Elementary Knowledge of Metalworking

E-mail: khirata@nmri.go.jp

I have built much experimental equipments, such as Stirling engines, fish robots and barrier-free equipments. This web site introduces machining for beginning students in mechanical engineering. In order to make learning easier, many examples and photographs are shown in the site.

The contents in this site may be incomplete. There also may be mistakes in description or translation.

Also, English version is still under construction...

Translated into English Only in Japanese


Chapter 1. Basic Machining and Tips

This chapter introduces the knowledge required before performing actual machining, and includes useful tips for working on a lathe and a milling machine.

Machining Flowchart: Outline and flow of machining.
Removal of Burrs: The most important tip for making accurate parts.
Measurements: How to use calipers and a micrometers.
Dimensional Tolerance: Importance of dimensional deviation.
Marking-off: Marking-off is required for accuracy.
Drilling: Elementaly Knowledge of the drilling.
Marking-off and Drilling a Cylinder: How to drill circumference holes on a cylinder.
Making a Screw Thread: How to cut inside and outside threads.
Grinders: A useful tool for machining.
Metal Materials: Typical mechanical materials.

Chapter 2. Cut-off Machines and Tools

Before using a lathe or a milling machine, the material must be cut to a suitable size. Here we discuss how to cut the material.

Bandsaw: This saw cuts boards.
Power Hacksaw: This saw cuts long pieces to size.
Hand Hacksaw: For cutting short and thin material.
Guillotine: Cuts thin plate or sheet metal quickly.
Drop Saw: Cuts angle or pipe quickly.
Oxy-Acetylene Cutting: How to cut with acetylene gas.
Other Cut-off Tools: Metal scissors, cutting pliers, a nipper and a stationery cutter and others.

Chapter 3. How to Use a Lathe

A lathe is one of the most-used machines in metalworking. It is typically used to make a cylinder-shaped part.

Basic Operation of a Lathe: Use a lathe and make a part.
Using a Side Tool: The side cutting tool is the most general tool.
Drilling and Boring Bar: Make a hole with a drill and a boring bar using a lathe.
Using a Cut-off Tool: Make a fin and a slot for an O-ring.
Making a Screw with a Lathe: If we cannot make our own taps and dies for screws...
Using a Four-jaw Chuck: Machine an eccentric hole or cylinder.
How to Use a Jig: We can make various irregular parts, if we use a jig.
Making Accurate Parts: Discussion on making accurate parts with a lathe.

Chapter 4. How to Use a Milling Machine

More complex-shaped parts can be made using a milling machine. The milling machine is mainly used to machine a plane.

Basic Operation of a Milling Machine: How to use it.
Drilling with a Milling Machine: Machining accurate holes.
Using an End Mill: An end mill is a required milling tool.
Machining Large Workpieces: Using a clamping kit and supporting table.
Milling with a Jig: Creating a more complex-shaped part using a jig.

Chapter 5. Welding and Soldering

The lathe and the milling machine are used for cutting.  Welding and soldering are used to join one piece to another.

Outline of Welding: Welding examples are shown here.
Arc Welding: The most popular welding method for steel.
Oxy-Acetylene Welding: The combustion gas becomes very hot so it can weld steel.
TIG Welding: A method that can weld stainless steel and aluminum.
Soldering: Useful for a wide variety of fabrication needs.

Chapter 6. Other Kinds of Machinings

Special machining and special machine tools are shown here.

Handling of FRP: FRP has high strength and is easily machined.
Plumbing: Needed for hydraulic machines.  It becomes a high pressure seal device.
Adhesives: A well-stocked supply of adhesives can be very convenient.



Safety Manual: Here is our machining safety manual.

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