Introduction

Since the day some clever Homo sapiens first used a rock to sharpen a tree branch, thus avoiding being eaten by a prehistoric pack of dingoes, humans have been making things. Starting with wood and stone tools, mankind's urge to manufacture would eventually lead to the invention of the wheel, agriculture and architecture, and - unfortunately - organized warfare.

Along the way, we figured out how to smelt and cast metals such as bronze and iron. We built printing presses, textile looms, mechanical clocks, and adding machines. But it wasn't until the development of steel and then metal-cutting machinery, however, that modern manufacturing quite literally picked up steam.

Without metal cutting, now known as machining, we'd still be stuck in the horse-drawn days. It is quite literally the foundation upon which the Industrial Revolution was founded. Mechanization would have been impossible without precisely machined components, and without mechanization, there would be no factories, steamboats, locomotives, automobiles, or airplanes.

Today we're facing the start of another industrial revolution. Modern metal-cutting machinery isn't responsible for it, although it can certainly take credit for getting us here. No, the next industrial revolution is digital. Its tools are data and computers and high-speed global networks, and like the other industrial revolutions, it too will change everything.

What does all that have to do with this book? Plenty. Machining and other forms of manufacturing technology may be small players in the current race toward mobility and global connectedness, but they've definitely been invited to the party. In fact, you can talk all you like about the importance of Big Data and the Internet of Things, but without machining, none of it would be possible. Nor would modern transportation. Planes wouldn't fly; ships would sink; cars and trucks would do naught but sit on the side of the road without the machined parts to drive them.

How about all the other things that make our daily lives comfortable? The appliances that keep our food cold and make our clothes clean? Take away machining and those devices couldn't be built. If you like watching movies, you'd better plan on going to the theater (the kind with live actors and performed by candlelight) in a postmachining world, because DVD players and 65-inch flat-screen TVs wouldn't exist.

And medicine? Forget it. Grandma would have to limp around without that new hip implant she was hoping for because there'd be no machined prosthetics, never mind CAT scans, X-rays, prescription drugs, or surgical equipment. Cancer and other diseases would have their way with us, and a simple gallbladder surgery might prove fatal.

Food and energy production, construction of housing and infrastructure, and just about every consumer product imaginable - I could go on all day about the technologies made possible by machining, but you probably get the idea. Simply put, machining brings a richness to our lives that few of us appreciate.

Enough said. Whether you're a curious consumer, a would-be hobbyist, or are (I hope) thinking about a career in manufacturing or just starting one, this book is intended to help make you just a little more knowledgeable on this important subject.

About This Book

If you read the front cover, you don't need me to tell you, but here it is: This book is about machining. "What's that?" you say. Simply put, machining is the act of transforming metal, plastic, and other materials into precision components used in all the industries just mentioned.

It's a complex process, which is why Machining For Dummies is broken up into bite-sized pieces. It begins with a little bit of history (because if you're like me, you slept through that class in school), then segues smoothly into tools: machine tools, cutting tools, and tools for holding workpieces (appropriately called workholding).

There's some programming in here and some much-needed discussion on accessories and shop safety. Toward the end, you'll find some valuable advice (at no additional charge) on ways to become a better machinist, as well as in-depth technical information on industry trends. Read it and you might improve your stock portfolio.

So it's time to set aside your machining angst, take the book to the counter or add it to your digital shopping cart, and whip out your credit card. Then sit back and enjoy the book. Machining is cool, and I'm sure you'll enjoy learning about it.

Foolish Assumptions

This book assumes you're interested in machining. That's it. No deep knowledge of metallurgical principles is required. No need for an advanced degree in mechanical engineering. If you've actually seen a milling machine or lathe at some point, or drilled a few holes during high school shop class, great, but neither is a prerequisite to reading this book.

It's also a fair assumption that you want to learn more about machining, considering the fact that you're leafing through a book on the topic while standing in the middle of a crowded bookstore with your kid tugging at your shirt and whining about going to the food court, or that you hurriedly downloaded a sample of the e-book at work, nervous as a politician during election season that the company's Internet police might be looking over your shoulder.

Still, you should probably know what a computer is. It would help if you understand that cars are assembled in factories and are made of metal and plastic (machining is big with automakers). Having worked on a car would be even better, as you would almost certainly have an appreciation of precision machined parts and the work that goes into making them.

But even having successfully assembled a piece of Ikea furniture would be a huge advantage, because then you'd know the definition of a screw, and would nod sagely when you hear the phrase, "righty-tighty, lefty-loosey," a term the old-timers in the shop say frequently, then chuckle quietly to themselves as they go back to work.

Icons Used in This Book

Every industry has tricks of the trade and machining is no different. Buy a veteran machinist a sandwich or a beer and you'll be sure to hear plenty of useful tidbits of information. Don't have one of those old-timers around? No problem; just keep an eye out for the Tip icon. You'll soon be impressing your friends and coworkers with your extensive knowledge of machining's darkest secrets.

Operating computerized machinery that costs more than your house is, by nature, a technical endeavor. If you want to understand the inner workings of machine tools or know the specifics of why climb milling is better than conventional milling, watch for the Technical Stuff icons.

Machinists have a lot on their minds, so sometimes they forget things; no one's perfect. After all, even non-machinists misplace their car keys or forget to feed the dog before leaving for work in the morning. Thanks to the abundance of Remember icons scattered throughout this book, its readers will have no reason to forget anything, ever again.

Machining is abundantly cool, but it can also be dangerous. Flying hunks of metal, pinch points that can catch unwary fingers, sharp cutting tools that move really, really fast. Pay attention to the Warning icons if you want to avoid a trip to the emergency room.

Remember that time you skipped chemistry class and missed hearing about atomic structures and wave-particle duality? You failed the test, didn't you? The Important Details icons are kind of like that long-ago day in high school, providing background information that will help make sense of various topics throughout the book.

Beyond the Book

In addition to what you're reading now, this book also comes with a free access-anywhere Cheat Sheet that gives you even more pointers on milling, turning, cutting tools, machining equipment and accessories, and how to be the best machinist ever. To get this Cheat Sheet, simply go to www.dummies.com and search for "Machining For Dummies Cheat Sheet" in the Search box.

Where to Go from Here

Answering that question depends on one thing: Where do you want to go? Once you've read the book, you might decide to quit your job as a dentist or investment broker and pursue a high-paying career in machining. Stranger things have happened. If so, you're in luck, as abundant resources exist to help people do just that. You can start by surfing cutting tool and equipment manufacturers' websites. Buy a copy of the Machinery's Handbook (after you read this book of course), referred to by many seasoned machinists as "The Bible."

Want to get serious? Enroll in the local vocational school, take some night classes at a community college, or convince some generous machine shop owner to give you a shot at climbing the ladder (as I did). All these roads lead to machining mastery.

Maybe you don't want a career, and are simply looking to trade in your stamp collecting hobby for a more meaningful pastime, one that lets you build useful stuff. Pick up a used lathe or mill and you could soon be machining candlesticks and metal birdhouses, never having to worry about what to give friends and loved ones for their birthdays again. If so, this...