Machinery Repairman

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11. 12. 13. 14. 15. 16. 17. 18. 19. 20. 21. Figure 7-60.—Angular milling. Move the work away from the cutter with the table and direct the coolant flow onto the cutter. Set the roughing depth of cut, using the graduated dial, and lock the saddle. Position the work to about 1/16 inch from the cutter, and then engage the power feed. After completing the cut, stop the spindle, and move the work back to the starting point before the next cut. Set the speed and feed for the finishing cut, and then unlock the saddle. Move the saddle in for the final depth of cut and relock it. Engage the spindle and take the finish cut. Stop the machine and return the work to the starting place. Shut the machine off. Remove the work from the vise. Handle it very carefully to keep from cutting yourself before you can deburr the work. Next, mount the work in the vise so the other end is ready to be machined. Mill this end in the same manner as the first, but be sure to measure the length before you take the finishing cut. Before removing the work from the vise, check it for accuracy and remove the burrs from the newly finished end. 7-34 ANGULAR MILLING Angular milling is the milling of a flat surface that is at an angle to the axis of the cutter. Normally, you will use an angular milling cutter, as shown in figure 7-60. However, you can perform angular milling with a plain, side, or face milling cutter by positioning the work at the required angle. Many maintenance or repair tasks require you to machine flat surfaces on cylindrical work. They include milling squares and hexagons, and milling two flats in the same plane. A square or hexagon is milled on an object to provide a positive drive, no slip area that can be grasped by various tools, such as wrenches and cranks. You will machine squares and hexagons frequently on the ends of bolts, taps, reamers, or other items that are turned by a wrench and on drive shafts and other items that require a positive drive. The following information will help you to understand the machining of squares and hexagons. Cutter Setup The two types of cutters you will use most often to machine squares or hexagons are side and end milling cutters. You can use side milling cutters to machine work that is held in a chuck and for heavy cutting. You can use end mills for work that is held in a chuck or between centers and for light cutting. If you use a side milling cutter, be sure the cutter diameter is large enough so you can machine the full length of the square or hexagon without interference from the arbor. If you use an end mill, be sure it is slightly larger in diameter than the length of the square or hexagon. The cutter thrust for both types should be up when the work is mounted vertically and down when it is mounted horizontally in order to use conventional (or up) milling. The reason for what appears to be a contradiction in the direction of thrust is the difference in the direction of the feed. You can see this by comparing figures 7-61 and 7-62. The cutter shown in figure 7-61 rotates in a counterclockwise direction and the work is fed toward the left. The cutter shown in figure 7-62 rotates in a clockwise direction and the work is fed upward.
Figure 7-62.—Milling a square on work held horizontally. Figure 7-61.—Milling a square on work held vertically. 7-35 Work Setup We have already discussed the methods that you will usually use to mount the work. Regardless of the workholding method, you must align the index spindle in either the vertical or the horizontal plane. If you machine work between centers, you must also align the footstock center. If you use a screw-on chuck, consider the cutter rotary thrust applied to the work. Always cut on the side of the work that will tend to tighten the chuck on the index head spindle. When you mount work between centers, a dog rotates the work. The drive plate,
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Naval Education and Training Comman
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MACHINERY REPAIRMAN NAVEDTRA 12204-
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PREFACE This Training Manual (TRAMA
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CONTENTS CHAPTER PAGE 1. 2. 3. 4. 5
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Another job description found in pr
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1-2, and 1-3 show some of the commo
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You must know the location of tools
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The correct way to measure an insid
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appropriate sides of the jaws on th
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Dial Bore Gauge The dial bore gauge
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Gear Tooth Vernier Use a gear tooth
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Surface Gauge A surface gauge (fig.
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Figure 1-20.—Center gauge. angle
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accuracy. They generally come in ma
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MICROMETERS is essentially the same
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meanings of these terms and the imp
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number is shown for roughness heigh
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Figure 2-7.—Master roughness scal
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Figure 2-11.—Checking surface fin
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Figure 2-17.—Laying out a 45-degr
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Figure 2-24.—Setting and using a
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Figure 2-29.—Bisecting an angle.
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prick-punch “witness marks” aro
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Figure 2-35.—Filing. The crosshat
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keyway broach requires a bushing th
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The steps involved in repairing a d
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SETTING UP OXYACETYLENE EQUIPMENT T
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GREASE IN THE PRESENCE OF OXYGEN UN
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Strength metal into thin sheets. Le
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and forming into plates, billets, b
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Each of the aluminum alloys has pro
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with an average carbon content of 1
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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
Page 168 and 169: produced by the same amount of seto
Page 170 and 171: cross-feed screw and the cross-slid
Page 172 and 173: When special threads are required b
Page 174 and 175: Figure 6-83.—Acme thread and form
Page 176 and 177: where An example of a pipe thread i
Page 178 and 179: The wire size you should use to mea
Page 180 and 181: Using the Thread-Cutting Stop Becau
Page 182 and 183: Figure 6-96.—Finishing the end of
Page 184 and 185: shown in figure 6-101. Two slots ar
Page 186 and 187: Figure 7-1.—Universal milling mac
Page 188 and 189: A. Spindle G. Spindle speed selecto
Page 190 and 191: with a split clamp to the overarm a
Page 192 and 193: to the table of the milling machine
Page 194 and 195: that most index heads have a 40 to
Page 196 and 197: Rapid indexing is used when a large
Page 198 and 199: or one complete turn plus 36 holes
Page 200 and 201: allows you to index divisions from
Page 202 and 203: from the one in which the pin is in
Page 204 and 205: Figure 7-24.—Side milling cutter.
Page 206 and 207: A. B. C. D. E. Figure 7-32.—Doubl
Page 208 and 209: Figure 7-36.—Inserted tooth face
Page 210 and 211: Figure 7-43.—Sprocket wheel cutte
Page 212 and 213: Figure 7-48.—Stub arbor. or on th
Page 214 and 215: Figure 7-54.—Spring collet chuck
Page 216 and 217: Figure 7-56.—Face milling. FACE M
Page 220 and 221: A. Lock screw for dog D. End mill B
Page 222 and 223: 8. 9. 10. 11. 12. 13. 14. 15. 16. 1
Page 224 and 225: 11. 12. 13. 14. 15. 16. 17. 18. 19.
Page 226 and 227: Figure 7-71.—Visual alignment of
Page 228 and 229: machine table. You will hold the cu
Page 230 and 231: Figure 7-77.—Boring with a fly cu
Page 232 and 233: Figure 7-79.—Vertical milling att
Page 234 and 235: Table 7-2.—Surface Cutting Speeds
Page 236 and 237: Table 7-4 shows recommended chip lo
Page 238 and 239: Figure 8-2.—A 36-inch vertical tu
Page 240 and 241: 28.194 Figure 8-3.—Refacing a val
Page 242 and 243: HORIZONTAL BORING MILL The horizont
Page 244 and 245: 7. After you have tightened the mou
Page 246 and 247: The table can be power driven to pr
Page 249 and 250: CHAPTER 9 SHAPERS, PLANERS, AND ENG
Page 251 and 252: Figure 9-3.—Swiveled and tilted t
Page 253 and 254: extent in planer and shaper work To
Page 255 and 256: the cutting speeds and related mach
Page 257 and 258: Figure 9-10.—Internal keyway: A.
Page 259 and 260: 7. 8. 9. 10. 11. 12. 13. 14. Replac
Page 261 and 262: or housing attached on one side of
Page 263 and 264: Figure 9-18.—Engraving machine. F
Page 265 and 266: CUTTER SPEEDS The speeds listed in
Page 267 and 268: 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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