Naval Education andTraining Command

NAVEDTRA 82204-ASeptember 19930503-LP-477-5800

Nonresident TrainingCourse (NRTC)

MachineryRepairman 2, 1& C

Only one answer sheet is included in the NRTC. Reproduce therequired number of sheets you need or get answer sheets from yourESO or designated officer.

DISTRIBUTION STATEMENT A: Approved for public release; distribution is unlimited.

Nonfederal government personnel wanting a copy of this documentmust use the purchasing instructions on the inside cover.

3 May 1994.Reviewed and approved for continued use on

DISTRIBUTION STATEMENT A: Approved for public release; distribution is unlimited.

Nonfederal government personnel wanting a copy of this document must write to Superintendent of Documents,Government Printing Office, Washington, DC 20402 OR Commanding Officer, Naval Publications and Forms Directorate,Navy Aviation Supply Office, 5801 Tabor Avenue, Philadelphia, PA 19120-5099, Attention: Cash Sales, for price andavailability.

MACHINERY REPAIRMAN 2, 1 & CNAVEDTRA 822Ø4-A

Prepared by the Naval Education and Training Program ManagementSupport Activity, Pensacola, Florida

Congratulations! By enrolling in this course, you have demonstrated a desire to improveyourself and the Navy. Remember, however, this self-study course is only one part of thetotal Navy training program. Practical experience, schools, selected reading, and yourdesire to succeed are also necessary to successfully round out a fully meaningful trainingprogram. You have taken an important step in self-improvement. Keep up the good work.

HOW TO COMPLETE THIS COURSE SUCCESSFULLY

ERRATA: If an errata comes with this course,make all indicated changes or correctionsbefore you start any assignment. Do notchange or correct the Training Manual(TRAMAN) or assignments in any other way.

TEXTBOOK ASSIGNMENTS: The TRAMAN for thiscourse is MACHINERY REPAIRMAN, NAVEDTRA122Ø4-A. The TRAMAN pages that you are tostudy are listed at the beginning of eachassignment. Study these pages carefullybefore attempting to answer the questions inthe course. Pay close attention to tablesand illustrations because they containinformation that will help you understand thetext. Read the learning objectives providedat the beginning of each chapter or topic inthe text and/or preceding each set ofquestions in the course. Learning objectivesstate what you should be able to do afterstudying the material. Answering thequestions correctly helps you accomplish theobjectives.

BLACK DOT INFORMATION: Black dots (l) may beused in the text and correspondence course toemphasize important or supplementalinformation and to highlight instructions foranswering certain questions. Read theseblack dot entries carefully; they will helpyou answer the questions and understand thematerial.

SELECTING YOUR ANSWERS: After studying theTRAMAN, you should be ready to answer thequestions in the assignment. Read eachquestion carefully, then select the BESTanswer. Be sure to select your answer fromthe subject matter in the TRAMAN. You mayrefer freely to the TRAMAN and seek advice

i

and information from others on problems thatmay arise in the course. However, theanswers must be the result of your own workand decisions. You are prohibited fromreferring to or copying the answers ofothers and from giving answers to anyoneelse taking the same course. Failure tofollow these rules can result in suspensionfrom the course and disciplinary action.

SUBMITTING COMPLETED ANSWER SHEETS:Complete all assignments as quickly aspossible to derive maximum benefit from thecourse. As a minimum, you must submit atleast one assignment per month. This is arequirement established by the Chief ofNaval Education and Training. Failure tomeet this requirement could result indisenrollment from the course.

TYPES OF ANSWER SHEETS: If you are a U.S.Navy enlisted member on active duty or adrilling U.S. Naval Reserve enlisted member,you should use the answer sheet attached atthe end of this course and follow theinstructions in section A below. If you arean enlisted U.S. Naval Reserve member who isnot attached to a drilling unit or if youare an officer, a civilian, or a member ofthe U.S. Army, Air Force. Marine Corps, orCoast Guard, you should use the AutomaticData Processing (ADP) answer sheets includedin the course package and follow theinstructions in section B.

