Table of Contents

Section 1: Introduction to Machine Tools

Unit 1: History of Machines

Section 2: Machine Trade Opportunities

Unit 2: Careers in the Metalworking Industry

Unit 3: Getting the Job

Section 3: Safety

Unit 4: Safety in the Machine Shop

Section 4: Job Planning

Unit 5: Engineering Drawings

Unit 6: Machining Procedures for Various Workpieces

Section 5: Measurement

Unit 7: Basic Measurement

Unit 8: Squares and Surface Plates

Unit 9: Micrometers

Unit 10: Vernier Calipers

Unit 11: Inside-, Depth-, and Height-Measuring Instruments

Unit 12: Gage Blocks

Unit 13: Angular Measurement

Unit 14: Gages

Unit 15: Comparison Measurement

Unit 16: The Coordinate Measuring System

Unit 17: Measuring with Light Waves

Unit 18: Surface Finish Measurement

Section 6: Layout Tools and Procedures

Unit 19: Basic Layout Materials, Tools, and Accessories

Unit 20: Basic or Semiprecision Layout

Unit 21: Precision Layout

Section 7: Hand Tools and Bench Work

Unit 22: Holding, Striking, and Assembling Tools

Unit 23: Hand-Type Cutting Tools

Unit 24: Thread-Cutting Tools and Procedures

Unit 25: Finishing Processes – Reaming, Broaching, and Lapping

Unit 26: Surface Finishing Processes

Section 8: Metal-Cutting Technology

Unit 27: Physics of Metal Cutting

Unit 28: Machinability of Metals

Unit 29: Cutting Tools

Unit 30: Operating Conditions and Tool Life

Unit 31: Carbide Cutting Tools

Unit 32: Diamond, Ceramic, and Cermet Cutting Tools

Unit 33: Polycrystalline Cutting Tools

Unit 34: Cutting Fluids – Types and Applications

Section 9: Metal-Cutting Saws

Unit 35: Types of Metal Saws

Unit 36: Contour Bandsaw Parts and Accessories

Unit 37: Contour Bandsaw Operations

Section 10: Drilling Machines

Unit 38: Drill Presses

Unit 39: Drilling Machine Accessories

Unit 40: Twist Drills

Unit 41: Cutting Speeds and Feeds

Unit 42: Drilling Holes

Unit 43: Reaming

Unit 44: Drill Press Operations

Section 11: The Lathe

Unit 45: Engine Lathe Parts

Unit 46: Lathe Accessories

Unit 47: Cutting Speed, Feed, and Depth of Cut

Unit 48: Lathe Safety

Unit 49: Mounting, Removing, and Aligning Lathe Centers

Unit 50: Grinding Lathe Cutting Tools

Unit 51: Facing Between Centers

Unit 52: Machining Between Centers

Unit 53: Knurling, Grooving, and Form Turning

Unit 54: Tapers and Taper Turning

Unit 55: Threads and Thread Cutting

Unit 56: Steady Rest, Follower Rests, and Mandrels

Unit 57: Machining in a Chuck

Unit 58: Drilling, Boring, Reaming, and Tapping

Section 12: Milling Machines

Unit 59: The Vertical Milling Machine

Unit 60: Cutting Speed, Feed, and Depth of Cut

Unit 61: End Mills

Unit 62: Vertical Mill Operations

Unit 63: Special Milling Operations

Unit 64: Horizontal Milling Machines and Accessories

Unit 65: Milling Cutters

Unit 66: Milling Machine Setups

Unit 67: Horizontal Milling Operations

Unit 68: The Indexing, or Dividing, Head

Unit 69: Helical Milling

Unit 70: Cam, Rack, Worm, and Clutch Milling

Section 13: Grinding

Unit 71: Types of Abrasives

Unit 72: Surface Grinders and Accessories

Unit 73: Surface Grinding Operations

Unit 74: Cylindrical Grinders

Unit 75: Universal Tool and Cutter Grinder

Section 14: Metallurgy

Unit 76: Manufacture and Properties of Steel

Unit 77: Heat Treatment of Steel

Unit 78: Testing of Metals and Nonferrous Metals

Section 15: Lean Manufacturing

Unit 79: Cellular Manufacturing

Unit 80: Continuous Improvement

Unit 81: Pull (Kanban) Systems

Unit 82: Total Productive Maintenance

Unit 83: Value-Stream Mapping

Unit 84: Workplace Organization

Section 16: Computer-Age Machining

Unit 85: The Computer

Unit 86: Computer Numerical Control

Unit 87: CNC Turning Center

Unit 88: CNC Machining Centers

Unit 89: CAD/CAM

Section 17: Advanced Manufacturing Technology

Unit 90: Nanotechnology

