Machinery Repairman

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quality assurance function of the plating activity and will as a minimum prepare the prospective operator to demonstrate a knowledge of the following: The technical aspects of brush electroplating Job safety for hazardous chemicals and electrical work The calculation of plating amperage, plating time, quantity of solution required, surface area, and ampere-hours The meaning of the terms current density, activation, anode, cathode, adhesion, burned deposits, modules, porosity stripping, etch, waterbreak, matte finish, volts, and amperes. Setup and operation of a power supply Preparation of metal surface for brush electroplating Selection, preparation of, and postuse care of the plating tools (anodes) and covers The attributes used to control plating thickness time and quality Prevention of contamination of plating solutions Proper masking technique Proper plating technique Proper surface finishing technique Evaluation of the deposit’s adhesion, thickness, and visual appearance Preparation of job records An operator will have passed a written examination covering these subjects. The examination will be administered either by the training activity or the plating activity, and approved by the quality assurance function of the plating activity. The operator will demonstrate to the quality assurance function of the plating activity that he or she is capable of performing brush electroplating by plating test specimens following MIL-STD-2197(SH) specifications. Requalification is required when the operator has not performed any production work for which he or she is qualified for a period of 12 months or more, or when 12-10 the quality assurance function of the plating activity has reason to question the ability of the operator to produce quality plating. PLATING PROCEDURES Brush electroplating will be performed to an approved written procedure. The procedure will contain as a minimum the following: A unique identifying number Date of approval Authorizing signature Applicable plating thickness Plating treatment’s, such as stress relief or peening, if required Required operators qualification Preliminary cleaning Electrocleaning and etching Rinsing Activating Plating solutions, preplate (if needed), current density, and anode to cathode speed Drying Postplate treatments, such as blasting or grinding, if required Records Inspection requirements and acceptance criteria In addition to MIL-STD-2197(SH) and MIL- STD-865, commercial manuals provided by brush electroplating solution and equipment contractors form the basis for information pertaining to brush electroplating. QUALITY ASSURANCE The quality assurance function of the plating activity shall enforce the requirements of M-STD- 2197(SH). The tests will include visual inspection, adhesion test, thickness of deposit, and dye penetrant inspection for classes 3 and 3A applications only.
CHAPTER 13 REPAIR WORK CHAPTER LEARNING OBJECTIVES Upon completing this chapter, you should be able to do the following: Explain the removal of broken studs and taps. Describe the repair and inspection of pumps. Explain the procedure used to straighten shafts. Describe the inspection of constant-pressure governors. Explain the uses of in-place machining equipment. Explain the purpose of METCAL. Explain the purpose of the quality assurance program. Explain the purpose of the planned maintenance system. In this chapter we’ll discuss some of the different jobs you may encounter as an MR. We’ll also discuss some of the things you need to know before you start the job, such as quality assurance, calibration, and planning. JOB PREPARATION There are a number of things you must do before you actually start a job in a machine shop. If you ignore these things, the job may turn out to be inaccurate. Even worse, it may be perfect but still not useable because of improper documentation. We’ll now discuss some of the things you must do to prepare for the job. As with any shop equipment you must observe all posted safety precautions. Review your equipment operators manual for safety precautions. Also read any chapters of Navy Occupational Safety and Health (NAVOSH) Program Manual for Forces Afloat, OPNAV Instruction 5100.l9B, that apply to the equipment. 13-1 CALIBRATION Calibration assures us that the parts we manufacture will fit together as they should. The increased complexity of ship systems has made it necessary to improve the accuracy of measurements. The Navy addressed this problem by creating the Navy Metrology and Calibration (METCAL) Program. This program ensures the traceability and accuracy of instrument calibration. To operating personnel, this means that any instrument used for quantitative measurement must be calibrated. Simply stated, you must always be sure the instruments you use for quantitative measurement are calibrated. Never use an instrument with an outdated calibration sticker. If you suspect a measuring instrument has been damaged, be sure it is taken out of use and calibrated. For more information on the METCAL program refer to Instrumentman 3 & 2, NAVEDTRA 10193-D. QUALITY ASSURANCE The philosophy of quality assurance (QA) is unique in that it does not recognize degrees of success. QA is
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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
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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 312 and 313: It can reduce the amount of masking
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
Page 362 and 363: 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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