A. Manually Scored Answer Sheets

If you are a U.S. Navy enlisted memberon active duty or attached to a U.S. NavalReserve drilling unit. your course will beadministered by your local command. Youmust use the answer sheet designed for

manual scoring, NETPMSA form 143Ø/5, StockOrdering Number Ø5Ø2-LP-216-Ø1ØØ. You mayget a supply of the forms from yourEducational Services Officer (ESO), or youmay reproduce the one in the back of thiscourse booklet. DO NOT USE THIS FORM FORCOURSES ADMINISTERED BY NETPMSA.

Recording Information on theManually Scored Answer Sheets: As youcomplete each assignment, submit thecompleted answer sheet to your ESO forgrading. You may submit more than one answersheet at a time. Remember, you must submitat least one assignment each month.

Grading: Your ESO will grade eachanswer sheet and notify you of any incorrectanswers. The passing score for eachassignment is 3.2. If you receive less than3.2 on any assignment, the ESO will list thequestions you answered incorrectly and giveyou an answer sheet marked "RESUBMIT." Youmust redo the assignment and complete theRESUBMIT answer sheet. The maximum score youcan receive for a resubmitted assignment is3.2.

Course Completion: After you havesubmitted all the answer sheets and haveearned at least 3.2 on each assignment, yourcommand should give you credit for thiscourse by making the appropriate entry inyour service record.

Student Questions: If you havequestions concerning the administration ofthis course, consult your ESO.

B. ADP Answer Sheets

If you are an enlisted U.S. NavalReserve member who is not attached to adrilling reserve unit or if you are anofficer, a civilian, or a member of the U.S.Army, Air Force, Marine Corps, or CoastGuard. use the ADP answer sheets provided inyour course package. You should use oneblank original ADP answer sheet for eachassignment. Use only the original ADP answersheet provided in your course package;NETPMSA will not accept reproductions.

Recording Information on the ADPAnswer Sheets: Follow the "MARKINGINSTRUCTIONS" on each answer sheet. Be surethat blocks 1, 2, and 3 are filled incorrectly. This information is necessary for

ii

your course to be properly processed and foryou to receive credit for your work.

As you work the course, be sure to markyour answers in the course booklet becauseyour answer sheets will not be returned toyou. When you have completed an assignment,transfer your answer from the course bookletto the answer sheet.

Mailing the Completed ADP AnswerSheets: Upon completing an assignment, mailthe completed answer sheet to:

COMMANDING OFFICERNETPMSA CODE Ø74649Ø SAUFLEY FIELD RDPENSACOLA FL 32559-58Ø0

Use envelopes to mail your answer sheets.You must provide your own envelopes orrequest them from your ESO. You may enclosemore than one answer sheet in a singleenvelope. Remember, regardless of how manyanswer sheets you submit at a time, NETPMSAshould receive at least one assignment amonth.

NOTE: DO NOT USE THE COURSE COMMENTSPAGE AS AN ENVELOPE FOR RETURNING ANSWERSHEETS OR OTHER COURSE MATERIALS.

Grading: NETPMSA will grade theanswer sheets and notify you by letterconcerning your grade for each assignment,your incorrect answers, and your finalgrade. The passing score for eachassignment is 3.2. If you receive less than3.2 on any assignment, you must rework theassignment. NETPMSA will enclose a new ADPanswer sheet in the letter notifying you ofthe questions you answered incorrectly.You will be required to redo the assignmentand resubmit the new answer sheet. Themaximum score you can receive for aresubmitted assignment is 3.2.

Course Completion: When youcomplete the last assignment, fill out the"Course Completion" form in the back of thecourse and enclose it with your last answersheet. NETPMSA will issue you a lettercertifying that you satisfactorily completedthe course. You should make sure thatcredit for the course is recorded in yourservice record. YOU MAY RETAIN THE TEXT.

