CHAPTER 1 - TOOLROOMS AND TOOLS
TOOLROOM SAFETY
Figure 1-1.--Method of tool storage.
Figure 1-2.--Method of tool storage.
Figure 1-3.--Method of tool storage.
Figure 1-4.--Common types of micrometers.
Figure 1-5.--Nomenclature of an outside micrometer caliper.
Figure 1-7.--Applications of a dial indicator.
Figure 1-8.--Vernier caliper.
Figure 1-9.--Vernier height gauge.
Figure 1-10.--Dial vernier caliper.
Figure 1-11.--Dial bore gauge.
Figure 1-12.--Universal vernier bevel protractor.
Figure 1-14.--Gear tooth vernier.
Figure 1-15.--Cutter clearance gauge.
Figure 1-17.--Setting a dimension on a surface gauge.
ACME THREAD TOOL GAUGE
Figure 1-21.--Feeler (thickness) gauge.
Figure 1-26.--Parallel blocks.
THREAD MEASURING WIRES
MICROMETERS
VERNIER GAUGES
CHAPTER 2 - LAYOUT AND BENCHWORK
Figure 2-1.--Basic dimension and tolerance.
Figure 2-2.--Relation of symbols to surface characteristics.
Figure 2-4.--Symbols indicating the direction of lay.
Figure 2-5.--Roughness height values for machine operations.
Figure 2-8.--The interference (surface-finish) microscope
Figure 2-9.--The profilometer measuring the surface roughness of an internal diameter.
Figure 2-11.--Checking surface finish on the machine.
Figure 2-15.--Laying out parallel lines with a combination square
LAYING OUT CIRCLES AND IRREGULAR LINES
USING THE SURFACE PLATE
Figure 2-24.--Setting and using a surface gauge.
GEOMETRIC CONSTRUCTION OF LAYOUT LINES
LAYING OUT VALVE FLANGE BOLT HOLES
Figure 2-30.--Flange layout terminology.
Figure 2-32.--Four-hole flange development.
Figure 2-34.--Checking a surface.
Figure 2-36.--Polishing.
HYDRAULIC AND ARBOR PRESSES
Figure 2-38.--Broaching a keyway on a gear.
Figure 2-39.--Screw thread insert.
OXYACETYLENE EQUIPMENT
Figure 2-41.--Typical oxyacetylene cylinder bank.
SETTING UP OXYACETYLENE EQUIPMENT
SAFETY: OXYACETYLENE EQUIPMENT
BACKFIRE AND FLASHBACK
CHAPTER 3 - METALS AND PLASTICS
Corrosion Resistance
TYPES OF METALS
Nonferrous Metals
ALUMINUM ALLOYS
DESIGNATIONS AND MARKINGS OF METALS
Table 3-1.--SAE Numbers with Their Corresponding Alloying Elements
Table 3-2.--Aluminum and Aluminum Alloy Classifications
Standard Marking of Metals
Figure 3-1.--Examples of continuous identification marking.
Table 3-3.--Rapid Identification of Metals
Figure 3-2.--Fundamental spark forms.
Figure 3-3.--Spark pictures formed by common metals.
Acid Test
MACHINING OPERATIONS
Table 3-4.--Major Groups of Plastic
Table 3-4.--Major Groups of Plastic--Continued
Lathe Operations
CHAPTER 4 - POWER SAWS AND DRILLING MACHINES
Figure 4-2.--Hacksaw blade.
CONTINUOUS FEED CUTOFF SAW
Band Selection and Installation
Figure 4-7.--Set and side clearance.
Polishing Bands
FILE BAND AND POLISHING BAND GUIDES
Selection Of Saw Bands, Speeds And Feeds
Sizing, Splicing, And Installing Bands
BAND LENGTH
Figure 4-17.--Upper wheel tilt adjustment.
Figure 4-18.--Work jaw and feed chain adjustment.
ANGULAR CUTTING
Figure 4-22.--Disk-cutting attachment.
Figure 4-24.--General purpose drill press.
Figure 4-27.--Radial drill press.
Figure 4-28.--The parts of a twist drill.
DRILLING OPERATIONS
Holding the Work
Figure 4-30.--Common types of clamping straps.
Figure 4-33.--Using a half-round chisel to guide a drill to the correct center.
Figure 4-36.--Examples of spotfacing.
Figure 4-38.--Equipment for drilling angular holes. A. Chuck; B. Guide plate; C. Guide holder; D. Slip bushing; E. Angular drill.
Figure 4-39.--Lathe setup for drilling an angular hole.
OPERATION
CHAPTER 5 - OFFHAND GRINDING OF TOOLS A N D SELECTION OF CARBIDE TOOLING
Figure 5-2.--Grinding on a pedestal grinder.
Figure 5-4.--Standard marking system for grinding wheels (except diamond).
Figure 5-5.--How bond affects the grade of the wheel. Wheel A, softer; wheel B, harder.
GRINDING WHEEL SELECTION AND USE
TRUING AND DRESSING THE WHEEL
Figure 5-10.--Crown on the working face of a wheel for a carbide tool bit grinder.
Figure 5-11.--Chip breaker grinder.
CEMENTED CARBIDE
Figure 5-12.--Three causes of tool breakage.
Figure 5-13.--Surface finish vs nose radius chart.
Figure 5-16.--Toolholders for carbide inserts.
Figure 5-17.--Boring bars for carbide inserts.
