Machinery Repairman

More documents

Recommendations

Info

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
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 34 and 35:
number is shown for roughness heigh
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
Page 86 and 87:
paragraphs contain the procedures f
Page 88 and 89:
Figure 4-22.—Disk-cutting attachm
Page 90 and 91:
Figure 4-26.—Sensitive drill pres
Page 92 and 93:
shops are the Morse taper shank, sh
Page 94 and 95:
Figure 4-30.—Common types of clam
Page 96 and 97:
Figure 4-34.—Two types of counter
Page 98 and 99:
andomly follow the straight sides a
Page 101 and 102:
CHAPTER 5 OFFHAND GRINDING OF TOOLS
Page 103 and 104:
Figure 5-4.—Standard marking syst
Page 105 and 106:
DIAMOND WHEELS Diamond grinding whe
Page 107 and 108:
WHEEL CARE AND STORAGE It’s easy
Page 109 and 110:
allows cutting speeds approximately
Page 111 and 112:
Figure 5-13.—Surface finish vs no
Page 113 and 114:
Figure 5-17.—Boring bars for carb
Page 115 and 116:
Figure 5-19.—Chip breakers. a rad
Page 117 and 118:
Internal-threading tool: The intern
Page 119 and 120:
Downcutting tool: You may grind and
Page 121 and 122:
Figure 5-32.—Grinding drill lip c
Page 123:
Figure 5-37.—Grinding a twist dri
Page 126 and 127:
ways in alignment with the headstoc
Page 128 and 129:
Figure 6-4 shows this plate for the
Page 130 and 131:
Before you insert a center or tooli
Page 132 and 133:
FEED ROD The feed rod transmits pow
Page 134 and 135:
lower lever has eight positions, ea
Page 136 and 137:
Figure 6-14.—Quick-change toolpos
Page 138 and 139:
Figure 6-21.—Three-jaw universal
Page 140 and 141:
Figure 6-26.—Cutaway showing the
Page 142 and 143:
Figure 6-32.—Thread dial indicato
Page 144 and 145:
TRACING ATTACHMENTS A tracing attac
Page 146 and 147:
2. Place the level across the bed a
Page 148 and 149:
Figure 6-41.—Aligning lathe cente
Page 150 and 151:
Figure 6-45.—Boring center hole.
Page 152 and 153:
ends of the mandrel when you press
Page 154 and 155:
Figure 6-52.—Centering work with
Page 156 and 157:
Figure 6-56.—Work mounted on a ca
Page 158 and 159:
FEED is the amount the tool advance
Page 160 and 161:
Rough Turning Figure 6-62.—Rough
Page 162 and 163:
Square, round, and “V” grooves
Page 164 and 165:
Figure 6-69.—Knurled impressions.
Page 166 and 167:
machined surfaces that could become
Page 168 and 169:
produced by the same amount of seto
Page 170 and 171:
cross-feed screw and the cross-slid
Page 172 and 173:
When special threads are required b
Page 174 and 175:
Figure 6-83.—Acme thread and form
Page 176 and 177:
where An example of a pipe thread i
Page 178 and 179:
The wire size you should use to mea
Page 180 and 181:
Using the Thread-Cutting Stop Becau
Page 182 and 183:
Figure 6-96.—Finishing the end of
Page 184 and 185:
shown in figure 6-101. Two slots ar
Page 186 and 187:
Figure 7-1.—Universal milling mac
Page 188 and 189:
A. Spindle G. Spindle speed selecto
Page 190 and 191:
with a split clamp to the overarm a
Page 192 and 193:
to the table of the milling machine
Page 194 and 195:
that most index heads have a 40 to
Page 196 and 197:
Rapid indexing is used when a large
Page 198 and 199:
or one complete turn plus 36 holes
Page 200 and 201:
allows you to index divisions from
Page 202 and 203:
from the one in which the pin is in
Page 204 and 205:
Figure 7-24.—Side milling cutter.
Page 206 and 207:
A. B. C. D. E. Figure 7-32.—Doubl
Page 208 and 209:
Figure 7-36.—Inserted tooth face
Page 210 and 211:
Figure 7-43.—Sprocket wheel cutte
Page 212 and 213:
Figure 7-48.—Stub arbor. or on th
Page 214 and 215:
