Modern Metalworking 11e, Online Textbook
Modern Metalworking provides a comprehensive introduction to the various tools, machines, and materials involved in metalworking, including machining, welding, casting, and sheet metal. Expanded coverage throughout the text introduces students to the equipment and processes required to pursue a career in the metalworking industry, including both traditional and modern metalworking technologies. Step-by-step procedures with a focus on safety are included for many processes and techniques. Updated content and illustrations ensure that the text is relevant and engaging for students as they master key vocabulary, concepts, and procedures through hands-on activities. Employability and Career Connection features provide inspiration and critical exposure to workplace skills—a primary request of employers.
Table of Contents
Abbreviated Contents
Modern Metalworking 11e, Online Textbook
- Modern Metalworking
- Copyright © 2023
- Preface
- About the Authors
- Acknowledgments
- TOOLS FOR STUDENT AND INSTRUCTOR SUCCESS
- Features of the Textbook
- New to this Edition
- Color Key
- Brief Contents
- Contents
- Feature Contents
- SECTION 1 Introduction to Metalworking
- CHAPTER 1 Introduction to Manufacturing
- CHAPTER 1 LEARNING OBJECTIVES
- CHAPTER 1 OUTLINE
- CHAPTER 1 TECHNICAL TERMS
- EMPLOYABILITY
- 1.1 Introduction to Manufacturing
- 1.2 Manufacturing Processes
- 1.3 Functions of a Manufacturing Company
- 1.4 Production Machines and Tooling
- 1.5 Production Facilities
- 1.6 Trends in Manufacturing
- 1.7 Manufacturing Process Improvement
- Chapter 1 Summary
- Chapter 1 Test Your Knowledge
- Chapter 1 Research and Development
- CHAPTER 2 Careers in Metalworking
- CHAPTER 2 LEARNING OBJECTIVES
- CHAPTER 2 OUTLINE
- CHAPTER 2 TECHNICAL TERMS
- EMPLOYABILITY
- 2.1 Introduction to Careers in Metalworking
- 2.2 Types of Careers in Metalworking
- 2.3 Leadership in the Metalworking Industry
- 2.4 Preparing for a Job in the Metalworking Industry
- 2.5 What Industry Expects of You
- 2.6 What an Employee Should Expect from Industry
- Chapter 2 Summary
- Chapter 2 Test Your Knowledge
- Chapter 2 Research and Development
- CHAPTER 3 Safety Practices
- CHAPTER 3 LEARNING OBJECTIVES
- CHAPTER 3 OUTLINE
- CHAPTER 3 TECHNICAL TERMS
- EMPLOYABILITY
- 3.1 Practicing Metalworking Safety
- 3.2 General Safety Practices
- 3.3 General Tool Safety
- 3.4 Machine Operation Safety
- 3.5 Fire Safety
- Chapter 3 Summary
- Chapter 3 Test Your Knowledge
- Chapter 3 Research and Development
- CHAPTER 4 Classifying Metals
- CHAPTER 4 LEARNING OBJECTIVES
- CHAPTER 4 OUTLINE
- CHAPTER 4 TECHNICAL TERMS
- CAREER CONNECTION
- 4.1 Metal Classifications
- 4.2 Ferrous Metals
- 4.3 Nonferrous Metals
- 4.4 Precious Metals
- 4.5 High-Temperature Metals
- 4.6 Rare Earth Metals
- 4.7 Metal-Based Composites
- 4.8 Safety Precautions for Handling Metals
- 4.9 Measurement of Metals and Standard Shapes
- Chapter 4 Summary
- Chapter 4 Test Your Knowledge
- Chapter 4 Research and Development
- Illustrated Glossary of Metals
- CHAPTER 5 Drawings and 3D Printing
- CHAPTER 5 LEARNING OBJECTIVES
- CHAPTER 5 OUTLINE
- CHAPTER 5 TECHNICAL TERMS
- CAREER CONNECTION
- 5.1 Elements of Drawings
- 5.2 Visualizing the Object on a Multiview Drawing
