Machinery Repairman

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number is shown for roughness height, it is the basic check (view E, fig. 2-3). The NOTES block of maximum permissible roughness height rating; if two the drawing will show any further surface finish are shown, the top number is the maximum (view B, requirements, such as waviness width or height. fig. 2-3). A point to remember is that the smaller the number in the roughness height rating, the smoother the surface. Waviness height values are shown directly above the extension line at the top of the long leg of the basic check (view C, fig. 2-3). Waviness width values are placed to the right of the waviness height values (view D, fig. 2-3). Where minimum requirements for contact or bearing surfaces must be shown, the percentage is placed at the top of the long leg of the Figure 2-4.—Symbols indicating the direction of lay. 2-4 Lay is the direction of the predominant surface pattern produced by the tool marks. The symbol indicating lay is placed to the right and slightly above the point of the surface roughness symbol, as shown in view F of figure 2-3. (Fig. 2-4 shows the seven symbols that indicate the direction of lay.) The roughness width value is shown to the right of and parallel to the lay symbol. The roughness width cutoff is placed immediately below the extension line and to the right of the long leg of the
asic check mark. These symbols for roughness width are shown in view G and H of figure 2-3. Figure 2-5 shows a sampling of some roughness height values that can be obtained by the different machine operations. READING SURFACE FINISH QUALITY A surface finish is seldom flat. We said earlier that close examination with surface finish measuring instruments shows the surface to be formed of irregular waves. On top of the waves are other smaller irregularities known as peaks and valleys. We will now discuss several ways to evaluate surface finish. VISUAL INSPECTION There are occasions when visual comparison with the naked eye will show that one surface is rougher than the other. This is possible only in cases of widely differing surfaces. You also can use visual inspection to detect large cracks in metal. You can make a visual comparison with illuminated magnifiers (fig. 2-6). Figure 2-5.—Roughness height values for machine operations. 2-5 Figure 2-6.—Magnifier with illuminator for surface inspection.
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 30 and 31: MICROMETERS is essentially the same
Page 32 and 33: meanings of these terms and the imp
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
Page 80 and 81: File Bands A file band consists of
Page 82 and 83: This prevents sagging of the file b
Page 84 and 85:
Figure 4-16.—Butt welder-grinder
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paragraphs contain the procedures f
Page 88 and 89:
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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