3D $7 793 SO 033 654 ROTE= Lindberg, Andrew; and Others Rints I:Aerials and Fabrication Methods I

Home , Soldering gun, Soldering iron

Docusist assess 3D $7 793 SO 033 654 ROTE= Lindberg, Andrew; And Others rints I:aerials and Fabrication Methods I. A Study Guide o the Scieace and laginuering Technician curriculum. INST1TOTION Saint Louis Coamunity Coll. at Florissant Valley, No. SPONS AGENCY National Science Foundation, \Washington, D.C. POE DATE 76 __Gam* NSF-GI-3376; NSF-NES76 -22284 -101; NSF-SED77 -17935 110T1 1314.; For related documents, see SE 033 647-657. Not available in paper copy due to copyright restrictions. Contains occasional aarginal

AVAILABLE FROM Alati nal Science Teachers Association, 17 Conn icut Ave., N.W., Washington, DC 2000 irate for c zrect price).

EDIS* PR 0101 Plus Postage." PC Sot Available from IDES. DESCRIPTORS Associate Degrees; *College Science; Engineering. Education; Rand Tools; *Instructional Materials; In...erdisciplinary-Approash; Manufacturing Industry; Metric Slates: *Postsecondary Education;- Science, Course Iaprovesent Projects; *Technical Education; *Tradeand Industrial Education _*science and Engineering Technician Curriculum IIDENTISINRS 6 A4STRACT This study guide is part of a curricula' entitled . 4 Sciencend Engineering Technician (SET) Curricular, a programof studies soh integrates elesents from thedisciplines of chemistry, physics. mathematics; aechaaical technclogy, andelectronic tecbsology. The purpose of this national. curd:casedevelopment project vasyto provide a fraaesurk fortraining technicians LI the n8of +ecironicinstruments and theiriapplipatius. This guide is designed to beused,as a supplesint to 4manufacturing processes text which deals with materials properties, heattreatment, and plastics. skills , Training La materials and fabrication methods, and in those which are useful in a technical laboratory environient, areprovided. The following topics are included in the/ text: (1)measurement; (2-) electrical fabrication; (3) hand tools; f41.) power hand tools; (5) power bench tools; and (6) metal fabricaon. (Author/SK)

**i*********44**************Ilar****,*********************************** * - RepreductiOns supplied by EDRS are the ,west that can bemade

. * * s from the original document. **********************************************************************It .Avamd2WOMmir 2.4mmood il0911. N ToriaktstionDate 14204041WPORNINT S)77 -17935 Seember 26 1971- Two _ 4. Am/attest-0f Award - itatetiels and laprfcation Methods 1: . f70,400 scum. Amt.) At'ittOr amide of the SciencetfldrIngineering TechnicianCurriculum 2.Type'w ,-,= fiha .11_1 , ' - . a. POWerm912 0,9999u9kot , 1 -- 128 pages 1SEPPredeat . St. Louis Community College at Florissant'Valley 9. Accession Number St. Louis, NO 63135 _ , 00378 h...-...... ------. 10. Perforrnkm Orwgzation it.Prlholgri Imm016.0001 Meld or 21160,0111V . Report; Number Donald RiMowery __ ., i Ilivrienbe J. moil , imerprowriumompw 13. SEINRYIplograns

-Sill O. Aldridge . DIES

. _ 4. 9111122 SmIlwagr-Imi :., , ,

. --* , M.:11616im'cl'- , Tffie stu#yguide is part of a curriculumentitled the Science andnuoinmainitVechnicilin which integrateselileflts-from the disciplines of Corti-Oulu*(err),a program of studies Me-- chinfitry, physics, mathematics,mechanical techndlogy,and electronic technology._ project was to provide a fraoomork fortra purpose of this nationalcurriculum development technicians in the use of ele4roflic instrulents-andtheir applications. . slanuf -Mats4als and Fabrication& Methods I isdOsignedto be -used as a supple:tent to a plaetices tuning predates! text which deals with taterlalsproierties, heat treatment,and materials `an fabric tion methods,-and-in thesis*kali which This guide provides training in included in the are useful in ktechnidillaboratorirtn;ironment. The folleingr topics are fabrication, (3) hand tools, (4) powerhand tools, 15) text: 11) measurements, (2) electrical power bench tools; and'6) metal fftbrication... -

St dy guides Equipment Maifttenance Iuctional Materials Laboratory Equipment late Degrees Machine Tools Sc enc. Curriculum Repair flooring Technicians

Whiodfters once and Engineering TechnicianCurriculum (SET)

91019 19. Target Audience,

nearing Education Two-Year College Students

AwiliMMNy 21. Ikepoiernerotal Notes Limited number of copiesavail:AA fromSt. Termination date includes one two month dieCommunity College at FloriasantValley, extension. One copy mss no 63135 '4 MATERIALS' ANA FABRICATIONMETHODS I

` A STUDY GUIDE OF THE SCIENCE AND ENGINEERING TECHNICIAN CURRICULUM

Author: Andrew Lindberg St. Louis Community College at Florissant Valley

Richard Stevens St. Louis Community Collegea"t Florissant Valley

With Assistance of:

Robert lie), St. Louis Community College at Florissant Valley

Rudy Walker St. Louis Comunity College at Florissant Valley.

Project Directors: BM G. Aldridge Donald R. Mowery Lawrence J. Wolf

-Study Guide Editor: Peggy Dixon Montgomery College, Takoma Park, MD

Address: SET Project St. Louis Community College at Florissant Valley St. Lbuis, Missouri 63135

Cepirright g 1976 by St. Louis Community College at FlorissantValley. Printed in the Gni States of.America.All rights reserved. This book or parts thereof may not be reproduced in any form without permission.

materials contained herein were develOped under Grant NumbersHES76-22284 A01, ;3378, and SED77-17935.

4 4. Measurements PAGE

1. Metric Units (6/) & EnglishUnits 1 2. Measuring Instruments 2 A. Length -,Iternier calipers, Scales andTapes 3 Dial Indicators 8, Angle Measurement 4 C. Speeds & Feed Rate 5 3. Layout, Radius, and Hole Gauges 7

II. Electrical Fabrication

1. Symbols and Schematics, 10 2. Coupon ents 11 3. Wiring Types and' Identification .17 4. Soldering . 47 5. Circuit Fabrication ,:, 56 4 6, Instrumentation Wiring 63

III. Hand Tools

1. Safety 71 2. Vises 72 3. Files 73 4. Hammers 74 5. Punches & Chisels & Impact Tools 75 6. Drills 77 7. Reamers 79 8. Thread Cutting 80 9. Fasteners 82 10. Gripping and Cutting Tools 85 11. Screw Drivers / 86 12. Saws 87 13. Wrenches 88

IV. Power Hand Tools

1. Safety 91 2. Hand Drills 92 3. SaberSaws 92 4. Stapler 92 5. Power Riveting 6. Nibbler 92 7. Power Saws 93 8. Routers 94 9. Sanders 94 10. Hand Grinders 94 11. Impact Wrenches 94 12. Impact Hammer 95

DEC 1 2 1980, A Power Bench Tools

96 1. Safety 97 2. Drill Press 98 3. Grinder 99 4. Band Saw 101 5. Saws 104 6. Arbor Press 105 7. Lathe 106 S. Mill

VI. Metal Fabrication 109 1. Safety 109 2. Shearing 111 3. Punching 112 4. Braking 114 5. Rolling 114 6.: Spot Welding _ 115 7. Soldering 117 S. Fasteners 119 9. Bonding & cementing

IntroduiiiOn

Materials and Fabrication Methods I isdesigned to_acquaint students with materials and tabil6ation Meihodssand skillswhich may be needed in a technical laboratory environment.Realizing many labs have limited technician types of equipment available orlimitations on what work the of hand tools, or port- can do, thecourse is'expected to stress,the use fabrication are able power tools.Safety and alternate methods of doing to be continuallystressed. included Lathe, drill.press and millingmachine operations should be repair of ac- where the industry needsbeinglilled re:40re knowledge or curately machined parts. manu- This manual should be used tosupplement a clear, easy-to-read heat facturing processes text withsections on'materials properties, treatment and plastics. I. MEASUREMENTS

COMM IMMIMWOMMtSfir lib work aro aide for lengths awe The two ecemen mite of measure are impornitterig, *sus (st) a metric spits% and English.

I. 1LENGTH - S.I. UNITS 1 METER(a) 39.37 (4n.) 1 (00ii1 OW .01 METERS int .= .3937(in.)

1 (ns) is 1(n)ii .001. NO si .03937 tin.) tPower ENGLISH Inane Symbol of 10 Pico-pf 10-12 1 (ft.) = 12tin.) .3048 (n) -'9 nano-n 10-6 1 tin.) la1 (ft)21 .02540 00 micro-u 10-3 IT 2.540 (cm) milli-m 10 centi-c 10-2 .001 (in.) .00254 (cm) deci-d loll .0254 (1111) deka-dk AG hecto-h 102 1 -YARD as 3 (ft.) is .9144 (a) kilo-k 103 mega x 1 106 LABORATORY The Maas* should knot bat to emelt unite fro* iblglish to metric mid bet* to Soglish. The prefixes Indicating powers of 10 ebeeld be Mown. I STUDENT PROBLEMS Convert each of the units using Table #1 of the Appendix.

A. 10 in.= = mm cm IL 6.3 cm = it ft.

C. 25.56 am m in. 1. CM a # II 2.625 in. = am is Manint spircifyeach of the units.

E. 2.56 meters = 256. in 2560 F 5,943400. sig 5.943 5943. 1.2 LENGTH MEASURING INSTRLDIENTS Linearmeasurementsare made with: SCAM - for larger measurements

7 H111111'111111[1

11411,41/4*-1-4 /14/11/111 2\. Jur_i_a_A ILLatta.

Nu" pst,*gnu mama1111:2 PRACTIONILL.necif

DIAL INDICATORS Micrometers for=iree measurement.

SPINDLE SLEEVE MASURING LOCK

=WINO 5.78 smi Metric micrometer reading of 5.78 mm

Vernier caliper for precise large measurements.

GRADUATE) BEAN

filtittItti4llPfltftti:2111411ifilsati ENGLISH

3 4, CLAMP SCREWS VERNIERGALIPER FOR PRECISE \LARGE MEASUREMENT Micrometer Reading

ENGLISH UNITS FINE ADJUSTING JAWS NUT VERNIER NIBS- PLATE

0.125 0.015 = 0.140 TOTAL INCHES Vernier Reading

The large #1 on the bar = 1.000 The smell #4 past 1 the #1 " x .100 = .400 ,rj "One line is visible past the #4 1 x .025 = .025 The 11th line on the vernier scale coincides with a line on the bar 11 x .001 = .011

Total reading = 1.436 in.

4k , Dialindicators and height gauges are used for precise vertical measurement.

Metric ernier Caliper

Metric Vernier Caliper Readi 47.75 mm

Steel Tapes SCRIBER for long lengths VERNIER

I 1.3 MSS __Ira laTermea =ere. The ere of an object ccaparing

PIVOT *mac uwiTs

MSS IS Ix iaLOGRAMsOW)

1 kg 7 1000 grams

ENGLISH ENGINE'S:1HG UNITS

'HASS IS IN Pow* (lb)

1 kg = 2.20462 lbs

TRIPLE BEAM SCALE

COUNTER =CERISE 1.4 ANGLES ONE ROTATION An angle is the measure of the RADIAN difference-in direction of one line or surface relative to another that interMocts it. 1 REVOLUTION Angles are measured in degrees, radians or revolutions. 271 RADIANS

-1 radian = 57.3 degrees

1 radian = 1 revolutions RADIAN - rad. 21t The radianis the plane angle formed 1 angle degree = 60 minutes ofangle by two radii gutting an arc equal in length td the radius. 1 minute of angle =-60 secondsof angle o

1/ .5.

Angles can be-measured directly with a protractor or indirectly by making length measur is using a sine bar.

ROTRACTOR HEAD

ANGLE

PRECISION GROUND ROLLERS

cl d d

souring an acute angle

Vernier Protractor 'Scale Humber of whdle deg:ees is indicated by degrees between the zero on the dial and the zero on the vernier plate. Number of minutes is indicated by the line on the vernier plate which matches a line on the dial Total reading 310--TIF

SPEEDS AND FEED RATE

Speed is a distance moved in a given time interval. Speed is also called a feed rate.

Ex: speed 10 feet 5 ft /min 2 minutes 3.05 m or .02542 m/s l20 sec ds 8 Angular' speed is angular movement in a gi en time--.- interval. it ArandAji 11.1211112Vitti 100 SPEED so 100 RPM time interval 1 minut g-val For examPle: 1,1. LABORATORY

The student shouldknow andbe CapablerOfiikihg length measurements and vernier calipers angle measurementsusing metric and English; mjcrometers, protractors;' and height gauges,scales, protractors, and vernier - STUDENT :PROBLEM

Read the micrometer, vernier and protractorscales shown;

.1 MICROBBTER

A.MIMMII01

, H.

4 3 I

sol 1.5 1./tEOLor

Layout is marking cuts and hole locations or bandsbefore making or fabricating farts. SCRIBER FollOwin; are examples of equipaient used for layout work.

SURFACE PLATE HOLE -GAUGES

COMBINATION, SQUARE Laying out parallel and perpendicular lines ith PRIG( PUNCH r.onhination square .nen the work has only one straight edge CONCAVE RECESSED CONVEX CORNER

/ CONVEX 'RADIUSI L/` RECESSED IGAUGE Alh

'CONVEX 1800 SEGMENT

RADIUS GAUGE---

US.*of V-Blocks in Layout Work Circles ars drawn on metal with DIVIDERS. 1t LABORATORY OBJECTIVESAND SKILLS having a lha atudant should beable to do a layout to two rsfaience of paratiel andparpandiaular lines relative MS and toindleato oinalas ce thelayout.

, ! STUDENT PEOSLENS A produce each of the N. Indicatethe/layout equipment necessary to

AcCircle Of 2.0 inch diameter.

of a %Two parallellinei parallel to the base block.

the edge of C.A straight line at anangle of 34°52' to a metalsheet., diameter radius D.Scribe, a rounded cornerwith a 1/4 inch tangent to twoperpendicular sides. E.Produce an accurate punchmark at theIntersection of two Scribedlines.-- Fig. Prob. 1 1.6 END OF CHAPTER' 'IEW PROBLEMS ensions in mm. 1. A drawing givc Convert the length tol inches.

1 mm = .03937 in. T 51 51 mm = 5i' mm x .03937inimm = 2.0079 in. ALi DIMENSIONS IN mm MARK THE ; 2. .DetetMinethe micrometerreading shown. READINGS.

0. 289 in. READING

MM Thk mseal' ing is composed of i 2Linograduations or 2 x 0.1001n. 0.290 in. 3 Ills.11 graduations, or x 0.025in.=0.075 in. and 14 graduations on the thimble or 14 \x 0:001 iA10 0.014 in. Totalreadps-as0.289'in. L-

STUDENT EXERCISE'S fr

Convert the dimensions frost the figure of problem 1 above Dig1J till1111111.111111/1i to English units.

18 ans in. 8inn in.

in. 21 ma in. 7 men i" .3

31 an in.

4!! Section Tmblees A.-r.284) B. (.441) C. (.400) V.(14.45)E. (4.80)

P.(9.00) 0. (7.028)H.(.8005)I.(1.795)J.(51.45)---

K. (55° 15) L.(120151)- Section1.5 Problems A. dividers scale B. surface plate height gaugeangle plate scriber

C. vernier protractor scriber t.1/4" radius gauge scriber END OF CHAPTER ANSWERS .7087 in. .3150 in. .8268 in. .2756 in. 1.2205in.

A.ANSWERS (Alt) .11.5.6j) (25.4) &ANSWERS (2.488) (.2067) (.0630) (6 (66.675) (.066675) Des (1.0063) (2.556) (.02556) misingtis (cia) F.RNSWERS (am). (km)

I .1 1)t.. .10m

I/. RIACTRUPALFABILICATIOti,

II:I Introduction r electrieal or electronicequip- ',attar understand fabricate-and/or Sometimes referred toas To assemble, eacheiatiedrawing is, necessary. ment4(hardware):i is a condensationof an circuit draining, theschematic diagram, an elementary repiesented by generallyaccepted Cymbals Components are elicirioalcircuit. routes used tointer- ozderlfsahner with theshortest possible Arranged in an' connectthese,symbold.

Witch I 40 ohm, 5 watt Resistor 0-100 ma .keter

6 V DC Dry Cell

DS1 3 V Lamp (Laini) 3 V

ScheMaticDiagram wiring Diagram

diagram in that itshii!si p at -to- from a schematic ova out- A wiringdiagram differs shown pictorally oras `pi between components point interconnections lines in theiractual locations. is important schematic diagram orwiring diagram it To understandeither the the componentsinvolved. to recognizeand understand

16 SYMBOLS 11.2COMPORIST IDENTrfICATION & SCR/MANIC

A. Resistors

The resistor symbol is perhaps the Fixed most frequently encountered,passive, electronic component. Variable The resistance is-measured in ohms 1\M-7Theos tat) and-Series to impede current flow (the movement-of electrons).

