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Figure 7-79.—Vertical milling attachment. the attachment and then set by the two rotary swivels so the cutter will cut at any angle to the horizontal or the vertical plane. The spindle of the attachment is driven by gearing connected to the milling machine spindle. VERTICAL MILLING ATTACHMENT You can use a vertical milling attachment (fig. 7-79) to convert the horizontal spindle machine to a vertical spindle machine and swivel the cutter to any position in the vertical plane. You can use a universal milling attachment to swivel the cutter to any position in both the vertical and horizontal planes. These attachments will help simplify otherwise complex jobs. HIGH-SPEED UNIVERSAL ATTACHMENT You can use a high-speed universal attachment to perform milling operations at higher speeds than those for which the machine was designed. This attachment is clamped to the machine and driven by the milling machine spindle, as you can see in figure 7-80. You can swivel the attachment spindle head and cutter 360° in both planes. The attachment spindle is driven at a higher speed than the machine spindle. You must consider the ratio between the rpm of the two spindles when you calculate cutter speed. Drive small cutters, end mills, and drills at high rates of speed to maintain an efficient cutting action. 7-48 RACK MILLING ATTACHMENT The rack milling attachment, shown in figure 7-81, is used primarily to cut teeth on racks, although it can be used for other operations. The cutter is mounted on a spindle that extends through the attachment parallel to the table T-slots. An indexing arrangement is used to space the rack teeth quickly and accurately. FEEDS, SPEEDS, AND COOLANTS Milling machines usually have a spindle speed range from 25 to 2,000 rpm and a feed range from 1/4 inch to 30 inches per minute (ipm). The feed is independent of the spindle speed; therefore, you can feed a workpiece at any rate available in the feed range regardless of the spindle speed. In the following paragraphs, we’ll discuss some of the factors concerning the selection of appropriate milling feeds and speeds. SPEEDS Heat generated by friction between the cutter and the work may be regulated by the use of proper speed, feed, and cutting coolant. Regulation of this heat is Figure 7-80.—High-speed universal milling attachment.
very important because the cutter will be dulled or even made useless by overheating. It is almost impossible to provide any fixed rules that will govern cutting speeds because of varying conditions from job to job. Generally speaking, you should select a cutting speed that will give the best compromise between maximum production and longest life of the cutter. In any particular operation, consider the following factors to determine the proper cutting speed: Hardness of the material being cut: The harder and tougher the metal being cut, the slower should be the cutting speed. Depth of cut and desired finish: The amount of friction heat produced is directly proportional to the amount of material being removed. Figure 7-81.—Rack milling attachment. Cutter material: You can operate high-speed steel cutters from 50 to 100 percent faster than carbon steel cutters because the high-speed cutters have better heat-resistant properties. Depending on the setup, you can operate carbide cutters at up to 4 times the speed of high-speed steel cutters. Type of cutter teeth: Cutters that have undercut teeth cut more freely than those that have a radial face. Therefore, you may run cutters with undercut teeth at higher speeds. Sharpness of the cutter: You can run a sharp cutter at a much higher speed than a dull cutter. Therefore, you can often make finishing cuts at Use of coolant: Sufficient coolant will usually a speeds 40 to 80 percent higher than that used cool the cutter so that it will not overheat even in roughing. at relatively high speeds. 7-49
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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
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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
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 218 and 219: 11. 12. 13. 14. 15. 16. 17. 18. 19.
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 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
Page 269 and 270: Figure 9-29.—Using an indexing at
Page 271: Any further movement of the work wi
Page 274 and 275: Figure 10-1.—Grain depth of cut;
Page 276 and 277: To select the proper work speed, ta
Page 278 and 279: Figure 10-8.—Magnetic chuck used
Page 280 and 281: 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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