Unit 91: Cryogenic Treatment/Tempering

Unit 92: Diamond Coating

Unit 93: Additive Manufacturing Technologies

Unit 94: Multi-Tasking Machines

Unit 95: Industry 4.0

Unit 96: Optical/Laser/Vision Measurement

Unit 97: Electrical Discharge Machining

Unit 98: Robotics

About the Author

Steve F. Krar spent 15 years in the trade, first as a machinist and finally as a tool and die maker. After this period, he entered Teachers’ College and graduated from the University of Toronto with a Specialist’s Certificate in Machine Shop Practice. During these 20 years of teaching, Mr. Krar was active in vocational and technical education and served on the executive committee of many educational organizations. For 10 years, he was on the summer staff of the College of Education, University of Toronto, involved in teacher training programs. Active in machine tool associations, Steve Krar is a Life Member of the Society of Manufacturing Engineers and former associate director of the GE Superabrasives Partnership for Manufacturing Productivity. He was inducted into the Canadian Manufacturers Hall of Fame in March 2009. Mr. Krar’s continual research over the past 50 years in manufacturing technology has involved many courses with lead- ing world manufacturers and an opportunity to study under Dr. W. Edwards Deming. Mr. Krar spent a week researching Nano- technology at leading research centers, universities, and industry in Switzerland. He is coauthor and consultant of over 80 technical books, such as Machine Shop Training, Machine Tool Operations, CNC Simplified, Superabrasives—Grinding and Machining, Exploring Advanced Manufacturing Technologies, some of which have been translated into 5 languages and used throughout the world.



Jonathan A. Gill graduated from high school with an Ontario Secondary School Diploma. He entered Ryerson University in the industrial engineering program and then went into geographical analysis. Mr. Gill attended Humber College for electronics engineering and then spent 2 years at Mohawk College for computer networking and security analysis. Mr. Gill is currently an independent contractor employed by Nexas Networks Inc. as an Applications Engineer and Support Manager, providing factory floor networking and information technology for the aerospace and automotive industry, jobbing shops, and production discrete manufacturing facilities. Mr. Gill assisted the authors with the research, artwork, and final production of manuscript for the textbook Computer Numerical Control Simplified and is coauthor of the book Changing World of Manufacturing.



Peter Smid graduated from high school with a specialty in machine shop training. He then entered industry, completed an apprenticeship program, and gained valuable experience as a machinist skilled on all types of machine tools. Mr. Smid immigrated to Canada in 1968 and spent the next 26 years employed in the machine tool industry as a machinist and tool and die maker. In the early 1970s, he became involved in Computer Numerical Control (CNC) as a programmer/operator and devoted the next 18 years to becoming proficient in all aspects of computerized manufacturing. In 1989, he became an independent consultant, and hundreds of companies have used Mr. Smid’s CNC and CAD/CAM skills to improve their manufacturing operations. He also wrote a comprehensive, 500-page CNC programming handbook, which is rapidly becoming the Bible of the trade. In 1995, he became a consultant/professor of Advanced Manufacturing focusing on industrial and customized training in CNC, CAD/CAM, and Agile Manufacturing. His many years of teaching, training, lecturing, and designing curriculum give him the opportunity to pass along his vast knowledge of modern manufacturing technology to students of all ages.