The resistor is rated in watts(power) (Potentiometer) which is a way of determining hermuch Variable current it can handle withoutburning or shorting out.

Resistor Symbols & Types

100 watt

20 watt The resistors shown in the adjacent figure may all have the 10 watt same value of resistance(measured in ohms) butodiffer in 5 watt their current handlingcapacitP' 2 watt (power). 1 watt 1/2 watt Resistors control currentflow 7 in electrical circuits.

' - 2 Watt 100it

Resistors whose power ratings arebelow 5 watts are usuallyidentified by color Above 1 Watt bands printsd.onthe resistor. S watt*, the.valueof riesistor is ,usually printed innumbers and letters. anumminumelposamwma -412, Watt

4 Watt,

Power .Resistor MD 1./10 Watt

Color-CodedResistorS MB:1=D--MIXED OTHER RESISTORCODES FOUND IML11111 1:01112:11-----

. .- . Failure Rate*, 2nd. DigitMultiplierTolerance let Digit D E B C .Color . A

, -, . 1 - Black 0 10 1 1% 1.0 1 . 0.1 Brown 1 100' * 2% 2 0.01 Red 2 1,000 i 3% 3 0.001 Orange 3 10,000 ± 4% 4 - Yellow 4 100,000 - k 5 5 -. Green 1,000,000 - , 6 ,Blue 6 - - 4 7 10,000,000 - Violet ..I 100,000,000 - Gray 8 a' - Solderable* 9 - . 9 t 5% White - , 0.1 - - Gold 4. 0.01 t10% Silver - t20% '' - - No Color , - indicates per,:ent when used oncoepoieitiOn resistors, vAdorin nand resistors, a whiteband E indicaths per 1,000hours, On film terminal. is &grapple of how to use col?r code.

Orange 7 3 I O Black - o0 a Green - ,000 ri8 0°0* Gold - tS%

10 W

Power Resistors

Power resistors, shown orl the right,are so called because they are designed to dissi- pate a large amount of power in the form of heat. Over a period of time their markings may burn off.

SOW

Power Resistors

0 4 VariAble sistors

Variable resistors make it Itible to vavarythe burrent or voltagin a circuit by vary*nq the resiStance.

The volumevontrol on your' reo . is an example of a variable re sistor.

'Variable Resistors, F Precision Resistor!

Many electroniccircuits require very precise and exactresistance.These resistors may take on oddshapes and rises to meet-thetolerinces and specifications,required. Precision Resistors

- - B. CONDUCTORS

Conductors interconnectelectronic Conductors Connected components( to forma pathfor current to flow. Conductors may be wires or 'narrow "ribbons*of metal, usually copper. On schematicdiagramsthey are shown assimple lines. Connections are dottedintersections. Conductors Connedted

Conductors Crossover (not c.innected)

Conductor SchematicSymbols (Dot System)

t. CAnductqrs on printedci cat boards 'may be byboisedwith, a tallic "paint". or etched from acompletely coveied,'cbpper-clad board. 111111

Printed Circuit .

L. /

Consideration must be given to the current, carrying capacity of various sizes of wires that may be used to interconn:Ot electronic equipment.Table I offers \ data an the current handling capacity fwiring of various sizes. / /FABLE I

. Current Carryi 4 Capacity of Conductors , ..implommly Cable Si AWG Continuous Duty Current - Amperes Si le Wire Amperes Rating of Wires in a Aluminum . Copper In Trees Air Single Conduit or Bundle // 22 -- 5 20 11 7.5 18 16 10 16 22 13 14 32 17 23 12 41 . 10 55 33

8 i 73 46

6 101 . 60 . 4 / 135 80 2 // 181 100 211 125 9/ .7_245 150

. 283 175 328 200- /000 . 225 / 0000 380 , 1 8 '60 36 6 83 50 4 108 .66

2 152. 'i 90 -1 174 _ 105 0 202 . 123 145 00 / 235 000 266{ 162 0000,' '190

Wirei in Bundles: Tables; cuBtent ratings for wires in bundles are baseduPno 15 or more wires carrying she _.than 20 percent of the total current carxpibg capacity of the bundle. smaller bundles; the allowable percentage of total current may be increased is the bundle approaChes the singlercible condition. For 20 ANG wire, example: 15 wires x 11- amps/wiris .20 gm 33 106i capacity 4' of buadle. Various coPored wire's may be used to serve differant functions. Table II is -a listing of the Military Standard (122) of colors for chassis wiring. AVG (American Wire Gauge) specified in circular mica on sizes above 0000 250 AUG 250'000 circular mios.of cross.section area. Below 0000 the MPG number is just a specific size. Table II

C4;i1dr code for chassiswiring

numerical circuit. abbrev. code . aNIMPIOMIM =.1N1.1.1=11, f rounded a extentsand returns BR Grounds filamenti off round BR Heaters of

emitters Yellow CathOdes

-5 Control rids base Greven .. Plates (anodes) collectors , Diu BL 6 Power supply,minus Violet V 7 for Purple) PR AC werlines Gra GY returns above orbelow w Miscellaneous, Whitt round AVC etc.

ca, Source:# ii Std 122.

22 Wire Types

Conductors are of two basic types: single-strand ( and sultistrand ware. Most wire used in electronics made of copper covered with some form of-insulating materia)/to prevent electrical connections with other wire and metal parts it may touch. Multistrand wire is more flexible than solid wire, .and for * this reasowit is preferred for most wiring. Because of its flexibility, multistrand.wireis also less subject to fatigue' failure produced by vibration. Both solid and multiple stranded wires are often pretinned for ease in soldering.

COLOR CODING STRIPES SOLID TINNED COPPER SOLID COPPER WIRE

PLAS IC INSULATI6N ENAMEL OR VARNISH (1)1 (a) BRAIDED SHIELD

I "STRANDS INDIVIDUALLY INSULATION TINNED .COPPER WIRE SOLID OR STRANDED CONDUCTOR (C) (d) Some types of wire used in electronics. (a), Solid hookup` wire. (b) - Magnet wire. (c) Stranded hookup wire. $d) Shielded wire.

r. somelifiria.coaxial cable ices. dt

3.81-

Skilr=lbi'loa the VOM

The'vOit-Ohmr-meter shown at the right is a vaIuahliFtool formeasuring continuity (does 06 circuit have a completepath for current to flown-, resistance,voltage, and current.

A voltohmmeter(VON). or multimeter

(voltohmmeter) or It is expected that the studentbe able to use the VOM 1. the function multimeter. ./n'particular, he/sheshould be able to describe adjust knob. of the range-selector switch,and the use of the zero

'where the rang -selector switch shouldbe set when 2. The student should know pointer deflected.. the meter is notln use and beable t explain why the meter test leads were to infinIty and then to zeroon the ter scale when the alternately opened(separLted)'and s orted together.

24 C. CAPACITOMS a.19.

A capacitor is a device for storing electric charge. In its simplest form it is a pair of I 1.-- c9nducting surfaces separated by a dielectric or (insulating) material. ,

1 The capacitor symbols at the right reflect Basic Capacitor the fact thathey are, constructed of two metal plates (usually of a metal foil) separated by la small space. The capacitaice id measured ih frac- 1 or 1 tions of farads, microfarads or pico- farads.*. Additionally, capacitors are rated according to the voltage that can be placed across their "plates" ElectrolyticCapacitors before breaking down or "arcing". General purpose capacitors represent the majority of capacitors found in electronics. or None are over 1-1/2 inches (4 cm) bang. Identifying marks are not as standardized as the color code on resistors. Variable Capacitors

Capacitor Schematic Symbols

(b) (c) (a) An assortment of general-purpose capacitor!. (a) Ceramic disk capacitor. (b) Ceramic plate (d) capacitor. (c) Microminiature 0 ceramic capacitor. (d) Molded tubular capacitor. (e) Molded' tubular capacitor. (f) Tubular ceramic capacitor. (g) High- voltage ceramic capdbitor. (h) Molded mica capacitor.

*1 farad = 1 celulomec4charge 1 volt potential difference between the plates. 1 ur - 10-6 F; 1 pr = 10-12 r, also 1 pull'. I

Capacitors have the ability to maintain(storel-an electric charge (for alimited flow since there is no cofiductor time). They serve also to block a DC current between capacitors. between the plates. Alternating current may flow back and forth

EleCtrelytic capacitors use a chemical, d.Wectric-in-the space between theplats. (b)

appTIOM: Electric current must flow,only Won* direction. When installing electrolytic capacitors be sure to considerthe "polarity".Failure to do so may destroy .-Surrountiing equipment.

Variable capacitor 2 (a) Twist-I Rotor plates Electrolytic capacitors. Variable prong -can.electrolyticcapacitor. capacitor 1 (b) Insulated-can dual electrolytic Metal frame capacitor. (a) Foil-type tantalum electrolytic capacitor. (d) Slug - Tuning shift Stator plates type tantalu electrolyticcapacitor. (e) Wax-filled Cardboard electrolytic capacitor. (f) Insulated'metal tubular electrolytic capacitor. Mounting holes Trimmers

(a)

Variable capacitors are used ''circuits which require the adjust - ment of capacitance. The two-gang Porcelain. frame Mica insulator variablecapacitors 1 and 2 are Terminal for Mechanically "linked" through the plate 1 shaft. Such a capacitor is found in radios and used to "tune" in Terminal for stations. plate 2 (b) Variable capacitors. (a) Two -gang vim% iable Capacitor. (b)Trimmer or padder Capacitor.

26 1

Hermetically sealed capacitors shown at the left use an oil or chemical electrolyte. They are also sealed to keep out moisture.. They are used in high voltage power supply circuits.

Hermetically sealed oil or paper capacitors. (a) Hermetically sealed high-voltage rectangular capacitor. (b) Hermetically'sealed bathtub capacitor.

Many different types of capacitors are used in electronic'circuits. Several of these capacitors are a own below.

A" 41Mylar is a plastic dielectric material.

g7. 22

D. INDUCTION

of,ioductors used in electronic equipment. They may be There is a wide variety DC identified' or classed according to their use. They are used in both AC and circuits- ifterent ways.

am. am. an. ...11110NIN or

(d) (a) (b) (c)

Inductor schematic symbols. (a) General symbols. (b) With fixed and variable taps. (c) With magnetic core. (d) With ceramic-type cote. a.

indicate the ::hjamitic symbols (c) and (d)(with lines above the coil symbol) The are used to type of core in the inductor. At low frequencies, magnetic cores materials increase the induced field. Ceramic cores are composed of magnetic called ferrites.

Inductance is measured in unitscalled henrys (H)*. When specifying an inductor, along with the value inductance.the _ a.dUrrent rating is usually necessary impedance and/or resistance of an inductor may also be a requiredspecification.

V-s *1 henry (H) = 1 volt-second/ampere (1 -3-)and depends on the dimensions and material of the Conductor (usuallya-coil).

.34

ls? _ .

Samples of Inductors

Powdered iron core (a) (a) (b)

Transformer -inside of can Technically rk a transformer (c) (c) High-frequency inductors. (a) Loop An assortment of shigua. (a) Low- antenna. 412) Rod,antenna. (c) In-' (b) Pi-wound r-f frequency choke. termidiatetfrequency transformer. (c) Toroidal choke. (d) Tubu- choke. (d) Oscillator coil. lar insulated chokes.

Insulated Spring metal Contacts spring Term.' dais Electrical leads buffer Insulated armature buffer Armature arm Pivot Armature Mounting bracket Iron core Coil

Motor housing_ Identificatlai label

Symbol for Above relay

2 (b)

1 Electric motors. (a) The leads receive an electrical input, while,the drive shaft delivers a mechanical output. A °deplete relay with the corresponding CL) Miniature type. schematic symbol.

DC Inductors in general are designed to produce mechanical motionand this convert electrical energy into mechanical energy.

AC Inductors are generally designed tomodify or change characteristics cf. current and voltage in a circuit. AC inductors are also classified according to _ their operating frequency.

CAUTION: Never operate a high frequency inductor at a lowerfrequency. .24- E. TEANSFORMERS changes pair of coils wountogether such that when current A transformer is a the other through one (the primary) thechanging fieldfield produces a current in The ratio of the nuer of windings in thecoils indicates (the secondary). greater whether the transformer is a"step-up" transformer (output voltage voltage lesi than in- than input voltage) or a"step-down" transformer (output put voltage). . ------PRI T

PRI SEC SEC 2r PRI (a) (b) SEC 412\,

P SEC SEC #3

(g) (d) (e) (f) / windings. (b) Tapped Transformer schematic symbols. (a) Iron core-two separate (c) Variable autotransformer. (d) Air core two separate autotransformer. (f),Air core variable coupling windings. (e) Air core-one adjustablewinding. transformer (iron core). inbetween windings.(g)Multiple winding power

Metallic containers arefrequently used for transformers toboth keep the magnetic field confinedand pre - vent ,a disruption by anoutside (a) (b) magnetic field.

Relay cases, hermetically,sealed. Low-frequency transformers. (b) Larger voltag (b) (a) Miniature: (a) Power Transformer. and current capacitywith hook Encapsulated. (t) Hermetically terminals. (c) Heavy-duty power

(d) High-voltage 1 sealed. relay. transformer. LABORATORY =Rpm - INVESTIGATING TRANSFORMERS AND INDUCTORS

Thestudent should be familiar with inductors and transformers. In particular the student should know-the difference between a transformer and a choke, in what aspects the con cf.a relay is similar to the coil of a choke, and what parts of an indmetor are not included in their schematic symbols. The student should bi Mae to describe what continuity tests could be made on inductors and transformers. T. Mean= CCONICTIONS

Often electro-mschanicalsystems are encountered where it is desirableto show both electrical and mechanical cceiWatlons. On vultematic drawings mechanical connections, enclosures,and shielded caponamtsare shown by broken lines. 3 12 4 6 7

RELAY

al sobdilif PAUL rr.1

280

MOTE411mNIMIPO CONTROL SWITCH Ganged Capacitor's Autopositioner

Relay Circuit

P J

Multiconductor DPDT $j.tcli Enclosed tiiniformer CI

G. SEucoubouroRDEVICES: devices which arereferred to broad classesof semiconductor and There are three These are thediode, transistor, -frequently assolid-state devices. that these devices.' Solid -staterefers to the fact in a ed circuit 4IC) jam:time which are"fused"--roljether with, dorrimueistain contents or There is no"gap" between f Vinln_ench assilicon or germanium. soldookuliating electrodes such as arefaxnUlmecuum tAbes". vacuum tubes. replaced- all but -a_few "specialized" Semiconductordevices have now devices becausethey devices axe sometimescalled "actives -- These solid-state prescribed manner. used,to control currentflow in some are J.

1. Diodes: are a varietyof semiconductoi deliices it thediode.' One of the simpler direction of current flow,called rectifiers. thesedevices for controlling the

Photodiode Zener Basic Diode or Rectifier

Temperature Sensitive Silicon Tunnel Vafactor Controlled Rectifier

DiodeSchematic Symbols Small Signal Diode

Power rectifier

ToityY Duty Power Weeks Parr Diiode Dr> Microwave Diode

A few of the variety of sines and shapes of diodes are 'how above. Specifications fordiodes usually call for a voltage (often a peak inverse voltage PIV) and a taavent rating.,

IASONATORY

able, . The student should -have enough familiarity with semi-conducting diodes to be to measure their resistance todeteraino if they-are good or bad, to identify the anode and cathode, and to determine the allowed direction -o_f current flow._

2 -Transistors: A transistor is a combination of several semi-conductor crystils bonded together. \ft serves as an electronic device for amplification and/or control. Transistors amain a variety of shapes and sixes. :gncept for very specialised devices for handling Power and high frequencies, ftiansistorized" circuits are being packaged in micro-miniature devices called integrated circuits.Power transistors which may control large currents mist be used with heat sinks to conduct heat awayfrail the solid-state junctions of dissimilar semitonductore and metallid contacts.

Collector

Emitter

Pni P-Type PIT N'TYPID FIT Basic Transistors Field Effect Transistors Drain 4(X Uni -Junction

Transistor Schematic eyebolts Small Signal Transistors \xx

Ppwer Transistors with Heat Sinks PaWU !transistors

Sat-Stiii " Power output transistor Lfr

When specifying transistors,, severalparameters must be considered. of these are-abort -circlait current transfer ratio, cut-offfrequency, input indand output impedances, voltage, and temperature,

LABORATORY

The student should have somefamiliarity with transistor leads, andconfigurations. Specifically, the student should be able to make anoutline drawing of the'base of two different types of transistor packagesidentifying the emitter, base and the "key" found on collector leads for each. Re/she should be able to explain most T0-5 transistor packages, to-name three materials used inthe,c4natruction of transistors and to knee( the advantagesand disadvantages.of usingsockets with transistors. 3. ;111teitrated Circuits fel aite%selid state devices since there is no gap between materialsand electrodes _0: contacts. They are the fastest growing circuit devices beingdeieloped today. -They are' not simple, *discrete" compoeentslike-the onespresented thUs far. Symbols Miry widely, but generally ere simple outlines or bloCkswith the device cuMber and letters presented as deten4ned by the senufaCturer. f

Integrated Circuit SchematicDiagrams

, .

je6the technology of IC's continues, it becomes less important to!show the detailed Circuit!. within. It is within reason nowapurchase an LS1 (Large Scale Inte- grated Circuit) which can perform almost any desired circuit function. Diserete components such as transistors, capacitors, resistors anddiodes are losing ground to the *microminiature* solid-state devices. H. Schematic Symbols

We have seen thus far only a few varieties of perhaps ahundred or so schematic symbols. Shosmbeloware a few more of the mire frequently ueed systole. P J PHONE JACK 040.14a selector switch/ 'PHONE JACK ballOst tube ,1:3712 wr MALI FEMALE, SLIDE SWITCI! KEE!PHONEJACK fluorescent lamp, Oo two-Urbane-1 PHONO JACK 14106 71t MULTI-CONT CT fluorescent loop, SWITCH four to SHIELDED 91" PAIR cold-Cathode glow SHIELD lamp, a-c tyype SHIELDED WIRE cold-cathode glow COAXIAL wafer (example shown: SHIELD 3-pole. 3 cifrcuit with 1emP, d-c tip, 2 nonshortingand 1 sm. Eswi COMMON shorting mooring contacts) incandescent GROUND lamp POWER .SWITCH S.P.S.T., WIRES SHIELDED -411- BETWEEN TWOPOINTS SWITCH PILO'S We S.P.D.T.