NOTE: YOUR OFFICIAL COURSE COMPLETIONDATE WILL BE THE DATE YOUR LAST ASSIGNMENT ISPROCESSED THROUGH THE NETPMSA ADP SYSTEM--NOTTHE DATE YOU DEPOSIT THE LAST ASSIGNMENT INTHE MAIL. This is especially important ifyou are taking the course for Naval Reserveretirement credit. You must mail your answersheets at least 6Ø days before youranniversary date. This will provide you withenough time for delays in the mail orreworking failed assignments. DO NOT MAILYOUR ASSIGNMENTS TO THE NAVAL RESERVEPERSONNEL COMMAND (NRPC).

Student Questions: Refer questionsconcerning this course to NETPMSA bymail (use the address on page ii) or bytelephone: DSN 922-1366 or commercial (9Ø4)452-1366.

NAVAL RESERVE RETIREMENT CREDIT

If you are a member of the NavalReserve, you will receive retirement pointsif you are authorized to receive them undercurrent directives governing retirement ofNaval Reserve personnel. For the purpose ofNaval Reserve retirement, this edition of thecourse is evaluated at 3 points. Thesepoints will be credited to you upon yoursatisfactory completion of the entire course.

NOTE: YOUR OFFICIAL COURSE COMPLETIONDATE WILL BE THE DATE YOUR LAST ASSIGNMENT ISPROCESSED THROUGH THE NETPMSA ADP SYSTEM--NOTTHE DATE YOU DEPOSIT THE LAST ASSIGNMENT INTHE MAIL. Refer to the Course Completionparagraph under section B. ADP AnswerSheets.

COURSE OBJECTIVES

Upon completing this course, the studentshould be able to answer questions on thefollowing subjects: Metal buildup, repairwork, gear cutting, heat treatment, readingsurface finish quality, balancing grindingwheels, vertical turret lathe, horizontalboring mill, and computer numerical controlmachines.

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Naval courses may include several types of questions—multiple-choice, true-false, matching, etc. The questionsare not grouped by type but by subject matter. They are presented in the same general sequence as the textbookmaterial upon which they are based. This presentation is designed to preserve continuity of thought, permittingstep-by-step development of ideas. Not all courses use all of the types of questions available. The student can readilyidentify the type of each question, and the action required, by inspection of the samples given below.

MULTIPLE-CHOICE QUESTIONS

Each question contains several alternatives, one of which provides the best answer to the question. Select thebest alternative, and blacken the appropriate box on the answer sheet.

SAMPLE

s-l. Who was the first person appointed Indicate in this way on the answer sheet:Secretary of Defense under theNational Security Act of 1947?

1. George Marshall2. James Forrestal3. Chester Nimitz4. William Halsey

TRUE-FALSE QUESTIONS

Mark each statement true or false as indicated below. If any part of the statement is false the statement is tobe considered false. Make the decision, and blacken the appropriate box on the answer sheet.

SAMPLE

s-2. All naval officers are authorized to Indicate in this way on the answer sheet:correspond officially with any systemscommand of the Department of theNavy without their respective com-manding officer’s endorsement.

1. True2. False

MATCHING QUESTIONS

Each set of questions consists of two columns, each listing words, phrases or sentences. The task is to selectthe item in column B which is the best match for the item in column A that is being considered. Items in columnB may be used once, more than once, or not at all. Specific instructions are given with each set of questions. Selectthe numbers identifying the answers and blacken the appropriate boxes on the answer sheet.

SAMPLE

In questions s-3 through s-6, match the name of the shipboard officer in column A by selecting from columnB the name of the department in which the officer functions. Some responses may be used once, more than once,or not at all.

A. OFFICER B. DEPARTMENT Indicate in this way on the answer sheet:

s-3. Damage Control Assistant 1. Operations Department

s-4. CIC Officer 2. Engineering Department

s-5. Disbursing Officer 3. Supply Department

s-6. Communications Officer

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ASSIGNMENT 1

Textbook Assignment: "Layout and Benchwork," chapter 2, pages 2-6 through 2-8; "EngineLathes," chapter 6, pages 6-21 through 6-23; "Vertical Turret Latheand Horizontal Boring Mill," chapter 8; "Precision Grinding Machines,"chapter 10, pages 10-4, 10-5, and 10-20 through 10-22; "ComputerNumerical Control Machines," chapter 11; and "Metal Buildup," chapter12, pages 12-1 through 12-7.

