Machinery repairman

MACHINERY REPAIRMAN
1993 Edition Prepared by MRCS Wayne T. Drew
NAVAL EDUCATION AND TRAINING PROGRAM
UNITED STATES, GOVERNMENT PRINTING OFFICE
WASHINGTON, D.C.: 1990
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CHAPTER 1 - TOOLROOMS AND TOOLS
TOOLROOM ORGANIZATION
You may be given responsibility for the operation of the tool crib or tool-issuing room. Make sure that the necessary tools are available and in good condition and that an adequate supply of consumable items (oil, wiping rags, bolts, nuts, and screws) is available. It’s easy to operate and maintain a toolroom if the correct procedures and methods are used to set up the system. Some of the basic considerations are (1) the issue and custody of tools; (2) replacement of broken, worn, or lost tools; and (3) proper storage and maintenance of tools.
Shipboard toolrooms are limited in size by the design of the ship. Therefore, the space must be used as efficiently as possible. Since the number of tools required aboard ship is extensive, toolrooms usually tend to be overcrowded. Certain peculiarities in shipboard toolrooms also require consideration. For example, the motion of the ship at sea requires that tools be made secure to prevent movement. The moisture in the air requires that the tools be protected from corrosion. It’s difficult to change permanent bins, shelves, and drawers in the toolroom. However, you can reorganize existing storage spaces by dividing larger bins and relocating tools to provide better use of space.
Hammers, wrenches, and other tools that do not have cutting edges are normally stored in bins. They also may be segregated by size or other designation. Tools with cutting edges require more space to prevent damage to the cutting edges. These tools are stored on shelves lined with wood or felt, on pegboards, or on hanging racks. Pegboards are especially adaptable for tools such as milling cutters. Make provisions to keep these tools from falling off the boards when the ship is rolling. Store precision tools (micrometers, dial indicators, and so forth) in felt-lined wooden boxes in a cabinet to reduce the effects of vibration. This arrangement allows a quick daily inventory. It also prevents the instruments from being damaged by contact with other tools. Use rotating bins to store large supplies of small parts, such as nuts and bolts. Rotating bins provide rapid selection from a wide range of sizes.
Place frequently used tools near the issuing door so they are readily available. Place seldom used tools in out of the way areas such as on top of bins or in spaces that cannot be used efficiently because of size and shape. Place heavy tools in spaces or areas where a minimum of lifting is required. Mark all storage areas such as bins, drawers, and lockers clearly to help locate tools. Make these markings permanent- either stencil them with paint or mark them with stamped metal tags.
TOOL INSPECTION
If you are the toolroom keeper, you’ll be responsible for the condition of all the tools and equipment in the toolroom. This is a very important job. Inspect all tools as they are returned to determine if they need repairs or adjustment. NEVER issue damaged tools since they may harm shop equipment or personnel. Set aside a space for damaged tools to prevent issue of these tools until they have been repaired. Send any dull cutting tools to the grind shop for regrinding. Properly dispose of any cutting tools that can’t be reground.
Wipe clean all returned tools and give their metal surfaces a light coat of oil. Check all precision tools upon issue and return to determine if they are accurate. Keep all spaces clean and free of dust to prevent foreign matter from getting into the working parts of tools. Plan to spend a portion of each day reconditioning damaged tools. This keeps the tools available for issue and prevents an accumulation of damaged tools.
CONTROL OF TOOLS
There are two common methods of tool issue control: the tool check system and the mimeographed form or tool chit system. Some toolrooms may use a combination of these systems. For example, you may use tool checks for machine shop personnel, and mimeographed forms for personnel outside the shop. Tool checks are either metal or plastic disks stamped with numbers that identify the borrower. In this system the borrower presents a check for each tool, and the disk is placed on a peg near the space from which the tool was taken. The advantage of this system is that very little time is spent completing the process.
If the tools are loaned to all departments in the ship, printed forms generally are used. The form has a space to list the tools, the borrower’s name, the division or department, and the date. This system allows anyone in the ship’s crew to borrow tools, and it keeps the toolroom keeper informed as to who has the tools and how long they have been out. You must know the location of tools and equipment out on loan, how long tools have been out, and the amount of equipment and consumable supplies you have on hand. To know this, you’ll have to make periodic inventories. The inventory consists of a count of all tools, by type, in the toolroom and those out on loan. Inventories help you decide whether more strict control of equipment is needed and if you need to procure more tools and equipment. Some selected items, called controlled equipage, will require an increased level of management and control due to their high cost, vulnerability to pilferage, or importance to the ship’s mission. The number of tools and instruments in this category is generally small. However, it is important that you be aware of controlled equipage items. You can get detailed information about the designation of controlled equipage from the supply department of your activity. When these tools are received from the supply department, your department head will be required to sign a custody card for each item, indicating a definite responsibility for management of the item. The department head will then require signed custody cards from personnel assigned to the division or shop where the item will be stored and used. As a toolroom keeper, you may control the issue of these tools and ensure their good condition. If these special tools are lost or broken beyond repair, you cannot replace them until the correct survey procedures have been completed. Conduct formal inventories of these items periodically as directed by your division officer or department head.
