Machinery Repairman

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MICROMETERS is essentially the same except that a standard must be placed between the anvil and the spindle to get a zero measuring reference. For example, a 2-inch micrometer is furnished with a 1-inch standard. To check for zero setting, place the standard between the spindle and the anvil and measure the standard. If zero is not indicated, the micrometer needs adjusting. Inside micrometers can be checked for zero setting and adjusted in about the same way as a micrometer caliper; the main difference in the method of testing is that an accurate micrometer caliper is required for transferring readings to and from the standard when an inside micrometer is being checked. Micrometers of all types should be disassembled periodically for cleaning and lubrication of internal parts. When this is done, each part should be cleaned in noncorrosive solvent, completely dried, and then given a lubricating coat of watchmaker’s oil or a similar light oil. VERNIER GAUGES Vernier gauges also require careful handling and proper maintenance if they are to remain accurate. The following instructions apply to vernier gauges in general: Always loosen a gauge into position. Forcing, besides causing an inaccurate reading, is likely to force the arms out of alignment. When taking a measurement, use only gentle pressure on the fine adjustment screw. Heavy pressure will force the two scales out of parallel. 1-22 Before putting a vernier gauge away, wipe it clean and give it a light coating of oil. (Perspiration from hands will cause the instrument to corrode rapidly.) Dials Dial indicators and other instruments that have a mechanically operated dial as part of their measurement features are easily damaged by misuse and lack of proper maintenance. The following instructions apply to dials in general: As previously mentioned, be sure the dial you have selected to use has the range capability required. When a dial is extended beyond its design limit, some lever, small gear, or rack must give to the pressure. The dial will be rendered useless if this happens. Never leave a dial in contact with any surface that is being subjected to a shock (such as hammering a part when dialing it in) or an erratic and uncontrolled movement that could cause the dial to be overtraveled. Protect the dial when it is not being used. Provide a storage area where the dial will not receive accidental blows and where dust, oil, and chips will not contact it. When a dial becomes sticky or sluggish in operating, it may be either damaged or dirty. You may find that the pointer is rubbing the dial crystal or that it is bent and rubbing the dial face. Never oil a sluggish dial. Oil will compound the problems. Use a suitable cleaning solvent to remove all dirt and residue.
CHAPTER 2 LAYOUT AND BENCHWORK CHAPTER LEARNING OBJECTIVES Upon completing this chapter, you should be able to do the following: Describe the process used to extract data from blueprints. Describe the procedures used to draft working drawings for parts manufacture and alteration. Explain surface characteristics of metal. Explain how to determine surface finish quality. Explain layout work. Explain the procedure used to lay out valve flange bolt holes. State the process used to hand scrape and blue parts and surfaces for flatness and fit. Explain filing operation. Explain the setup and operation of pressure. Explain the setup and operation of oxyacetylene equipment. Explain the use of helicoils. As an MR, you will repair or help repair many types of equipment used on ships. You will make replacement parts, disassemble and assemble equipment, make layouts of parts to be machined, and do precision work to lit mating parts of equipment. This is known as benchwork and it includes practically all repair work other than actual machining. This chapter contains information that you need to make effective repairs. Read Blueprint Reading and Sketching, NAVEDTRA 10077-F1, for additional information on working drawings. Other sources of information that you should study for details on specific equipment include the Naval Ships’ Techical Manual, the manufacturers technical manuals, and the training manuals for the equipment you are working on. 2-1 As with any shop equipment you must observe all posted safety precautions. Review your equipment operators manual for safety precaustions and any chapters of Navy Occupational Safety and Health (NAVOSH) Program Manual for Forces Afloat (OPNAV) Instruction 5100.19B that pertain to the equipment. LIMITS OF ACCURACY You must work within the limits of accuracy specified on the drawing. A clear understanding of TOLERANCE and ALLOWANCE will help you to avoid small, but potentially dangerous, errors. These terms may seem closely related, but each has a very precise meaning and application. We’ll point out the
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 18 and 19: appropriate sides of the jaws on th
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 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
Page 68 and 69: with that of known specimens. Many
Page 70 and 71: Gray cast iron produces a spark str
Page 72 and 73: Table 3-4.—Major Groups of Plasti
Page 74 and 75: Lathe Operations Lathe operations a
Page 76 and 77: mechanism is also attached to the s
Page 78 and 79: 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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Machinery Repairman

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