INTRODUCTION TO THE MACHINE SHOP GENERAL …

1 TC 9-524 Chapter 1 INTRODUCTION TO THE MACHINE SHOPGENERAL INFORMATIONFORMS, RECORDS, AND REPORTSA ccurate records are valuable. Unit officers are responsiblefor completion of forms, records, and reports. DA Pam 738-750 lists records, reports, and authorized forms that arenormally used for inspection and repair. Properly executedforms authorize and record repair or replacement of forms, records, and reports document the work required,follow the progress of the work within the shops , and indicatethe status of the material upon completion of REPORT OF ACCIDENTSThe reports necessary to comply with the requirements ofthe Army Safety Program are prescribed in detail in AR 385-40. These reports are required for any accidents involvinginjury or damage. For a listing of all forms, refer to DA deficiencies detected in the equipment covered hereinshould be immediately reported in accordance with DA Pam738-750.

2 These reports will be submitted as an EquipmentImprovement Recommendation on SF OF MACHINE TOOLSM achine tools are power-driven equipment designed todrill, bore, grind, or cut metal or other OF MACHINE TOOLSA complete list of MACHINE tools including specializedmachine tools currently authorized for issue is in ComponentList C 3405 MACHINE TOOLSIn view of the different design and operating featuresincorporated in specialized MACHINE tools (cylinder boringmachines, brake reliners, valve seat grinders. and so forth) byvarious manufacturers, no attempt has been made to includeinformation pertinent to them in this manual. For completeinformation on these tools, see pertinent TM 9-3400-, TM 9-5100-, and TM 9-9000-series technical manuals covering thespecific assure a high degree of safety, no MACHINE -tool is to beused unless the risk management process as outlined below isunderstood and applied by the user and the supervisor:1.

3 Identify the potential hazard(s) that the MACHINE tool Assess the probability and severity of the hazard(s) byutilizing the Risk Assessment Matrix in figure 1-1. Riskacceptance decision authority for the risk levels is as follows:a. Extremely high - CG, TRADOC; DCG, TRADOC;or the Chief of Staff, High - Major subordinate commands, installationcommanding generals, and school commandants of generalofficer Moderate and low - Delegated to the appropriatelevel in your unit chain of Determine the risk control measures that will eliminate thehazard(s) or reduce the the risk control measures before and duringoperation of the MACHINE tool to eliminate the hazards orreduce their and evaluate the process. Enforce theestablished standards and risk control measures. Evaluate theeffectiveness of the control measures and adjust/update themas - Individual soldier/item - Occurs often inthe career/equipment service life.

4 All soldiers or iteminventory exposed - Continuously experienced - Individual soldier/item - Occurs several timesin career/equipment service life. - All soldiers or Occursfrequently - Individual soldier/item. - Occurssometimes in career/equipment service life. All soldiersor item inventory exposed. Occurs sporadically, orseveral times in inventory service or - Individual soldier/item - Possible to occurin career/equipment service life. All soldiers or iteminventory exposed, Remote chance of occurrence -Expected to occur sometime in inventory service life - Individual soldier/item - Can assume willnot occur in career/equipment/service life. All soldiersor item inventory exposed. - Possible, but improbable;occurs only very rarely during CATASTROPHIC - Death or permanent totaldisability. System loss. Major property CRITICAL - Permanent partial disability.

5 Temporarytotal disability in excess of 3 months. Major system property MARGINAL - Minor injury. Lost workday accidentwith compensable injury/illness. Mirror system property NEGLIGIBLE - First aid or minortreatment. Minor system LEVELS supportive medicalEXTREMELY HIGH -Loss of ability to - Significantly degrades mission capabilities in termsof required mission Degrades mission capabilities in terms ofrequired missions - Little or no impact on accomplishment of 9-524 MACHINE SHOP WORKSCOPEM achine shop work is generally understood to include allcold-metal work by which an operator, using either powerdriven equipment or hand tools, removes a portion of themetal and shapes it to some specified form or size. It does notinclude sheet metal work and OUT WORK Laying out is a shop term which means to scribe lines,circles, centers, and so forth, upon the surface of any materialto serve as a guide in shaping the finished workpiece.