Figure 7-54.—Spring collet chuck
Page 216 and 217:
Figure 7-56.—Face milling. FACE M
Page 218 and 219:
11. 12. 13. 14. 15. 16. 17. 18. 19.
Page 220 and 221:
A. Lock screw for dog D. End mill B
Page 222 and 223:
8. 9. 10. 11. 12. 13. 14. 15. 16. 1
Page 224 and 225:
11. 12. 13. 14. 15. 16. 17. 18. 19.
Page 226 and 227:
Figure 7-71.—Visual alignment of
Page 228 and 229:
machine table. You will hold the cu
Page 230 and 231:
Figure 7-77.—Boring with a fly cu
Page 232 and 233:
Figure 7-79.—Vertical milling att
Page 234 and 235:
Table 7-2.—Surface Cutting Speeds
Page 236 and 237:
Table 7-4 shows recommended chip lo
Page 238 and 239:
Figure 8-2.—A 36-inch vertical tu
Page 240 and 241:
28.194 Figure 8-3.—Refacing a val
Page 242 and 243:
HORIZONTAL BORING MILL The horizont
Page 244 and 245:
7. After you have tightened the mou
Page 246 and 247:
The table can be power driven to pr
Page 249 and 250:
CHAPTER 9 SHAPERS, PLANERS, AND ENG
Page 251 and 252:
Figure 9-3.—Swiveled and tilted t
Page 253 and 254:
extent in planer and shaper work To
Page 255 and 256:
the cutting speeds and related mach
Page 257 and 258:
Figure 9-10.—Internal keyway: A.
Page 259 and 260:
7. 8. 9. 10. 11. 12. 13. 14. Replac
Page 261 and 262:
or housing attached on one side of
Page 263 and 264:
Figure 9-18.—Engraving machine. F
Page 265 and 266:
CUTTER SPEEDS The speeds listed in
Page 267 and 268:
can readily see it after grinding t
Page 269 and 270:
Figure 9-29.—Using an indexing at
Page 271:
Any further movement of the work wi
Page 274 and 275:
Figure 10-1.—Grain depth of cut;
Page 276 and 277:
To select the proper work speed, ta
Page 278 and 279:
Figure 10-8.—Magnetic chuck used
Page 280 and 281:
can do on a surface grinder. Use th
Page 282 and 283:
for straight cylindrical grinding o
Page 284 and 285:
Figure 10-15.—Typical tooth rest
Page 286 and 287:
of the work. Raise or lower the whe
Page 288 and 289:
Figure 10-23.—Staggered-tooth sid
Page 290 and 291:
Figure 10-28.—Grinding the periph
Page 292 and 293:
Once the teeth are uniform, they sh
Page 294 and 295:
After you have honed out the inaccu
Page 296 and 297:
MACHINES With the rapid development
Page 298 and 299:
Figure 11-3.—Slant bed for CNC la
Page 300 and 301:
Figure 11-6.—A typical CNC contro
Page 302 and 303:
Figure 11-8.—Continuous-path angl
Page 304 and 305:
CHAPTER 12 METAL BUILDUP CHAPTER LE
Page 306 and 307:
Figure 12-1.—Typical installation
Page 308 and 309:
Figure 12-5.—A typical sandblaste
Page 310 and 311:
Clean, dry air is essential for pro
Page 312 and 313:
It can reduce the amount of masking
Page 314 and 315:
quality assurance function of the p
Page 316 and 317:
pass-fail. In our educational syste
Page 318 and 319:
straighten a shaft, however, always
Page 320 and 321:
Figure 13-4.—Lapping tools. has t
Page 322 and 323:
pipe in which the valve is installe
Page 324 and 325:
Figure 13-10.—Constant-pressure g
Page 326 and 327:
When you install the control valve
Page 328 and 329:
casing wearing rings, impeller wear
Page 330 and 331:
Figure 13-17.—Removing a broken b
Page 332 and 333:
Figure 13-23.—Metal disintegrator
Page 334 and 335:
Figure 13-25.—Portable boring bar
Page 336 and 337:
Figure 14-1.—Cutting specially sh
Page 338 and 339:
For example, use the following proc
Page 340 and 341:
at an angle to each other, as long
Page 342 and 343:
Figure 14-6.—Development of evenl
Page 344 and 345:
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 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
show all

Machinery Repairman

You also want an ePaper? Increase the reach of your titles

Delete template?

Save as template?