1-1. Which of the following instrumentsis used to measure the differencesin the depths of surfaceirregularities?

1. Micrometer2. Profilometer3. Barton meter4. Depth gauge

1-2. The interference microscopemeasures in what increments?

1. Inches2. Thousandths3. Ten thousandths4. Microinches

1-3. Which of the following methods maybe used to level an engine lathe?

1. Optical2. Test bar3. Spirit level4. Each of the above

1-4. What is the first step in levelingan engine lathe?

1. Loosen the lag screws on theside of the lathe away from theheadstock

2. Loosen the lag screws on theside of the lathe that supportsthe headstock

3. Check the level on the sideaway from the headstock

4. Check the level on the sidethat supports the headstock

1-5. An engine lathe should be leveledto within what degree of accuracy?

1. 10 seconds of arc2. 20 seconds of arc3. 0.0005 in.4. 0.0010 in.

1-6. Vertical turret lathes areparticularly suited for machiningwhat type of work?

1. Multiple workpiecessimultaneously

2. Heavy or awkward workpieces3. Nonsymmetrical workpieces4. Small precision parts

1-7. The size of a vertical turret latheis designated by what dimension(s)?

1. The height of the rails2. The diameter of the bed3. The diameter of the spindle4. The diameter of the table

1-8. Power feed to the main head of avertical turret lathe permits thehead to move in what direction(s)?

1. Vertically only2. Vertically and horizontally3. Vertically and diagonally4. Horizontally and diagonally

1-9. When the vertical and horizontalfeeds are engaged simultaneously ona vertical turret lathe, what taperwill be cut?

1. 30°2. 45°3. 60°4. 90°

1-10. When using a vertical turret latheto cut a 40-degree angle, youshould swivel the main turret headwhat amount?

1. 5°2. 10°3. 15°4. 20°

1

1-11. When using a vertical turret latheto cut a 53-degree angle, youshould swivel the main turret headin the direction of the angle bywhat amount?

1. 16°2. 32°3. 47°4. 53°

1-12. The spindle speed and hand feedcontrols are contained in what partof a horizontal boring mill?

1. The saddle2. The backrest3. The head4. The end support

1-13. Which of the following factors isused to determine the size of ahorizontal boring mill?

1. The maximum thickness of workthe table will hold

2. The maximum size boring andfacing head that will fit themachine

3. The largest diameter boring barthe machine will hold

4. The largest diameter fly cutterthe machine will hold

1-14. When you set up a boring and facinghead, you should take which of thefollowing safety precautions beforeshifting the spindle back-gear intoneutral?

1. Engage the spindle overrunningclutch

2. Extend the spindle of theboring and facing head from thesleeve

3. Rotate the sleeve by jogging ituntil the heavy side of thefacing head is down

4. Remove the boring and facinghead from the machine

1-15. You are operating a horizontalboring mill equipped with a boringand facing head, and you can hear acontinuous ratcheting sound. Whatis the problem?

1. The feed is engaged and theslide is clamped

2. The feed is disengaged3. The slide is unlocked4. The feed is too fast

1-16. What part of a horizontal boringmill supports the boring bar on thefoot end?

1. The bed2. The chuck3. The tailstock assembly4. The backrest assembly

1-17. You are using a horizontal boringmill to cut threads and you havemade your first cut. To move thecutting tool back to the startingpoint, you must take what action?

1. Remove the cutting tool2. Reverse the direction of the

feed3. Reverse the direction of the

spindle driving motor4. Move the boring bar back

1-18. The reference point used to dial ina split-sleeve bearing is marked onwhat surface?

1. A horizontal flange2. The front face3. A circumferential flange4. The inside diameter

1-19. What is the preferred method toline bore a split casing pump?

1. Use the boring and facing head2. Use a standard boring bar3. Use dummy bearings and

manufacture a boring bar to fitthem

4. Use a fly cutter

2

1-20.

