Machinery repairman

436 Pages·1993·14.712 MB·English

by  Wayne T Drew, Naval Education and Training Program Management Support Activity (U.S.)

NAVEDTRA 12204-A
Naval Education and September 1993 Training Manual
Training Command 0502-LP-477-5600 (TRAMAN)
Machinery Repairman
DISTRIBUTION STATEMENT A: Approved for public release; distribution is unlimited.
Nonfederal government personnel wanting a copy of this document
must use the purchasing instructions on the inside cover.
Although the words “he,” “him,” and “his” are
used sparingly in this manual to enhance
communication, they are not intended to be gender
driven nor to affront or discriminate against
anyone reading this text.
DISTRIBUTION STATEMENT A: Approved for public release; distribution is unlimited.
Nonfederal government personnel wanting a copy of this document must write to Superintendent of Documents, Government
Printing Office, Washington, DC 20402 OR Commanding Officer, Naval Publications and Forms Directorate, Navy Aviation
Supply Office, 5801 Tabor Avenue, Philadelphia, PA 19120-5099, Attention: Cash Sales, for price and availability.
MACHINERY REPAIRMAN
NAVEDTRA 12204-A
1993 Edition Prepared by
MRCS Wayne T. Drew
COMMANDING OFFICER
NETPDTC
6490 SAUFLEY FIELD RD
PENSACOLA, FL 32509-5237
ERRATA #1 18 April 2000
Specific Instructions and Errata for the
TRAMAN
MACHINERY REPAIRMAN, NAVEDTRA 12204-A
1. No attempt has been made to issue corrections for errors in typing,
punctuation, etc.
2. Make the following changes to the Machinery Repairman text:
Page Column Paragraph Chancre
2-2 1 3rd complete Change paragraph to read as follows: "If a
paragraph dimension is given as 3.000 inches, the. . . is
±0.005 inch: or if the dimension. . . is ±0.010
inch." vice "If a dimension is given as 3.000
inches., the. . . is ±0.0005 inch: or if the
dimension... is ±0.005 inch."
5-6 1 1 Change line six to read "blotter may be no more
than 0.025 inch thick and a" vice "blotter may
be no more than 0.0025 inch thick and a."
7-12 1 lastl ine Change formula to read as follows:
40 40
= = 5 turns
N 8
11-8 2 Figure 11-10 Change top "X AXIS" in figure to read
"Z AXIS."
12-3 2 Figure 12-4 Change figure caption to read as follows:
"Powder feed unit." vice "Power feed unit."
13-4 2 Number 6 Change number 6. to read as follows: "6. Face,
center drill, and drill the end of the shaft.
The diameter of the hole should be about 1/4 of
the diameter of the shaft; the depth of the
hole should be at 5/8 inch per inch of shaft
diameter minus 1/8 inch."
13-4 2 Number 8 Change number 8, line 2 to read as follows:
"The stub should be 1/8 inch larger in diameter
and 3/8."
3. Wherever you see "Blueprint Reading and Sketching, NAVEDTRA 10077-F1," in the
text, change it to read "Blueprint Reading and Sketching, NAVEDTRA 12014."
4. Wherever you see "Navy Occupational Safety and Health (NAVOSH) Program Manual
for Forces Afloat, OPNAV 51.000.19B," in the text, change it to read "Navy
Occupational Safety and Health (NAVOSH) Program Manual for Forces Afloat, OPNAV
51.000.19."

PREFACE
This Training Manual (TRAMAN) and Nonresident Training Course (NRTC)
form a self-study package to teach the theoretical knowledge and mental skills
needed by a Machinery Repairman. This package may be combined with on-the-job
training to provide the necessary elements of practical experience and observation
of techniques demonstrated by more senior Machinery Repairmen.
Completion of the NRTC is the usual way to satisfy the requirement to complete
the TRAMAN. Learning objectives are included at the beginning of each chapter
of the TRAMAN. Assignments in the NRTC have supporting questions to help the
student learn the materials in the TRAMAN.
SCOPE OF REVISION
This training manual contains the following major revisions: Chapter 5 has new
material on grinding hand tools and sharpening twist drills, and on the selection and
use of carbide tooling. Chapter 11 has new material on computer numerical control
machines. Chapter 15 has new material on heat treating. Information on obsolete
equipment such as the horizontal turret lathe has been deleted.
1993 Edition
Stock Ordering No.
