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Figure 10-28.—Grinding the peripheral teeth of an end mill. Figure 10-29.—Grinding the end teeth of a shell end mill. possible to avoid removing the temper at the end of the the same procedure that you would use to sharpen a cutter. Be sure to relieve the center of the end in the same plain milling cutter except for the method of mounting way as on the original cutter. the cutter. Mount the end mill in a universal workhead Generally, it will not be necessary to sharpen the (fig. 10-28) instead of between centers. You must peripheral teeth. However, if you must grind them, use remember that whenever you grind the peripheral teeth 10-18
of an end mill, you change the size (diameter) of the cutter. Therefore, you must show that the cutter size has been changed. Either mark the new size on the cutter or grind off the old size and leave the cutter unmarked. Use the following steps to sharpen the end teeth: 1. Mount the end mill in a universal workhead. 2. Swivel the wheelhead to 89°. 3. Use a centering gauge to bring the cutting edge of a tooth into the same horizontal plane as the wheelhead spindle axis. Place the gauge on top of the wheelhead and raise or lower the wheelhead enough to place the blade of the gauge on the tooth’s cutting edge. This also will align the cutting edge with the centerline of the wheel. 4. Lock the workhead spindle in place to prevent the cutter from moving. 5. Clamp the tooth rest blade onto the workhead so that its supporting edge rests against the underside of the tooth to be ground. 6. Swivel the workhead downward to the desired clearance angle and clamp it in position. At this point, make sure the tooth next to the one being ground will clear the wheel. If it does not, raise or lower the wheelhead until the tooth does clear the wheel. 7. Unclamp the workhead spindle and begin grinding the mill. 8. After you have ground all of the primary lands, tilt the workhead to the secondary clearance angle and grind all the secondary lands. On end mills with large diameter wheels, it is often a good idea to back off the faces of the teeth toward the center of the cutter, similar to the teeth of a face mill. An angle of about 3° is enough, allowing a land of 3/16 to 5/16 inch long. You must use as much care when you grind the comers of the teeth as when you grind the faces of the peripheral teeth. If not, the cutting edges will dull rapidly, and they will produce a poor finish. The comers of the teeth are usually chamfered 45° by swiveling the workhead or table and are left 1/6 to 1/8 inch wide. To sharpen the end teeth of a shell end mill (fig. 10-29), mount the cutter on an arbor set in a taper shank mill bushing. Then, insert the bushing into the taper shank mill bushing sleeve held in the universal workhead. To get the desired clearance angle, swivel the workhead in the vertical plane and swivel it slightly in the horizontal plane to grind the teeth low in the 10-19 Figure 10-30.—Involute gear cutter. center of the cutter. Turn the cutter until one of the teeth is horizontal; then raise the wheel until that tooth can be ground without interference. Formed Cutters Two methods are commonly used to sharpen formed milling cutters. The first method uses a formed cutter sharpening attachment and is by far the most convenient. In the second, set up the cutter on a mandrel, grind the backs of the teeth, and then reverse the cutter to sharpen the cutting faces. The involute cutter (fig. 10-30) will serve as an example. Since the teeth of these cutters have a specific shape, the only correct way to sharpen them is to grind their faces. It is most important that the teeth are ground uniformly and that they all have the same thickness from the back face to the cutting face. To get this uniformity, grind the back faces of all new cutters before you use them. Grind only the back faces, since the cutting faces are already sharp and ready to use.
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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
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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
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
Page 282 and 283: for straight cylindrical grinding o
Page 284 and 285: Figure 10-15.—Typical tooth rest
Page 286 and 287: of the work. Raise or lower the whe
Page 288 and 289: Figure 10-23.—Staggered-tooth sid
Page 292 and 293: Once the teeth are uniform, they sh
Page 294 and 295: After you have honed out the inaccu
Page 296 and 297: MACHINES With the rapid development
Page 298 and 299: Figure 11-3.—Slant bed for CNC la
Page 300 and 301: Figure 11-6.—A typical CNC contro
Page 302 and 303: Figure 11-8.—Continuous-path angl
Page 304 and 305: CHAPTER 12 METAL BUILDUP CHAPTER LE
Page 306 and 307: Figure 12-1.—Typical installation
Page 308 and 309: Figure 12-5.—A typical sandblaste
Page 310 and 311: Clean, dry air is essential for pro
Page 312 and 313: It can reduce the amount of masking
Page 314 and 315: quality assurance function of the p
Page 316 and 317: pass-fail. In our educational syste
Page 318 and 319: straighten a shaft, however, always
Page 320 and 321: Figure 13-4.—Lapping tools. has t
Page 322 and 323: pipe in which the valve is installe
Page 324 and 325: Figure 13-10.—Constant-pressure g
Page 326 and 327: When you install the control valve
Page 328 and 329: casing wearing rings, impeller wear
Page 330 and 331: Figure 13-17.—Removing a broken b
Page 332 and 333: Figure 13-23.—Metal disintegrator
Page 334 and 335: Figure 13-25.—Portable boring bar
Page 336 and 337: Figure 14-1.—Cutting specially sh
Page 338 and 339: 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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