Side Cutting Edge
GROUND-IN CHIP BREAKERS
Figure 5-20.--Lathe tools and their application.
GRINDING HIGH-SPEED ENGINE LATHE CUTTING TOOLS
SHAPER AND PLANER TOOLS
GRINDING HANDTOOLS
Figure 5-27.--Checking the squareness of the end of a screwdriver
Figure 5-32.--Grinding drill lip correctly.
Figure 5-34.--Three steps for grinding a twist drill with a grinder
SHARPENING A TWIST DRILL TO DRILL BRASS
CHAPTER 6 - ENGINE LATHES
Figure 6-1.--Gear-head engine lathe.
Figure 6-2.--Rear view of lathe.
Figure 6-3.--Sliding gear-type headstock
Figure 6-6.--Cross section of a tailstock.
Figure 6-7.--Side view of a carriage mounted on the bed.
Figure 6-9.--Rear view of a lathe apron.
FEED ROD
QUICK-CHANGE GEAR MECHANISM
COMPOUND REST
Figure 6-13.--Castle-type toolpost and toolholder.
Figure 6-14.--Quick-change toolpost.
Figure 6-19.--Quick-change toolholder.
Figure 6-21.--Three-jaw universal chuck.
LATHE CENTERS
Figure 6-26.--Cutaway showing the construction of a hall bearing center.
Figure 6-29.--Center rest.
GRINDING ATTACHMENT
Figure 6-34.--Grinder mounted on a compound rest.
OTHER TYPES OF ENGINE LATHES
Figure 6-37.--A gap lathe.
The Spirit Level Method
PREPARING THE CENTERS
SETTING THE TOOLHOLDER AND CUTTING TOOL
Holding Work Between Centers
Figure 6-45.--Boring center hole.
Holding Work on a Mandrel
Figure 6-48.--A split-shell expansion mandrel.
Holding Work In Chucks
RUBBER FLEX COLLET CHUCK
Holding Work On a Faceplate
Using the Center Rest and Follower Rest
CUTTING SPEEDS AND FEEDS
COOLANTS
Figure 6-60.--Right-hand side tool.
Rough Turning
PARTING AND GROOVING
DRILLING AND REAMING
Figure 6-68.--Application of boring bar holder.
SETTING UP THE TOOLPOST GRINDER
Figure 6-73.--Position of the diamond dresser.
Figure 6-75.--Tapers.
Methods of Turning Tapers
USING the COMPOUND REST
USING THE TAPER ATTACHMENT
Methods of Boring Tapers
Figure 6-81.--Screw thread nomenclature.
V-FORM THREADS
Figure 6-82.--Threading tool setup for V-form threads.
The Acme Screw Thread
Buttress Thread
CLASSES OF THREADS
Figure 6-88.--Measuring threads with a thread micrometer.
CUTTING SCREW THREADS ON THE LATHE
Position of Compound Rest for Cutting Screw Threads
Engaging the Thread Feed Mechanism
Figure 6-44--Strew pitch gauge.
Figure 6-98.--Setup for left-hand external threads.
Figure 6-99.--Comparison of single- and multiple-lead threads
THREADS ON TAPERED WORK
CHAPTER 7 - MILLING MACHINES AND MILLING OPERATIONS
Figure 7-3.--Vertical spindle milling machine.
MAJOR COMPONENTS
Figure 7-6.--Universal knee and column milling machine with horizontal spindle.
Figure 7-7.--Spindle drawbolt.
ARBOR SUPPORT
RIGHT-ANGLE PLATE
CIRCULAR MILLING ATTACHMENT
Figure 7-13.--Dividing head mechanism.
INDEXING EQUIPMENT
DIRECT INDEXING
PLAIN INDEXING
ANGULAR INDEXING
COMPOUND INDEXING
DIFFERENTIAL INDEXING
WIDE RANGE DIVIDER
ADJUSTING THE SECTOR ARMS
Figure 7-22.--Plain milling cutters.
Figure 7-23.--Milling cutter terms.
Figure 7-24.--Side milling cutter.
Figure 7-30.--Screw slotting cutter.
Figure 7-33.--End mill cutters.
Figure 7-35.--End mill terms.
Figure 7-36.--Inserted tooth face milling cutter.
Figure 7-42.--Corner rounding cutter.
Figure 7-45.--Fly cutter arbor and fly cutters.
Figure 7-47.--Standard milling machine arbors.
Shell End Arbor
Cutter Adapter
MILLING MACHINE OPERATIONS
PLAIN MILLING
Figure 7-56.--Face milling.
Figure 7-57.--Aligning vise jaws using an indicator.
Figure 7-60.--Angular milling.
Figure 7-61.--Milling a square on work held vertically.
Figure 7-63.--Milling a square using an end mill.
Figure 7-65.--Diagram of a hexagon.
Square or Hexagon Work Mounted Between Centers
Machining Two Flats in One Plane
SLOTTING, PARTING, AND MILLING KEYSEATS
Figure 7-69.--Aligning the cutter using a paper strip.
Figure 7-71.--Visual alignment of a cutter.
Figure 7-73.--Woodruff keyseat cutter.
Figure 7-74.--Milling a Woodruff keyseat.
Figure 7-75--Dimensions for a Woodruff keyseat.
Figure 7-76.--Offset boring head and boring tools.
