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Walker, John R., Machining Fundamentals, Goodheart-Wilcox Company, Inc., South Holland, Ill., 1989, Chap. 13. Chapter 6 How to Run a Lathe, Rev. ed. 56, South Bend Lathe, South Bend, Ind., 1966. McCarthy, Willard J., and Repp, Victor E., Ed.D, Machine Tool Technology, Bennett and McKnight, Encino, Calif., 1984, Sets. 4 and 9. Oberg, Erik, et al., Machinery’s Handbook, 23d ed., Industrial Press Inc., New York, 1988, pp. 1475-1648. Chapter 7 Kibbe, Richard R., et al., Machine Tool Practices, 3d ed., John Wiley and Sons, New York, 1987, Sets. J through L. Walker, John R., Machining Fundamentals, Goodheart-Wilcox Company, Inc., South Holland, Ill., 1989, Chap. 12. Chapter 8 Equipment Manual for Lathe, Turret, Vertical, NAVSEA 0991-LP-125-7010, Naval Sea Systems Command, Washington, D.C. 1968. Moltrecht, K. H., Machine Shop Practice, Vol. 2, Industrial Press Inc., New York, 1981, Chap. 10. Chapter 9 Model ITF-V, Operating Instructions, New Hermes Inc., Decater, Ga. Moltrecht, K. H., Machine Shop Practice Vol. 2, Industrial Press Inc., New York, 1981, Chaps. 1 through 3. Chapter 10 Kibbe, Richard R., et al., Machine Tool Practices, 3d ed., John Wiley and Sons, New York, 1987, Sec. N. Moltrecht, K. H., Machine Shop Practice, Vol. 2, Industrial Press Inc., New York, 1981, Chap. 14. Chapter 11 Seames, Warren S., Computer Numerical Control: Concepts and Programming, 2d ed., Delmar Publishers Inc., Albany, N.Y., 1990. Thyer, G. E., Computer Numerical Control of Machine Tools, 2d ed., Butterworth-Heinemann LID, Oxford, England, 1991. Chapter 12 Brush Electroplating on Marine Machinery, MIL-STD-2197 (SH), Naval Sea Systems Command, Washington, D.C., 1989. AV-2
Process Instruction for Thermal Spray Procedures for Machinery Repair, 24-1583-Rev. B, Shore Intermediate Maintenance Activity, San Diego, Calif., 1991. Thermal Spray Processes for Naval Ship Machinery Applications, MIL-STD-1687A (SH), Naval Sea Systems Command, Washington, D.C., 1987. Chapter 13 Maintenance Manual for Valves, Traps, and Orifices (non-nuclear), S9253-AD-MMM-010, Naval Sea Systems Command, Washington, D.C., 1990. Technical Manual for Description and Repair of Centrifugal Pumps, S6225-AP-MMl-0101, Naval Sea Systems Command, Washington, D.C., 1990. Vera-Mil Operation and Service Manual, NAVSEA 0392-LP-072-4000, Naval Sea Systems Command, Washington, D.C., 1985. Chapter 14 McCarthy, Willard J., and Repp, Victor E., Ed.D., Machine Tool Technology, Bennett and McKnight, Encino, Calif., 1984, Sec. 10. Oberg, Erik, et al., Machinery’s Handbook, 23d ed., Industrial Press Inc., New York, 1988, pp. 1765-2038. Chapter 15 Heat Treatment and Properties of Iron and Steel, NBS Monograph 88, National Bureau of Standards, Washington, D.C., 1966. Johnson, Carl G., and Weeks, William R., Metallurgy, 5th ed., American Technical Publishers, Inc., Alsip, Ill., 1977. AV-3
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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
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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
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 396 and 397: HONING—Finishing machine operatio
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 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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