontal Saw Operations

      2. Vertical Saw Operations

      3. Abrasive Saw Operations

    5. Chapter Conclusion

  9. Drill Presses

    1. Safety

      1. Rotating hazards

      2. Pinch hazards

      3. Sharp hazards

      4. Slipping hazards

    2. Machine Maintenance

      1. Lubrication

      2. Cleaning

    3. Machine Components

      1. Base

      2. Column

      3. Table

      4. Head

      5. Motor

      6. Pulleys

      7. Spindle

      8. Quill

      9. Quill Stop

    4. Workholding

      1. Drill press vise

        1. Screw-actuated vise
        2. Cam actuated vise

      2. Parallels

      3. Clamp

        1. C-clamp
        2. Cantilever clamp
        3. Fixture clamps

    5. Work Setup

      8.5.1 not in text.

      1. Step by step process for work setup

    6. Tool Holding

      1. Morse Taper

      2. Drill Chuck

      3. Jacobs Taper

    7. Tooling

      1. Center Finder (wiggler)

      2. Center Drill

      3. Spot Drill

      4. Twist Drill

      5. Twist Drill Components

        1. Shank
          1. Straight Shank
          2. Taper shank
          3. Reduced shank
        2. Body
          1. Flute
          2. Margin
          3. Body clearance
          4. Web
        3. Tip
          1. Chisel point
          2. Cutting edge
          3. Heel

      6. Reamer

      7. Tap

      8. Countersink

      9. Counterbore

    8. Tool Setup

      1. Getting Started

      2. Straight Shank

      3. Morse Taper Shanks

        1. Step by step process removing Morse tapers
        2. Step by step processes installing Morse tapers

      4. Jacobs taper

        1. Step by step process for removing Jacobs tapers
        2. Step by step processes for installing Jacobs tapers

    9. Speed and Feed

      1. Spindle Speed

        1. Drilling example

      2. Feed Rate

      3. Speed and Feed Adjustments for Different Tooling

        1. Reaming
          1. Reaming example
        2. Countersinking and counterboring
          1. Countersinking example
          2. Counterboring example

    10. Drilling

      8.10.1 not in text

      1. Step by step process for drilling

      2. Tolerances

      3. Drilling Large Holes and Pilot Drilling

    11. Reaming

      8.11.1 not in text

      1. Prior Allowances

      2. Step by step process for reaming

      3. Tolerances

    12. Tapping

      8.12.1 not in text

      1. Prior Allowances

      2. Step by step process for tapping by hand

      3. Step by step process for power tapping

      4. Tolerances

    13. Countersinking

      8.13.1 not in text

      1. Prior Allowances

      2. Step by step process for countersinking

      3. Tolerances

    14. Counterboring

      8.14.1 not in text

      1. Prior Allowances

      2. Step by step process for counterboring

      3. Tolerances

    15. Chapter Conclusion

  10. Manual Vertical Milling Machines

    1. Safety

      1. Rotational Hazards

      2. Sharp Hazards

      3. Slipping Hazards

      4. Pinch Points

    2. Machine Maintenance

      1. Lubrication

      2. Cleaning

    3. Machine Components

      1. Base

      2. Column

      3. Ram

      4. Head

      5. Motor

      6. Knee

      7. Saddle

      8. Table

      9. Power Feed

      10. Digital Readout Alt: Digital Read Out, DRO

    4. Work Holding

      1. Mill Vise

      2. Fixture Clamps

    5. Work Setup

      1. Tramming the Mill Head

      2. Replacing Vise Jaws

      3. Vise Squaring

      4. Seating The Work Against Parallels

      5. Edge Finding Alt: Edge Finder

        1. Step by Step Process for Edge Finding

    6. Tool Holding

      1. End Mill Holder

      2. Spring Collet

      3. Draw Bar

      4. Drill Chuck

    7. Tooling

      1. Tooling Materials

      2. Face Mill

      3. End Mill

      4. Boring Head

      5. Slitting Saw

      6. Form Tool

      7. Hole-making Tools See also: 8.7 Drill Presses → Tooling

    8. Tool Setup

      1. Loading Tools into and Removing Tools from the Milling Machine

    9. Spindle Speed, Feed Rate, Depth of Cut and Finish Allowances

      1. Spindle Speed

      2. Feed Rate

      3. Depth of Cut

      4. Finishing Allowance

      5. Conventional Milling and Climb Milling

    10. Face Milling

    11. Block Squaring

    12. Side Milling

    13. Slotting

    14. Pocketing

    15. Angle Milling

      Subsections raised by one level; actually subsections of 9.15.1

      1. Milling an angle using angle blocks

      2. Milling an angle by dialing in the part at an angle in the vise

      3. Milling angles by tilting the milling head

      4. Cutting 45-degree chamfer angles

    16. Radius Cutting

    17. Boring

    18. Slitting

    19. Indexing

    20. Hole Making

      1. Countersinking/Counterboring

        Note: Best example of depth control by quill stop & knee.