MILLING MACHINE ATTACHMENTS
VERTICAL MILLING ATTACHMENT
FEEDS, SPEEDS, AND COOLANTS
Table 7-3.--Cutter Speeds in Revolutions Per Minute
FEEDS, SPEEDS, AND COOLANTS - Continued
Table 7-4.--Recommended Chip Loads
VERTICAL TURRET LATHE
Figure 8-2.--A 36-inch vertical turret lathe.
VERTICAL TURRET LATHE TOOLING
Figure 8-3.--Refacing a valve seat in a vertical turret lathe.
Figure 8-6.--Head setting for 30 to 45 angles.
Figure 8-8.--Horizontal boring mill.
COMBINATION BORING AND FACING HEAD
BORING MILL OPERATIONS
Figure 8-11.--Drilling in the horizontal boring mill.
Reconditioning Split-Sleeve Bearings
Figure 8-13.--Line shaft bearing that has had the "cheeks" or oil reservoir grooves cut into it.
CHAPTER 9 - SHAPERS, PLANERS, AND ENGRAVERS
CROSSRAIL ASSEMBLY
Figure 9-4.--Mechanical table feed mechanism.
Figure 9-5.--Toolhead assembly in various positions.
Figure 9-7.--Toolholders.
Figure 9-8.--Squaring the table and the vise.
Table 9-1.--Recommended Cutting Speeds for Various Metals
Figure 9-9.--Cutting a keyway in the middle of a shaft.
Figure 9-10.--Internal keyway: A. Shaping an internal keyway in a gear. B. Depth of keyways.
Figure 9-11.--Shaping irregular surfaces.
VERTICAL SHAPERS
MAJOR COMPONENTS
OPERATING THE PLANER
Figure 9-16.--Correct and incorrect clamp applications.
Figure 9-19.--Computer-controlled engraving machine.
SETTING THE PANTOGRAPH
Figure 9-20.--Cutter grinder.
Grinding Single-Flute Cutters
GRINDING THE CHIP CLEARANCE
PANTOGRAPH ATTACHMENTS
PANTOGRAPH ATTACHMENTS - Continued
ENGRAVING A DIAL FACE
ENGRAVING A DIAL FACE - Continued
CHAPTER 10 - PRECISION GRINDING MACHINES
Figure 10-1.--Grain depth of cut; center-type machine.
Figure 10-3.--Surface grinding a cylindrical workpiece.
Figure 10-4.--Overlapping disk balancing ways (roller type).
CROSS TRAVERSE TABLE
Figure 10-8.--Magnetic chuck used for holding a tool grinding fixture.
Figure 10-10.--Grinding a spacer on a surface grinder.
CYLINDRICAL GRINDER
CYLINDRICAL GRINDER OPERATION
Figure 10-12.--Tool and cutter grinder (workhead and footstock).
Figure 10-13.--Tool grinding setups on a tool and cutter grinder. A. Straight wheel grinding a milling cutter. B. Cup wheel grinding a reamer.
Setting the Clearance Angle
Figure 10-18.--Cutter clearance angles.
Plain Milling Cutters (Helical Teeth)
Side Milling Cutters
Figure 10-23.--Staggered-tooth side milling cutter.
Figure 10-26.--Resting the face of a tooth on its corresponding side of the tooth rest blade.
End Mills
Figure 10-30.--Involute gear cutter.
PORTABLE HONING EQUIPMENT
STATIONARY HONING MACHINE
HONING HINTS
CHAPTER 11 - COMPUTER NUMERICAL CONTROL MACHINES
Figure 11-1.--CNC vertical spindle milling machine.
CNC VERTICAL SPINDLE MILLING MACHINE
Figure 11-4.--CNC programming station.
NUMERICAL CONTROL SYSTEMS
Figure 11-6.--A typical CNC controller.
Figure 11-7.--Point-to-point angles and arcs.
Figure 11-8.--Continuous-path angles and arcs.
Figure 11-11.--Incremental positioning system.
THERMAL SPRAY SYSTEMS
Figure 12-1.--Typical installation for combustion gas spraying.
Powder-Oxygen-Fuel Spray
PREPARING THE SURFACES
Figure 12-8.--Profile of an anchor-tooth pattern.
APPLYING THE COATING
CONTACT ELECTROPLATING
Figure 12-10.--Electroplating equipment.
OPERATOR QUALIFICATION
PLATING PROCEDURES
CHAPTER 13 - REPAIR WORK
PLANNED MAINTENANCE SYSTEM
Figure 13-2.--Steps in making a shaft.
REPAIRING VALVES
Figure 13-3.--Examples of spotted-in valve seats.
Figure 13-4.--Lapping tools.
Figure 13-7.--Typical ball stop swing-check valve for seawater service
Figure 13-8.--Cutaway view of a gate stop valve (rising stem type).
Figure 13-9.--Cross-sectional views of gate stop valves (nonrising stem type).
Figure 13-10.--Constant-pressure governor for main feed pump.
CONTROL AND MAIN VALVE
Repairing Double-Seated Valves
Repairing Duplex Strainer Plug Valves
Figure 13-14.--Stuffhg box on a centrifugal pump.
Figure 13-16.--Removing a broken stud with locking pliers.
Figure 13-17.--Removing a broken bolt with a prick punch.
Figure 13-22.--Using a plug weld to remove a broken tap.
Figure 13-23.--Metal disintegrator removing a broken stud.
