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It can reduce the amount of masking and disassembly required. It permits plating of small areas of large assembled components or parts too large for available plating tanks. By plating to the required thickness, it can often eliminate finish machining or grinding of the plated surface. Damaged or defective areas of existing plating can be touched up instead of complete stripping and replating of the entire part. ELECTROPLATING EQUIPMENT We will discuss contact electroplating equipment in the following paragraphs. These are the power pack, Figure 12-10.—Electroplating equipment. 12-8 plating tools, solutions, and plating tool coverings, and they are shown in figure 12-10. We will cover them briefly because your plating machine operators manual covers them in depth. Power Pack Contact plating power packs are available in the following dc output ranges: 0 to 15 amperes at 0 to 20 volts and 0 to 150 amperes at 0 to 40 volts. They operate on 115- or 230-volt, 60-Hz, single- or three-phase ac input. The intermediate sizes, 25 to 100 ampere maximum output, are the most common. They are portable, weighing less than 150 lbs, yet can provide the required power for most shipboard and shop work A unit in the 60- to 100-ampere range is recommended as basic
contact plating shop equipment. It will remain useful even if changes in the workload require smaller or larger units to supplement it. Plating Tools Contact plating tools consist of a stylus handle with a conductive core, which is insulated for operator safety, and an insoluble anode normally of high-quality graphite. Since considerable heat is generated during plating operations, there must be a means of cooling the plating tool. The handles of plating tools have cooling fins to dissipate heat, but you may need to cool larger tools with plating solution or water. Graphite anodes are brittle and are not practical where a very small diameter anode is required. For plating holes less than 1/2 inch in diameter, or narrow slots and keyways, anodes made of 90 percent platinum and 10 percent iridium material are recommended. The equipment manufacturers offer removable anodes in a wide range of standard sizes and in three basic shapes: cylindrical or convex to plate inside diameters, concave for outside diameter’s, and flat or spatula shaped. You also may purchase graphite material to manufacture special tools. Solutions The solutions used in contact plating include preparatory solutions used to clean and activate the surface to be plated, plating solutions used to deposit pure or alloy metals, and stripping solutions used to remove defective plating. These solutions are manufactured and sold by the process equipment manufacturers. You can use solutions of any trade name if the deposits meet the applicable plating specification and if they are certified by procedure tests. However, do NOT use plating and preparatory solutions of different manufacturers for the same plating job. For plating operations, pour solution into a shallow glass or plastic dishes or beakers for dipping, or use them in a pump that dispenses solution through the tool. Plating Tool Coverings The most common tool covering is cotton batting of surgical grade U.S.P. long fiber, sterile cotton. It is fastened to the anode to hold and distribute the solution uniformly. You can use cotton batting alone for jobs that involve a few short preparing and plating operations, or to ensure maximum tool to workpiece contact for plating in corners or on irregularly shaped areas. When 12-9 you need longer tool cover life, place cotton, Dacron, or cotton-Dacron tubegauze sleeving over the cotton batting. You also may use Dacron batting, Pellon, and treated Scotchbrite to cover plating tools. APPLICATIONS The contact plating process is a rapidly expanding field. When used to deposit a corrosion-resistant coating, electroplating has shown enough success to permit almost unrestricted use. The vast field of possible applications in the repair of worn or damaged parts of high-speed rotating and reciprocating machinery is limited only by the knowledge and skills of the operator in areas where plating is allowed. Electroplating applications are classified as follows: Class 1: Class 2: Class 3: Class 3A: Class 4: Plating used for decorative or corrosion prevention functions only Plating on parts to restore dimensions on surfaces that remain in static contact with gaskets, O-rings, or other metal surfaces Plating on parts that make rubbing or intermittent contact with other plated or unplated parts, including electrical contacts except those in class 3A Plating on rubbing contact surfaces of turbines, reduction gears, electric power generating units, main propulsion shaft seals, steam valves, and other sliding contact areas when specified Plating on parts under the cognizance of the Nuclear Propulsion Directorate Refer to MIL-STD-2197(SH) for plating applications for each of these classes. OPERATOR QUALIFICATION Operators will be qualified by the quality assurance function of the plating activity before being permitted to perform contact electroplating. Before examination for qualification, each prospective operator will successfully complete a manufacturer-sponsored training course or one provided by the plating activity. The course shall be approved by the
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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
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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
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 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 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
Page 348 and 349: 6. Find the NPD. 7. Find the 8. Fin
Page 350 and 351: FA - Face angle OD - Outside diamet
Page 352 and 353: 7. Pitch diameter (PD)—This is th
Page 354 and 355: SELECTING A BEVEL GEAR CUTTER To cu
Page 356 and 357: Figure 14-20.—Profiling a bevel g
Page 358 and 359: . Use the following formulas to sol
Page 360 and 361: 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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