0502-LP-477-5600
Published by
NAVAL EDUCATION AND TRAINING PROGRAM
MANAGEMENT SUPPORT ACTIVITY
UNITED STATES
GOVERNMENT PRINTING OFFICE
WASHINGTON, D.C.: 1993
i
THE UNITED STATES NAVY
GUARDIAN OF OUR COUNTRY
The United States Navy is responsible for maintaining control of the
sea and is a ready force on watch at home and overseas, capable of strong
action to preserve the peace or of instant offensive action to win in war.
It is upon the maintenance of this control that our country’s glorious
future depends; the United States Navy exists to make it so.
WE SERVE WITH HONOR
Tradition, valor, and victory are the Navy’s heritage from the past. To
these may be added dedication, discipline, and vigilance as the watchwords
of the present and the future.
At home or on distant stations as we serve with pride, confident in the
respect of our country, our shipmates, and our families.
Our responsibilities sober us; our adversities strengthen us.
Service to God and Country is our special privilege. We serve with
hona.
THE FUTURE OF THE NAVY
The Navy will always employ new weapons, new techniques, and
greater power to protect and defend the United States on the sea, under the
sea, and in the air.
Now and in the future, control of the sea gives the United States her
greatest advantage for the maintenance of peace and for victory in war.
Mobility, surprise, dispersal, and offensive power are the keynotes of
the new Navy. The roots of the Navy lie in a strong belief in the future, in
continued dedication to our tasks, and in reflection on our heritage from the
past.
Never have our opportunities and our responsibilities been greater.
ii
CONTENTS
CHAPTER PAGE
1. Toolrooms and Tools . . . . . . . . . . . . . . . . . . . . . . . . . 1-1
2. Layout and Benchwork . . . . . . . . . . . . . . . . . . . . . . . . 2-1
3. Metals and plastics . . . . . . . . . . . . . . . . . . . . . . . . . .3-1
4. Power Saws and Drilling Machines . . . . . . . . . . . . . . . . . 4-1
5. Offhand Grinding of Tools and Selection of Carbide Tools . . . . . 5-1
6. Engine Lathes . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-1
7. Milling Machines and Milling Operations . . . . . . . . . . . . . . 7-1
8. Vertical Turret Lathe and Horizontal Boring Mill . . . . . . . . . . 8-1
9. Shapers, Planers, and Engravers . . . . . . . . . . . . . . . . . . . 9-1
10. Precision Grinding Machines . . . . . . . . . . . . . . . . . . . . 10-1
11. Computer Numerical Control Machines . . . . . . . . . . . . . . 11-1
12. Metal Buildup . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12-1
13. Repair Work. . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13-1
14. Gears and Gear Cutting . . . . . . . . . . . . . . . . . . . . . . . 14-1
15. Metallurgy and Heat Treating . . . . . . . . . . . . . . . . . . . . . 15-1
APPENDIX
I. Glossary . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . AI-1
II. Tabular Information of Benefit to a Machinery Repairman . . . AII-1
III. Formulas for Spur Gearing . . . . . . . . . . . . . . . . . . . . AIII-1
IV Derivation Formulas for Diametral Pitch System . . . . . . . . AIV-1
V. References Used To Develop The TRAMAN . . . . . . . . . . . AV-1
INDEX . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . INDEX-1
iii
CHAPTER 1
TOOLROOMS AND TOOLS
CHAPTER LEARNING OBJECTIVES
Upon completing this chapter, you should be able to do the following:
Describe toolroom organization.
Explain how to inspect tools for damage.
State the process used to issue tools.
Describe the use of measuring tools in shop manufacture.
Describe the procedure used to check the accuracy of measuring instruments.
Before we discuss toolrooms and tools, we’ll give certain types of jobs, it may be capable of accepting
you an overview of the Machinery Repairman (MR) many others. Your imagination will probably be your
rating. limiting factor; and if you keep your eyes, ears, and
mind open, you will discover that there are many
The official description of the scope of the MR
things going on around you that can broaden your
rating is to “perform organizational and intermediate
base of knowledge. You will find pleasure and pride
maintenance on assigned equipment and in support of
in developing new and more efficient ways to do
other ships, requiring the skillful use of lathes, milling
something that has become so routine everyone else
machines, boring mills, grinders, power hacksaws,
simply accepts the procedure currently being used as
drill presses, and other machine tools; portable
the only one that will work.
machinery; and handtools and measuring instruments
found in a machine shop.” That is a very general
The skill acquired by an MR in the Navy is easily
statement not meant to define completely the types of
translated into several skills found in the machine
skills and supporting knowledge that an MR is
shops of private industry. In fact, you’d be surprised
expected to have in the different paygrades.