PUG RECEPTACLE SWITCH (I) (1) D.P.S.T. NEON LAMPS MACRINE ROTATING- 6ib push button, circuit METER 0 motor closing (make) 41,10 PLUG push button, circuit

POWDERED-IRON ' opening (break) CORE INDUCTOR1 METER genets'

RELAYS CIRCUIT BREAKER ANTENNA(AERIAL(

symmetrical FUSE OR NO phot6cOnductive 11. 11transducer 4_11AkINAL BOARD ONE CELL OR Ltr OR STRIP --AO:"A" BATTERY , GOMM PUOMPKONg photovoltaic MULTI -CELL. OM ,transducer "B" BATTERY 1"1400' PIEZOELECTRIC =MAI ri Sian multiplieF phototube general .:1(plosive 49.

*tit. integral beater igniter tOP x-ray tube with internal-1y Control grid

heater sensing }ink 0"+

x-ray tube with grounded with integral insulated shield heater TiMERksTOR heater-4101 general -e-- senicaductor double -focus x -ray tube thermocouple, temperature with inteeiral heater with rotating anode Measuring 40 054 semiconductor thermocouple, current mitasuring VACUUM TUBES cathode-ray tube, electrostatic deflection 3-Element Vacuum tube 4triode)

cathode-ray tube, magnetic pentode deflection

THEMBOSTAT twin triode equipotential cathode CAPACITORS

ticermostat: with make split stator -4 contact_, 4 OBI 4 -"1-1347" cold- cathode voltage regulator dual electrolytic thermostat withintegral heater and transfer- cil. contacts vacuum photottUbe Tb For examp The Student should be ableto identify electronichardware. following component should "ole able to draw theschematic symbol for the ,CAPACITOR LAMP BULB, NEON

LAMP BULB, CAPACITOR, ILLUMINATING ELECTROLYTIC

k; CAPACITOR, METER VARIABLE

CRYSTAL, RESISTOR' PIEZOELECAIC

RESISTOR, ADJ. (POTENTIOMETER,

SWITCH, SPST OR rem

. INDUCTOR

'JACi, PHONO SWITCH, ROTARY

TRANSISTOR TRANSFORMER, IRON CORE

TRANSFORMER, ADJ. POWDERED IRON.CORE POWER-TRANSFORMER

33 -33- J. lefrence Designations

To help recognize schematic eyehole and to be able to` list components on a parts list, components are usually assigned a letter and number. The following list gives soave of the more commonly used letters used to designate componenti.

Commonly accepted names are lowercase; names thatarestandard items in Federal serviceare capital letters.

ecePlerometer A COUNTER, ELECTRICAL INDICATOR (except meter or thermometer) DS ADAPTER.. CONNECTOR CP COUNTESPOISt, ANTIENA inductor alarm DS COUPLE!. DIRECTIONA.. DC instrument mapaifier( except r,tating) AR coupling (aperture, loop, or CP INSULATOR AWLIFIRLI, MAZNETIc (except, probe) rotating) AR crystal detector (SINICONDOCTOR Interlock, mechanical OW DEVICE, DIODE) CS amplifier. rotating interlock, safety, electrical -(TPlulating generator) G crystal diode (SEMICONDUCTOR inverter DITTOR-GENZRATOR) S DEVICE. DIODE CR AWITINA E inverter, static, (DC'to AC) PS AMBESTER, LIGHTNING E crystal diode, breakdown VR isolator AT assembly A crystal unit (SEMICONDUCTOR lack DEVICE. DIODE) CR AVTIMUWOn (flea, OR -juntion (coaxial or wave- guide) CP VARIABLE) AT crystal unit, piezoelectric (CRYSTAL UNIT, QUARTZ) junttiOn. hybrid NY audible signalling device as A KEY, TELIVRAPH S BUZZER: RINGER, TELEPHONE cutout. fuse (FUSE CUTOUT) SIREN,- SOUNDER, TELEGRAPH cutout, thermal LAM, FLUORESCENT OS

T INS auto7Eransformer DELAY LINE DL LAMP, GLOW ballast tube or lamp detector, crystal (SEMI- LAMP. INCIUIDESCENT DS (RESISTOR. CURAENT- CONDUCTOR DEVICE, DIODE) Ca lamp, pilot (LAMP, INCANDESCENT, AVEHJVPING) NT device, indicating (INDICATOR) LAMP, GL M) DS barrier photoJell V except meter or thermometerDs lamp resistance RT battery BT dipole antenna (ANTENNA) lamp, signal.(LAMP. INCANDESCENT: bimetallic strip E disconnecting device LAMP. GLOM) OS block. connecting (TERPUISAL (connector, receptacle) LAWHOLDER BOARD) TB disconnecting device line, artificial V (connector. plug) P blocking layer cell line, delay (DELAY LINE) DL S blower (FAN, CENTRIF(X GAL) 17 disconnecting device (switch) loop antenna (ANTENNA) E ELECTRICAL CONTACT E discontinuity. (usually co- WiU.. EOUDSPEAKER LS axial or wave-guide BUS transmission) z MAGNET, PERMANENT cable assembly cable DYNAMOTOR MG mechanical part MP No.1h connectors) lI ,ELECTION TUBE V meter capacitance bushing ac Mt equalizer (NETWORK. , MICROPHONE CAPACITOR EQUALIZER) mode suppressor CAVITY. TUNED FACSIMILE SET A node transducer MT BT cell. Wattery fan A modulator A cell, light - sensitive, photo- filter ' FL enlealVe (PHOTOELECTRIC CELL) V MOTOR B flasher (circuit interrupter) DS choke coil MOTOR-GENERATOR MG frame MP CHOPPER. ELECTRONIC mounting (not electrical frequency changer (rotating) circuit, not a socket) MP , CIRCUIT BMW CB MSS ," neon lamp (LAMP, GIOW) DS coil. hybrid HY FUSEMOLDER NETWORK, HYBRID CIRCUIT HY ',OIL, RADIO FREQUENCY GAGE (meter; thermometer, network, general (where COIL (all others not classified 'train gage) specific class letters as transformers) do not fit) gap (horn, protective, or sphere) E A COMPUTER oscillator (excluding elec- GENERATOR 0 'O LECTOR. PLUG. ELECTRICAL tron tube) GYROSCOPE MP CONNECI046 RECEPTACLE, ELECTRICAL J magnetostriction Y Hall effect device COPT ACT. ELECTRICAL OSCILLOGRAPH HANDSET CIS contactor (manually, mechanical - OSCILLOSCOPE 1Y, or thermally operated) hardware (common fasteners, etc.) H pad (RITINUATOR, FIXED) AT contactor (RELAY, ARMATURE, head (ERASER. MACATIC, HEAD, pert, miscellaneous electri- MAY. SOLENOID) SOUND; with various modifiers) PU I\ cal' converter (rotating mach*le) MG HEADSET, ELECTRICAL HT part, miscellaneous dechani - CORE, ADJUSTABLE TUNING, CORE. HEATER HR cal (bearing, coupling, ELICPPONaGnE7, core, inductor; gear, shaft, etc.) MP HORN LS core, Amory, core, trellis., part. structural MP roper hydraulic part HP -3 a

games shittimg Ranier! taper, citadel or waym-gwido T S DIDTUERS.SSIORS-CISURIDIG) llllliR A V plototglo ONIORIELRCPRIC CELLI A pickup, erasing head; drafting Pt/ ISINSNRL 6m44J/ideal) 4601,Pdeducing TERRORL MOD Ts LI OA. 'flectrieel PLt1G. SIRCARICA,LP terilieaties. relistiet AT S TS Ft T, sinolia < block

PtAidir inflater(ISSISVON, teet paket (Sot ectually a re- YebtAlrzsI tenors designation) Tr Puma APPLY P S then deter nr Air OR arse core) I. 1111111000UPLE TC ssztIva. SA010 RE thers generator PS readmer. tabiplioue headset TNIMMOsTaT SinclisCAL) NIA INdEE! timer. electric receptacle (namsettor. statics- transiting, NT ary.portioa) transducer. mode Rt 4 recorder, elapsed ties Tomposninn T REOZADAR, SOUND A', TIMISTIrros "recordist unit tVOOMMiellian path noting* limnicOmmeroi onerzcs. a 010021 CR Ishlwrrniz. RADIO rectifier (corpleta poor toed circuit I Ps supply omit/ twister. anootrical (RESINTOR. NO' RV reed. vibrating VoLThat SENSITIVE) ANEOLP4D1.. VOLVOS foolvdss varietor, adyemmtrick tube regulaterel V 0311CPCIOR swim, DUCE; rectifier, metallic) CR oiler (aLsr. AMARIONI. slAY. AOLSODIDI relay, need, molar- VIARNVOR. IIISTARPTIO lR solid-state) vino' ifignsllieg device as vissips:ms AR voltage regulator (IIRCOLATolt, A VA lermasOcsn, 'VOLTAGE) AT V resistive CS NAYS GOIAS P = ABSINVON wsys-surce runs (plain) sT IESISTOR,=em InGuLwrins VAVE.SUID6 PLAMOr (choke) ISSINVOR, MIDI= V Sesinne. VIRE OR CAALE RV Oesisits.VOLTAGE SANSITIVA

resolver(SYMCHRO, RESOLVER) resonator (gNVITY TONED) I "MOSTA? rotary jot (microwave) e SATORAILE olteium cell (rectifierl CA sensor (transducer to electric poor) A shield. electrical shifter. phase (NETWORK, ,VMASS-CMANG.NG Mort looerlal transmission) =Orr. serrnunnsr lip ring (RING, ELWTIICAL ACT) SR I

sofe4oid OSOLENOID,ELSCZ14- CJ141 spenur (1AU0SPEAKER1 1.S ELECTRIC SQ squib. implosive Sc strip. terminal (TERMINAL MAIO) Ts structural part NP 1 aubaneobly A

P OTTER $ 4

a -35- For example, given the The 01%;41ent should be able to Identify schematicsymbols. pastor .mopply schematic below he/sheshould identity mach component. ri Ti r _-

Ot-4't)4"

P1 CR1 Cl

Ti CR2 C2

CR3 C3

D61 CR4 R.I. -

R2 Si CR5

Jl CR6 R3

J2 "'he student should also be able to Identify electronichardWare by performing the fr)_lowing; dimensions for a 1 watt 1. Lis.ing the catalog provided-r-giVe the physical carbon resistor:-

2. Using the catalog provided, find the cost(per each) for a DP3T slide switch if you purchaie in quantities of200 switches.

following components. 3. List two manufacturers for each of the

Resistors

pacitors

Connectors

Transistors

y Transformers

_ (subminiature) rf inductor 4. List all the information found on the smallest with a 0.75smicro-henry value,

of the uses of potting materials. S. Prom the catalogue provided, list some

4 45 41 Wirminals and Connections

Mire are many terminals and types of connectionsused to assemble electronic components.

1. Solder terminals

#41f4 HOLUM WG

4 e FLAT HOOK BIFURCATED FEED-THHG

Terminal styles for component boards. SPACER 41U (c) (a)

COMPONENT BOARD

INSULATION (a) (b) (b) Types of terminal boards and (d) ZCHASSIS terminal strips. (a) Solder- type terminal strip. (lb) Board mountintmethods. Terminal board. (a) Plain bracket. (b) Special bracket. (c) Spacer. (d) Insulation plate. 00' soldering All of the above terminals holdelectronic components in place by their leads in place.

4 21.7 -37..

2. Solderless Terminals

As the name implies, solderless terminals do notrequire soldering. Examples of solderless terminals are shown below.

Rarely are wires simply connected to screw type terminals. They usually are crimped to a terminal lug.

Hole for wire

Hole for screw Screw Terminals

40-

Hole for wire

Hole for screw

Crimping tool

For rapid assembly and bread-boarding, plug-in boards are very vsluable tine Step StepStep savers. 1 2 3 Solder or Crimp Soldrlese, Test wire lead Terminal Crimp Lug

( Flexible wire

. \Test clips The use of a crimping tool.

. 43 -

Wire-wrap is now a fairly widelyUseid method for making several permanent connections im a very compact space. Shown at the right is anassembly that makes maximum use of solderless connections.

squaxshaped ter- Wire-wrap tool shAting how endof tool is inserted overthe the square terminal shaftmust bersharp to minal. At least two corners of "bite" into V-Ae wire for a goodconnection. ,

We can expect to see more newtools on the market every year forspeeding up the process of makingconnections. On the right is a new tool called a"Wiring Pencil" for making fast connectionson a breadboard. LABORATORY

The student should know how to make a solderlessconflation using "a crimping tool. Be /she should know advantages and disadvantages' of using solderless terminal lugs, 4 types of solder meerials, and what is wire wrapping.

3. Semipermanent Connections - Cable Connectors

limn semipermanent connections are desired between majok units of electronic equipment, Connectors of the types to follow are of great value. The variety -- often INSMS endlesslike all other components_of electronic hardware.

Flat Cable Connectors

eAlM; __Printed Circuit CUM Connector- Plugs & Jacks AL-Al Miniature Connector

Coaxial-Connectors

yrswila Miniature Connectors Rack and Panel

The characteristic of "push-pull" coupling tofacilitate making and breaking make the tae of these type of connectors veryconvenient.

46 41.

identifying the pins in Winiatiire connectors requires a wordof explanation., Its the diagrams below.

Start of Alphabet

Line: Indicates That a Letter is Missing

Broken Transition Between Capitals, Lower Case and Double Letters he 'aver- Expanding Orbital Sequential Typical _Diagram of Alphabet Identification lumbering System

Connector failures of the'minature connectors are relatively infrequent, but when they do occur it'is usually because the contacts are not properly seated (locked) into place.

The assembly of connectors with individual pinsand matina contacts is aradually `giving way to the flat cable and coipatible connectors with permanent contacts that are mated (connected) to the fiat Cable wiring by means of a special tool. The tool forces away' the wire insulation and' makes contact with the wire inside the connector. Unfortunately, ahy change in wiring must,be made on the opposite side of the flat cable connector - within the unit being connected.

41 73 3. alstemalrimg coaxialConnectsins place the centercontact in the Crimping conductoi of tool. Insert the center the cable in the contactcrimp barrel so that the insulationtouches the back of the oontact'and compressthe crimping meciti They" anise, completing thecrimpcyCla. crimp tool is designed so tat the = will not be releaseduntil a couple perfect crimp has beenmade.

a Crimping Sleeve 4. the center Seal Two series of 4indents secure 41, of the co- Retainer N contact- to-theinner conductor strength exceeding C Crimp axial cable with a Protection Sleevethat of the cableitself. (60/ Teflon eeve

1 sleeve Place the crimping protection sleeve "C" retainer Push the crimp "S" and the seal center contact andunder the coaxial over the crimped nut "A" over conduc- the exposed portionof thehouter cable. tor of the cable. Inner Conductor Inner insulation Outer Conductor Outer Jagket illi....10sli 1--- 2 6. sleeve "D" over thecrimp Prepare thecoaxial cable Push the Teflon contact ridge. in the mannerillustrated, contact and past the hold the contact according ",:o theindicatedTo accompliih this, 1/4 sleeve slowly into dimensions. front and push the its position. Crimping Sleeve 7. assembly through the Seal Insert the entire shell and tighten Retainer Nut back of the connector This widi-DOr the seal retainernut "A". Note: Use of hot wire alignment of theinner con- stripper is recommended.mit automatic ductor.

11/ 9/16 on all cables upto .110 overall dia. L 11/16 on all cables largerthan --I.115 overall dia. Irm111.mill -1g . The eraser is valuab in cleaning contacts on printed circuits and other "exposed" !,contacts or'terminals.- The knife is useful in cutting or scraping materials where the diagonal cutter does not sees to fit the job.A pair of toe-nail,clip- pers are found'in the tool box of experienced electronic technicians. They are mid to clip smalriares.- especially the excessive lead lengthson component wires .vben =hinting on printed circuit boards.

The soldering 'aid is used to hold a wire or component lead in place while soldering or in removing a soldered connection. They may be purchased commercially; however, the best solder aids come from discarded dental tools.

