xxii GREEN METALWORKING GREEN METALWORKING Renewable and Nonrenewable Resources...................6 Environmentally Conscious Manufacturing.................10 Clean Work Environments ..........................................26 Recycling Scrap into Steel..........................................48 Recycling Carbide Inserts...........................................50 Super Magnets ...........................................................58 Reducing Power Consumption ...................................82 Greening the Manufacturing Environment ................108 Green Lighting ..........................................................129 Wind Turbines ...........................................................139 Environmentally-Friendly Adhesives .........................194 Recycling Sand.........................................................211 Recycling Casting Material .......................................229 Recycling and Conserving Materials ........................235 Bio-Based Forming Fluids ........................................266 Environmentally Friendly Machines..........................282 Biodegradable Coolants ...........................................302 Extruding Recycled Aluminum ..................................310 Bio-Based Cutting Fluids ..........................................340 Reducing Chips with Process Improvement .............411 Recycling Cutting Tools.............................................426 Energy Efficiency and Sustainability .........................481 Recycled Shop Rags ................................................531 Lead-Free Solder......................................................541 Proactive Preventive Maintenance ............................554 Recycling Metal Dust ................................................590 Improving Quality and Reducing Waste....................611 Ultraviolet-Cured Powder Coating ............................632 Wrought Metal Finishes............................................659 Procedures Measuring with an Outside Caliper ............................90 Measuring with an Inside Caliper ...............................91 Reading an Inch-Based Micrometer ...........................94 Reading an Inch-Based Vernier Micrometer ...............94 Reading an Inside Micrometer....................................97 Reading a 25-Division Vernier Plate Measuring Tool .....................................................100 Reading a 50-Division Vernier Plate Measuring Tool .....................................................100 Reading an Inch-Based Dial Caliper ........................102 Reading a Universal Vernier Bevel Protractor ...........102 Using a Telescoping Gage........................................106 Reading a Dial Indicator ...........................................109 Scribing a Layout ......................................................129 Broaching a Keyway on an Arbor Press....................165 Making a Sand Mold .................................................206 Vacuum Molding Process .........................................211 Basic Metal Casting Procedure ................................216 Creating a Shell Mold Casting..................................218 Hemming Sheet Metal Edges...................................250 Spinning a Simple Form ...........................................267 Sharpening a Drill by Hand ......................................342 Drilling a Hole with a Drill Press ...............................343 Drilling a Hole on a Round Workpiece......................345 Using a Traditional Countersink ................................346 Using Machine Reamers ..........................................349 Tapping Holes on a Drill Press .................................349 Knurling on a Lathe ..................................................413 Removing an Arbor or Adapter from a Horizontal Mill ......................................................454 Milling Flat Surfaces on a Horizontal Milling Machine....................................................460 Squaring Stock on a Horizontal Milling Machine....................................................462 Face Milling on a Horizontal Milling Machine ...........462 Positioning a Side Cutter to Mill a Slot......................464 Milling Flat Surfaces on a Vertical Milling Machine....................................................469 Milling a Slot or Keyway on a Vertical Milling Machine....................................................471 Finding the Center of a Hole using a Mechanical Edge Finder ......................................473 Chemical Milling Procedure ......................................528 Steps in Chem-Blanking...........................................529 Tinning a Soldering Copper......................................542 Soldering a Lap Joint ................................................543 Soldering a Seam Joint ............................................543 Sweat Soldering a Joint ............................................544 Silver Brazing ...........................................................545 Silver Brazing More Than One Joint on the Same Piece..........................................................547 Using a Welding Rod................................................558 Preparing and Adjusting Gas Equipment ..................558 Lighting a Gas Torch .................................................559 Shutting Down the Torch ...........................................559 Striking an Arc ..........................................................574 Hardening Steel ........................................................602 Tempering Carbon Steel ...........................................602 Using a Shaped Hardwood Block .............................643 Using a Sandbag and Mallet ....................................644 Using Forming Blocks...............................................644 Using a Raising Stake ..............................................645 Beating Down on a Hardwood Stake........................645