IN PLACE MACHINING
Figure 13-25.--Portable boring bar.
MATERIALS USED FOR GEARS
SPUR GEAR TERMINOLOGY
DIAMETRAL PITCH SYSTEM
Figure 14-3.--Measuring gear teeth with a vernier caliper.
MACHINING THE GEAR
HELICAL GEARS
Figure 14-7.--Development of the helix angle.
Figure 14-8.--Formulation of a lead triangle and a helix angle.
Table 14-2.--Corrected Tooth Constant
Corrected Chordal Addendum and Chordal Thickness
Center-to-Center Distance
MANUFACTURING A HELICAL GEAR
Figure 14-13.--Other forms of bevel gears.
Figure 14-14.--Development of the mating gear triangle.
Figure 14-15.--Parts of a bevel gear.
Figure 14-16.--Development of bevel gear formulas.
BEVEL GEAR NOMENCLATURE
Backlash Allowance of a Bevel Gear
MILLING THE BEVEL GEAR TEETH
Rolling The Gear Blank
Figure 14-21.--Worm and worm gear.
Figure 14-23.--Development of lead angle and linear pitch (normal).
SELECTING A WORM WHEEL CUTTER
WORM WHEEL HOBS
CUTTING WORM WHEEL TEETH ON A MILLING MACHINE
AMERICAN STANDARD SYSTEM
Figure 14-26.--Development of setover and depth increase.
Figure 14-27.--Types of sprockets.
MATERIAL FOR SPROCKETS
CHAPTER 15 - METALLURGY AND HEAT TREATMENT
CRYSTALS AND GRAINS
Figure 15-1.--Atom arrangement in a space lattice system.
Figure 15-3.--Microscopic structure called martensite magnified 2,500 times.
INTERNAL STRUCTURE OF METALS
HEAT-TREATING EQUIPMENT
Figure 15-7.--Exploded view of electric furnace used for heat-treating.
Figure 15-8.--Grid for heat-treating furnace.
Table 15-2.--Oxide Colors for Steel of Various Temperatures
Table 15-3.--Average Cooling Rates of Some Liquids and Gases Used for Cooling, as Compared with Cooling Rate of Water at 65F
Figure 15-10.--Portable quenching tank for use in heat-treating.
Figure 15-11.--Iron-carbon phase diagram.
TRANSFORMATION TEMPERATURES
Figure 15-13.--Phase diagram for carbon steels.
Figure 15-14.--Microstructural constituents of slowly cooled carbon steel (all etched with either picral or nital).
EFFECTS OF HEATING, HOLDING, AND COOLING
Isothermal Transformation
Continuous Cooling
Figure 15-17.--Influence of carbon on the start of martensite (Ms ) transformation of high-purity, iron-carbon alloys.
Figure 15-18.--Heat treatment temperature ranges.
TEMPERING
Figure 15-19.--Microscopic structure called spherodite magnified 1,000 times.
CASE HARDENING
Table 15-4.--Heat-Treating Temperatures and Quenching Medium for Standard SAE Steels
HEAT-TREATING NONFERROUS METALS
Figure 15-22.--Two designs for undercutting a form tool. A. Poor design. B. Correct design.
SIZE CHANGES
ROCKWELL HARDNESS TEST
Figure 15-24.--Principle of the Rockwell hardness test.
FILE HARDNESS TEST
APPENDIX I - GLOSSARY
APPENDIX I - GLOSSARY - Continued
APPENDIX II - TABULAR INFORMATION OF BENEFIT TO A MACHINERY REPAIRMAN
Table AII-2.--Decimal Equivalents of Millimeters
Table AII-3.--Dividing a Circle into Parts
Table AII-4.--Formulas for Dimension, Area, and Volume
Table AII-4.--Formulas for Dimension, Area, and Volume--Continued
Table AII-5.--Number, Letter and Fractional Identification of Drill Sizes (Letter drills are larger than number drills; they begin where number drills end.)
Table AII-6.--Units of Weight, Volume, and Temperature
Table AII-7.--Screw Thread and Tap Drill Sizes (American National)
Table AII-8.--American National Pipe Thread
Table AII-9.--3-Wire Method of Measuring American National Standard Threads
Table AII-10.--Diagonals of Squares and Hexagons
Table AII-11.--Circles
Table AII-12.--Keyway Dimensions
Table AII-13. - Taper Per Foot Corresponding Angles
Table AII-14.--Taper in Inches (Brown and Sharpe)
Standard Tapers (Morse)
Table AII-16.--Drill Sizes for Taper Pins
Table AII-16.--Drill Sizes for Taper Pins--Continued
APPENDIX III - FORMULAS FOR SPUR GEARING
APPENDIX III - FORMULAS FOR SPUR GEARING - Continued
APPENDIX III - FORMULAS FOR SPUR GEARING - Continued
APPENDIX IV - DERIVATION OF FORMULAS FOR DIAMETRAL PITCH SYSTEM
APPENDIX IV - DERIVATION OF FORMULAS FOR DIAMETRAL PITCH SYSTEM - Continued
APPENDIX IV - DERIVATION OF FORMULAS FOR DIAMETRAL PITCH SYSTEM - Continued
APPENDIX V - REFERENCES USED TO DEVELOP THE TRAMAN
APPENDIX V - REFERENCES USED TO DEVELOP THE TRAMAN - Continued
APPENDIX V - REFERENCES USED TO DEVELOP THE TRAMAN - Continued
TOOLROOM SAFETY
Figure 1-1.--Method of tool storage.
