Machinery Repairman

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Milling machine cutter selection, 7-26 Milling machine feeds, speeds, and coolants, 7-48 coolants, 7-52 feeds, 7-51 speeds, 7-48 Milling machine indexing, 7-11 adjusting sector arms, 7-17 angular, 7-13 compound, 7-14 differential, 7-15 direct, 7-11 plain, 7-11 wide-range divider, 7-15 Milling machine operations, 7-30 angular milling, 7-34 drilling, reaming, and boring, 7-45 face milling, 7-32 fly cutting, 7-45 plain milling, 7-30 slotting, parting, and milling keyseats, 7-40 Milling machine workholding devices, 7-7 circular milling attachment, 7-8 indexing equipment, 7-8 right angle plate, 7-7 toolmaker’s knee, 7-7 vises, 7-7 MR/civilian job descriptions, 1-1 N Nickel alloys, 3-5 K-monel, 3-5 nickel-copper, 3-5 Nongraduated gauges, 1-18 gauge blocks, 1-20 machinist's square, 1-19 parallel blocks, 1-19 ring and plug gauges, 1-20 sine bar, 1-19 straightedges, 1-18 thread and measuring wires, 1-20 Numerical control systems, 11-5 O Oxyacetylene equipment, 2-22 P INDEX-6 adjusting the flame, 2-24 backfire and flashback, 2-26 extinguishing the flame, 2-25 safety, 2-25 setting up, 2-24 Pantagraphs, 9-14 attachments, 9-20 cutter speeds, 9-17 engraving a dial face, 9-22 engraving a graduated collar, 9-22 grinding cutters, 9-17 major components, 9-16 setting copy, 9-16 setting the pantagraph, 9-16 using a circular copy plate, 9-22 Plain-carbon steel, 3-3 high-carbon steel, 3-4 low-carbon steel, 3-4 medium-carbon steel, 3-4 Planer operations, 9-13 feeds, 9-13 holding the work, 9-14 rail elevation, 9-13 table speeds, 9-13 Planers, 9-11 major components, 9-12 operations, 9-13 Plastics, 3-14 characteristics, 3-15 lathe operations, 3-18 machining operations, 3-15 major groups, 3-15
Stub tooth gears, 14-27 American standard system, 14-27 Fellows stub-tooth gear system, 14-27 method of manufacture, 14-28 Surface characteristics of metal, 2-3 Surface grinder, 10-5 T cross traverse table, 10-5 operation, 10-7 sliding table, 10-6 wheelhead, 10-6 workholding devices, 10-6 Thermal spray systems, 12-1 applications, 12-1 applying the coating, 12-6 preparing surfaces, 12-4 qualification of personnel, 12-2 quality assurance, 12-7 surface finishing, 12-6 types of thermal spray, 12-2 Thermal spray; preparing surfaces, 12-4 cleaning, 12-4 surface roughening, 12-5 undercutting, 12-5 Tool and cutter grinder, 10-10 cutter sharpening, 10-11 cutter sharpening setups, 10-14 Toolrooms and tools, 1-1 U care and maintenance of measuring instruments, 1-20 control, 1-4 inspection, 1-4 measuring instruments, 1-6 organization, 1-2 safety, 1-2 Upright drill presses, 4-37 V general-purpose drill press (round column), 4-38 heavy-duty drill press (box column), 4-39 sensitive drill press, 4-16 Vertical shapers, 9-11 Vertical turret lathe, 8-1 W INDEX-8 taper turning, 8-4 tooling, 8-3 Worms and worm gears, 14-22 center-to-center distance, 14-25 cutting teeth on a milling machine, 14-26 formula development, 14-23 hobs, 14-25 selecting a cutter, 14-24 worm and worm wheel nomenclature, 14-23
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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
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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 and 430: Engine lathes, 6-1 attachments and
Page 431: Layout methods, 2-8 M forming angul
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