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with an average carbon content of 1.00 percent (last three digits). Navy blueprints and the drawings of equipment furnished in the manufacturers’ technical manuals usually specify materials by federal or military specification numbers. For example, the coupling on a particular oil burner is identified as cast steel, class B, MIL-S-15083. This particular cast steel does not have a designation under any other metal identification systems because there are no chemically similar castings. On the other hand, a valve stem designated MIL-S-862, class 410 (a chromium stainless steel) may be cross referenced to several other systems. Some of the chemically similar designations for MIL-S-862, class 410 are as follows: SAE = J405 (51410) Federal Spec. = QQ-S-763(410) AISI = 410 ASTM = A176(410) ASM = 5504 ASME = SA194 Unified Numbering System for Metals and Alloys is a very useful book to use when cross referencing numbers. Table 3-2.—Aluminum and Aluminum Alloy Classifications Alloy Percent of Aluminum Aluminum 99.00 percent pure Copper Manganese Silicon Magnesium Magnesium and Silicon Zinc Other Unused Numbers 1xxx 2xxx 3xxx 4xxx 5xxx 6xxx 7xxx 8xxx 9xxx 3-8 Nonferrous Metal Designations Nonferrous metals are generally grouped according to their alloying elements. Examples of these groups are brass, bronze, copper-nickel, and nickel-copper. Specific designations of an alloy are described by the amounts and chemical symbols of the alloying elements. For example, a copper-nickel alloy might be described as copper-nickel, 70 Cu-30 Ni. The 70 Cu represents the percentage of copper, and the 30 Ni represents the percentage of nickel. The following list contains common alloying elements and their symbols: Aluminum . . . . . . . . . Al Carbon . . . . . . . . . . . C Chromium . . . . . . . . . Cr Cobalt . . . . . . . . . . . Co Copper . . . . . . . . . . . Cu Iron. . . . . . . . . . . . . Fe Lead . . . . . . . . . . . . Pb Manganese . . . . . . . . . Mn Molybdenum . . . . . . . . Mo Nickel . . . . . . . . . . . Ni Phosphorus . . . . . . . . . P Silicon . . . . . . . . . . . Si Sulphur . . . . . . . . . . . S Tin . . . . . . . . . . . . Sn Titanium . . . . . . . . . . Ti Tungsten . . . . . . . . . . W Vanadium . . . . . . . . . V Zinc . . . . . . . . . . . . Zn In addition to the designations previously described, a trade name (such as Monel or Inconel) is sometimes used to designate certain alloys. The Aluminum Association uses a four-digit designation system similar to the SAE/AISI system described for steels. The numerals assigned, with their meaning for the first digits of this system, are listed in table 3-2. The first digit identifies the major alloying element, and the second digit indicates alloy
modifications or impurity limits. The last two digits identify the particular alloy or indicate the aluminum purity. In the 1xxx group for 99.00 percent minimum aluminum, the last two digits show the minimum aluminum percentage to the right of the decimal point. The second digit shows modifications in impurity limits. If the second digit in the designation is zero, there is no special control on individual impurities. If the second digit is 1 through 9, it shows some special control of one or more individual impurities. As an example, 1030 indicates a 99.30 percent minimum aluminum without special control on individual impurities. Designations 1130, 1230, 1330, and so on, indicate the same purity with special control of one or more individual impurities. Designations 2 through 8 are aluminum alloys. In the 2xxx through 8xxx alloy groups, the second digit indicates any alloy modification. The last two of the four digits identify the different alloys in the group. In addition to the four-digit alloy designation, a letter or letter/number is included as a temper designation. This designation follows the four-digit alloy number and is separated from it by a dash. As an example, 2024-T6 is an aluminum-copper alloy solution. The T6 designation shows the metal is heat treated, then artificially aged; T6 is the temper designation. The following list contains the aluminum alloy temper designations and their meanings: F O H W T Fabricated Annealed recrystallized (wrought only) Strain hardened (wrought only) H1, plus one or more digits, strain hardened only H2, plus one or more digits, strain hardened, then partially annealed H3, plus one or more digits, strain hardened, then stabilized Solution heat treated, unstable temper Treated to produce stable tempers other than F, O, or H T2 T3 T4 Annealed (cast only) Solution heat treated, then cold worked Solution heat treated and naturally aged to a substantially stable condition 3-9 T5 Artificially aged only T6 Solution heat treated, then artificially aged T7 Solution heat treated, then stabilized T8 Solution heat treated, cold worked, then artificially aged T9 Solution heat treated, artificially aged, then cold worked T10 Artificially aged, then cold worked Note that some temper designations apply only to wrought products and others to cast products; but most apply to both. A second digit may appear to the right of the mechanical treatment. This second digit indicates the degree of hardening; 2 is 1/4 hard, 4 is 1/2 hard, 6 is 3/4 hard, and 8 is full hard. For example, the alloy 5456-H32 is an aluminum/ magnesium alloy, strain hardened, then stabilized, and 1/4 hard. Standard Marking of Metals Metals used by the Navy are usually marked by the producer with the continuous identification marking system. We’ll explain the system in the following paragraphs. Do not depend only on the markings to be sure you are using the correct metal. Often, the markings will be worn off or cut off and you are left with a piece of metal you are not sure about. Additional systems, such as separate storage areas or racks for different types of metal or etching on the metal with an electric etcher could save you time later. The continuous identification marking system, which is described in Federal Standards, is a means for positive identification of metal products even after some portions have been used. In this system, the markings are actually “printed” on the metal with a heavy ink that is almost like a paint, and they appear at intervals of not more than 3 feet. So, if you cut off a piece of bar stock, the remaining portions will still carry the proper identification. Some metals, such as small tubing, coils of wire, and small bar stock cannot be marked readily by this method. On these items, tags with the marking information are fastened to the metal.
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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
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 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
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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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