DENTAL TOOL

Dental tool soldering aid. The thin curved ends are ideal for holdingsome- in place while soldering or prying up leads whenunsoldering

valuable specialized tools aimineeded for specific jobs. The heat, gun shown is used for attachingheat shrinkable plastic tubing to exposedcon- nections. Special heat shrinkable connections arenow available for use where criiping\"was formerly used. The special holding fixture nr vise shown will hold a printed circuit card in almost any position to makeit easier to repair or modify a circuit.

°Holding Vise Variable Heat Heat Gun Soldering Iron

The variable heat soldering iron is usefulwhen a variety of soldering require: ments are encountered. The required heat is dialed and ina short time soldering can begin on either miniature or large terminals andconnection:3.

49_ Soldering Irons soldering / is availabl . The correct type of A large selectionof soldering irons rateac- soldering task. Solderingroman are primarily iron depends upon the For conveniencethey the 'amount-of heatthey prod . cOrding to wattage-or larie in'"pencil","pistol grip" tglan),or an "wand" with fa4ly are produced soldedng irons arereferred and perhapsaole handle. The pencil and gun type oopvenient for smallelectronic equipment. the right amount Ofheat primary importance becausejus The wattage rating is of damage components test is very important. Too much hea, may or the soldering too long to melthe solder,and again being soldered. Toolittle heat may of time which maybecome sufficiently damage the,00mponentbeing soldered because electronic component. long as to conduct toosuch heat into the the A for soldering a number20 AWG wire to As a general rule,the wattage rating than 50 watts. solfer4terminalishown earliershould not be higher variety of will require less heat. Printed Smeller terminal* andsmaller diameter wires discrete components such astransistors, capacitors, circuit boards containing of 25 watts should never be exposedto heat in excess resistors, diodes, etc., circuits The smaller connectionsfor integrated f-----7-3451rimesthoin about 5seconds. wattage -a110 o* 15 watt solderingiron. At these lower (IC) may require on] because of the closeproximity to ratings the pencil typeiron is preferred itself which is mucheasier. 'adjacent connectionsand control of the iron

from heat. Tip Heating Element Handle with protection

replaceable parts. The Soldering"Pencil" Iron showing

REPLACEABLE TIP SET SCREWS CIAMP CONDT.I0TORS TIPHEAT GENERATED HERE OF TIP ASSEMBLY

HEXAGONAL THREADED FITTINGS SECURE ssT IP

PRWARFANT HEAVY HEAVY CONDUCTORS BRAZED CONDUCTORS PERMANENT PART COWNSCTIONS PART OF TIP AsSEMBLY OF GUN The Soldering Canshowing replaceable tips.

14 Jeftof the soldering gun should be limited to temporaryrepairs of larger components and connections.

The e,of the tip of a soldering ironis determined by the type or shape the tip should beones of connection being soldeied. As a' rule the shape of to that provides the greatest surface areaof contact with the connection be so large as to damage be soldered.At the same time the tip should not adjacent components or connections.A variety of tip shapes arepresented below.

(a) C=1310 t C_1a) . (c)

(d) O (e)

(f)

Fig. 14-3Common soldering tip shapes. (a) Pyramidal.- (b) Beveled. (c) Chisel. (d) Tapered chisel.(e) Conical. (f) Pointed chiselz.

copper alloys#niiTirdguently plated with gold, Tips of soldering irons are These tips should never iron or nickel to preventoxidation of the'copper. be filed or sanded. LABORATORY irons, and in the use oftypical soldering familiar with their use. He/she The studentshould be associated with know thesafety precautions for a specific 'articular should power ratingand heat necessary should know therelationship between job.

N. Tinning molten solderalloy spreading of athin layer of 'inning is definedas the preheated. previously beencleaned and over asurface that has permit the maximumtransfer of soldering iron mustbe tinned to The tip of the connection to besoldered. tip to thejoint or heat ftom the to 'removemetal- plasticized resin orweak acid used flux used in,tinning is a -oxides from thesurface of metals.

Tip. Tinning theSoldering Iron

sponge. 1. Lightly dampen p soldering ironand allow, 2. Plug in the it to get hot.

the sponge. 11- Wipe the tip on with a flux coreto 4. Apply solder thetip. solder off onthe 5. Wipe the excess sponge. wipe This process may moist sponge to Inspect thetip. Use of a 6. times soldering iron. have to berepeated several the tip of a from the to removeall the oxides soldering irontip.

iron tip willbe 7. The ooldering film tinned. when asmooth Aim tip. can be seento cover the LASOMATOMT

The student should be able to tin a solderingiron. He/she should know why resin is used during tinning.

0. Soldering

Soldering is the process of uniting two clean metalsurfaces with a thin layer of a third metal alloy. In this process the correct amount of heat, theappli- cation of a flux, and the type of solder must be considered-

For electronic equipment, the flux is aplasticized resin. The flux is necessary to remove metal oxides from the surfacesof the metals to be soldered. Never use an acid as a flux as it willeventually dissolve the copper conductor.

Solder is an alloy of tiii andlead. For electronics, an alloy of 60% tin and 40% lead is normilly*ed. For convenience, wire solder used todayhas an inner core of the resin flux. As the-wire solder melts on the heated metal surfaces,'the flux runs out of the solder cleaning the surfaces so that the solder will penetrate ,e metal and form agood "joinevr connection.

The amount of solder used on a joint is as important as the fittingtogether of the-two metals to be united. The diagrams illustrate the correct methodsof soldering wires to- terminals and to printed circuitsolder connections.

./mportant aspects Of soldering include having adequate work-space,good lighting and a well-ventilated room.

53 --; 1. Soldering Defects: dullchalky, or crystallized as COLD SOLDER: Theconnection appears movement of the joint asit the result ofinsufficient heat or cools. solder on the wireattached to the terminal EXCESS SOLDER: The thi kness of of the wire. should be no more thanone-third the thickness terminal should be As a rule, theoutline of the wire and visible. connection of the This products anuncertain union or INSUFFICIENT SOLDER: vibration. metal parts and maynot hold up under the thin coatof flux The metal. parts maybe joined only by RESINCONNECTION: been applied, andthus even thougheufficient solder has will separate easily.

2. Wire Connections: R important to "strip* insulation from wires tobe connectedfit is In removing the 4 the wire withoutdamaging it. insulation: for stripping liresof their There are essentiallythree major methods and pulling itoff the wire. ,Nechanical cutting the insulation it from the plastic insulationto remove herpal. heating and melting the wire. insulation in a chemicalsolvent. Chemical -dissolving the

t- WIRE GRIPPERS STRIPPING KNIVES

HWK-UP WIRE GRIP WIRE ADJUSTABLE STOP -FIRMLY IN HAND POWER CO

Thermal wirestrippers". strippers. Examples ofmechanical wire These will not nicktheconductors Imseuzion &HUMled sine sandpaper Color Coding stripes covered wire

rj Exposed wire strands

.Correctly st4pped wire Removing enamel insulation.

Insulation Ink eraser Tinned solid lead . torn off Broken wire strands eo*"

licked wire strands . Wire strands

4 spread out Incorrectly st.ripiled wire Cleaning componenttinned leads.

Cover and support Preparing Shielded Wires for Soldering with sleeving Ground wire or electrical tape Braid strands Solder Braided shield Braided-shield

Insulator

Irierconductor (a) Awl (a)

Ground Lead Ground wire

Insulator Cover and.support compression type, Inner conductor sleeving crimped. connector (b) (b) (a) Combing the braid strands. k`taching the groundwire. (a) Solder - (b) Use of the braid strands for ! g the ground wire. (b) Crimping the ground lead. ole ground wire. -50- LIN

Stripping a shieldedconductor by pulling out the centerconductor through the shield. (a) Bunch the shield near hole the jacket. (b) Carefully open a where the shield hasbeen gathered, (c) Bend the wire asshown. (d) Work the center. conductorthrough the hole. (e) Breakout complete;center conductor is completelywithdrawn.

3. Mounting and SolderingComponentp For good mechanicalsupport all wires should wrap aroundterminals. The standard practice isto wrap a lead . _Component leads least three-fourths around a terminal at use the upper of a turn, but notin excess of one section complete turn.

Wrap shall be: 3/4 turn minimum 1 turn maximum

Terminal board Smooth bends

1/16" Minimum

PPI 1.14*

1/32" Minimum 1/8" Maximum

'Requirements for mountingtubular Interconnecting wires components onterminal boards use the lowersection

Specifications forwrapping wire around turretterminals. P / c 32" Tight wrap 1/8" Maximum 1/32" Mini 1/8" Maximum overlap

Tight wrap 7 Mo overlap

Wrapping a wire around a hook terminal Wrapping a wire on a flat to 1 when approached from side.

R = 2 x LEAD DIA:

X= 1/16 + 1/16 + 2(R) +D+ COMPONENT BODY LENGTH

BEAD

\\ Bending MA Mounting Components 1/32" Minimum on a Printed CircuitBoard. 1/8" Maximum

Semiconductor diode All strands-- inside of pot plited through hole 11114411=W. 1/32" Maximum Pad Bent lead

Mounting a stranded wire in solder pot type terminal. 1/2" ikximum LABORATORY the have enough practice withsoldering techniques to answer The student should following:. sandpaper is used whenremoving enamel insul- 1. What will happen if a coarse, 'ation?

when the diameter of a wireconductor is reduced? . 2. What haSpens to the current 4 electric current if a strand of awire in a conductor 3. What will happen to the is broken?

objectionable? 4. Why is torn insulation Yarn how to remove solder from asoldered joint? (/ 5. Why is it imnortant to know soldering. 6. State the advantages ofusing resin-core solder for

soldering iron be placed underthe soldered joint 7. Why must the tip of the when removing solder?

in a tinned conditionwhen\unsoldering 8. Why mustthe soldering iron tip be a,. joint? disadvantages of a solderingaid. 9. List the advantages and in removing solder with a copperbraid. 10. Explain the procedure involved cut a resistor in halfwhenreplacing it? 11. Why is it acceptable to

12. Describe a printed-circuitboard. printed- be observed whenmounting a resistor on a 13. List the specifications to circuit board. disadvantages of aprinted-circuit board. 14. List the advantages and /7 -53-

P. Assembly Techniques

The use of integrated circuits (IC's)and digital circuits is rapidly changing the techniquesfor assemblying electronic circuits showi equipment. The maze of wiring and panels of in the figure below are going tngive away to a maze of wiring and the small integrated circuitpackages all neatly arranged on a small plug-incircuit board.

m a 1.1

5 kr R. Tools specialized tools anelectronic. technician While there exists alarge variety of be most useful inbuilding or re- needs, the followingbasic hand tools will aid,.most of. With the exceptionof the soldeting pairing electronicequipment. _these toolsshould be quite familiar.

SCPSWDRIVER

IDNG-NOSE PLIERS

mommommmak

4'4"dr PENCIL SOLDERING IRON WIRE STRIPPERS

a+, 1.0 RULER

for the beginne, of these tools willbecome obvious even the value and use of most Omitted from the basictools when attempting to work onelectronic equipment. shown is a phillips orcross-point screwdriver. - sm. 60 .II....- 45- 1 1 Minimum Miftilmmsra4ius 01;031"

Bonded Copper foil

Heat cannot be transferred 1/10" Maximum by point only lapinated Component Clinched lead ttleetic should Improper application of heat. touch board `Mounting Components on Printed Circiit Boards. Moteshape of 'Abider. Solder

Solder

Heat sink Gaps Hot Edge of insulation wire Would not be burned I

Cool wire . 1 Solder should not be used Diode to fill gaps. Coarse appearance Using II heat Mink to avoid damage not acceptable to coMponents while soldering. I t terminal End of solder flow Dull finish Clean solid , Bright wire lead finish

Too much Solder .

Contour of wire ;1; Stranded wire is visible ""A%-medfl _ ,*.

e; Solder tapers % Runover not Insulation off acceptable

Proper Contour soldering. Improper soldering results. t

replaced The large, involved circuitsof the recent past are being shown below.. by the breadboard andproduction IC circuit boards insulation-with copper conductors and A breadboard is aplastic sheet of The plastic is reinforced components mountedthrOugh holes in the board. with glass fibers or cloth.

Production IC CircuitBoards Plug-in IC Breadboard

1. Integrated CircuitAssemblies: from The great redtctionin space resulting interconnection problem the use of IC'smakes the because of the numerous,closely more complex with the spaced connectionleads that must mate "flat packs" or"DIP" IC packages. Interconnection or wiringdrawings and schematics take newform - generallywith circuit' less information asto the complex that may be insidethe IC. A-a SERIAL AWCONVERTER TRANSMITTER THERMOCOUP The diagram showli at the 'right is aremotely monitored and controlled heating procegs with. four IC's' (t0 the right AMPLIFIER of the Digital fetal-nil). DIGITAL The only discrete circuit TERMINAL- HEATER elements_are the heater, relay and thermocouple., DOFF RELAY 110 V ' 60 Hz

Circuit diagram for an automatic/manual heater control.

2. Printed Circuit Assemblies.

Printed circuit boards are usually production assemblies, however, the simplicity with which they can be made make their use valuable even for-prototypework. A,printe4 circuit board (PCB) is a plastic laminated board ofglass- epoxy, bakelite, or phenolic resin upon whichribbons of copper foil have. been etched or conductivepaint ptinted to form conductors interconnecting variouselectronic components. To etch a copper clad PCB, the following steps are taken.

a. Clean the Copper Clad Board with Ammonia Persulfate 209 and air dry.

b.; Apply Iodak KPR4 Photo-Resist in subdued or yellow light.

6,3

_ 04. Dry in an oven for c. Bake the Photo-Resist approximately 250 seconds at atemperature not to exceed 260°C. d. Expose the preparedboard in,a photo-printer (ultravioletsource)/ through a photo negative mask of the desiredcircuit.

Develop the photo-resistin Tri-Chloro- Ethylene (trade nameTriad). with f. Rinse off theunpolymerized residue running water.

g. Dry gently withforoed air. copper by immersingin a h. Etch the unwanted solution of ferricchloride.: A Pyrex dish may be used. The solutionshould be heated and the trayagitated gently.

Cut or trim theboard to size, drill i. strip holes for mountingthe coMponents,then copper' the polymerizedPhoto-Resist from the -surface of the remainingconductors. components and solder to j. Finally, mount the the PCB connectors.

Preparing the photo-negativehas been simplified through the lice ofadhesive aids. As shown in the simply lays out thedesired circuit. figure below, one This making space only forthe size of thecomponents. photographed to obtain master art workthen should be the photo-negativemask.

6 DONUT' PAD

TEARDROPS TWIN BLACK NO SMEAR PADS PRESSURE SENSITIVE TAPE Universal/

corners ,

Laying out master artwork with precut adhesive Crafting aids.

3. PCB Component Mounting &Soldering

Generally, components areflush mounted to-the-PCB. Component leads are bentand formed as outlinedearlier under Mounting and w Soldering Components. The following figureswill also help in'asspOblyingcomponents on,PCB's.

4. STRAIGHT THROUGH - leads run'through board. -without bending or crimping and are cut to length. A fikture oef some kind is usually necessary to hold component in place during soldering.

SPACER - the same as "StraightThrough," except that a standoff or spaceris used to keep the component parallel tothe board and to provideinsulation.

OFFSET - used when thespacing of the leads on a component is too closeto accommodate the desired terminal area,or to allow adequate room forconductors to pass betweenterminal, areas. Leads must be formed tofit.

SPREADER accomplishes the semi purpose asthe "Offset" configuration,while providing support andinsulation.-

-///,/,/7//I,//

_ the board, INVERTED - componentis- fastened to eliminating the needfor a holdingfix- ture duringsoldering. This method provides support forthe component 414_ m and reduces strain- onthe leads.

of CLIP OR HEAT 'SINK -combines the advantages component supportwith heat dissi- pation. Terminal"area locations arr: restricted only by leadlength and spacing requirements.

- -

422. 6t"40 .:1 ft **!..

. -0646. ANIL SURFACE - leads are formed and STAGGERED - leads are formed in a trimmed to size. A_holding fixture staggered pattern and inserted in is usually necessary while leads are the board. This method ptoVides Moldered. clearance between terminal areas to allow for conductor paths. -DUAL IN,-LINE ,PACKAGES

44.411111111L

STANDARD - leads are usually flat, "PLUG-SIN"- receptacle ismounted on but terminal areasare selected by printedcircuit board and soldered. calculating the,leed as if it were The component is then plugged into a (.508mm) diameter wire. -he receptacle. Useful where IC's ,nay be interchanged or replaced often.

CLINCHED Component leads may be bent over or "clinched" or simply placed straight into the drilled hole in the PCB. Note outline of contour solder connectioLs. STRAIGHT viRouGH 2. Touch the solder to the iron, the 1. Place the tip of the solder- foil, Jand the .wire at thepoint where. ing iron firmly against thecir- Remove the solder as soon wire or they meet... cuit board foil and the as it begins to meltand flow; then -lug to be soldered. remove the iron quickly.

3.' Check the' connection; a good,solder .joint should look smooth andbright, and the solder should adhereevenly to both the wire and .thecircuit board foil..

