Machinery Repairman

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Figure 11-3.—Slant bed for CNC lathe. Figure 11-4.—CNC programming station. 11-4
the opposite side of the saddle (fig. 11-3) and the machine has a slant bed. The slant bed allows the chips to fall into the chip pan, rather than on tools or bedways. Despite this odd appearance, the slant bed CNC lathe functions just like a conventional lathe. As with CNC milling machines, you must have the controller manual for your machine’s controller to program it and operate the machine. CNC TOOLING There are many different tool-holding devices used for CNC machines. They can be as simple as a quickchange tool post or as complicated as an automatic tool change system, but they all serve the same purpose. The tool-holding devices for each shop will vary since each machine comes with different tooling and because shop personnel will purchase the tooling they prefer. Cutting tools are available in three basic material types: high-speed steel, tungsten carbide, and ceramic. Since we covered cutting tools in chapter 5, we will only briefly discuss them now. High-speed steel is generally used on aluminum and other nonferrous alloys, while tungsten carbide is used on high-silicon aluminums, steels, stainless steels, and exotic metals. Ceramic inserts are used on hard steels and exotic metals. Inserted carbide tooling is becoming the preferred tooling for many CNC applications. COMPUTER-AIDED DESIGN/COMPUTER-AIDED MANUFACTURING Computer technology has reached the stage where a machinist can use computer graphics (fig. 11-4) to Figure 11-5.—Direct numerical control. 11-5 design a part. The computer is used to place the design elements (lines, curves, circles, and so on) and dimensions on the computer display screen. The machinist defines the geometry of the part to the computer using one or more input devices. These devices may be the keyboard, a mouse, a digitizer, or a pen light. When the design has been edited and proofed, the computer can be instructed to analyze the geometry of the part and calculate the tool paths that will be required to machine the part. Each tool path is translated into a detailed sequence of machine axes movement commands that will enable a CNC machine tool to produce the part. No engineering drawing is required. The computer-generated instructions can be stored in a central computer for direct transfer to a CNC machine tool for parts manufacture as shown in figure 11-5. This is known as direct numerical control (DNC). The data also can be stored on disk for future use. The system that makes all this possible is computeraided design/computer-aided manufacturing (CAD/ CAM). There are several CAD/CAM software programs. They are constantly being upgraded and made more user friendly. To state it simply, CAD is used to draw the part and to define the tool path. CAM is used to convert the tool path into codes that the computer on the machine can understand. NUMERICAL CONTROL SYSTEMS A CNC machine consists of two major components: the machine tool and the controller, which is an onboard computer. These components may or may not be
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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
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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
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 290 and 291: Figure 10-28.—Grinding the periph
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 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
Page 340 and 341: at an angle to each other, as long
Page 342 and 343: Figure 14-6.—Development of evenl
Page 344 and 345: Table 14-1.—"K" Factor Table Tabl
Page 346 and 347: 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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