6 Thislaying out procedure is similar to shop drawing but differsfrom it in one important respect. The lines on a shop drawingin the finished workpiece, For that reason, all scribed linesshould be exactly located and all scriber, divider, and centerpoints should be exact and LINES ON METALThe shiny surface, found on most metals, makes it difficultto see the layout dye (Figure 1-2), when applied to the metal surface,makes it easier for the layout lines to be seen. Layout dye isusually blue and offers an excellent contrast between the metaland the layout used for reference purposes only and are not measured ortransferred. In layout work, even a slight error in scribing aBefore applying layout dye, ensure that all grease and oilline or center may result in a corresponding or greater errorhas been cleaned from the work surface. Otherwise the dyewill not adhere 9-524 COMMON LAYOUT TOOLSS criberTo obtain an accurate layout, fine lines must be scribed inthe metal.

7 A scriber (Figure 1-3) is the layout tool that is usedto produce these lines. The point is made of hardened steeland is kept chain by honing on an laying out circles, arcs, and radii, it is best to use thedivider (Figure 1-4). The legs of the divider must be of thesame length and be kept sharp. The divider cart be used tolay out and measure distances (Figure 1-5). To set the dividerto the correct length, place one point on an inch mark of asteel rule and open the divider until the other leg matches thecorrect measure-merit required (Figure 1-6).1-4TC 9-524 TrammelWhen scribing circles, arcs, and radii that are too large to beproduced with the divider, a trammel should be used (Figure1-7). The trammel is made of three main parts: the beam, twosliding heads with scriber points, and an adjusting screw thatis attached to one of the heads. The trammel can be made toscribe larger distances with the use of extension rods.

8 Thislayout tool is set in the same manner as the CaliperThe hermaphrodite caliper (Figure 1-8) is a tool used to layout lines that are parallel with the edges of the workpiece(Figure 1-9). It can also be used to locate the center ofcylindrical shaped workplaces (Figure 1-10).Surface GageA surface gage (Figure 1-11) is used for many purposes, butis most often used for layout work. The gage can be used toscribe layout lines at any given distance parallel to the worksurface (Figure 1-12).1-5TC 9-524 The spindle may be adjusted to any position with respect tothe base and tightened in place with the spindle nut (Figure 1-11). The rocker adjusting screw provides for finer adjustmentof the spindle by pivoting the spindle rocker bracket. Thescriber can be positioned at any height and in any desireddirection on the spindle by adjusting the scriber. A surfaceplate and combination square (Figure l-13) are needed to setthe surface gage to the correct PlateA surface plate (Figure l-14) provides a true, smooth, planesurface.

9 It is used in conjunction with surface and height gagesas a level base on which the gages and the workpiece areplaced to obtain accurate measurements. These plates aremade of semi-steel or granite and should never be used forany job that would scratch or nick the 9-524 Vernier Height GageThe vernier height gage (Figure 1-15) is a caliper with aspecial foot block to adapt it for use on a surface plate. Heightgages are available in several sizes: the most common are the10, 18, and 24 inch gages in English measure and the 25 and46 cm gages in metric measure. Like the vernier caliper, theseheight gages are graduated in divisions of inch and avernier scale of 25 units for reading measurements tothousandths of an inch. Always be sure the bottom of the footblock (Figure 1-15) is clean and free from 1-16 shows the height gage with a tungsten carbidemarker. This marker is used to lay out lines on glass, hardenedsteel.

10 Or other hard 1-17 illustrates the use of an offset scriber with theheight gage. This scriber reaches below the gage base. Do notattempt to adjust the sliding jaw while it is clamped to theCombination Square SetThe combination square set (Figure 1-18) is used for anumber of layout operations. The set consists of a blade(graduated rule), square head, protractor, and center 9-524 BladeThe blade is designed to allow the different heads to slidealong the blade and be clamped at any desired location. Thegroove in the blade is concave to eliminate dirt buildup andpermit a free and easy slide for the heads. By removing all theheads, the blade may be used alone as a HeadThe square head is designed with a 45 and 90 edge, whichmakes it possible to be used as a try square and miter extending the blade below the square, it can be used as adepth rule.