4. After the solder has hardened, clip off the wire close to the circuitboard foil.

If solder is accidentallybridged between two foils, it can be cleaned off by heating the connection carefully, and quickly wiping orbrush- ing away, the excess solder with a soft cloth or brush.

Plugged holes may be clearedby heating the solder over the hole while, gently pushing the lead of a resistor through the.holefromthe other side; withdraw the leadbe- fore the solder rehardens 6n 4. Component Layout and Assembly Experience has proven that an orderly layout of components pays in circuit performan :e. If components are hap-haard inarrangement shorts may develop or unwanted"feedback" of signals may occur. The figures below show component layouts.

CORRECT INCORRECT

Perf-Board Breadboard

60 CIRCUIT PATTERN COMPONENT LA OUT

Printed Circuit Board with component layout on one side and circuit pattern on reverse side.

5: Cable and Connector Assembly

While flat conductor cables willnot eet every connection requirement, theconvenie ce and wide use makes them worth considering_her

Cable- iring Diagram Flat //I Conductor A Cable ! E JlPl.

Rigid Nylon ileconnector connector

Flat Conductor Cable Connectors

97 I

Connector Assembly Tool

Heat Shrinkable Tubing

Fluxed Solder Ring Sealing Insert

4011°1'

Solder Sleeve Repair Connector Flat Conductor Cables and hccessories

Types of Connectors -66-

TB 144-B2 12149/1-B4

re-- tE14/3-B5 WIRING F

" R14 TB 12/2-B4 HARNESS r-- l TB/14/2-B6 R145/3 -B7 / R101/2-B9"/

r COLOR CODE ---- w m 0 'BLACK 1 BROWN ,2 RED 3 ORANGE 4 YELLOW 5 GREEN 6 BLUE TB1 7 VIOLET 9 WHITE

Wiring Harness "HighwayDiaqram" using American NationalIdentification system. Screw Type terminal terminal board lugs Twice cable diameter Mine

Cable ties

Nylon Cable tieskeep wiring harness orderly

.7 9y -67-

Spot tie-/

Protecting a cable from damage.

Plastic sleeving Mounting bracket

Slot

6. Insulating Aids: ; Often it is necessary to mount components without allow- ingthe part to make electrical (a) contact with the chassis. To do this, insulators of different types are available. Four such aids are shown at the right. (d) Insulating Aids: (a) Porcelain standoff mounting support (b) Rubber grommet (c) Fiber shoulder washer (d) Plastic N sleeving.

7. Chassis

Generally it is desirable to mount electronic components in a protective box or "chassis" to ( L-4keep out dust, oil, moisture and avoid shock due to exposed connections. Today it is not necessary tb form such adcontainpr from sheet metal because several mairafacturiers make chassis in many sizes and shapes.

7 -68«.,

From large cabinets andspecial assembly techniques to miniature boxes one can now simply sele5t a suitablechassis for packaging electronic hardware.

to a particular Laying out components in achassis is generally not restricted application. The shape, size or terminal locationexcept as required by the organiza- figures below are examples of twochassis lay-outs. One has a better for the application tion of components than theother - both are probably good of-the equipment.

Iw U Chassis Lay-Out P1

The chassis Layout above (an explodedview) was made from the PowerSupply Schematic below.

To make a cOmplete electronicassembly some or all of the followingdrawings may be required.

a.) Schematic diagram z' b.) Component outline drawing (size &shape )cf components.). C.) PCB layout and connector pattern. 75 IA% -70- d.) Aessmbly drawings of PCB and chassis e.) Layout drawings of chassis, panel, etc. f.) miring diagram, cable diagramiring harness, etc. g.)' Installation drawing \ 9. Potting Compounds and encapsulating:

The potting and. encapsulating of components and electronic assemblies provides protection from moisture, dust and displacement during shock and vibration.

The difference between potting and encapsulating is the method of application. In potting,the component or assembly is completely encased. The potting material in liquid form is then poured into the encased hardware where,it soon hardensor cures. In encapsulating, the component or assembly is- simply coated in a viscous liquid that also hardens.

Before encapsulating or potting,moisture is removed from components or assemblies by heating or baking in a vacuum.

Examples of various materials used for potting and/or encapsulating electronic hardware include:

a. Epoxy resins

b. Polyurethane resins

, c. Silicones (silicone rubbers1

Occasionally these potting and encapsulating materials Will have "fillers" added to them to decrease the amount of material Tyquired or to improve the thermal conductivity of/thecompounds.

Electronic components and assemblies are not easily repairable once potted or encapsulated.

Lower density compounds called "foams" can be used to reduce the weight associated with gotting components ana assemblies while still providing mechanical support and electrical benefits. .These foams are made of the same materials mentioned earlier but with an agent that generates a gas in the compounds while curing. -71-

hand tools are smi11 tools, whichart. hand held and operated.

111-1 HAND TOOL SAFETY REQUIRES PROCEDURES AND EQUIPMENTWHICH MINIMIZE THE CHANCE OF ACCIDENT

Proper procedures and equipment include:

1. Proper tool use.

2. Proper tool adjustment.

3. Proper holding of work.

4. Protect sharp edges.

5. Proper wearer protection.

6. Properly maintained clean and organized workarea.

7. Proper safety glasses worn.

Proper state of mind, being relaxed andnot hurried.

9. Pxoper cutting tools sharpness.

Proper equipment and uses are describedon the following pages.

111.2 LABORATORY

The student should know proper maintenance,application of hand tools, and operator practice to promote safety whenusing hand tools. . -72-

41-2 VISES

SwivelVise

Do. I

1. Use soft brass or copper caps to protect part held.

Clamp work tight.

3. Tighten swivel.

4. bolt dawn-solidly.

Do Not.

1., Turn handle with pipe extension.

Pound handle with hammer.

3. Heat work between vise jaws.

4. Pound on hardened jaws with hammer punch orchisel.

Woodworkin9 Vises

Mount vise to sturdy support. J.

04 2. Wood faces mount on jaws. 3. Do not over tighten by pounding on handle. 11 th)

5 LABORATORY

student should know proper vise uso.y and correct manner to hold work.

111-3 FILES

A file is a steel tool with a rOligh, ridged surface for smoothing,

grinding or cutting. .

Do.

1. Hold file level during stroke.

2. Clamp wiirk securely.

3. Keep file teeth clean with file card.

4. Use handle on tang.

5. Keep cutting teeth free of oil.--....%\

_6. Keep files separated to prevent dulling of cutting edges.

7. File with long slow strokes. Do not force file.

8. Apply pressure on forward stroke and remove on return stroke.

FILE CARD

O HANDLE

For smooth finish and For finer finish for hard materials soft materials For rough finish and t-materials-

For finer finish for For finest finish harder materials

LABORATORY The student should file plastic, wood, and metal parts using a variety of file types. The student should know file nomenclature and use.

AA -74- III-4 HAMMERS

A hammer is a tool for pounding,usually with a metal head anda wooden handle.

CLAW HAMMER

Claw

For wood work. Head Tight Handle smooth and not cracked For striking soft and rounded edges steel or iron nails.

Hard Face should be smooth and flat. BALL PEEN HAMMER Peen should be smooth to prevent marring of metal.

owZrice.01041 For striking punches or 9111044...c setting rivets. (face) -"w--Smooth Head Crack Free Handle For forming metal. (peen)

Face should be smooth and flat.

'SLEDGE HAMMER ,Rounded Edge NOTE: Hardened head should not strike hardened material. Head Handle smooth and 0 not cracked For driving steel wedges. Smooth Flat Face Head Tight For driving wood or steel posts. Hammers should be held at the far end of handle, and one hand at head which moves to rear -to finalize stroke. SOFT FACED HAMMER

Head Tight Safety glasses should be worn.

Soft face for striking hard objects without marring. Smooth Handle inspect all hammers for loose Soft Caps Secure heads and broken handles.

LABORATORY The student should know typesand proper use of hammers.

/t IT .r) runelu:;, ChInols .1nd TinpoelTools tools N11 atp edge. le.eptcuting oncutt For Metal or Plastic

PRICK PUNCH 31 toolshaVestViking For marking centers. All flat noctacks Otooth with sxltface elips. CENTER PUNCH Anreie a

For making large 9d center punch nark.

For driving out pins:

FLAT CHISEL For cutting soft netal rivets or sheet retal.

ROUND NOSE CHISEL For cutting grooves or keyways.

DIAMOND POINT CHISEL For cutting square corners.

CAPE CHISEL For cutting grooves or keyways.

For Wood

WOOD CHISEL For cutting rectangular recesses in wood for hinges, locks, or openi-rigs.

WEDGE For splitting boards or separating heavy wood pieces. -76-

Striking facelkapt smooth and free of cracks. r

Driving Tools

Hand impact driver for removingcoded Rotation or tight epoxy bonded,thread screws and on impact bolts.

,rStriking pin face

Handle Hand guard ring

For driving studs in metal, plastic, masonary Driven Stud or wood.

___,Striking face

For cutting new gaskets from rubber, Handle plastics or composite materials. , Gasket Cutters

LABORATORY The student should know- uses ofpunches, ,Ihisels, and impafl tools in fabrication technues. ECI.6 DRILLS produce or enlargeholes in or throughmaterial. Drills are used to (Tables of drill sizes The Uxills may be hand oxelectric powered, are usuallyposted in the lab.)

drill gauge. A dr2,11 size ischecked for size us'_ng a

Drill sizes areexpressed by the followirm series.

METRIC - "3rn(0.1181-in, diameter) to-/trm(2.9921-in. diameter) 0 or-Drill Gauge

INCHES AND FRACTIONS '_/64 -in. to 371/2-in. diameters.

NUMB:RS- #80 to#1 (0.0135-in. to- 0.2280 -in. diameters).

LETTERS - A to Z(0.234-in. to 0,.413-in. diameters). Drill Index

Cutting Straight Flute Edge -Shaak Sadnk types are:

Straight for Handdrlills )and small drill presses.

. ,

raper for largedrills.

Square tangfor wood. or,

Special drills or bits formetal, plastic, wood, and masonry include:

Dole saw with pilot drill PA' oP/ 1" to 6" size.

Power drill '11) Wood bits For 1" toljlucnes in dtareter. --- Counter ink 4 Body 1:oo0 Tits, for ;'arid Erace Standard -4 -- Pilot drill 1" up 1". Sdew pilot 4 drill for flat head wood screws Exliarsion type Cminter sink 1" to 3" Power masonry GIMMOMMMM=7. Drill nit,, Carbide Tipped for Brick and 4==m-7% Concrete. 4ET2=7: o Angles of 60 and 90 0 are also made.

Spot fay and counter bore

Shank Pilot

Rotate slowly Hand Masonry Cutting1,4a* Star Drill

LABORATORY Point of the Star Drill The student should be able toidentify and use drills fbr metal, masonry, plastic, and wood. He/she should know the safe use of drills indoing fabrication of partS.

SECTION ITEMS inches. 1. A D size letter drill has adiameter of (.24C) 1mm. 2. A D size letter drill has adiameter of (6.248)

drill a hole with a diameterof 3. A mei.ric drill of 14 mm will inches. (0.5512 inches)

to but smaller than 0.1480inche? 4. What number drill size is (26)

A drill size chart should-bestandard equipment in all shops. 111.7 REAMER

Reamf,r-, are prf.ct,Lon ground citter that remove up to 1/32 of ATI inch of materlul from th diameter of a hole to produce u round, straight, smooth hole of,I,ecific size. Hand reamers have a square end. A reamer 1-, fed through a hole 1/64" to 1/32" undersize. Turn reamer slowly using cutting oil. After full cut is made withdraw reamer from hole without rotation. Rotation on removal. will cut a spiral groove. nand Reamers have a square'end. Hand Reamer Power Reamer's Imm1Chucking,Reamer

AJANNEEEINO Adjustable Reamer Nuts Move Blades s

Screw Expands Reamer Body ill----611011"Expansion Reamer

Special Reamers are Qii1=1=3Roughing Taper Reamer made to.

ut tapered holes fo. holding taper shank rills and pins. -Enlarge holes in sheet metal. -.Remove burrs from hole edges. -Produce precision holes Taper Pipe Reamer to to foot. in metal and plastics. -Match holes intwo piepes by reaming on assembly. thite Taper shank Length00(1Y-----4`

Margin Blade Land?or 'E dv Clearance -Lemd Angle A le of chamfer Margin

Rake Angle Reamer Parts Fake Angle and Right !land Rotation Shown

LABORATORY, c

ThrE tudent snould be able to identify and use reamers in lab prodects by and reaming holes in metal and plastic. The student should be able to distinguish hard and power reamers. The student should match reang for dowel pins on assembly of critical paits. Tee Wrencb

Ili.8THREAD CUTTING

Thread cutting is the process of forming internal,, Hand Tap Wrench threads (tapping) or external, -.threads (using, a die). Hand tapping is done with one Bottoming Plug Taper of three tap shapes depending on the depth of hole and depth of thread in the hole. Oil is used to lubricate the tap and remove "chips. The hole size to be drilled ,called "Tap Drill Size" and the standard thread specifications are available in nand books. Ta 'ps are turned with a-tee,wrench or hand tap wrench. Care must be used to start tapsstraight in the tap" drill size hole. A bottoming tap cuts full threads to the bottom of the hold which isfirst tapped with a standard tap.

Starting Jeepest Standard Thread_i\ Eiternal threads are cutvising a die and die stoLk. Standard>hread specifications and rod outside diameters are specified on published thread tables.

Have tarstraight.

Food to he threaded .

.iland Die Stc)c4

...... Adjustable Die -81- Cutting Oil

Thread Cutting Pipe threading Die Turn

Pipe breading requir a tapered' Pipe thread t obtain Alignment a seal. e standard Sleeve to pipe taper is 3/4" per start die foot and the sizes are straight shown in Table A with 0, the outside diameter (0.D.) Turn tap with Pipe to be aid the tap drill size. hand held tap threaded held twist handle to Pipe Vise wrench. in Pipe Vise cut deeper ti Pipe Tap

Turn Clause ' Chain Pipe Vise

Schedule 40 Pipe Dimen ions Rotate to s...4! Standard Table A zw

Always lubricate thread Dimensions in inches. Thre d's Tap , - "-Drill cutting taps and dies. Actual Actual P-..! Size' size Outside ,In h Size

De not force - clean 1/8 .270 .450; 271 11/32 out chips often 1/4 .364 .540 18 7/16 3/8 .494 .675 18 1.9/32 __J./2 ____.413--.-8440 14 23/32-- 3/4 .824 1.050 14 . 15/16 Pipe is specified by 1.048 1.315. 11 1/21 5/32 schdule which specifies a 1. standard wire tnicknes:. 1 1/4 1.3P0 1.660 11 1/21 1/2 and dimensions. 1 1/2 1.610 1.900 11 1/2'1 23/32 2 2.067 2.375 11 1/22 3/16 2 1/2 2.468 2.875 8 2 5/8

LABORATORY

The studeit should understand threading and tapping procedures and should gain familiarity with standard hole and thread sizes using standard threading charts.

SECTION ITEM c

1. A 1/2 inch by 13 threads per inch tap rer:uires what'tap drill size?...... - (0.450) r_ -82-

III-9 FASTENERS Tt- or more parts may be held together withmechanical fasteners, such as bolts, screws, rivets, retaining rings, dowel pins,keys, and adhesives. Selection is based cn application, ease of assembly and cost. Bolt length equals thickness of Bolts are used to fasten parts material to be fastened plus 1 1/2 together which may later be taken thickness of nut. apart. Use mottinery hambook to -,select head shape, diameter, length, -- LENGTH- -1 4.4:LENGTHpH and material. Tap Bolts II DIAMETER 41\1\\II BODE BODY IV Round Head Flat Head Stove Bolts, SCREWS --- Machine Screwse Set Screws Bolt Heads V 111Round Points HexagonHexagon "Cup Head -Head C) filii\ Round Thumb Ii Screws Carriage Flat i Bolt Fillister .Macnine Stud Colt ;Lead aHanger Oval Dog Head timmomp Vicasmp IIII Cone /FlatHead Round Head +al Head Wood Screws WASHERS Bolt

Washers are used asa bearing surfacefor bolts, screws, and nuts. They distribute the loadover a greater area and preventdeformation. Bolt Lock Nut INIIT Nut Nut4' AMCZE:qp---Lock Washer

tiat 11 t1 al Double Nut andFlat Washer Washer Spring Type Use of Lock Washer NUTS used to-scr-m on boltsand studs. The size is determined by the diameter of the bolt or stud on which itscrews Its shape will match the bolt with which-it is used. Cotter Pin

.4--

Wing Nut Castle Nut Square Pexagon

Cap or Acorn Nut achine flerel., Nuts Jan Nut )IIntern/Ili Cotter. pins are used tr,'lock castle nutand slotted ,its in plfce. Jam nuts are thinner than standard nutsand are used to lock -a.standard_nut in place. Cap nuts are for appearance. External-Internal

63* 0.83.0

ILI.9 SCREWS

Self tapping and thread forming screw-1 form matingthreads by squeezing or displacing material as they twist and cut into holes. They are available in various lengths, head styles,'body diameters(according to screw gauge numbers), and are manufactured from many 'metals. Self tapping screws may be hand or power driven. They are hard, and their use eliminates the needfor tapping holes.

