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appropriate sides of the jaws on the surface to be measured and read the caliper from the side marked inside or outside as required. There is a difference in the zero marks on the two sides that is equal to the thickness of the tips of the two jaws, so be sure to read the correct side. Vernier calipers are available in sizes ranging from 6 inches to 6 feet and are graduated in increments of thousandths (0.001) of an inch. The scales on vernier calipers made by different manufacturers may vary slightly in length or number of divisions; however, they are read basically the same way. See USE and CARE of HAND TOOLS and MEASURING TOOLS, NAVEDTRA 12085, for instructions on how to interpret the readings. Vernier Height Gauge A vernier height gauge (fig. 1-9) is used to lay out work for machining operations or to check the Figure 1-9.—Vernier height gauge. 1-10 dimensions on surfaces that have been machined. Attachments for the gauge include the offset scribe shown attached to the gauge in figure 1-9. The offset scribe lets you measure from the surface plate with readings taken directly from the scale without the need for calculations. As you can see in figure 1-9, if you were using a straight scribe, you would have to calculate the actual height by taking into account the distance between the surface plate and the zero mark. Some models have a slot in the base for the scribe to move down to the surface and a scale that permits direct reading. Another attachment is a rod that permits depth readings. Small dial indicators that connect to the scribe permit extremely close work when you check or lay out work. Read a vernier height gauge the same way you read a vernier caliper.
Dial Vernier Caliper A dial vernier caliper (fig. 1-10) looks much like a standard vernier caliper and is also graduated in one-thousandths (0.001) of an inch. The main Figure 1-10.—Dial vernier caliper. 1-11 difference is that instead of a double scale, as on the vernier caliper, the dial vernier has the inches marked only along the main body of the caliper and a dial that indicates thousandths (0.001) of an inch. The range of the dial vernier caliper is usually 6 inches. 28.315
Page 1 and 2: Naval Education and Training Comman
Page 3 and 4: MACHINERY REPAIRMAN NAVEDTRA 12204-
Page 6 and 7: PREFACE This Training Manual (TRAMA
Page 8 and 9: CONTENTS CHAPTER PAGE 1. 2. 3. 4. 5
Page 10 and 11: Another job description found in pr
Page 12 and 13: 1-2, and 1-3 show some of the commo
Page 14 and 15: You must know the location of tools
Page 16 and 17: The correct way to measure an insid
Page 20 and 21: Dial Bore Gauge The dial bore gauge
Page 22 and 23: Gear Tooth Vernier Use a gear tooth
Page 24 and 25: Surface Gauge A surface gauge (fig.
Page 26 and 27: Figure 1-20.—Center gauge. angle
Page 28 and 29: accuracy. They generally come in ma
Page 30 and 31: MICROMETERS is essentially the same
Page 32 and 33: meanings of these terms and the imp
Page 34 and 35: number is shown for roughness heigh
Page 36 and 37: Figure 2-7.—Master roughness scal
Page 38 and 39: Figure 2-11.—Checking surface fin
Page 40 and 41: Figure 2-17.—Laying out a 45-degr
Page 42 and 43: Figure 2-24.—Setting and using a
Page 44 and 45: Figure 2-29.—Bisecting an angle.