- 5.3 Common Information Found on Multiview Drawings
- 5.4 Dimensions
- 5.5 Tolerances
- 5.6 Geometric Dimensioning and Tolerancing (GD&T)
- 5.7 Types of Working Drawings
- 5.8 Prints
- 5.9 Computer-Aided Design and Drafting (CADD)
- 5.10 3D Printing Techniques
- 5.11 Planning a Metalworking Project
- Chapter 5 Summary
- Chapter 5 Test Your Knowledge
- Chapter 5 Research and Development
- CHAPTER 6 Measurement
- CHAPTER 6 LEARNING OBJECTIVES
- CHAPTER 6 OUTLINE
- CHAPTER 6 TECHNICAL TERMS
- CAREER CONNECTION
- 6.1 The Rule
- 6.2 Calipers
- 6.3 The Micrometer Caliper
- 6.4 Vernier Measuring Tools
- 6.5 Gages and Inspection Tools
- 6.6 Dial Indicators
- 6.7 Coordinate Measuring Machine (CMM)
- 6.8 Optical Inspection and Measuring Technologies
- Chapter 6 Summary
- Chapter 6 Test Your Knowledge
- Chapter 6 Research and Development
- CHAPTER 7 Layout Work
- CHAPTER 7 LEARNING OBJECTIVES
- CHAPTER 7 OUTLINE
- CHAPTER 7 TECHNICAL TERMS
- EMPLOYABILITY
- 7.1 Preparing Metal for Layout
- 7.2 Layout Tools
- 7.3 Measuring Angles
- 7.4 Other Layout Tools and Equipment
- 7.5 Making a Layout
- 7.6 Safety Precautions for Layout Work
- Chapter 7 Summary
- Chapter 7 Test Your Knowledge
- Chapter 7 Research and Development
- CHAPTER 8 Hand Tools
- CHAPTER 9 Hand Tools That Cut
- CHAPTER 10 Hand Threading
- CHAPTER 10 LEARNING OBJECTIVES
- CHAPTER 10 OUTLINE
- CHAPTER 10 TECHNICAL TERMS
- EMPLOYABILITY
- 10.1 Unified Screw Thread System
- 10.2 ISO Metric Screw Thread System
- 10.3 Cutting Threads
- 10.4 Internal Threads
- 10.5 Cutting External Threads
- 10.6 Hand Threading Safety
- Chapter 10 Summary
- Chapter 10 Test Your Knowledge
- Chapter 10 Research and Development
- CHAPTER 11 Fasteners
- SECTION 2 Casting
- CHAPTER 12 Sand Casting
- CHAPTER 12 LEARNING OBJECTIVES
- CHAPTER 12 OUTLINE
- CHAPTER 12 TECHNICAL TERMS
- CAREER CONNECTION
- 12.1 Industrial Sand Casting
- 12.2 Sand Casting in the School Laboratory
- 12.3 Other Sand Casting Processes
- 12.4 Applications of 3D Printing in Sand Casting
- Chapter 12 Summary
- Chapter 12 Test Your Knowledge
- Chapter 12 Research and Development
- CHAPTER 13 Metal Casting Techniques
- CHAPTER 13 LEARNING OBJECTIVES
- CHAPTER 13 OUTLINE
- CHAPTER 13 TECHNICAL TERMS
- EMPLOYABILITY
- 13.1 Choosing a Casting Technique
- 13.2 Casting Processes that Use Expendable Molds
- 13.3 Casting Processes that Use Permanent Molds
- Chapter 13 Summary
- Chapter 13 Test Your Knowledge
- Chapter 13 Research and Development
- CHAPTER 14 Powder Metallurgy
- CHAPTER 14 LEARNING OBJECTIVES
- CHAPTER 14 OUTLINE
- CHAPTER 14 TECHNICAL TERMS
- CAREER CONNECTION
- 14.1 Materials and Applications
- 14.2 The Powder Metallurgy Process
- 14.3 Costs of Powder Metallurgy
- 14.4 Metal Injection Molding (MIM)
- Chapter 14 Summary
- Chapter 14 Test Your Knowledge
- Chapter 14 Research and Development
- SECTION 3 Sheet Metal and Metal Forming
- CHAPTER 15 Sheet Metal
- CHAPTER 15 LEARNING OBJECTIVES
- CHAPTER 15 OUTLINE
- CHAPTER 15 TECHNICAL TERMS
- CAREER CONNECTION
- 15.1 Sheet Metal
- 15.2 Patterns
- 15.3 Cutting Sheet Metal
- 15.4 Bending Sheet Metal
- 15.5 Making Common Sheet Metal Joints
- 15.6 Fastening Sheet Metal with Rivets
- 15.7 Sheet Metal Safety
- Chapter 15 Summary
