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Heat-treating equipment, 15-6 cooling equipment, 15-10 heating equipment, 15-7 Heat-treating ferrous metals, 15-20 alloy tool steels, 15-24 annealing, 15-22 austempering, 15-22 carbon tool steels, 15-23 case hardening, 15-23 hardening, 15-20 martempering, 15-23 normalizing, 15-22 spheroidizing, 15-22 tempering, 15-21 Heat-treating nonferrous metals, 15-25 Heat-treating problems, 15-25 blistering, 15-28 cracking, 15-27 design problems, 15-25 size changes, 15-27 soft spots, 15-27 spalling, 15-27 warping, 15-27 Helical gears, 14-5 dimensions, real and normal, 14-8 gear train ratio, 14-12 manufacturing, 14-13 Honing equipment, 10-20 honing hints, 10-21 portable equipment, 10-20 stationary honing machine, 10-21 stone selection, 10-21 Horizontal boring mill, 8-6 combination boring and facing head, 8-7 operations, 8-8 right-angle milling attachment, 8-8 Horizontal shaper components, 9-1 crossrail assembly, 9-2 drive assembly, 9-1 main frame assembly, 9-1 table feed mechanism, 9-3 toolhead assembly, 9-4 Horizontal shaper operations, 9-5 shaping a rectangular block, 9-7 shaping angular surfaces, 9-8 shaping internal keyways, 9-9 shaping irregular surfaces, 9-10 shaping keyways in shafts, 9-8 speeds and feeds, 9-6 Horizontal shapers, 9-1 components, 9-1 operations, 9-5 vises and toolholders, 9-4 Hydraulic and arbor presses, 2-19 I Identification of metals, 3-11 L INDEX-4 acid test, 3-14 spark test, 3-11 Layout and benchwork, 2-1 filing, 2-18 hydraulic and arbor presses, 2-19 layout methods, 2-8 limits of accuracy, 2-1 oxyacetylene equipment, 2-22 reading surface finish quality, 2-5 scraping and bluing, 2-17 screw thread inserts, 2-20 surface characteristics of metal, 2-3 Layout limits of accuracy, 2-1 allowance, 2-2 tolerance, 2-2
Layout methods, 2-8 M forming angular lines, 2-9 geometric construction of layout lines, 2-13 laying out circles and irregular lines, 2-10 laying out valve flange boltholes, 2-14 lines square or parallel to edges, 2-8 using the sine bar, 2-12 using the surface plate, 2-11 Measuring instruments, 1-6 adjustable gauges, 1-7 fixed gauges, 1-16 Metal buildup, 12-1 contact electroplating, 12-7 thermal spray systems, 12-1 Metal, designations and markings, 3-6 ferrous metal designations, 3-6 nonferrous metal designations, 3-8 standard markings, 3-9 Metallurgy and heat treatment, 15-1 hardness test, 15-28 heat-treating ferrous metals, 15-20 heat-treating nonferrous metals, 15-25 heat-treating problems, 15-25 heat-treating equipment, 15-6 principles of heat-treating ferrous alloys, 15-13 structure of metal, 15-1 Metals, 3-1 designations and markings, 3-6 identification, 3-11 properties, 3-1 types, 3-3 Metals and plastics, 3-1 metals, 3-1 plastics, 3-14 INDEX-5 Micrometers, 1-7 ball, 1-8 blade, 1-8 depth, 1-8 groove, 1-8 inside, 1-7 outside, 1-7 thread, 1-8 Milling machine arbors, 7-27 cutter adapter, 7-29 fly cutter, 7-28 screw, 7-29 screw slotting cutter, 7-28 shell end, 7-28 spring collet chuck, 7-30 standard, 7-27 stub, 7-28 taper adapter, 7-29 Milling machine attachments, 7-47 high-speed universal, 7-48 rear milling, 7-48 universal, 7-47 vertical, 7-48 Milling machine components, 7-3 Milling machine cutters, 7-18 angle, 7-21 concave and convex, 7-25 corner rounding, 7-25 end mill, 7-22 face mill, 7-24 fly, 7-26 gear, 7-25 gear hob, 7-26 half-side milling, 7-20 metal slitting saw, 7-20 plain milling, 7-18 screw slotting, 7-20 side milling, 7-20 side milling (interlocking), 7-20 sprocket wheel, 7-26 T-slot, 7-24 woodruff key seat, 7-25
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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
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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
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 424 and 425: Walker, John R., Machining Fundamen
Page 427 and 428: A Adjustable gauges, 1-7 adjustable
Page 429: Engine lathes, 6-1 attachments and
Page 433 and 434: Stub tooth gears, 14-27 American st
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