Figure 1-2.--Method of tool storage.
Figure 1-3.--Method of tool storage.
Figure 1-4.--Common types of micrometers.
Figure 1-5.--Nomenclature of an outside micrometer caliper.
Figure 1-7.--Applications of a dial indicator.
Figure 1-8.--Vernier caliper.
Figure 1-9.--Vernier height gauge.
Figure 1-10.--Dial vernier caliper.
Figure 1-11.--Dial bore gauge.
Figure 1-12.--Universal vernier bevel protractor.
Figure 1-14.--Gear tooth vernier.
Figure 1-15.--Cutter clearance gauge.
Figure 1-17.--Setting a dimension on a surface gauge.
ACME THREAD TOOL GAUGE
Figure 1-21.--Feeler (thickness) gauge.
Figure 1-26.--Parallel blocks.
THREAD MEASURING WIRES
MICROMETERS
VERNIER GAUGES
CHAPTER 2 - LAYOUT AND BENCHWORK
Figure 2-1.--Basic dimension and tolerance.
Figure 2-2.--Relation of symbols to surface characteristics.
Figure 2-4.--Symbols indicating the direction of lay.
Figure 2-5.--Roughness height values for machine operations.
Figure 2-8.--The interference (surface-finish) microscope
Figure 2-9.--The profilometer measuring the surface roughness of an internal diameter.
Figure 2-11.--Checking surface finish on the machine.
Figure 2-15.--Laying out parallel lines with a combination square
LAYING OUT CIRCLES AND IRREGULAR LINES
USING THE SURFACE PLATE
Figure 2-24.--Setting and using a surface gauge.
GEOMETRIC CONSTRUCTION OF LAYOUT LINES
LAYING OUT VALVE FLANGE BOLT HOLES
Figure 2-30.--Flange layout terminology.
Figure 2-32.--Four-hole flange development.
Figure 2-34.--Checking a surface.
Figure 2-36.--Polishing.
HYDRAULIC AND ARBOR PRESSES
Figure 2-38.--Broaching a keyway on a gear.
Figure 2-39.--Screw thread insert.
OXYACETYLENE EQUIPMENT
Figure 2-41.--Typical oxyacetylene cylinder bank.
SETTING UP OXYACETYLENE EQUIPMENT
SAFETY: OXYACETYLENE EQUIPMENT
BACKFIRE AND FLASHBACK
CHAPTER 3 - METALS AND PLASTICS
Corrosion Resistance
TYPES OF METALS
Nonferrous Metals
ALUMINUM ALLOYS
DESIGNATIONS AND MARKINGS OF METALS
Table 3-1.--SAE Numbers with Their Corresponding Alloying Elements
Table 3-2.--Aluminum and Aluminum Alloy Classifications
Standard Marking of Metals
Figure 3-1.--Examples of continuous identification marking.
Table 3-3.--Rapid Identification of Metals
Figure 3-2.--Fundamental spark forms.
Figure 3-3.--Spark pictures formed by common metals.
Acid Test
MACHINING OPERATIONS
Table 3-4.--Major Groups of Plastic
Table 3-4.--Major Groups of Plastic--Continued
Lathe Operations
CHAPTER 4 - POWER SAWS AND DRILLING MACHINES
Figure 4-2.--Hacksaw blade.
CONTINUOUS FEED CUTOFF SAW
Band Selection and Installation
Figure 4-7.--Set and side clearance.
Polishing Bands
FILE BAND AND POLISHING BAND GUIDES
Selection Of Saw Bands, Speeds And Feeds
Sizing, Splicing, And Installing Bands
BAND LENGTH
Figure 4-17.--Upper wheel tilt adjustment.
Figure 4-18.--Work jaw and feed chain adjustment.
ANGULAR CUTTING
Figure 4-22.--Disk-cutting attachment.
Figure 4-24.--General purpose drill press.
Figure 4-27.--Radial drill press.
Figure 4-28.--The parts of a twist drill.
DRILLING OPERATIONS
Holding the Work
Figure 4-30.--Common types of clamping straps.
Figure 4-33.--Using a half-round chisel to guide a drill to the correct center.
Figure 4-36.--Examples of spotfacing.
Figure 4-38.--Equipment for drilling angular holes. A. Chuck; B. Guide plate; C. Guide holder; D. Slip bushing; E. Angular drill.
Figure 4-39.--Lathe setup for drilling an angular hole.
OPERATION
CHAPTER 5 - OFFHAND GRINDING OF TOOLS A N D SELECTION OF CARBIDE TOOLING
Figure 5-2.--Grinding on a pedestal grinder.
Figure 5-4.--Standard marking system for grinding wheels (except diamond).
Figure 5-5.--How bond affects the grade of the wheel. Wheel A, softer; wheel B, harder.
GRINDING WHEEL SELECTION AND USE
TRUING AND DRESSING THE WHEEL
Figure 5-10.--Crown on the working face of a wheel for a carbide tool bit grinder.
Figure 5-11.--Chip breaker grinder.
CEMENTED CARBIDE
Figure 5-12.--Three causes of tool breakage.
Figure 5-13.--Surface finish vs nose radius chart.
Figure 5-16.--Toolholders for carbide inserts.
Figure 5-17.--Boring bars for carbide inserts.