- Chapter 15 Test Your Knowledge
- Chapter 15 Research and Development
- CHAPTER 16 Metal Spinning
- CHAPTER 16 LEARNING OBJECTIVES
- CHAPTER 16 OUTLINE
- CHAPTER 16 TECHNICAL TERMS
- EMPLOYABILITY
- 16.1 Conventional Spinning
- 16.2 Spinning Equipment
- 16.3 Spinning Safety
- 16.4 Spinning Simple Forms
- 16.5 Forming a Bead
- 16.6 Shear Spinning
- 16.7 Spinning Deep Forms
- 16.8 Advantages of Spinning
- 16.9 Industrial Applications
- Chapter 16 Summary
- Chapter 16 Test Your Knowledge
- Chapter 16 Research and Development
- CHAPTER 17 Cold Forming Metal Sheet
- CHAPTER 18 Forging
- CHAPTER 19 Extrusion Processes
- SECTION 4 Machining
- CHAPTER 20 Sawing and Cutoff Machines
- CHAPTER 20 LEARNING OBJECTIVES
- CHAPTER 20 OUTLINE
- CHAPTER 20 TECHNICAL TERMS
- CAREER CONNECTION
- 20.1 Metal-Cutting Saws
- 20.2 Reciprocating Hacksaw
- 20.3 Band Saw
- 20.4 Using Reciprocating and Band Saws
- 20.5 Reciprocating and Band Saw Problems
- 20.6 Metal-Cutting Circular Saw
- 20.7 Power Saw Safety
- Chapter 20 Summary
- Chapter 20 Test Your Knowledge
- Chapter 20 Research and Development
- CHAPTER 21 Drills and Drilling Machines
- CHAPTER 21 LEARNING OBJECTIVES
- CHAPTER 21 OUTLINE
- CHAPTER 21 TECHNICAL TERMS
- EMPLOYABILITY
- 21.1 Drills
- 21.2 Workholding Devices
- 21.3 Cutting Speeds and Feeds
- 21.4 Cutting Fluids
- 21.5 Sharpening Drills
- 21.6 Drilling Holes
- 21.7 Other Drill Press Operations
- 21.8 Industrial Applications
- 21.9 Drill Press Safety
- Chapter 21 Summary
- Chapter 21 Test Your Knowledge
- Chapter 21 Research and Development
- CHAPTER 22 Grinding
- CHAPTER 22 LEARNING OBJECTIVES
- CHAPTER 22 OUTLINE
- CHAPTER 22 TECHNICAL TERMS
- EMPLOYABILITY
- 22.1 Abrasives
- 22.2 Abrasive Belt Grinders
- 22.3 Bench and Pedestal Grinders
- 22.4 Offhand Grinding Wheels
- 22.5 Portable Hand Grinders
- 22.6 Precision Grinding
- 22.7 Precision Grinding Wheels
- 22.8 Grinding Safety
- Chapter 22 Summary
- Chapter 22 Test Your Knowledge
- Chapter 22 Research and Development
- CHAPTER 23 Metal Lathe
- CHAPTER 23 LEARNING OBJECTIVES
- CHAPTER 23 OUTLINE
- CHAPTER 23 TECHNICAL TERMS
- CAREER CONNECTION
- 23.1 Lathe Size
- 23.2 Major Parts of a Lathe
- 23.3 Preparing the Lathe for Operation
- 23.4 Lathe Toolholders
- 23.5 Lathe Cutting Tools
- 23.6 Cutting Speeds and Feeds
- 23.7 Workholding Attachments
- 23.8 Turning Work between Centers
- 23.9 Using Lathe Chucks
- 23.10 Quick-Changeover of Workholding Attachments
- 23.11 Parting Operations
- 23.12 Cleaning the Lathe
- 23.13 Lathe Safety
- Chapter 23 Summary
- Chapter 23 Test Your Knowledge
- Chapter 23 Research and Development
- CHAPTER 24 Other Lathe Operations
- CHAPTER 24 LEARNING OBJECTIVES
- CHAPTER 24 OUTLINE
- CHAPTER 24 TECHNICAL TERMS
- EMPLOYABILITY
- 24.1 Drilling and Reaming
- 24.2 Boring
- 24.3 Knurling
- 24.4 Filing and Polishing
- 24.5 Using a Lathe Mandrel
- 24.6 Grinding
- 24.7 Milling
- 24.8 Industrial Applications
- 24.9 Lathe Safety
- Chapter 24 Summary
- Chapter 24 Test Your Knowledge
- Chapter 24 Research and Development
- CHAPTER 25 Cutting Tapers and Screw Threads on a Lathe
- CHAPTER 26 Milling Machines
- CHAPTER 26 LEARNING OBJECTIVES
- CHAPTER 26 OUTLINE
- CHAPTER 26 TECHNICAL TERMS
- EMPLOYABILITY
- 26.1 Types of Milling Machines