I-4

Drive screws are made of hardened steel with multiple DRIVE SCREWS' ZrT, threads and a pilot nose. This thread forming screw, when driven fnto a pilot hole slightly larger than its pilot end, forms chip free threads by displacing material within the hole arid makes a permanent fastening in metal, plastic, plaster, and other materials.

TYPE U DRIVE TYPE 21 DRIVE cz m. SCREW SCREW" c Ntli 8O gCOUNTERSUNK RIVETS- are soft metal fastening pins wpich may be hollow, solid, or split and are used tb make permanent assemblies.They are available in vari s sizes and head shapes, are s't by hand or machine while cold or hot. Po rivets, drive pin rivets and explosive type rivets are examples of special rivets for unique holding conditions.

q* t43'

0,°;' d#0,0

POP RIVET 4 RIVET SET SETTING TOOL RIVET SET

MANDREL BREAKS FREE

RIVFE PEEN IS DIA OF RIVET ,RIVETING BLOCK

80 -811- RETAINING RINGS

Retaining rings are fastening devices for external andinternal applications. Most retaining rings are seated in grooves, while self-locking type rings do not require a recess. Special pliers are used to install and removetherings.

DOWEL PINS

Dowel pins are used to hold two mating parts (gars.on shafts) and support a major part of the load placedpon the composite unit. Most pins are tapered and fit into tapered reamed holes of 1/4 inch per foot.

Pratt and Whitney Key SE GibKey /WOODRUFF KEY

/Square KEYS

Keys are made' in several shapes and used to prevent a pulley or gear fromrotating on a shaft. One-halfof_the_ key fits into a keywayinthe shaft while the ocher-half fits into the pulley or gear. KEYWAY KEYSEAT GIB HEAD KEY

ADHESIVES

One fastening techniqueutilizes a load bearing bona which contributes to the strength of the structure: Thisrmechanical bonding sometimes yielids a point stronger than the materials being joined. Adhesives require a clean surface that mate,

ktid us, bachining, drilling,etc., are el inated. The surface must be clam an,fit properly before applying the adhesive. The adhesive may be sprayed,,dipped, brushed or rolled on the mating surfazesbefore assembly. Some applications require pressurefor curing, others cure by evaporation.

0-(j III.10 GRIPPING AND CUTTING TOOLS

Plit.,rs are to be used forgripping, twisting, or cutting. Pliers are designed for many Locking pliers special applications, but shouldbe used on :ion - machined surfacessince they may mar the -nirface.

Hand gripping tools and their usesinclude:

Clamping parts or turningtight studs. Combination or slip joint pliers Holding parts to be soldered. Turning fasteners. Bending or cutting wire. Wire cutting, bending and Linemans pliers insulation stripping. Turning wire connectors.

Holding small parts, cutting and bending fine wire-. Straight needle-nosed pliers

Cutting wire close to a surface.

Diagonal pliers

Bending solid wire without nicking surface for electrical eonnections.

Round-ncse pliers- Gripping large diameter tubing, nuts, pipe fittings, or parts. (Normally used for plumbing.)

Curved joint pliers Cutting nails, wire, and small bolts.

End cutting nippers Expanding small retainer rings.

Snap ring pliers Stiippinc insulation from solid or

standard electrical wires of , aluminum or copper.

Wire stripper )1,1,11,....1111110011

Cutting steel bolts And wire aslarge 7,1gall. as 1/444-to 3/8". Wire and bolt cutter .

..e -86..

AIM . 11 SCREW DRIVERS Do. Use screwdriver A screw driver is a / size that just fits Handle screw head. chisel shaped tool Keep screw driver with a blunt end to properly ground. fit into the slot in the head of a screw.

Screw drivers are designed Hollow Ground to install and remove screw fasteners. Screw drivers may have Square for turning spring clips, magnetic blade with a wrench. or split blade to hold screws for positioning in hard-to-reach places. Split blade may be damaged bytoo much torque. Improper Procedure Shank

Phillister Phillips inflating Prying Hammering handle with wrench Standard Blade

standard screw blade types 44,

Offset*, Screw driver screw drivers for socket Autonr.tir: for tight places set return screw driver Jewelers screw for fast drivers for installation small screws removal of screws -87.. ni.12 SAWS Hand saws are designed to cut metals, plastics, and wood. Handle Hand saw cutting bldes are Adjustable Frame designed to cut with a steady light pressure on the work piece. Maximum cutting speed should be 60 strokes per minute. Faster seeds dull the cutting edges and cause rougher Blade surfaces. Tightening Screw and Nut Downward pressure is applied HAND HACKSAW- on forward stroke only. For cutting metals

Cutting edges should have fine enough teeth to prevent hooking on the material being cut.

Correct method ,f holding hacksaw

Bad Good

Teeth PerInch 'Metal Thickness 18 up`o 1/4" 14 1/4" to 1/2" 10 V2" to 2" 8 ?"to larger Jewelers Sa Blade

For fine cuts in metals

p" Blade

A special blade milde from tungsten carbide is used Cross Cut Saw for very hard materials. for cutting lumber to length Blade--)P- Key Hole Saw for small ppenings in large pieces Tungsten carbide made fastened to small wire Hacksaw// for holes in largef metal or plastil sheets. -88- Adjustable Wrench DZ.13 WRENCHES

A wrench is a tool used for turning -nuts, bolts, pipes, etc. Box Combination Wrench End

Open Wrenches are used for turning End fasteners or parts by pulling toward the body. Wrenches are in metric sizes (mm), fractional sizes (inches) and whitworth (English). Box End Allen Wrenches should always be kept Wrench Wrench clean and fully engaged with the item to be turned. Partial engagement causes damage to the wrench and the work piece. Bad

Special wrenches include:

-Adjustable wrenches for turning nuts, C bolts, tubing couplings of various Pipe Wrench . sizes. Always pull against solid jaw. Box and open end wrenches of fixed size to turn square or hex head fasteners with great force. qmimism- Allen wrenches-to turn cap screws or

-' Allen head screws. Torque Wrench Pipe wrenches to tighten pipe-or-pipe couplings in asse Torque wrenches to measure torque applied to rotate a fastener. Strap wrenches to hold or turn round or irregular shaped objects. Strap Wrench Spanner wrenches to turn large diameter or hollow parts and fasteners. Socket wrenches to get in hard to reach 90°, / Force areas and speed installation or removal Angle of fasteners such as bolts. Torque = Force x Distance Socket Wrench Set

. 40-0M0 Ratchet Extension 8.9==m-k----17=e1E:5411 Breaker Bar 0 Universal CI Deep Socket Coupling Socket 9 111.9-13. LABORATORY

The student should.be able to choose and identify fasteners and use them in assembly. ffe/she shoul be capable of identifying, selecting, and using. a number of grpping and cutting tools. The student shoulddevelokknowledg of identification, selection and use of screw drivers._ He /she sh uld develop knowledge of identification of types of saws and e application of various saws to fabrication work through pro ects with Wood; plastic,, and metal. The student should learn theroper use of wrenches_while fabricating or servicing an assembly 111.14END OF CHAPTER PROBLEMS

WORKED EXAMPLES

1 A 5/1E-18 thread is to be'tapped in a hole. What tap drill size is required? Use thread table and find the thread specified. Read to the right and find the tap drill size of--P A letter drill of size F would be used.

2. A 1/8 inch pipe is to be threaded into abrais connector. What tap drill size is required? Look at table A of Section MI.8 "Standard PipeDimensions". Find nominal pipe size of 1/8 inch. Read to right to tap drill size column. Tap drill is 11/32 inch.

STUDENT PROBLEMS

1. An adjustable wrench ( )does, ( ) does not, mar the head of a bolt which is being turned. A toolbox for a lab technician who doesassembly, wiring, and pipi'g work might have which of the basichand tools pre- in the chapter. 1. (Name 14-15 items)

(Linemans pliers or long nose pliers, visegripping pliers, Phillips screw driverset, standard screw driver set,adjustable wrench or open end wrench, hammer and pin punch, Allen wrench set,file, drill set, pop rivet set, jewelers screw driver set, hacksaw, assortmentof fasteners, wire stripper.)

3. Hand toolsafety requires: (PROPER TOOLS) (TURN OFF POWER TO EQUIPMENT BEINGSERVIctD) (PROTECT SHARP EDGES)

I (CLAMP WORK AND HOLD TOOL WITH TWO HANDS) mm diameter 4. A drill of 17/64 will drill a hole. (6.747 mm)- Iv .1. POWER HAND TOOLS -91- Power hand tools are small hand -held tools, operated using mechanical or electrical power

1. Safety

Power hand tool safety requires procedures and equipment which minimize the chance of accident. Best safety practice is to use proced res and equipment which require a minimum of two faults to cause i jury. .Before use, look for danger points andpossible /cases'where safe guards may not be functioning. Power hand tools may be electrically, hydraulically or pneumatically,(air) powered. Electric cords or lines tc the tool must be kept clear of moving parts of the power tool. SAFETY PRACTICES Good tools When you feel p .ductive Good mood and rested Plenty of light Clean work area Dry ground or area Know equipment When not hurried EQUIPMENT SAFETY OPERATOR SAFETY

Automatic Shut Off Wear ear plugs for pneumatic tools. Reinforced Two Handles Wear safety glasses. Wire

Hold power (N Rol1 up 0$11111041 tool with shirt two hands srfNr:\ry,,,. Keeppower11104641 when possible. 4/1 \ cor clear. --;-._-'.: ,.. 7 Blade Support work Guard and clamp down Slip clutch when possible. Stand in steady

to minimize kick position with . back- feet apart to brace against Wear rubber soled kick back. -4- Grounded safety shoes. Plug electrical / doubly-insulated Electric cord or scuff system to prevent electro- resistant air line. cution of operator from a ground fault.

Tools must be strong and rigid enough to prevent breaking or binding. ZV.2 Hand Drills -92--

Hand Brace Jacobs Chuck

Hand Drills

Electric Pneumatic

IV.3 SABER SAWS 3"" Teeth'

Saber saws are used to cut steel, plastic, rubber and woods producing intricate curved open2ngs or holes using a reciprocatin blade. Metal and_thin work is cut using a fine' tooth blade with 32 teeth/inch. Wood' and metal 1/8" or greater 14 teeth/inch.

IV.4 STAPLERS

Staplers are used to fasten together wood, paper or fiber with wire staples or nails. A spring driven hammer drives the staple into the material. IV.5 POWER RIVETING Power riveting uses electric, hydraulicor pneumatic power to cri a rivet. Pull AI Push

Hydraulic Pop For crimping Pop Riveter Rivets Rivet

IV.6NIBBLER A nibbler is a shear that makes small_cuts in metal by punching Out a, small piece oemetal. Nibblers are used to cut ".sheee metal up to 1/16 inch Air In thick. Nibblers can cut intricate cutter punches through 'thin shaped holes in large sheet sheet metal to produce cut. starting from a drilled hole. 9,J Operations done with an electric drill.

Drill Masonry

Drill Plastic & Drive Bore Metal Screws Wood

, IV .1-6 ABORATORY

The student should learn safe operating proCedures and proper care of powe'r hand tools to minimize the chante of injury. The student will use power hand tools for making parts and develop- ing safety habits. The student should gain knowledge of the type and uses of hand power drills by drilling wood, metal, plastic and masonry. He/she -sinould gain knowledge of types and experience in the proper use of a saber saw. The'student should know loading and proper use of power stapler. He/she should know identification and process of setting and crimping solid, tubular and pop rivets. The student should be able to identify pd.use a nibbler to t:- mt,t,11

IV .7 POWER SAWS

For cutting wood, plywood, plastic, and metal with proper cutting blades. Rips Dadcas Miters

Cut Off Portable Hacksaw 11. . T7. 8 ROUTFAS .--Pneumatic A router is a high speed motor turning Air In a cutter to cut different shapes.

Groving & Trimming Molding.& Shaping Cuts Cuts IV .9 SANDERS Sanders use a moving abrasive surface male upof ceramic particles bonded to a'backing sheet to remove material from a surface. Dust Collector

Belt Sander Air Line Finish sanding Rough & finish sanding of large Orbital Disk Sander of uneven flat surfaces Sander surfaces

3)/.10 HAND GRINDERS

Hand grinders are-used-to deburr, grind, saw, and polish component parts of an asst 'y. Grinders turn troir 12,001 J 25,000 RPM. Small grinding, cutting, and polishing wheels are mounted on or 1 inch diameter shafts: 8 Impact wrenches are used to IV .11 IMPACT WRENCHES loosen or tighten nuts orbolted fasteners. A hammer action during rotation produces high turning torques with little torque onthe operator.

Pneumatic Air

IV.12 IMPACT HAMMER

Impact hammers rotate a drill or star drilland cause a pounding action towards the piece being drilled. Drilling holes in masonry and concrete for anchors is. the main application.

1 Cc, -95-

DEMO-HAMMER For Heavy DutyDemolition Chiseling, etc. LABORATORY

The student should be able to use hand power saws to cut wood,metal, and plastics. He/she should develop familiarity with components and operation of a router. He/she should be able to shape, trim or groove wood and plastics. The student should have knowledge of types and proper usesof sanders. The student should learn application of hand grinders to remove burrs and grind couponent parts of an assembly. He/she should have knowledge of types of and uses for impact wreAphes in fabrication. The student must be knowledgable of the uses of imodbt hammersin drilling hard concrete or masonry. IV. CHAPTER ITEMS

Worked Items

1. A minimal power hand tool selection-tor a science labmight include which tools?

(electric or pneumatic hand drill)

(saber saw)

2. Thicker pieces to be sawed can be dut with courserblades having fpwer . (teeth per inch)

Student-Items

1. List six basic safety practices when using power handtools.

(wear safety glassss, have good lighting, clamp work,hold tool with both hands, keep cords clear of work, be'fresh and,alert.)

2. List four basic safety practices in the design of powerhand tools.

(rigid, durable power cord, guards on cutting edges, safety switch.) -96-

V POWER BENCH TOOLS

Y.I. SAFETY

Safe operation of power equipment mustbe a conceptual part of the workers attitude-A basic understandingof safe operating procedures of the will enable the worker to worksafely without memorizing all many safety rules foreach piece of equipment.The following concepts MUST be an integral part of theoperator's safe work attitude.

SHORT HAIR OR WEAR A SMALL CAP SAFETY GLASSES WITH SIDE SHIELDS REMOVE OR EMPTY POCKETS NO SWEATER CLEAN APRON THAT FITS NECKTIE TUCKED INTO SHIRT CLOSELY AROUND THE BODY BETWEEN THE 1ST AND 2ND BUTTONS NO WRIST WATCH, RING SLEEVES ROLLED UP OR CUT OR GLOVES OF ABOVE THE ELBOWS APRON HANGS DOWN TO THE STEEL TOED SAFETY SHOES KNEE?, SECURE WITH KNEE TIES RUBBER INSULATED SOLES STRONG APRON STRINGS DRESSED SAFELY FOR WORK TIED AT THE BACK

* The ABC Of Safety is Always Be Careful Guards are for the protection of the worker, do not operate * -,... equipment without protective guards. * Use the minimum amount of exposed blade orcutter needed-to-- do the job * ,Machines and equipment have physical limitations,which if exceeded will not only overload the machine, but also pose a threat to the operator * If it is not safe, don't do .t.t. * For one's own protection it is necessary to wear & usethe appropriate safety apparel * One operator per machine * Make machine adjustments when the equipment is notoperating * Machines should be rigidly, mounted c* Follow safety procedures & rules for the machine orequipment being operated * Keep areas around machines free of debris * Select proper cutting tool, speed, feed and set up todo the jab safely * Keep hands, loose garments, tools, etc., awayfrom moving parts * Be sure to cut only the correct material * Work safely for your fellow worker.Your fellow workers safety is your responsibility

11 2,-.1 -97- SPEED ADJUSTING MECHANISM V._ DRILL PRESS

The frill press isused to drill,. bore, and tap holes in materials with accuratepositioning of the .rutting tools. WITCH Small drill presses hold only astraight shank drill in a'Jacobs Chuck. Larger drill presses hold the drill with a self-locking tapershank. The drill is removed with a drifts. -DEPTH GAUGE Allwork should be SPINDLE clamped to the LOCK CLAMP worktable. See published table to '- determine drilling speeds JACOBS CHUCK .- and feeds. DRIFT 9

TABLE CLAMP WORKTABLE LEVER

-4 CLAMP FOR POSITIONINGTABLE SQUARE OR AT AN ANGLE COLUMN -11 WITH THE SPINDLE

BASE STRAIGHT TAPER 4-u SHANK SHANK

CHUCKS

CLAMPINGDEVICES GROUND PARALLEL BARS ARE USED TO SUPPORTWORK CLAMP \.4,, FLY CUTTER STEP

ROUND FLAT STOCK V -BLOCK BLOCK

ANGLE VISF

WORK CORRECTLY CLAMPED -98- SECTION ITEMS

1. Using published tables determine the drilling speed(SFPM) for drilling machinery steel with a 3/8 inch drill. SFPM (110)

2. Using problem number 1 determine what thefeed rate in inches per revolution should be. inches per revolution. (.006)

3. The approximate rotational speed of a drillis in revolutions per minute (RPM). It is found using the following equation. SFPM x 4 RPM.=

SFPM = surface feet per minute

D = drill diameter

For a 3/8 inch drill and SFPM of 110determine the RPM. (1173. RPM)

V.3 GRINDER

Grinding machines or special purpose grinders are used tosharpen tools, to remove material that is too hard for machining, topolish surfaces to' close tolerances and to cut hard metals. The bench grinder powered by ,p1 electric motor rotates two abrasive wheels. Tools to be sharpened are held against the face of the wheel as it rotates andabrasives within the grinding wheel cut particles from the tool to remove metal. This operation is known as tool sharpening. When the face of the grinding wheel becomes irregular, a wheel dresser s used to true the face of the wheel.As the grinding wheel rotates, the wheel dresser is pressed against the face of the wheel and passed, across the face EYE removing abrasives from the grinding EYE SHIELD _LAW wheel,.leaving,the-wheel face true. SHIELD 114 PLACE UP

SHARPENING WOOD CHISEL BOTH HANDS ON CHISEL

OPERATOR MUST WEAR SAFETY GLASSES

, AND USE 4X t EYE SHIELD

"-GRINDING WATER TOOL BIT *- ) COOLING TOOL PAN Brr

10 -99- DO NOT STAND IN LINE WITH WHEELROTATION-ALWAYS STAND TO SIDE WHEN MACHINE IS FIRST TURNED ON. 1/16" CLEARANCE BETWEEN TOOL KEEP CLEAR OF FLYING PIECES IF THE WHEEL SHATTERS. REST AND WHEEL USE DUST ATTACHMENT TO EXHAUST PARTICALS KEEP HANDS & LOOSE CLOTHING USING GRINDER CLEAR OF THE ROTATING WHEELS TO SHARPEN .COLD CHISEL, NEVER FORCE WORK AGAINST GRINDING \ GRINDING WHEEL WHEEL

\ MAKE ADJUSTMENTS ONLY WHEN MACHINE HAS STOPPED ROTATING

ti) GRINDING USING WHEEL DRESSER TO TRUE THE 441-"/ WHEEL a FACE OF THE GRINDING WLEEL -\EYIE SHIELD TOOL., KEEP BOTH HANDS ON TOOL WHEN REST ' .11N PLACE GRINDING

BOTH 1 . /

HANDS 1 / GRINDING WHEEL ON cks., CHISEL \590 TOOL REST DRILL GRINDING DRILL BY HAND

V. 4. BAND SAW

- The band'saw is used to cut andshape materials with minimum horsepower and least material.waste. (Seepublished tables for cutting blade data and operating speeds.)