        See Also: 8.9.3.2 Drill Press → Countersinking/Counterboring Examples

      2. Power Tapping

    21. Chapter Conclusion

  11. Manual Lathes

    1. Safety

      1. Rotational Hazard

      2. Sharp Hazard

      3. Pinch Points

      4. Fire Hazards

    2. Machine Maintenance

      1. Lubrication

      2. Cleaning

    3. Machine Components

      1. Bed

      2. Headstock

      3. Spindle

      4. Motor

      5. Gears

      6. Carriage

      7. Cross Slide

      8. Compound Rest

      9. Tool Post

      10. Apron

      11. Quick Change Gearbox

      12. Tailstock

      13. Digital Readout (DRO)Alt: Digital Read Out

    4. Workholding

      1. Three Jaw ChuckAlt: 3 Jaw, 3-Jaw, 3Jaw

      2. Four Jaw Chuck

      3. Face Plate

      4. Centers

      5. Lathe Dog

      6. Steady Rest

      7. Follower Rest

    5. Work Setup

      1. Removing and Installing Workholding Devices

      2. End Runout

      3. Concentricity at Chuck Jaws

      4. Tailstock

      5. Between Centers

      6. Steady Rest

      7. Follower Rest

    6. Tool Holding

      1. Rocker Tool Post

      2. Square Indexable Tool Post

      3. Quick Change Tool Post

      4. Drill Chuck

      5. Morse Taper

    7. Tooling

      1. Cutting Tool Materials

      2. Facing/Turning Tools

      3. Grooving Tools

      4. Threading Tools

      5. Boring Bars

      6. Grooving Bars

      7. Threading Bars

      8. Part-off Blades

      9. Form Tools

      10. Knurling Tools

    8. Tool Setup

      1. Insert Replacement

      2. Aligning the Tool Post

      3. Tool Height Centering

      4. Tailstock Tool Removal and Installation

    9. Spindle Speed, Feed Rate, Depth of Cut and Finish Allowances

      1. Spindle Speed

      2. Feed Rate

      3. Depth of Cut

      4. Finishing AllowanceAlt: Finish Allowance

    10. Facing

    11. Turning

    12. Boring

    13. Taper Turning

      10.13.1 not in text

      1. Tailstock Offset Method

      2. Taper Attachment Method

      3. Compound Rest Method

      4. Taper Measurement

    14. Radius Cutting

      Sub-sections raised by one level; actually subsections of 10.14.1

      1. Step by step process for cutting a convex radius

      2. Step by step process for cutting a concave radius

    15. Chamfering

    16. GroovingSee also: 10.21 Parting

      Sub-sections raised by one level; actually subsections of 10.16.1

      1. Step by step process for cutting a single plunge groove

      2. Step by step process for cutting a multi-plunge groove

    17. Threading

      10.17.1 not in text

      1. Terminology

        1. Nominal Diameter
        2. Major Diameter
        3. Minor Diameter
        4. Pitch Diameter
        5. Threads Per Inch (TPI)
        6. Pitch
        7. Lead
        8. Crest
        9. Root
        10. Flank
        11. Step by step process for external threading
        12. Step by step process for internal threading

      2. Thread Measurement

        1. Threaded ring and plug gages
        2. Thread micrometer
        3. Thread wires

    18. Tailstock Cutting Operations

    19. Tapping

    20. Knurling

      Subsections raised by one level; actually subsections of 10.20.1

      1. Step by step process for knurling with a scissor knurler

      2. Step by step process for knurling with a bump knurler

    21. Parting

    22. Chapter Conclusion

  12. Surface Grinders

    1. Common Surface Grinders

      1. Horizontal

      2. Vertical

      3. Cylindrical

    2. Grinding Wheels

      1. Shape

      2. Abrasive

      3. Grit

      4. Grade

    3. Operations

      1. Safety

      2. Workholding

      3. Wheel Dressing

      4. Grinding

      5. Problems

    4. Application

    5. Chapter Conclusion

Check Your Knowledge: Chapter Review Questions

  1. Chapter 1: Knowledge Check

  2. Chapter 2: Knowledge Check

  3. Chapter 3: Knowledge Check

  4. Chapter 4: Knowledge Check

  5. Chapter 5: Knowledge Check

  6. Chapter 6: Knowledge Check

  7. Chapter 7: Knowledge Check

  8. Chapter 8: Knowledge Check

  9. Chapter 9: Knowledge Check

  10. Chapter 10: Knowledge Check

  11. Chapter 11: Knowledge Check

Appendices

  1. Legal References

  2. About the Authors

  3. Glossary