Side Cutting Edge
GROUND-IN CHIP BREAKERS
Figure 5-20.--Lathe tools and their application.
GRINDING HIGH-SPEED ENGINE LATHE CUTTING TOOLS
SHAPER AND PLANER TOOLS
GRINDING HANDTOOLS
Figure 5-27.--Checking the squareness of the end of a screwdriver
Figure 5-32.--Grinding drill lip correctly.
Figure 5-34.--Three steps for grinding a twist drill with a grinder
SHARPENING A TWIST DRILL TO DRILL BRASS
CHAPTER 6 - ENGINE LATHES
Figure 6-1.--Gear-head engine lathe.
Figure 6-2.--Rear view of lathe.
Figure 6-3.--Sliding gear-type headstock
Figure 6-6.--Cross section of a tailstock.
Figure 6-7.--Side view of a carriage mounted on the bed.
Figure 6-9.--Rear view of a lathe apron.
FEED ROD
QUICK-CHANGE GEAR MECHANISM
COMPOUND REST
Figure 6-13.--Castle-type toolpost and toolholder.
Figure 6-14.--Quick-change toolpost.
Figure 6-19.--Quick-change toolholder.
Figure 6-21.--Three-jaw universal chuck.
LATHE CENTERS
Figure 6-26.--Cutaway showing the construction of a hall bearing center.
Figure 6-29.--Center rest.
GRINDING ATTACHMENT
Figure 6-34.--Grinder mounted on a compound rest.
OTHER TYPES OF ENGINE LATHES
Figure 6-37.--A gap lathe.
The Spirit Level Method
PREPARING THE CENTERS
SETTING THE TOOLHOLDER AND CUTTING TOOL
Holding Work Between Centers
Figure 6-45.--Boring center hole.
Holding Work on a Mandrel
Figure 6-48.--A split-shell expansion mandrel.
Holding Work In Chucks
RUBBER FLEX COLLET CHUCK
Holding Work On a Faceplate
Using the Center Rest and Follower Rest
CUTTING SPEEDS AND FEEDS
COOLANTS
Figure 6-60.--Right-hand side tool.
Rough Turning
PARTING AND GROOVING
DRILLING AND REAMING
Figure 6-68.--Application of boring bar holder.
SETTING UP THE TOOLPOST GRINDER
Figure 6-73.--Position of the diamond dresser.
Figure 6-75.--Tapers.
Methods of Turning Tapers
USING the COMPOUND REST
USING THE TAPER ATTACHMENT
Methods of Boring Tapers
Figure 6-81.--Screw thread nomenclature.
V-FORM THREADS
Figure 6-82.--Threading tool setup for V-form threads.
The Acme Screw Thread
Buttress Thread
CLASSES OF THREADS
Figure 6-88.--Measuring threads with a thread micrometer.
CUTTING SCREW THREADS ON THE LATHE
Position of Compound Rest for Cutting Screw Threads
Engaging the Thread Feed Mechanism
Figure 6-44--Strew pitch gauge.
Figure 6-98.--Setup for left-hand external threads.
Figure 6-99.--Comparison of single- and multiple-lead threads
THREADS ON TAPERED WORK
CHAPTER 7 - MILLING MACHINES AND MILLING OPERATIONS
Figure 7-3.--Vertical spindle milling machine.
MAJOR COMPONENTS
Figure 7-6.--Universal knee and column milling machine with horizontal spindle.
Figure 7-7.--Spindle drawbolt.
ARBOR SUPPORT
RIGHT-ANGLE PLATE
CIRCULAR MILLING ATTACHMENT
Figure 7-13.--Dividing head mechanism.
INDEXING EQUIPMENT
DIRECT INDEXING
PLAIN INDEXING
ANGULAR INDEXING
COMPOUND INDEXING
DIFFERENTIAL INDEXING
WIDE RANGE DIVIDER
ADJUSTING THE SECTOR ARMS
Figure 7-22.--Plain milling cutters.
Figure 7-23.--Milling cutter terms.
Figure 7-24.--Side milling cutter.
Figure 7-30.--Screw slotting cutter.
Figure 7-33.--End mill cutters.
Figure 7-35.--End mill terms.
Figure 7-36.--Inserted tooth face milling cutter.
Figure 7-42.--Corner rounding cutter.
Figure 7-45.--Fly cutter arbor and fly cutters.
Figure 7-47.--Standard milling machine arbors.
Shell End Arbor
Cutter Adapter
MILLING MACHINE OPERATIONS
PLAIN MILLING
Figure 7-56.--Face milling.
Figure 7-57.--Aligning vise jaws using an indicator.
Figure 7-60.--Angular milling.
Figure 7-61.--Milling a square on work held vertically.
Figure 7-63.--Milling a square using an end mill.
Figure 7-65.--Diagram of a hexagon.
Square or Hexagon Work Mounted Between Centers
Machining Two Flats in One Plane
SLOTTING, PARTING, AND MILLING KEYSEATS
Figure 7-69.--Aligning the cutter using a paper strip.
Figure 7-71.--Visual alignment of a cutter.
Figure 7-73.--Woodruff keyseat cutter.
Figure 7-74.--Milling a Woodruff keyseat.
Figure 7-75--Dimensions for a Woodruff keyseat.
Figure 7-76.--Offset boring head and boring tools.