Page 46 and 47: prick-punch “witness marks” aro
Page 48 and 49: Figure 2-35.—Filing. The crosshat
Page 50 and 51: keyway broach requires a bushing th
Page 52 and 53: The steps involved in repairing a d
Page 54 and 55: SETTING UP OXYACETYLENE EQUIPMENT T
Page 56 and 57: GREASE IN THE PRESENCE OF OXYGEN UN
Page 58 and 59: Strength metal into thin sheets. Le
Page 60 and 61: and forming into plates, billets, b
Page 62 and 63: Each of the aluminum alloys has pro
Page 64 and 65: with an average carbon content of 1
Page 66 and 67: The manufacturer is required to mak
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with that of known specimens. Many
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Gray cast iron produces a spark str
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Table 3-4.—Major Groups of Plasti
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Lathe Operations Lathe operations a
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mechanism is also attached to the s
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Band Selection and Installation The
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File Bands A file band consists of
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This prevents sagging of the file b
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Figure 4-16.—Butt welder-grinder
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paragraphs contain the procedures f
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Figure 4-22.—Disk-cutting attachm
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Figure 4-26.—Sensitive drill pres
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shops are the Morse taper shank, sh
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Figure 4-30.—Common types of clam
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Figure 4-34.—Two types of counter
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andomly follow the straight sides a
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CHAPTER 5 OFFHAND GRINDING OF TOOLS
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Figure 5-4.—Standard marking syst
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DIAMOND WHEELS Diamond grinding whe
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WHEEL CARE AND STORAGE It’s easy
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allows cutting speeds approximately
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Figure 5-13.—Surface finish vs no
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Figure 5-17.—Boring bars for carb
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Figure 5-19.—Chip breakers. a rad
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Internal-threading tool: The intern
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Downcutting tool: You may grind and
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Figure 5-32.—Grinding drill lip c
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Figure 5-37.—Grinding a twist dri
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ways in alignment with the headstoc
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Figure 6-4 shows this plate for the
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Before you insert a center or tooli
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FEED ROD The feed rod transmits pow
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lower lever has eight positions, ea
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Figure 6-14.—Quick-change toolpos
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Figure 6-21.—Three-jaw universal
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Figure 6-26.—Cutaway showing the
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Figure 6-32.—Thread dial indicato
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TRACING ATTACHMENTS A tracing attac
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2. Place the level across the bed a
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Figure 6-41.—Aligning lathe cente
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Figure 6-45.—Boring center hole.
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ends of the mandrel when you press
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Figure 6-52.—Centering work with
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Figure 6-56.—Work mounted on a ca
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FEED is the amount the tool advance
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Rough Turning Figure 6-62.—Rough
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Square, round, and “V” grooves
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Figure 6-69.—Knurled impressions.
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machined surfaces that could become
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produced by the same amount of seto
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cross-feed screw and the cross-slid
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When special threads are required b
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Figure 6-83.—Acme thread and form
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where An example of a pipe thread i
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The wire size you should use to mea
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Using the Thread-Cutting Stop Becau
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Figure 6-96.—Finishing the end of
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shown in figure 6-101. Two slots ar
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Figure 7-1.—Universal milling mac
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A. Spindle G. Spindle speed selecto
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with a split clamp to the overarm a
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to the table of the milling machine
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that most index heads have a 40 to
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Rapid indexing is used when a large
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or one complete turn plus 36 holes
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allows you to index divisions from
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from the one in which the pin is in
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Figure 7-24.—Side milling cutter.
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A. B. C. D. E. Figure 7-32.—Doubl
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Figure 7-36.—Inserted tooth face
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Figure 7-43.—Sprocket wheel cutte
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Figure 7-48.—Stub arbor. or on th
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Figure 7-54.—Spring collet chuck
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Figure 7-56.—Face milling. FACE M
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11. 12. 13. 14. 15. 16. 17. 18. 19.
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A. Lock screw for dog D. End mill B
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8. 9. 10. 11. 12. 13. 14. 15. 16. 1
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11. 12. 13. 14. 15. 16. 17. 18. 19.
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Figure 7-71.—Visual alignment of
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machine table. You will hold the cu
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Figure 7-77.—Boring with a fly cu
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Figure 7-79.—Vertical milling att
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Table 7-2.—Surface Cutting Speeds
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Table 7-4 shows recommended chip lo
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Figure 8-2.—A 36-inch vertical tu
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28.194 Figure 8-3.—Refacing a val
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HORIZONTAL BORING MILL The horizont
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7. After you have tightened the mou
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The table can be power driven to pr
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CHAPTER 9 SHAPERS, PLANERS, AND ENG
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Figure 9-3.—Swiveled and tilted t
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extent in planer and shaper work To
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the cutting speeds and related mach
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Figure 9-10.—Internal keyway: A.