VERTICAL BAND SAW UPPER PULLEY

BUTT WELDER SPEED INDICATOR CONTROL PANEL

POST

AIR JET AND COOLANT SAW AND FILE GUIDES WORK TABLE,

TABLE TILT VARIABLE SPEED PULLEY

LOWER PULLEY COOLANT TANK FLOOR SWITCH TABLE CONTROL

1I r" NA.

-100. HORIZONTAL Position blade guides as close BAND CUT OFF SAW to work as possible.

Lower blade slowly into work.

The band saw ha§ many applications.

LESS HORSEPOWERREQUIRED PRECISION TOOTH

ANGULAR CUTTING MINIMUM OF TOOTH . ...._ Alk.- AL_ 1 A. I MATERIAL REDUCED TO CHIPS 'BUTTRESS TOOTH

LEAST MATERIALWASTE

SLOTTING

, THREE-DIMENSIONAL CUTTING

1r RADIUS CUTTING'

BLADE WIDTH RADIUS

1/2" 2 1/2"

3/8" 1 1/4"

1/4" 5/8" REMOVES WHOLE 3/16" 3/8" SECTIONS CUT DIRECTLY 7/32" 1/8" TO FINISH LINE 3/32" 1/8" ltht; -101-

6V.5. SAWS - TABLE & RADIAL

FENCE SAW GU MITER' GAUGE

TABLE SAW TABLE -+-

BLADE ADJUSTMENT HAND WHEEL OVERARM TURRET ARM COLVON MOTO GU BLADE FENC

RADIAL SAW

.4 TABLE Circular or table saws and radial saws are used for crosscutting, ripping,joint cutting and making specialty cuts. A variety of attachments makes these saws highly valuable\for cutting all kinds of materials.-

FENCE

DEPTH OF CUT

SURFACE PLANE DADO ANGLE CUT

USING TABLE SAW TO CUTOFF STOCK tr"

-102-6 JIG SAWS TENSION SLEEVE Principal parts of a jigsaw OVERARM UPPER MUCK. TABLE' OTOR DRIVE MECHANISM GUARD

. BASE FRAME'

Jigsaws also known as scro,11 saws are geneially used to cut irregular shapes. Using gne of a variety of possible blades almost all materials may be sawed or filed to desired contours,Inside curves are easily cut by first boring a'hole through the inner waste section, insertiri4.sa Blade through:CI the hole, then securing the blade ends it the lower and upper chucks. Blade selection is de- pendent upon stroke speed and material to be cut. (Use saw cutting speed charts for best cutting speeds.)

RECIPROCAL MOTION

. Freehand sawing on the jigsaw

EXTERNAL CUT INTERNAL CUT

Externd1 cuts determine the outr Olape-tf a design Making on inside cut on the jigsaw.,

r- f. -103-

Using a straightedge to guide the cut. 1111111ri Cutting pieces on the Jig saw.

BLADE CUT TEETH/ SHAPE INCH .SHARP CURVES, VENEER, & HARD d11101110 & SOFT WOOD LESS 20 THAN 1/8" Tv",..K

MEDIUM CURVES,'

1 FIBER BOARD, PRESSED WOOD,& 15 HARD & SOFT WOOD LESS THAN 5/8" THICK

LONG CURVEiS, & HARD 6 SOFT 10 WOOD LESS THAN 1" THICK Jigsaw blades are 5" in length with a 5/8" blank on each end. The teeth per inch and of the blade depend on the cut.

SECTION ITEMS

1. A band saw blade 3/8 inch wide will cut radius of inches. (1.25)

2. The cutting speed for a band saw cutting low carbon steel without coolant is (125 SErM) An extra guide is eguired, since the saber blade iseld only by the 3. A band saw has a blade that Wanders. lower chuck. 110 List the five items that might cause the problem. (bladetensi4

(feed heavy)

(blade tracking)*

(guides far apart)

(blade dull on one side)

- V. 6.. ARBOR PRESS . - The Arbor Ptess is used to apply for a ,part for bending,straightening, or pu,hivg.

4, The Arbor Press should not be overloaded. PRE.DS LAIA( ITY I IN I t .2._Lengthening the handle with a levetmay ( f,Ailuie of the press. V1,2 operator should hot hang on th handle but apply a,;te.id.. keeping-feet on the floor. THRol.T RAM APPLICATION OF AN ARBOR PRE ,S

TABLE

RAM

FORt_E PRESS OUT BUSHINGS BUSHING

TABLE HYDRAULa ARE,1:

TABLE HAND ARBOR PRESS BASE

OTHER USES INCLUDE Pressing out roll pins.

Pressing in bearings or seals,.

Broaching key ways in pulley or gear hubs.

rressing hubs on mandrals for turning betweencenters.

ng heavy metal parts to shape.

V. 7. 'METAL LATHE Cutting Tools Angles Vary For Different BACK...RARE Materials SIDE CUTTING.. sirg.RAme a ANGLE ANGIE EDGE ANGLE

END CIT/TING. EDGE ANGLE LATHE QMETAL) Lathes Machine -105- Taper Turning Cylindrical Surfaces Facing Between Centers I law Chuck Turning Lathe Between cent&rsDog work 1,,,,, viAtc r,, 1 tutt,r

NW,c7.140 Center (enter ri-.7".'0". ;Al%-...., ,..t , if Reaming Reamer 3 Jaw Drilling Chuck 3 Jaw Chuck Jacobs Chuck

Knurling Jaw and Live Tail Stock Center

COMPOUND SLIDE HANDWHEEL VARIABLE SPEED CONTROL -DEAD CENTER

HEADSTOCK N TAI LS TOCK BACKGEAR --- LOCK CONTROL KNOB TAI LSTOCK BACKGEAR TAI LS TOCK LOCK PIN MOTOR CONTROL--- LEVER -+4,( .;s lilt4) HANDWHEEL RACK LEAD SCREW DIRECTION LEVER we, ...../ phorallLIN If LEAD SCREW SELECTOR Kr0B----- k----matiti1:111.111.r"alii-----' 1 BED QUICKCHANGE CHIP GEAR BOX THREAD AND FEED SELECTOR HANDLE

CARRIAGE HANDWHEEL

CARRIAGE APRON - THREADING DI AL POWE R FEED Mai R-- -CLUTCH AND BRAKE HANDLE LEVER HALF-NUT

1I1 -106 - V.8. VERTICAL MILLING MACHINE Milling machines are machine tools used to produce plane and formedsurfaces. The cutting tool is a multiple tooth cutter. The workpiece is generally mounted on the machint table in a DRAW BAR vise and fed into the revolving /SPINDLE SPEED INDICATOR Cutting speeds'are ad- SPINDLE STARTING I SPINDLE SPEED SELECTOR cutter. AND REVERSIN(, justed for the kind of material oeing machined. A variety of y. cutters are available or milling SPINDLE BRAKE AND LOCK IGH-LOW SPEED SELECTOR many kinds of surfaces and for QQUILL FINE FEEDHANDWHEEL QUILL POWER FEED SELECTOR peiforminq many different QUILL FEED HAND LEVER kinds of mill noerations. MICRO-QUILL STOP-littr:°11, ki -or--QUILL LOCK LEVER Pti . . See tables for cutting speeds, feeds, and formulas. HEAD SWIVELLING SHAFT TILTING SHAFT

RAM POSITIONING LEVER

STOP DOG

Woodruff key and keyseat cutter '40--TABLE LOCK LEVER 1 KNEE LOCK LE\EP

TABLE TRAVERSE HANDWHEEL CROSS TABLE LOCK LEVER LUBRICATOR-, CROSS TABLE TRAVERSEHANDWHEEL --VERTICAL TRAVERSE LEVER

SHOULDER MILLING Machining a Flat Angular Surface with HOLE DRILLING Shell -End hill

fl MILLING A RECESSED MILLING DOVETAIL MILLING A CHAMFnR T-SLOT MILLING'

MILLING SECTION ITEMS A GROOV1 What RPM should the 1. A 2 inch diameter steel baris to be turned. lathe spindle run? (180-200) in textbook. What angles shoulci 1)4, 2. Cutting tool' nomenclature is shown used in ,harpening a lathe bit toturn low carbon steel? (10°) side relief angle (10°) side ral. angle (10°) end relief angle flute end mill cutting low carbon 3. Calculate the RPM of a 1" diameter two steel. 4229 RPM) determine the proper feed rate in inches 4. Using problem 3 and data from textbool, per minute. IMP (2.29)IMP

1 1 -107-

LABORATORY - CHAPTER V

1. The student should develop safety procedures for operatingpower bench tools, and proper attitudes for safe practices.

2. The student should learn names of drillpress components and of accessories used on the machine, and shoulduse the machine to do drilling operations on plastic, metal, and woodprojects.

3. The student should know proper operation and differentapplications of the bench grinder and be able to sharpen ascrew driver, a lathe bit, a chisel, -and a center punch.

4. The student should learn componentnames and procedures to safely, run vertical and horizontal band saws and practice by cutting metal, plastic,and wood.

5. The student' should learn components and operation of a table saw and jig saw.

6. The student should learn properuse of an arbor press for straightening, pushing, or bending.

7. The student should learn basic lathe terminology and setups for machining different cyslindrical surfaces and be able to machine threads. He/she should be able to calculate approximate turning speed using

WPM x,14 RPM De Diameter of work. WPM - Splodge& D passes cutter in swifts feet per min. a. The student should learn terminology 'and arplication of the vertical milling machine to fabricate carts with flat or cylindrical surfaces.

4,0

1I- -108-

END OF CHAPTERPROBLEMS WORKED PROBLEMS 1. A drill press is used to drill a 5/8 inch hole in brass.What RPM should be used? From text book Drilling Brass - SFPM = 200 - 250 200 x 4 SFPM x 4 RPM) RPM = D = 5/8 inches RPM - - (1280 D 5/8\ 2. A .750'inch diameter rod of aluminum is tobe turned in the lathe. What RPM should the spindle turn? Using text bookFor Aluminum - SFPM = 200- 1500 200 x 4 1500 x 4 . SFPM x4 (1067. RPM) UPTO (8000 RPM) .75 .75 Speed will be limited by the heat generatedand how badly the allminum galled. STUDENT PROBLEMS 1. Find the spindle speed forturning a 2.5 inch diameter fiber drum on the lathe. (128 RPM)

2. A 1 3/8 inch hole is to bedrilled in an aluminum plate. What RPM -should it turn? (582 RPM) -109.

VI. METAL FABRICATION VI . 1. SAFETY Metal fabrication requires both safe dress and safe working procedures.Safe dress includes:. 1. Safety glasses for protection from springs or loose chips which may Hy from equipment. 2. Safety shoeS for protection from dropped parts or sharp tools. 3. Short sleeve shirt near rotating equipment. No rings or ties: 4. Electricalinsulationto minimize shock hazard. 5. Hard hat wheii working in or below part of equipment.

-., Safe procedures include: 1. Only one man operates a machine at one time. 2. Turn off power, disconnect or lock out power source.

3. When using flame, always have a fire extinguisher available. g,

4. Gloves and apron as heat protection when welding or soldering.\\

5. Never use open flame near flammable materials. E 6. Never push machine away from body to guard against slipping or falling. 7. Remove burrs ind sharp edges from parts to prevent scratches,and cuts. 8. AlWays get prompt medical aid for burns, scratches, cuts or splinters. 9. Do not stand in path of chips.

LABORATORY

The student should develop safe working habits when fabricating and assembling parts of metal.

IV.2 SHEARING

Shearing is the process of cutting materials between two cuttingedges.

CUT uNLY 16 GAGE OR CUT NOTCH WITH POINT THINNER METAL OF SNIP Cut CROSSHEAD

BLADE GUARD \ BED GAGE RIGHT HAND SNIP

LEFT HAND SNIP

Keep feet clear of treadle Squaring Shear

ir; -110-

CUT ONLY 20 GAGE OR THINNER METAL V

BOLT POINT Using Snips

Using Hawk's Bill Scroll Snil Snips used to c et metal. Circular pattern snips. Straight snips.

Using Double-Cutting Shear to Cut a C$rlinder

CUTONLY 22 TO 16 zGAel- SHEETMETAL Aviation Snips A. Cuts Left B. Cuts Straight C. 'Cuts, Right VISE TO 4 FEET LONG \Bench Shear'

LABORATORY The student should shear sheet metal usina a number of shearing methods in the fabrication of projects.

0 -t11ro VI -3 PUNCHING

Punching Is the operation of shearing to produce a markor hole.

CENTER PUNCH HOLE PUNCH SOLID PUNCH SHEET METAL

VISE_' WOODEN BLOCK'

SOLID PUNCH Punching a Holt in Sheet Metal with a Solid Punch

HOLLOW PUNCH Hold punch with pliers.

SHEET METAL

HAND PUNCH . Using a hollow punch to cut holes in sheet metal or gaskets. a LABORATORY

The student should use a number of punching mathods in the fabrication of metal parts. 117 112 ,/1 fitHINc ,prrT "1TAL Bending is the process of forming metal to adesired Using blotk shape by usingblocks, guides, clamps or fixtures.

i1.1X-21 rlottino /

Box and -)an brake

Setting down with a setting hammer

on...ste

Forrinclon edge wIth handseanor.

'Ti wort,

'1(ndinq seuare I \ Nose

I Bending square edge

Using hand groover to set a seam

Forming blocks in place on brakc

(B)-Make the Fold. Making a hemmed edge.(A) Adjust depth gauge to size (C) Flatten fold 1 Using blocks of wood to make a bend in sheet metal Using a wood block to nake an angular bend.

Single Hen Double Hem

Step I Step 2 Step 3 laking a wired Edge

Bending a conical sectionover a blovilorn stake Step 1 Step 2 Making a Grooved team ci_ Step 1 Step 2 step 3 Makling.a Double Sean

Step 1 Step 2 Making a Corner Fold Sending a conical sectionovera nEris AND SEAMS t.lowhorn stake. LABORATORY

The student should do bending of sheet metal and strap iron in the fabrication of boxes,* ducts, or braCkets. N..

'1A RI' -1I

. VI -5 ROLLING /tt 'Rolllng is the forming ofMaterial by bending the material betw ena set of three

eblilotte+

Slip roll formingmachine.

VI-6. SPOT WELDING .' clamped between Spot welding is resistancewelding in which metals to be welded are passed between the two electrodes antithe two electrodes. The electric current is heats the metal at the point electrical resistance of themetal between the electrodes of contact and fuses the piecestogether. ELECTRODE

WELD JOINT

ELECTRODE

HOLD TIME OFF TIME SQUEEZE TIME WELD TIME Spot welding sequence,

Metals to be welded must beclean and in full contact for goodweld. Also, proper'current and time of application mustbe used. PORTABLE SPOT WELDER

LABORATORY The student shoulu use aslip roll to form, cylindrical components uscng of sheet metal and rod. The student should fabricate a part a spot welder. -115- VI-7 SOLDERING SHEET METAL metallic material 'oldering is the bonding of two ormore pieces of The bond is mechanical using a low meltingpoint, non - ferrous alloy. metal,oxides. Flux, a rosin and requires surfacesclean and free of or weak acid, assists inremoval of oxides.