MILLING MACHINE ATTACHMENTS
VERTICAL MILLING ATTACHMENT
FEEDS, SPEEDS, AND COOLANTS
Table 7-3.--Cutter Speeds in Revolutions Per Minute
FEEDS, SPEEDS, AND COOLANTS - Continued
Table 7-4.--Recommended Chip Loads
VERTICAL TURRET LATHE
Figure 8-2.--A 36-inch vertical turret lathe.
VERTICAL TURRET LATHE TOOLING
Figure 8-3.--Refacing a valve seat in a vertical turret lathe.
Figure 8-6.--Head setting for 30 to 45 angles.
Figure 8-8.--Horizontal boring mill.
COMBINATION BORING AND FACING HEAD
BORING MILL OPERATIONS
Figure 8-11.--Drilling in the horizontal boring mill.
Reconditioning Split-Sleeve Bearings
Figure 8-13.--Line shaft bearing that has had the "cheeks" or oil reservoir grooves cut into it.
CHAPTER 9 - SHAPERS, PLANERS, AND ENGRAVERS
CROSSRAIL ASSEMBLY
Figure 9-4.--Mechanical table feed mechanism.
Figure 9-5.--Toolhead assembly in various positions.
Figure 9-7.--Toolholders.
Figure 9-8.--Squaring the table and the vise.
Table 9-1.--Recommended Cutting Speeds for Various Metals
Figure 9-9.--Cutting a keyway in the middle of a shaft.
Figure 9-10.--Internal keyway: A. Shaping an internal keyway in a gear. B. Depth of keyways.
Figure 9-11.--Shaping irregular surfaces.
VERTICAL SHAPERS
MAJOR COMPONENTS
OPERATING THE PLANER
Figure 9-16.--Correct and incorrect clamp applications.
Figure 9-19.--Computer-controlled engraving machine.
SETTING THE PANTOGRAPH
Figure 9-20.--Cutter grinder.
Grinding Single-Flute Cutters
GRINDING THE CHIP CLEARANCE
PANTOGRAPH ATTACHMENTS
PANTOGRAPH ATTACHMENTS - Continued
ENGRAVING A DIAL FACE
ENGRAVING A DIAL FACE - Continued
CHAPTER 10 - PRECISION GRINDING MACHINES
Figure 10-1.--Grain depth of cut; center-type machine.
Figure 10-3.--Surface grinding a cylindrical workpiece.
Figure 10-4.--Overlapping disk balancing ways (roller type).
CROSS TRAVERSE TABLE
Figure 10-8.--Magnetic chuck used for holding a tool grinding fixture.
Figure 10-10.--Grinding a spacer on a surface grinder.
CYLINDRICAL GRINDER
CYLINDRICAL GRINDER OPERATION
Figure 10-12.--Tool and cutter grinder (workhead and footstock).
Figure 10-13.--Tool grinding setups on a tool and cutter grinder. A. Straight wheel grinding a milling cutter. B. Cup wheel grinding a reamer.
Setting the Clearance Angle
Figure 10-18.--Cutter clearance angles.
Plain Milling Cutters (Helical Teeth)
Side Milling Cutters
Figure 10-23.--Staggered-tooth side milling cutter.
Figure 10-26.--Resting the face of a tooth on its corresponding side of the tooth rest blade.
End Mills
Figure 10-30.--Involute gear cutter.
PORTABLE HONING EQUIPMENT
STATIONARY HONING MACHINE
HONING HINTS
CHAPTER 11 - COMPUTER NUMERICAL CONTROL MACHINES
Figure 11-1.--CNC vertical spindle milling machine.
CNC VERTICAL SPINDLE MILLING MACHINE
Figure 11-4.--CNC programming station.
NUMERICAL CONTROL SYSTEMS
Figure 11-6.--A typical CNC controller.
Figure 11-7.--Point-to-point angles and arcs.
Figure 11-8.--Continuous-path angles and arcs.
Figure 11-11.--Incremental positioning system.
THERMAL SPRAY SYSTEMS
Figure 12-1.--Typical installation for combustion gas spraying.
Powder-Oxygen-Fuel Spray
PREPARING THE SURFACES
Figure 12-8.--Profile of an anchor-tooth pattern.
APPLYING THE COATING
CONTACT ELECTROPLATING
Figure 12-10.--Electroplating equipment.
OPERATOR QUALIFICATION
PLATING PROCEDURES
CHAPTER 13 - REPAIR WORK
PLANNED MAINTENANCE SYSTEM
Figure 13-2.--Steps in making a shaft.
REPAIRING VALVES
Figure 13-3.--Examples of spotted-in valve seats.
Figure 13-4.--Lapping tools.
Figure 13-7.--Typical ball stop swing-check valve for seawater service
Figure 13-8.--Cutaway view of a gate stop valve (rising stem type).
Figure 13-9.--Cross-sectional views of gate stop valves (nonrising stem type).
Figure 13-10.--Constant-pressure governor for main feed pump.
CONTROL AND MAIN VALVE
Repairing Double-Seated Valves
Repairing Duplex Strainer Plug Valves
Figure 13-14.--Stuffhg box on a centrifugal pump.
Figure 13-16.--Removing a broken stud with locking pliers.
Figure 13-17.--Removing a broken bolt with a prick punch.
Figure 13-22.--Using a plug weld to remove a broken tap.
Figure 13-23.--Metal disintegrator removing a broken stud.
IN PLACE MACHINING
Figure 13-25.--Portable boring bar.