- 26.2 Milling Categories
- 26.3 Milling Methods
- 26.4 Milling Cutters
- 26.5 Cutting Speeds and Feeds
- 26.6 Workholding Attachments
- 26.7 Horizontal Milling Operations
- 26.8 Vertical Milling Machine Operations
- 26.9 Industrial Applications
- 26.10 Milling Safety Practices
- Chapter 26 Summary
- Chapter 26 Test Your Knowledge
- Chapter 26 Research and Development
- CHAPTER 27 Introduction to Computer Numerical Control (CNC) and Automation
- CHAPTER 27 LEARNING OBJECTIVES
- CHAPTER 27 OUTLINE
- CHAPTER 27 TECHNICAL TERMS
- CAREER CONNECTION
- 27.1 Automation Fundamentals
- 27.2 Introduction to Computer Numerical Control (CNC)
- 27.3 Positioning Systems
- 27.4 Movement Systems
- 27.5 CNC Processing Equipment
- 27.6 Robotics
- 27.7 Flexible Automation
- 27.8 CNC Safety
- Chapter 27 Summary
- Chapter 27 Test Your Knowledge
- Chapter 27 Research and Development
- CHAPTER 28 Introduction to CNC Programming and Machining
- CHAPTER 28 LEARNING OBJECTIVES
- CHAPTER 28 OUTLINE
- CHAPTER 28 TECHNICAL TERMS
- EMPLOYABILITY
- 28.1 CNC Programming Methods
- 28.2 CNC Programming Codes
- 28.3 CNC Modal Commands
- 28.4 Planning the CNC Program
- 28.5 Writing the CNC Program
- 28.6 Setting Work Offsets and Tool Offsets
- 28.7 Verifying the CNC Program without the Workpiece
- 28.8 Verifying the CNC Program with the Workpiece
- 28.9 CNC Safety
- Chapter 28 Summary
- Chapter 28 Test Your Knowledge
- Chapter 28 Research and Development
- CHAPTER 29 Nontraditional Machining Techniques
- CHAPTER 29 LEARNING OBJECTIVES
- CHAPTER 29 OUTLINE
- CHAPTER 29 TECHNICAL TERMS
- CAREER CONNECTION
- 29.1 Electrical Discharge Processes
- 29.2 Electrochemical Machining
- 29.3 Chemical Machining
- 29.4 Hydrodynamic Machining
- 29.5 Electron Beam Machining
- 29.6 Laser Beam Machining
- 29.7 Ultrasonic Machining
- Chapter 29 Summary
- Chapter 29 Test Your Knowledge
- Chapter 29 Research and Development
- SECTION 5 Welding
- CHAPTER 30 Soldering and Brazing
- CHAPTER 30 LEARNING OBJECTIVES
- CHAPTER 30 OUTLINE
- CHAPTER 30 TECHNICAL TERMS
- CAREER CONNECTION
- 30.1 Soldering Conditions
- 30.2 Tinning a Soldering Copper
- 30.3 Soldering a Lap Joint
- 30.4 Soldering a Seam Joint
- 30.5 Sweat Soldering a Joint
- 30.6 Brazing
- 30.7 Silver Brazing
- 30.8 Soldering and Brazing Safety
- Chapter 30 Summary
- Chapter 30 Test Your Knowledge
- Chapter 30 Research and Development
- CHAPTER 31 Oxyfuel Gas Welding
- CHAPTER 31 LEARNING OBJECTIVES
- CHAPTER 31 OUTLINE
- CHAPTER 31 TECHNICAL TERMS
- EMPLOYABILITY
- 31.1 Oxyfuel Gas Welding
- 31.2 Oxyacetylene Welding Equipment
- 31.3 Oxyacetylene Welding Rods
- 31.4 Fluxes
- 31.5 Equipment Preparation and Adjustment for Oxyacetylene Welding
- 31.6 Welding Joints
- 31.7 Forehand Welding
- 31.8 Backhand Welding
- 31.9 The Weld Pool
- 31.10 Braze Welding
- 31.11 Oxyacetylene Welding Safety Precautions
- Chapter 31 Summary
- Chapter 31 Test Your Knowledge
- Chapter 31 Research and Development
- CHAPTER 32 Shielded Metal Arc Welding
- CHAPTER 32 LEARNING OBJECTIVES
- CHAPTER 32 OUTLINE
- CHAPTER 32 TECHNICAL TERMS
- CAREER CONNECTION
- 32.1 Arc Welding Equipment and Accessories
- 32.2 Welding Symbols
- 32.3 Preparing to Arc Weld
- 32.4 Safety Precautions for Arc Welding
- Chapter 32 Summary
