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Figure 2-29.—Bisecting an angle. To bisect an angle, let’s assume angle ABC (fig. 2-29) is given. With B as a center, draw an arc cutting the sides of the angle at D and E. With D and E as centers, and with a radius greater than half of arc DE, draw arcs intersecting at F. Then, draw a line from B through point F to bisect angle ABC. LAYING OUT VALVE FLANGE BOLT HOLES Before describing the procedure used to make valve flange layouts, we need to clarify the terminology used in the description. Figure 2-30 shows a valve flange with the bolt holes marked on the bolt circle. The straight-line distance between the centers of two adjacent holes is called the PITCH CHORD. The bolt hole circle itself is called the PITCH CIRCLE. The vertical line across the face of the flange is the VERTICAL BISECTOR, and the horizontal line across the face of the flange is the HORIZONTAL BISECTOR. The bolt holes center on the pitch circle and are equal in distance. The pitch chord between any two adjacent holes is exactly the same as the pitch chord between any other two adjacent holes. Note that the two top holes and the two bottom holes straddle the vertical bisector; the vertical bisector cuts the pitch chord for each pair exactly in half. This is the standard method used to place the holes for a 6-hole flange. In the 4-, 8-, or 12-hole flange, the bolt holes straddle both the vertical and horizontal bisectors. This system of hole placement permits a valve to be 2-14 installed in a true vertical or horizontal position. This assumes that the pipe flange holes are also in the standard location on the pitch circle. Before you do a valve flange layout job, find out whether the holes are to be placed in the standard position. If you are working on a “per sample” job, follow the layout of the sample. Assuming you are sure of the size and number of holes and the radius of the pitch circle, use the following procedure to set up the layout for straight globe or gate valve flanges. 1. Fit a fine grain wood plug into the opening in each flange. (See fig. 2-30.) The plug should fit snugly and be flush with the face of the flange. 2. Apply layout dye to the flange faces, or, if dye is not available, rub chalk on the flange faces to make the drawn lines clearly visible. 3. Locate the center of each flange with a surface gauge, or use a center head and rule combination if the flange diameter is relatively small. (See view A, fig. 2-24 and fig. 2-19.) After you locate the exact center point on each flange, mark the center with a sharp prick-punch. 4. Use dividers to scribe the pitch or bolt circle. Check to see that the pitch circle and the outside edge of the flange are concentric. 5. Draw the vertical bisector. This line must pass through the center point of the flange and must be visually located directly in line with the axis of the valve stem (see fig. 2-30). 6. Draw the horizontal bisector. This line also must pass through the center point of the flange and must be laid out at a right angle to the vertical bisector. (See fig. 2-30 and fig. 2-27.) Up to this point, the layout is the same for all flanges regardless of the number of holes. Beyond this point, however, the layout differs with the number of holes. The layout for a 6-hole flange is the simplest one and we’ll describe it first. Six-Hole Flange Set your dividers exactly to the dimension of the pitch circle radius. Place one leg of the dividers on the point where the horizontal bisector crosses the pitch circle on the right-hand side of the flange. (Point 1 in view A of figure 2-3 1.) Draw a small arc across the pitch circle at points 2 and 6. Next, place one leg of the dividers at the intersection of the pitch
Figure 2-30.—Flange layout terminology. circle and the horizontal bisector on the left-hand side circle with the dividers. Each pitch chord must be of the flange point 4. Draw a small arc across the equal to the setting of the dividers. If it is not, you pitch circle line at points 3 and 5. These points (1 to have an error in hole mark placement that you must 6) are the centers for the holes. Check the accuracy of correct before you center punch the marks for the the pitch chords. To do this, leave the dividers set holes. After you are sure the layout is accurate, center exactly as you had them set to draw the arcs. Starting punch the hole marks and draw a circle of appropriate from the located center of any hole, step around the size around each center-punched mark and Figure 2-31.—Development of a 6-hole flange. 2-15
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 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
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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
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quickly cooled to and held at a som
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Available information indicates tha
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slowly from the tempering temperatu
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Table 15-4.—Heat-Treating Tempera
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Figure 15-20.—Design of a cam. A.
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In carburized steel, spalling is ca
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used to make positive identificatio
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HONING—Finishing machine operatio
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Table AII-2.—Decimal Equivalents
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Table AII-4.—Formulas for Dimensi
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Table AII-5.—Number, Letter and F
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Table AII-7.—Screw Thread and Tap
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Table AII-9.—3-Wire Method of Mea
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Table AII-11.—Circles Circumferen
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Table AII-13.—Taper Per Foot and
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p 1 I vi 2 P F \ = = a AII-16
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Table AII-16.—Drill Sizes for Tap
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Having Circular pitch Circular pitc
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APPENDIX IV DERIVATION OF FORMULAS
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(1) NT is the connecting link betwe
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Walker, John R., Machining Fundamen
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A Adjustable gauges, 1-7 adjustable
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Engine lathes, 6-1 attachments and
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Layout methods, 2-8 M forming angul
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Stub tooth gears, 14-27 American st
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