MATERIALS USED FOR GEARS
SPUR GEAR TERMINOLOGY
DIAMETRAL PITCH SYSTEM
Figure 14-3.--Measuring gear teeth with a vernier caliper.
MACHINING THE GEAR
HELICAL GEARS
Figure 14-7.--Development of the helix angle.
Figure 14-8.--Formulation of a lead triangle and a helix angle.
Table 14-2.--Corrected Tooth Constant
Corrected Chordal Addendum and Chordal Thickness
Center-to-Center Distance
MANUFACTURING A HELICAL GEAR
Figure 14-13.--Other forms of bevel gears.
Figure 14-14.--Development of the mating gear triangle.
Figure 14-15.--Parts of a bevel gear.
Figure 14-16.--Development of bevel gear formulas.
BEVEL GEAR NOMENCLATURE
Backlash Allowance of a Bevel Gear
MILLING THE BEVEL GEAR TEETH
Rolling The Gear Blank
Figure 14-21.--Worm and worm gear.
Figure 14-23.--Development of lead angle and linear pitch (normal).
SELECTING A WORM WHEEL CUTTER
WORM WHEEL HOBS
CUTTING WORM WHEEL TEETH ON A MILLING MACHINE
AMERICAN STANDARD SYSTEM
Figure 14-26.--Development of setover and depth increase.
Figure 14-27.--Types of sprockets.
MATERIAL FOR SPROCKETS
CHAPTER 15 - METALLURGY AND HEAT TREATMENT
CRYSTALS AND GRAINS
Figure 15-1.--Atom arrangement in a space lattice system.
Figure 15-3.--Microscopic structure called martensite magnified 2,500 times.
INTERNAL STRUCTURE OF METALS
HEAT-TREATING EQUIPMENT
Figure 15-7.--Exploded view of electric furnace used for heat-treating.
Figure 15-8.--Grid for heat-treating furnace.
Table 15-2.--Oxide Colors for Steel of Various Temperatures
Table 15-3.--Average Cooling Rates of Some Liquids and Gases Used for Cooling, as Compared with Cooling Rate of Water at 65F
Figure 15-10.--Portable quenching tank for use in heat-treating.
Figure 15-11.--Iron-carbon phase diagram.
TRANSFORMATION TEMPERATURES
Figure 15-13.--Phase diagram for carbon steels.
Figure 15-14.--Microstructural constituents of slowly cooled carbon steel (all etched with either picral or nital).
EFFECTS OF HEATING, HOLDING, AND COOLING
Isothermal Transformation
Continuous Cooling
Figure 15-17.--Influence of carbon on the start of martensite (Ms ) transformation of high-purity, iron-carbon alloys.
Figure 15-18.--Heat treatment temperature ranges.
TEMPERING
Figure 15-19.--Microscopic structure called spherodite magnified 1,000 times.
CASE HARDENING
Table 15-4.--Heat-Treating Temperatures and Quenching Medium for Standard SAE Steels
HEAT-TREATING NONFERROUS METALS
Figure 15-22.--Two designs for undercutting a form tool. A. Poor design. B. Correct design.
SIZE CHANGES
ROCKWELL HARDNESS TEST
Figure 15-24.--Principle of the Rockwell hardness test.
FILE HARDNESS TEST
APPENDIX I - GLOSSARY
APPENDIX I - GLOSSARY - Continued
APPENDIX II - TABULAR INFORMATION OF BENEFIT TO A MACHINERY REPAIRMAN
Table AII-2.--Decimal Equivalents of Millimeters
Table AII-3.--Dividing a Circle into Parts
Table AII-4.--Formulas for Dimension, Area, and Volume
Table AII-4.--Formulas for Dimension, Area, and Volume--Continued
Table AII-5.--Number, Letter and Fractional Identification of Drill Sizes (Letter drills are larger than number drills; they begin where number drills end.)
Table AII-6.--Units of Weight, Volume, and Temperature
Table AII-7.--Screw Thread and Tap Drill Sizes (American National)
Table AII-8.--American National Pipe Thread
Table AII-9.--3-Wire Method of Measuring American National Standard Threads
Table AII-10.--Diagonals of Squares and Hexagons
Table AII-11.--Circles
Table AII-12.--Keyway Dimensions
Table AII-13. - Taper Per Foot Corresponding Angles
Table AII-14.--Taper in Inches (Brown and Sharpe)
Standard Tapers (Morse)
Table AII-16.--Drill Sizes for Taper Pins
Table AII-16.--Drill Sizes for Taper Pins--Continued
APPENDIX III - FORMULAS FOR SPUR GEARING
APPENDIX III - FORMULAS FOR SPUR GEARING - Continued
APPENDIX III - FORMULAS FOR SPUR GEARING - Continued
APPENDIX IV - DERIVATION OF FORMULAS FOR DIAMETRAL PITCH SYSTEM
APPENDIX IV - DERIVATION OF FORMULAS FOR DIAMETRAL PITCH SYSTEM - Continued
APPENDIX IV - DERIVATION OF FORMULAS FOR DIAMETRAL PITCH SYSTEM - Continued
APPENDIX V - REFERENCES USED TO DEVELOP THE TRAMAN
APPENDIX V - REFERENCES USED TO DEVELOP THE TRAMAN - Continued
APPENDIX V - REFERENCES USED TO DEVELOP THE TRAMAN - Continued
