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 lastline 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 The official description of the scope of the MR mind open, you will discover that there are many rating is to “perform organizational and intermediate things going on around you that can broaden your maintenance on assigned equipment and in support of base of knowledge. You will find pleasure and pride other ships, requiring the skillful use of lathes, milling in developing new and more efficient ways to do machines, boring mills, grinders, power hacksaws, something that has become so routine everyone else simply accepts the procedure currently being used as drill presses, and other machine tools; portable machinery; and handtools and measuring instruments the only one that will work. 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.