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7. 8. 9. 10. 11. 12. 13. 14. Replac
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or housing attached on one side of
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Figure 9-18.—Engraving machine. F
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CUTTER SPEEDS The speeds listed in
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can readily see it after grinding t
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Figure 9-29.—Using an indexing at
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Any further movement of the work wi
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Figure 10-1.—Grain depth of cut;
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To select the proper work speed, ta
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Figure 10-8.—Magnetic chuck used
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can do on a surface grinder. Use th
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for straight cylindrical grinding o
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Figure 10-15.—Typical tooth rest
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of the work. Raise or lower the whe
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Figure 10-23.—Staggered-tooth sid
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Figure 10-28.—Grinding the periph
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Once the teeth are uniform, they sh
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After you have honed out the inaccu
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MACHINES With the rapid development
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Figure 11-3.—Slant bed for CNC la
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Figure 11-6.—A typical CNC contro
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Figure 11-8.—Continuous-path angl
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CHAPTER 12 METAL BUILDUP CHAPTER LE
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Figure 12-1.—Typical installation
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Figure 12-5.—A typical sandblaste
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Clean, dry air is essential for pro
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It can reduce the amount of masking
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quality assurance function of the p
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pass-fail. In our educational syste
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straighten a shaft, however, always
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Figure 13-4.—Lapping tools. has t
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pipe in which the valve is installe
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Figure 13-10.—Constant-pressure g
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When you install the control valve
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casing wearing rings, impeller wear
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Figure 13-17.—Removing a broken b
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Figure 13-23.—Metal disintegrator
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Figure 13-25.—Portable boring bar
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Figure 14-1.—Cutting specially sh
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For example, use the following proc
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at an angle to each other, as long
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Figure 14-6.—Development of evenl
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Table 14-1.—"K" Factor Table Tabl
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Figure 14-11.—Standard universal
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6. Find the NPD. 7. Find the 8. Fin
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FA - Face angle OD - Outside diamet
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7. Pitch diameter (PD)—This is th
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SELECTING A BEVEL GEAR CUTTER To cu
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Figure 14-20.—Profiling a bevel g
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. Use the following formulas to sol
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Figure 14-25.—Milling machine set
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9. Diametral pitch (DP) METHOD OF M
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explains the classes and the manufa
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GRAINS (irregularly shaped crystals
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Figure 15-2.—Microscopic structur
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Figure 15-5.—Typical structure of
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Figure 15-8.—Grid for heat-treati
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Table 15-3.—Average Cooling Rates
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cases. A wide variety of quenching
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These various temperature arrests o
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known as pearlite, and the A1 tempe
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quickly cooled to and held at a som
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Available information indicates tha
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slowly from the tempering temperatu
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Table 15-4.—Heat-Treating Tempera
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Figure 15-20.—Design of a cam. A.
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In carburized steel, spalling is ca
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used to make positive identificatio
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HONING—Finishing machine operatio
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Table AII-2.—Decimal Equivalents
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Table AII-4.—Formulas for Dimensi
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Table AII-5.—Number, Letter and F
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Table AII-7.—Screw Thread and Tap
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Table AII-9.—3-Wire Method of Mea
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Table AII-11.—Circles Circumferen
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Table AII-13.—Taper Per Foot and
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p 1 I vi 2 P F \ = = a AII-16
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Table AII-16.—Drill Sizes for Tap
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Having Circular pitch Circular pitc
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APPENDIX IV DERIVATION OF FORMULAS
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(1) NT is the connecting link betwe
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Walker, John R., Machining Fundamen
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A Adjustable gauges, 1-7 adjustable
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Engine lathes, 6-1 attachments and
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Layout methods, 2-8 M forming angul
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Stub tooth gears, 14-27 American st
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