Pressure Wire Wood Stick Solder 1 Solder Hot Hot Drops Soldering Soldering Flux of Copper Copper Flux

Metal

Molten solder alwaysflows pieces together until Hold sheet metal towards hot copper.' the molten soldersolidifies

Always clean and fluxbefpre assenbly.

Torch

Molten solder flows Solder towards hot spot.

Solder Torch Soldering - partsheld together with softironwire. Copper Tubing Gas torch soldering with heat. -116. Clean"& prefluxsurtaces.betote heating.

Torch soldering Applying solder at edge of joint.

steel --Prraze'tip to 1/4" thick Sweat Saljering soldering Copper a joint. Apuly heat at corner. Heat Shield Solder will flow Shield reduces towards heat. -heat lost.

Rosin Core , M711111r ik:ammAL4.7

A::$1;1:00°°:1

Electric soldering iron LABORATORY and.cooper uSinqa soldering The student shouldsolder brass, steel electric soldering copper, or anelectric solder- copper, propane torch, solid solder and coredsolder and acid ing gun. He/she should use both and paste flux. p .417 VI-R FASTENERS Fasteners shown in Chapter III are used in manyassemblies. STR. CONNECTOR 5/16-18 x 1" 1/4-20 5/8 3/16 x 3/16 x 1 3/8 LG. 0C. SET SCRFW MOTOR KEY HEX. CAP SCREW (4 req'd.) (Cup-I Pt.) 5/16-18 HEX. ir FULL NUT filill (4 req'd.) .----1)

1/4 WASHER --1ST (4 req'd.) CONDUIT

.11; ... VIIF Nr. TANK \ ELBOW CONNECTOR :10TOR PULLEY 050-074 WASHER 10-.)R 3;6E. (,5/8" Bore) MOTOR BASE MOTOR BASE 1/2-13 HEX S2REW MOTOR PULLEY SCREW FULL NUT (? rel'I.) (7/8" Bore)

CARRIAGE LOCK BOLT

696-074 MOTOR BASE'. 1/2-13 HEX ';'CREW FULL NUT eq'd.) DIN 1/2-11 HEX WASHER gpii FULL 'MT (4 req'd.)'' 1: x 1 /2 SPACER DAPPING 6,(2 req'd.) ,CRFW 5/16 - 18 HEX FULL NUT ER LIP 3/8-13 HEX (4 req'd.) FtTLL NUT 1 WIPER I I.P _LIP (2 u!i'd.)

411E. CARRIAGE SHIM (4 req'd.) SHIM (4 req'd.) TAILSTOCK BASE

Y5/16 -18 x 2 1/4 698-074 CARRIAGE CLAMP SOC. SET SCREW CLAMP STUD 7/16 WASHER (Oval Pt.) (2 req'd.) HOLD DOWN SPRING (2 req'd.) 3/16 x 3/4" WASHEF ROLL PIN (2 req'd.) CLAMP E/16 -18 x 1" 1/2-20 WASHER- SOC. CAP'SCREW CONE LOK NUT (2 req'd.)

1-0 4rti -118-

048-052 BAR RETAINER 1/4-20 x 1/2 698-C98 (2 n ALLEN CAP SCREW BEARING STUD FLAT HD. 3/8 LOCK (2 req.d.) RETAINER (2 req'd.) WASHER 3/8-16 HEX I (4'rwild.) C' SHAFT SPINDLE FULL NUT SCREW COVER RETAINER (4 rcq'd.) OSHAFT PULLEY KEY

1/4-20 x 1/' 1 RETAINER SOC. SET SCREW RETAINER 4 (Cup Pt.) STEP PULLEY 1/8 x 3/8 ROLL PIN

1/4-20 x 7/8 1/4-20 HEX KEY SCREWS HANDLES CIRCLIP SHAFTS HD. LESS SET SCREW J / -M 11W

COLLARS WASHERS 0-PING KEY 1741-10PLUGS SCREWS

DRAIN PIPE PLUG SPRING

PLUG BALL /( WASHER VALVE PIPE ELBOW CLIP SPRING SCREW ANCHORS 0-RING SCREWS (SCREWS AND BOLTS) @\ LEAD PIN PLUNGER ASSY SET SCREW

SPRING 0 CLIP LEVER ASSY PLATE SPRING BRACKET CLAMP TANK SCREW SLEEVE CONCRETE- AND MASONRY ANCHORS FOR BLIND HOLDS MASONRY ANCHOR IN WOOD OR PLASTIC (Hammer Drive Riveta)

4:1;21111E0WALLGRIPS SCREW ANCHCS

LABORAMPY A student lab project shouldinclude a studyof fasteners used in different commercial products. I 119. VI-9. ADHESTVE BONDING 6 CEMENTING The process of connecting two pieces by a mechanical bonding adhesive or by melting the pieces together with a solvent cement.

trMATERIAL ADHESIVE de

MATERIAL-P

SIMPLE LAP

JOGGLE LAP

'oRNER JOINTS

-DOUBLE SCARF LAP

TONGUE AND GROOVE LAP JOINTS

LANDLD SCARF TONGUE AND GROOVE

TONGUE AND GROOVE JOINTS

Joints f;ilitdble for Adhesive Bonding BUTT SCARF LAP JOINT Manufacturers literature specifies L adhesive selection, information, and specifications.

PEELING II [II]14 CLEAVAGE,/ TENSION

Forc."t.. Which Adhesive. are Sublertud

l4.0 .120-

LABORATORY

The student should make and assemble different types of bonded and cemented joints using a variety of adhesives and materials.

SECTION ITEMS

1. Using techical tables determine the curing time for pliobondcement. (24 hrs)

2. A fire safe contact cement is needed. Determine a possible supplier. (WiIhold Glum Inc.)

3. An epoxy is needed which will set within 20 minutes.,Determine a supplier. (L.A. Kling Enterprises)

\.) 111,e. 4.,tj -121 TABLEI The Metric System of Measurement

The mltric system in use today is a nodern version of the metric system estab- lished by international agreement. It provides a logical and interconnected framework for all measurements in science, industry, andcommerce. Officially abbreviated SI, the system is built upon a foundation ofseven base units, which appear on this chart along with their definitions.All other SI units are de- rived from these units. Multiples and stibmultiples are empressed in a decimal system. Use of metric weights and measures was legalized in the United States in 1,866, and. since 1893 the yard and pound have beendefined interms of the meter and the kilogram. The base units for time, electric current, amount of substance, and luminous intensity are the same in both the customary English and metric systems.

THE INTERNATIONAL SYSTEM OF UNITS-SI COMMON CONVERSIONS Accurate to Six Significant Figures Whenou Know Multiply by To Find Symbol in inches a 25.4 millimeters mm ft feet 0.3048 meters yd yards 0.9144 meters mi miles 1.609 34 km 2 kilometers yd square yards 0.836 127 square meters m2 acres 0.404 686 chectares ha 3 yd cubic yards 0.764 555 cubic meters m3 qt quarts (lc') 0.946 353 d liters oz ounces (avdp) 28.349.5 grams 9 lb pounds (avdp] 0.453 592 kilograms kg F Fahrenheit a5/9 after Celsius oc temperature subtracting temperature 32) mm millimeters 0.039 370 1 inches in meters 3.280 84 feet ft meters 1.093 61 yards yd km kilometers 0.621 371 miles mi m2 square meters 1.195 99 square yards yd2 ha chectares 2.471 05 acres 3 cubic meters 1.307 95 cubic yards yd 1 liters 1.056 69 quarts (1q) qt g grams 0.035 274 0 ounces (avdp) oz kg kilograms 2.204 62 pounds (avdp) lb* °C Celsius ag/5 (then Fahrenheit of add 32) temperature aexact bfor example 1 in = 25.4 mm, so 3 inches would be (3 in)(25.4 71)=76.2Mm c hectare is a common name for 10,000 square meters d liter is a common name for fluid volume of 0.001 cubicmeter Note: Most symbols are written with lower case letters; exceptions are units named after persons for which the symbols are capitalized. Periods are not used with any symbols. * 1 LBM = pounds (avdp) -122-

TABLE II

Fluxes for Soft Soldering

Metal to be Chemical Name

Soldered Flux , of Flux Brass Cut acid Zinc chloride Copper Rosin Colophony 1 Sal 4moniac Ammonium chloride Zinc Cut acid Zinc chloride Galvanized Raw acid Hydrochloric iron (zinc (muriatic acid coated) acid) Iron Cut acid Zinc chloride Steel Sal ammoniac Ammonium chloride Tin Rosin Colophoay Tin plate Cut acid Zinc'chloride Pewter, Rosin Colophcny Tallow Nickel Chloride Zinc chloride Silver Aluminum Special fluxes by different manufacturers

1Sal anioniac - a white solid substance that lookslike rock salt or rock candy; it is used as a solderingflux. Sal ammoniac changes state directly from a solid to a gas (sublimes).

10 -1.23-

TABLE III

SizesofTaps &Drills'

wemPltf.,3 4., Rear *, -.1""'''`' """. --...iii.:11fir.7''',!t!; :'1 UNC f .,-rr:-.7--"rrs ft,,-77---Tr NC NF ( , tom) Icarl/M.It OM) ._ . . " " 4 .., #0-80.0.0600 0.0438 ... 'N;4 0.0489 *31 0.0670 0.0076 1-61 ... 0.0730 0:0527 53 ... 0.0595 #47 0.0785 0.0055 =1-720.0730 0.0550 53 ... 0.0595 *47 0.0785 0.0055 02-56 . . 0.0860 0.0628 50 ... 0.0700 #42 0.0935 0.0075 #2-640.0860 0.0657 50 ... 0.0700 #42. 0.0935 awn *3-48 ... 0.0990 0.0719 47 . 0.0785 *36 0.1065 0.0075 #3-560.0990 0.0758 45 ... 0.0820 *36 0.1065 0.0075 =4-40' . . 0.1120 - 0.0795 43 0.0890 #31 0.1200 0.0060 #.4-480.1120 0.0849 42 ... 0.0935 #31 0.1200 0.0080 =5-40 . . 0.1250 0.0925 38 0.1015 #29 0.1380 0.0110 a #5-440.1250 0.0955 37. ... 0.1040 #29 0.1360 0.0110 #6 .'12 0.1380 0.0974 38 0.1065 #25 0.1495 0.0115 6-400.1380 0.1055 33 ... 0.1130 #25 0.1495 0.0115 *8-32 . ,. 0.1640 0.1234 29 ... 0.1380 #16 0.1770 0.0130 *8-360.1640 0.1279, 29 0.1380 #16 0.1770 0.0130 #10-2( . 0.1900 0.1359 25 .. . 0.1495 134;4 0.2031 0:0131 *10-32 0.19(X) 0.1494/ 21 .. . 0.1590 "i6., 0.2031 0.0131 #12-24 .. . 0.2160 0.1619 16 0.1770. .732 0.2187 0.0027 #12-280.2160 0.1690. 14- .. 0.1820 7 0.2187 0.0027 . I/4"-20 ... 0.2500 0.1850 7 ... 0.2010 ' 7 4 0.2656 0.0156 %"-280.2500 0.2036 3 0:2130 ' 744 0.2856 0.0156 r,i6"-18 ... 0,312.5 0 2403 F .. . 0.2570 2144 0.3281 0.0158 rri "-240.3125 0.2.584 1 . . 0.2720 2' 4J 0.3281 ,().0156 N,"-16 ... 0.3750 0.2938 .. . r,/, ,, 0.3125 23;;`,"0.3906 0.0158 0.3750 0.32(19 3.,"-24 Q . 0.3320 254.4 0.3906 0.0156 ... 714...-14 0.4375 0.:3447 t_' ... 0.3680 2%4 0.4531 0.0156 7 i n"-200.4375 0.3725 25,, , - 0.3906 2"," 04531 .0.0156 V.2"-13 . . 05000 0.4001 27 4 0.4219 33 4 0.5156 0.0156 1,i2"-20 0.5(XX) .0.4350 ... 2194;4 0.4531 334;.4 0.5156 0.0156 'Y, ,r-12 ... 0.5625 0.4542 3 I/I.; 4 0.4844 "7;,4 0.5781 0.0156 9/14"-180.5625 0.4903 ... '';4 0.5156,37iI4 0.5781 0.0156 '3;, "-11 062.550 . .. 0.5069 . 17;., 0.5312 4I,4 0.6406 0.0156

r,"-18 0.6.'.50 0.5528 374;4 0.5781 41%1 0.64(16 0.0158 3' "-I 0 - 0.75(X) 0.6201 . 21,32 0.6562 40," 0.7656 0.0156 .,',"- 160.7500 0.6688 11-; ,, 076875 4944 0.7656 0.0156 7M"- 9 ... 0.8750 0.7307 41)414 0.7656 fi74f 4 0.8906 0.0156 Tf g -140.8750 0.7822 ... Ili 6 0.8125 n744 0.8906 0.0156 ... 7/ 1"- 8 1.(XXX) 0.8376 ... m 0.8750 1'E, 1.0156 0.0156 1"-14 1.0(M)0 0 9072 ... I r;; 0 0.6375 p , 1.0156 0.0156

12; -3.24-

11.

Index

Adhesives; 84 Jig saws; 102-103 Angles; 4 Keys; 84 Arbor press; 104 Knife; 54 Band saw; 99-100 Lathe; metal; 104-105 Beam balance; 4 Mass; 4 Bending materials; 112-113 Mechanical connections; 25 Bonds & cements; 119 Meter; 69 Box and pan brake; 112 Micrometer; 2 Breadboard; 56 Mounting and soldering components; 50-51 Cable connectors; 39 Multimeter: 18 'Capacitors: Basic; 19- Nibbler; 92-93 Electrolytic; 19-20 Nut driver; 54 Variable; 19-20 Nuts; 82 Chassis; 67-70 Offset; 60 Circuit assemblies; Integrated; 56-57 Ohm's; 11 Printed; 57-58 PCB component mounting & soldering; 59 Cirduit pattern; 64 Pliers: 54,85 Clip or heat sink; 60 Long-nose; 54 Coaxial connectors; 42 Portable spot welder; 114 Combination square; 7 Power riveting; 92 Component layout; 64 Power saws; 93 Conductors; 14 Power transistors; 27 Cutting tools; 85 Prick punch; 7 Diagonal cutters; 54 Printed circuit; 14 Diode; 26 Punches, chisels and impact tools; 75-76 Dividers; 7 Radian; 4 Powel pins; 84 Reamers; 79 Drill gauge; 77 Rectifiers; 26 Drill press; 97 Reference dcsignations; 33-34 Drills; 77-78 Regular range indicator; 3 Dual in-line packages: Standard; 61 Resins: Epoxy; 70 Plug-in; 61 Polyurethane Clinched; 61 Resistance; 22 Elementary circuit; 10 Resistors; 11 English units; 1 Power; 13 Eraser; 54 Variable; 13 Fasteners; 82, 117-118 Precision; 14 Ferrites; 22 Retaining rings; 84 Files; 73 Rivets; 83 Flat packs: Surface; 61 Routers; 94 Staggered; 61 Ruler; 54 Grinder; 98 Saber saws; 92 Hammers; 74 Safety: Equipment; 91 Hand drills; 92 Operator; 91 Hand grinders; 94 Power bench tools; 96 Heat gun; 43 Metal fabricat_on; 109 Height gauge; 7 Sanders; 94 ,Henrys; 22 Saws: 87 Holding vise; 43 Table; 101 Impact wrenches; 94 Radial; 101 Impedapce; 22 Schematic diagram; 10 Inductors; 22 Schematic symbols; 30-32, Integrated circuits; 26,29 Screwdriver; 54,86 Inverted; 60 Screws; 82-83 130 Semiconductor dewsces; 26 Semipermanent connections; 39

Silicones; 70 ' Sine bar; 5 5.1. units; 1 Slip roll forming machine; 114 Socket wrench set; 88 eolderinq; 47 Soldering aid; 54 Soldering defects; 48 Soldering irons; 115-116 Solder terminals; 36 Solderless terminals; 37 Spacer; '60 Speeds and feedrate;, 5 Spreader; 60 Squaring shear; 109 Staplers; 92 Steel tapes; 3 Straight through; 60 Tables: Metric conversion; 121 Flexes fdr soft soldering; 122 Sizes of taps and drills; 123 ,...,Threadcutting.; 80-81 Tinning; 46 Tin snips; 109-110 Transformers; 24 (Transistor; 26-27 Triple beam balance; 4 Variable heat soldering irons; 43-45 V- Blocks; 7 Vernier Calyser; 2 Vernier Protractor; 5 Vertical milling machine; 106 Vises; 72 'Volt-Ohm-Meter; 18 Washers; 82 Wire: Multistrand; 17 Single-strand; 17 Wire connectors; 48-50 Wiring diagram; 10 Wire strippers; 48,54 Wrenches; 88

131