at the depth and range of your knowledge and skill
The job of restoring machinery to good working compared to your civilian counterpart, based on a
order, ranging from the fabrication of a simple pin or somewhat equal length of experience. The machinist
bushing to the complete rebuilding of an intricate gear trade in private industry breaks job descriptions into
system, requires skill of the highest order at each task many different titles and skill levels.
level. Often, in the absence of dimensional drawings
or other design information, an MR must depend upon
The beginning skill level and one in which you
ingenuity and know-how to successfully fabricate a
will surely become qualified is machine tool operator,
repair part.
a job often done by semiskilled workers. The primary
One of the important characteristics you will gain requirement of the job is to observe the operation,
from becoming a well-trained and skilled MR is disengage the machine in case of problems, and
versatility. As you gain knowledge and skill in the possibly maintain manual control over certain
operation of the many different types of machines functions. Workers who do these jobs usually have the
found in Navy machine shops, you will realize that ability to operate a limited number of different types
even though a particular machine is used mostly for of machines.
1-1
Another job description found in private industry This training manual will provide information on
is layout man. The requirement of this job is to lay the tools and instruments used primarily by an MR.
You can find additional information on tools used by
out work that is to be machined by someone else. An
the many different naval ratings in USE and CARE of
understanding of the operation and capabilities of the
HAND TOOLS and MEASURING TOOLS,
different machines is required, as well as the ability to
NAVEDTRA 12085.
read blueprints. As you progress in your training in
the MR rating you will become proficient in
interpreting blueprints and in planning the required TOOLROOM SAFETY
machining operations. You will find that laying out
The toolroom is relatively small, and a large
intricate parts is not so difficult with this knowledge.
quantity of different tools are stored there. It can
A third job description is set-up man, a job that become very dangerous if all items are not kept stored
in their proper places. At sea the toolroom can be
requires considerable knowledge and skill, all within
especially hazardous if you don’t secure all drawers,
what you can expect to gain as a MR. A set-up man is
bins, pegboards, and other storage facilities. Fire
responsible for placing each machine accessory and
hazards are sometimes overlooked in the toolroom.
cutting tool in the exact position required to permit
When you consider the flammable liquids and wiping
accurate production of work by a machine tool
rags stored in or issued from the toolroom, you realize
operator.
there is a real danger present.
An all-around machinist in private industry is the
As a toolroom keeper, you play a very important
job for which the average MR would qualify as far as
part in creating a safe working environment. Several
knowledge and skill are concerned. This person is
of your jobs are directly connected to the good
able to operate all machines in the shop and working order and safe use of tools in the shop. If you
manufacture parts from blueprints. Some MRs will issue an improperly ground twist drill to someone
advance their knowledge and skills throughout their who does not have the experience to recognize the
Navy career to the point that they can move into a job defect, the chances of the person being injured if the
as a tool and die maker with little trouble. They also drill “digs in” or throws the workpiece out of the drill
acquire a thorough knowledge of engineering data press would be very real. A wrench that has been
sprung or worn oversize can become a real
related to design limitations, shop math, and
“knucklebuster” to any unsuspecting user. An outside
metallurgy. There are many other related fields in
micrometer out of calibration can cause trouble when
which an experienced MR could perform—
someone is trying to press fit two parts together using
instrument maker, research and development
a hydraulic press. The list of potential disasters that
machinist, toolroom operator, quality assurance
you can prevent is endless. The important thing to
inspector and, of course, the supervisory jobs such as
remember is that you as a toolroom keeper contribute
foreman or superintendent.
more to the mission of the Navy than first meets the
eye. If you are ever in doubt concerning toolroom
The obvious key to holding down a position of
safety, consult your supervisor or Navy Occupational
higher skill, responsibility, and pay is the same both in
Safety and Health (NAVOSH) Program Manual for
the Navy and in private industry. You must work
Forces Afloat, OPNAVINST 5100.19B.
hard, take advantage of the skills and knowledge of
those around you, and take pride in what you do
regardless of how unimportant it may seem to you. TOOLROOM ORGANIZATION
You have a great opportunity ahead of you as an MR
in the Navy; a chance to make your future more You may be given responsibility for the operation
secure than it might have been. of the tool crib or tool-issuing room. Make sure that
the necessary tools are available and in good
Your proficiency as an MR is greatly influenced
condition and that an adequate supply of consumable
by your knowledge of tools and your skills in using
items (oil, wiping rags, bolts, nuts, and screws) is
them. You will need to become familiar with the
available.
correct use and care of the many powered and
nonpowered handtools, measuring instruments, and It’s easy to operate and maintain a toolroom if the
gauges you will use in your job. correct procedures and methods are used to set up the
1-2