US Army - Fundamentals of Machine Tools TC 9-524.pdf - US army - piotrzachu69

] TC 9-524

TC 9-524

Preface

The purpose of this training circular is to provide a better understanding of power-driven machine tools. It also

supplements technical manuals in the 9-3400-series covering power-driven machine tools.

One of the main objectives is for this publication is to be clear and understandable. Illustrations throughout this

publication show the step-by-step process of many machine shop operations. The tables, charts, formulas, weights,

and measurements in this publication can be a ready reference for selecting the proper tooling and math formulas

for machining different materials.

The proponent of this publication is HQ TRADOC. Send comments and recommendations on DA Form 2028

directly to the Department of the Army, Training Directorate, ATTN: ATCL-AO, 801 Lee Avenue, Fort Lee,

Virginia 23801-1713.

Unless this publication states otherwise, masculine nouns and pronouns do not refer exclusively to men.

TC 9-524

Chapter 1

INTRODUCTION TO THE MACHINE SHOP

GENERAL INFORMATION

machines, brake reliners, valve seat grinders. and so forth) by

various manufacturers, no attempt has been made to include

information pertinent to them in this manual. For complete

information on these tools, see pertinent TM 9-3400-, TM 9-

5100-, and TM 9-9000-series technical manuals covering the

specific machines.

FORMS, RECORDS, AND REPORTS

Accurate records are valuable. Unit officers are responsible

for completion of forms, records, and reports. DA Pam 738-

750 lists records, reports, and authorized forms that are

normally used for inspection and repair. Properly executed

forms authorize and record repair or replacement of materiel.

The forms, records, and reports document the work required,

follow the progress of the work within the shops, and indicate

the status of the material upon completion of repairs.

RISK-MANAGEMENT

To assure a high degree of safety, no machine -tool is to be

used unless the risk management process as outlined below is

understood and applied by the user and the supervisor:

FIELD REPORT OF ACCIDENTS

1. Identify the potential hazard(s) that the machine tool can

generate.

The reports necessary to comply with the requirements of

the Army Safety Program are prescribed in detail in AR 385-

40. These reports are required for any accidents involving

injury or damage. For a listing of all forms, refer to DA Pam

25-30.

2. Assess the probability and severity of the hazard(s) by

utilizing the Risk Assessment Matrix in figure 1-1. Risk

acceptance decision authority for the risk levels is as follows:

Any deficiencies detected in the equipment covered herein

should be immediately reported in accordance with DA Pam

738-750. These reports will be submitted as an Equipment

Improvement Recommendation on SF 368.

a. Extremely high - CG, TRADOC; DCG, TRADOC;

or the Chief of Staff, TRADOC.

b. High - Major subordinate commands, installation

commanding generals, and school commandants of general

officer rank.

DEFINITION OF MACHINE TOOLS

c. Moderate and low - Delegated to the appropriate

level in your unit chain of command.

Machine tools are power-driven equipment designed to

drill, bore, grind, or cut metal or other material.

3. Determine the risk control measures that will eliminate the

hazard(s) or reduce the risk.

LISTING OF MACHINE TOOLS

4. Implement the risk control measures before and during

operation of the machine tool to eliminate the hazards or

reduce their risks.

A complete list of machine tools including specialized

machine tools currently authorized for issue is in Component

List C 3405/70-lL.

5. Supervise and evaluate the process. Enforce the

established standards and risk control measures. Evaluate the

effectiveness of the control measures and adjust/update them

as necessary.

SPECIALIZED MACHINE TOOLS

In view of the different design and operating features

incorporated in specialized machine tools (cylinder boring

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TC 9-524

PROBABILITY

SEVERITY

FREQUENT - Individual soldier/item - Occurs often in

the career/equipment service life. All soldiers or item

inventory exposed - Continuously experienced during

operation/mission.

I. CATASTROPHIC - Death or permanent total

disability. System loss. Major property damage.

II CRITICAL - Permanent partial disability. Temporary

total disability in excess of 3 months. Major system damage.

Significant property damage.

LIKELY - Individual soldier/item - Occurs several times

in career/equipment service life. - All soldiers or item

inventory

frequently during

exposed.

- Occurs

III. MARGINAL - Minor injury. Lost workday accident

with compensable injury/illness. Mirror system damage.

Minor property damage.

operator/mission.

OCCASIONAL - Individual soldier/item. - Occurs

sometimes in career/equipment service life. All soldiers

or item inventory exposed. Occurs sporadically, or

several times in inventory service or operations/mission.

supportive medical

IV. NEGLIGIBLE - First aid or minor

treatment. Minor system impairment.

RISK LEVELS

REMOTE - Individual soldier/item - Possible to occur

in career/equipment service life. All soldiers or item

inventory exposed, Remote chance of occurrence -

Expected to occur sometime in inventory service life or

operation/mission.

Loss of ability to accomplish

EXTREMELY HIGH -

mission.

HIGH - Significantly degrades mission capabilities in terms

of required mission standards.

UNLIKELY - Individual soldier/item - Can assume will

not occur in career/equipment/service life. All soldiers

or item inventory exposed. - Possible, but improbable;

occurs only very rarely during operation/mission.

MODERATE- Degrades mission capabilities in terms of

required missions standards.

LOW - Little or no impact on accomplishment of mission.

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TC 9-524

MACHINE SHOP WORK

SCOPE

in the finished workpiece, For that reason, all scribed lines

should be exactly located and all scriber, divider, and center

points should be exact and sharp.

Machine shop work is generally understood to include all

cold-metal work by which an operator, using either power

driven equipment or hand tools, removes a portion of the

metal and shapes it to some specified form or size. It does not

include sheet metal work and coppersmithing.

SCRIBING LINES ON METAL

The shiny surface, found on most metals, makes it difficult

to see the layout lines.

LAYING OUT WORK

“Laying out” is a shop term which means to scribe lines,

circles, centers, and so forth, upon the surface of any material

to serve as a guide in shaping the finished workpiece. This

laying out procedure is similar to shop drawing but differs

from it in one important respect. The lines on a shop drawing

Layout dye (Figure 1-2), when applied to the metal surface,

makes it easier for the layout lines to be seen. Layout dye is

usually blue and offers an excellent contrast between the metal

and the layout lines.

are used for reference purposes only and are not measured or

transferred. In layout work, even a slight error in scribing a

Before applying layout dye, ensure that all grease and oil

has been cleaned from the work surface. Otherwise the dye

will not adhere properly.

line or center may result in a corresponding or greater error

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US Army - Fundamentals of Machine Tools TC 9-524.pdf

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