- Chapter 32 Test Your Knowledge
- Chapter 32 Research and Development
- CHAPTER 33 Other Welding Processes
- CHAPTER 33 LEARNING OBJECTIVES
- CHAPTER 33 OUTLINE
- CHAPTER 33 TECHNICAL TERMS
- EMPLOYABILITY
- 33.1 Gas Tungsten Arc Welding
- 33.2 Gas Metal Arc Welding
- 33.3 Flux-Cored Arc Welding
- 33.4 Submerged Arc Welding
- 33.5 Arc Stud Welding
- 33.6 Resistance Welding
- 33.7 Electron Beam Welding
- 33.8 Friction Welding
- 33.9 Ultrasonic Welding
- 33.10 Cold Welding
- 33.11 Laser Beam Welding
- 33.12 Plasma Arc Welding
- 33.13 Thermal Spraying
- Chapter 33 Summary
- Chapter 33 Test Your Knowledge
- Chapter 33 Research and Development
- SECTION 6 Other Metalworking Applications
- CHAPTER 34 Heat Treatment of Metals
- CHAPTER 34 LEARNING OBJECTIVES
- CHAPTER 34 OUTLINE
- CHAPTER 34 TECHNICAL TERMS
- EMPLOYABILITY
- 34.1 Heat Treatment Processes
- 34.2 Heat Treatment Furnaces
- 34.3 Hardening Carbon Steel
- 34.4 Tempering Carbon Steel
- 34.5 Case Hardening Low Carbon Steel
- 34.6 Hardness Testing
- 34.7 Other Heat-Treatable Metals
- 34.8 Heat Treating Safety
- Chapter 34 Summary
- Chapter 34 Test Your Knowledge
- Chapter 34 Research and Development
- CHAPTER 35 Quality Assurance and Inspection
- CHAPTER 35 LEARNING OBJECTIVES
- CHAPTER 35 OUTLINE
- CHAPTER 35 TECHNICAL TERMS
- CAREER CONNECTION
- 35.1 Process Variation and Capability
- 35.2 Statistical Process Control
- 35.3 Inspection Practices
- 35.4 Inspection Technologies
- Chapter 35 Summary
- Chapter 35 Test Your Knowledge
- Chapter 35 Research and Development
- CHAPTER 36 Metal Finishing Processes
- CHAPTER 37 Art Metal
- CHAPTER 37 LEARNING OBJECTIVES
- CHAPTER 37 OUTLINE
- CHAPTER 37 TECHNICAL TERMS
- EMPLOYABILITY
- 37.1 Metalsmithing
- 37.2 Annealing and Pickling
- 37.3 Art Metal Tools
- 37.4 Types of Metal
- 37.5 Raising Metal
- 37.6 Joining Metal
- 37.7 Surface Finishes
- 37.8 Polishing
- 37.9 Art Metal Safety
- Chapter 37 Summary
- Chapter 37 Test Your Knowledge
- Chapter 37 Research and Development
- CHAPTER 38 Wrought Metal
- CHAPTER 38 LEARNING OBJECTIVES
- CHAPTER 38 OUTLINE
- CHAPTER 38 TECHNICAL TERMS
- EMPLOYABILITY
- 38.1 Project Planning
- 38.2 Wrought Metalwork Tools and Equipment
- 38.3 Bending and Forming with Hand Tools
- 38.4 Bending and Forming with Machines
- 38.5 Assembling Wrought Metal Pieces
- 38.6 Finishing Wrought Metals
- 38.7 Wrought Metal Safety
- Chapter 38 Summary
- Chapter 38 Test Your Knowledge
- Chapter 38 Research and Development
- Appendix
- Common Shapes of Metals
- Color Codes for Marking Steels
- Metal Sheet Materials Chart
- Order of Ductility of Metals
- Physical Properties of Metals
- Cutting Speeds for Round Stock
- Rules for Determining Speeds and Feeds
- Feeds and Speeds for HSS Drills, Reamers, and Taps
- Feeds and Speeds for HSS Drills in Various Metals
- 60° V-Type Thread Dimensions—Fractional Sizes
- 60° V-Type Thread Dimensions—Metric Sizes
- Tap Drill Sizes
- Conversion Table: US Customary to SI Metric
- Conversion Table: SI Metric to US Customary
- Metric–Inch Equivalents
- Number and Letter Size Drills Conversion Chart
- Grade Marking for Bolts
- Machine Screw and Cap Screw Heads
- Cutting Fluids for Various Metals
- Metric Prefixes, Exponents, and Symbols
- Formulas
- Glossary
- Index