Shipboard toolrooms are limited in size by the design of the ship. Therefore, the space must be used as efficiently as possible. Since the number of tools required aboard ship is extensive, toolrooms usually tend to be overcrowded. Certain peculiarities in shipboard toolrooms also require consideration. For example, the motion of the ship at sea requires that tools be made secure to prevent movement. The moisture in the air requires that the tools be protected from corrosion. It’s difficult to change permanent bins, shelves, and drawers in the toolroom. However, you can reorganize existing storage spaces by dividing larger bins and relocating tools to provide better use of space.
Hammers, wrenches, and other tools that do not have cutting edges are normally stored in bins. They also may be segregated by size or other designation. Tools with cutting edges require more space to prevent damage to the cutting edges. These tools are stored on shelves lined with wood or felt, on pegboards, or on hanging racks. Pegboards are especially adaptable for tools such as milling cutters. Make provisions to keep these tools from falling off the boards when the ship is rolling. Store precision tools (micrometers, dial indicators, and so forth) in felt-lined wooden boxes in a cabinet to reduce the effects of vibration. This arrangement allows a quick daily inventory. It also prevents the instruments from being damaged by contact with other tools. Use rotating bins to store large supplies of small parts, such as nuts and bolts. Rotating bins provide rapid selection from a wide range of sizes.
Place frequently used tools near the issuing door so they are readily available. Place seldom used tools in out of the way areas such as on top of bins or in spaces that cannot be used efficiently because of size and shape. Place heavy tools in spaces or areas where a minimum of lifting is required. Mark all storage areas such as bins, drawers, and lockers clearly to help locate tools. Make these markings permanent- either stencil them with paint or mark them with stamped metal tags.
TOOL INSPECTION
If you are the toolroom keeper, you’ll be responsible for the condition of all the tools and equipment in the toolroom. This is a very important job. Inspect all tools as they are returned to determine if they need repairs or adjustment. NEVER issue damaged tools since they may harm shop equipment or personnel. Set aside a space for damaged tools to prevent issue of these tools until they have been repaired. Send any dull cutting tools to the grind shop for regrinding. Properly dispose of any cutting tools that can’t be reground.
Wipe clean all returned tools and give their metal surfaces a light coat of oil. Check all precision tools upon issue and return to determine if they are accurate. Keep all spaces clean and free of dust to prevent foreign matter from getting into the working parts of tools. Plan to spend a portion of each day reconditioning damaged tools. This keeps the tools available for issue and prevents an accumulation of damaged tools.
CONTROL OF TOOLS
There are two common methods of tool issue control: the tool check system and the mimeographed form or tool chit system. Some toolrooms may use a combination of these systems. For example, you may use tool checks for machine shop personnel, and mimeographed forms for personnel outside the shop. Tool checks are either metal or plastic disks stamped with numbers that identify the borrower. In this system the borrower presents a check for each tool, and the disk is placed on a peg near the space from which the tool was taken. The advantage of this system is that very little time is spent completing the process.
If the tools are loaned to all departments in the ship, printed forms generally are used. The form has a space to list the tools, the borrower’s name, the division or department, and the date. This system allows anyone in the ship’s crew to borrow tools, and it keeps the toolroom keeper informed as to who has the tools and how long they have been out. You must know the location of tools and equipment out on loan, how long tools have been out, and the amount of equipment and consumable supplies you have on hand. To know this, you’ll have to make periodic inventories. The inventory consists of a count of all tools, by type, in the toolroom and those out on loan. Inventories help you decide whether more strict control of equipment is needed and if you need to procure more tools and equipment. Some selected items, called controlled equipage, will require an increased level of management and control due to their high cost, vulnerability to pilferage, or importance to the ship’s mission. The number of tools and instruments in this category is generally small. However, it is important that you be aware of controlled equipage items. You can get detailed information about the designation of controlled equipage from the supply department of your activity. When these tools are received from the supply department, your department head will be required to sign a custody card for each item, indicating a definite responsibility for management of the item. The department head will then require signed custody cards from personnel assigned to the division or shop where the item will be stored and used. As a toolroom keeper, you may control the issue of these tools and ensure their good condition. If these special tools are lost or broken beyond repair, you cannot replace them until the correct survey procedures have been completed. Conduct formal inventories of these items periodically as directed by your division officer or department head.
CONTENTS
- Toolrooms and Tools
- Layout and Benchwork
- Metals and plastics
- Power Saws and Drilling Machines
- Offhand Grinding of Tools and Selection of Carbide Tools
- Engine Lathes
- Milling Machines and Milling Operations
- Vertical Turret Lathe and Horizontal Boring Mill
- Shapers, Planers, and Engravers
- Precision Grinding Machines
- Computer Numerical Control Machines
- Metal Buildup
- Repair Work
- Gears and Gear Cutting
- Metallurgy and Heat Treating
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