Machinery Repairman

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HONING—Finishing machine operation using stones vice a tool bit or cutting tool. INVOLUTE —Usually referred to as a cutter used in gearing. KNOOP—Trade name used in hardness testing. MANDREL—Tool used to mount work usually done in a lathe or milling machine. NORMALIZING —Heating iron-base alloys to approximately 100°F above the critical temperature range followed by cooling to below that range in still air at room temperature. PERPENDICULAR —A straight line that meets another straight line at a 90 degree angle. Also a vertical line extending through the outline of the hull ends and the designer’s waterline. PIG IRON—Cast iron as it comes from the blast furnace in which it was produced from iron ore. PINHOLE—Small hole under the surface of the casting. PLAN—A drawing prepared for use in building a ship. PLASTICITY —The property that enables a material to be excessively and permanently deformed without breaking. PREHEATING—The application of heat to the base metal before it is welded or cut. PUNCH, PRICK—A small punch used to transfer the holes from the template to the plate. Also called a CENTER PUNCH. QUENCHING—Rapid cooling of steels at different rates. REAMING—Enlarging a hole by revolving in it a cylindrical, slightly tapered tool with cutting edges running along its sides. RECHUCKING —Reversing of a piece of work on a faceplate so that the surface that was against the faceplate may be turned to shape. REFERENCE PLANE—On a drawing, the normal plane from which all information is referenced. RPM—Revolutions per minute. AI-2 SCALE—The ratio between the measurement used on a drawing and the measurement of the object it represents. A measuring device such as a ruler, having special graduations. SECTOR—A figure bounded by two radii and the included arc of a circle, ellipse, or other central curve. SPOT FACING—Turning a circular bearing surface about a hole. It does not affect a pattern. STANDARD CASING—The half of a split casing that is bolted to the foundation, as opposed to the half, or cover, which can be removed with minimum disturbance to other elements of the equipment. STRAIGHTEDGE —Relatively long piece of material whose working edge is a true plane. STRENGTH—The ability of a material to resist strain. STRESS RELIEVING—Heat treatment to remove stresses or casting strains. STUD—(1) A light vertical structure member, usually of wood or light structural steel, used as part of a wall and for supporting moderate loads. (2) A bolt threaded on both ends, one end of which is screwed into a hole drilled and tapped in the work, and used where a through bolt cannot be fitted. SYNTHETIC MATERIAL—A complex chemical compound that is artificially formed by the combining of two or more simpler compounds or elements. TEMPER—To relieve internal stress by heat treating. TEMPLATE—A pattern used to reproduce parts. TOLERANCE—An allowable variation in the dimensions of a machined part. VICKERS—A scale or test used in metal hardness testing. VITRIFIED BOND—A man-made bond used in grinding wheels. WAVINESS—Used as a term in the testing finish machining of parts. ZINC—An alloy used widely in die casting.
APPENDIX II TABULAR INFORMATION OF BENEFIT TO A MACHINERY REPAIRMAN Table AII-1.—Decimal Equivalents of Fractions (inch) AII-1
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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
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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
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
Page 364 and 365: explains the classes and the manufa
Page 366 and 367: GRAINS (irregularly shaped crystals
Page 368 and 369: Figure 15-2.—Microscopic structur
Page 370 and 371: Figure 15-5.—Typical structure of
Page 372 and 373: Figure 15-8.—Grid for heat-treati
Page 374 and 375: Table 15-3.—Average Cooling Rates
Page 376 and 377: cases. A wide variety of quenching
Page 378 and 379: These various temperature arrests o
Page 380 and 381: known as pearlite, and the A1 tempe
Page 382 and 383: quickly cooled to and held at a som
Page 384 and 385: Available information indicates tha
Page 386 and 387: slowly from the tempering temperatu
Page 388 and 389: Table 15-4.—Heat-Treating Tempera
Page 390 and 391: Figure 15-20.—Design of a cam. A.
Page 392 and 393: In carburized steel, spalling is ca
Page 394 and 395: used to make positive identificatio
Page 398 and 399: Table AII-2.—Decimal Equivalents
Page 400 and 401: Table AII-4.—Formulas for Dimensi
Page 402 and 403: Table AII-5.—Number, Letter and F
Page 404 and 405: Table AII-7.—Screw Thread and Tap
Page 406 and 407: Table AII-9.—3-Wire Method of Mea
Page 408 and 409: Table AII-11.—Circles Circumferen
Page 410 and 411: Table AII-13.—Taper Per Foot and
Page 412 and 413: p 1 I vi 2 P F \ = = a AII-16
Page 414 and 415: Table AII-16.—Drill Sizes for Tap
Page 416 and 417: Having Circular pitch Circular pitc
Page 419 and 420: APPENDIX IV DERIVATION OF FORMULAS
Page 421: (1) NT is the connecting link betwe
Page 424 and 425: Walker, John R., Machining Fundamen
Page 427 and 428: A Adjustable gauges, 1-7 adjustable
Page 429 and 430: Engine lathes, 6-1 attachments and
Page 431 and 432: Layout methods, 2-8 M forming angul
Page 433 and 434: Stub tooth gears, 14-27 American st
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