1-21.

1-22.

1-23.

1-24.

1-25.

What method is used to balancelarge grinding wheels?

1. Grind the heavy side of thewheel

2. Adjust the weights in theflanges

3. Grind the heavy side of theflange

4. Add weld buildup to the lightside of the flange

A honing stone has air voids forwhat reason(s)?

1. To make the stone break downfaster

2. To collect metal and abrasive3. To help the coolant clear chips

and dissipate heat4. To help the stone cut true

Honing will change the axiallocation of a hole.

1. True2. False

What type of finish should you seeon a properly honed surface?

1. Crosshatch lines2. Ovals3. Circles4. Straight lines

What is the greatest advantage ofNC machining?

1. The operator doesn't get tiredas easily

2. The machines are less expensive3. The machines allow unerring and

rapid positioning movements4. The machines run cooler

A qualified CNC machinist canprogram and produce a single parteconomically.

1. True2. False

3

1-26. Some CNC lathes have slant beds forwhat reason?

1. Access is easier2. The operator can see the work

better3. Chips fall into the chip pan

rather than on the tools orbedways

4. The machine runs quieter

1-27. You are using CAD to design a part.Once it has been designed, edited,and proofed, your next step is totell the computer to take whataction?

1. Manufacture the part2. Select the tooling to be used3. Analyze the geometry of the

part4. Select the proper machine

1-28. What type of tooling is preferredfor many CNC applications?

1. High-speed steel2. Cobalt3. Cemented carbide4. Inserted carbide

1-29. A CNC machine consists of what twomajor components?

1. The design computer and tooling2. The machine tool and onboard

computer3. The servo and design computer4. The computer disk and tooling

1-30. When cutting an arc, a point-to-point NC machine uses what type ofcuts?

1. Straight line2. Continuous3. Radial4. Inverted

1-31. Most newer NC machines have whattype of control system?

1. Point-to-point2. Radial3. Continuous path4. Straight path

1-32. What type of servos are usuallyinstalled on large NC machines?

1. Stepper2. AC3. DC4. Hydraulic

1-33. The Cartesian coordinate system isthe basis for all machine movement.

1. True2. False

1-34. Within the Cartesian coordinatesystem, spindle motion is alwaysassigned what axis?

1. A2. X3. Y4. Z

1-35. To determine whether movement ispositive or negative, programs arewritten as though what part ismoving?

1. The work2. The tool3. The motor4. The chuck

1-36. The machine coordinate system andthe part coordinate system on a CNCmachine usually do not coincide.What is the correct method to makethem coincide?

1. Set up a fixture2. Move the work3. Move the chuck4. Set point zero

1-37. When you are using a CNC machine,what is the best type ofpositioning system?

1. Digital2. Incremental3. Absolute4. Numerical

1-38. What is the basic principle ofspray metalizing?

1. Spraying powdered metal on amelted surface

2. Spraying melted droplets ofmetal on a surface

3. Coating the metallic surfacewith a metallic spray paint

4. Wiping a heated metal surfacewith metallic alloys that havea low melting point

1-39. Thermal spray coatings are NOTuseful for which of the followingpurposes?

1. To rebuild worn shafts2. To apply hard surfacing3. To apply ornamental chrome4. To protect surfaces against

heat and corrosion

1-40. Separate bond and buildup coatingsare eliminated by using what typeof thermal spray coating?

1. Fine2. Fibrinoid3. Coarse4. Exothermic

1-41. A wire-oxygen-fuel thermal spraysystem is usually used for whatpurpose?

1. To build up pump shafts2. To spray strainer plugs3. To coat carbide tool bits4. To spray coatings for corrosion

control

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1-42. Thermal spray is NOT approved for 1-47. What are the steps in preparing awhich of the following machinery surface to receive a thermal sprayapplications? coating?

1. Repair of static fit areas2. Repair of pump shaft sleeves3. Buildup of babbitt bearings4. Repair of reduction gears

1-43. When using a sandblaster to surfaceroughen a part for thermalspraying, what mesh size sandblastgrit is recommended?

1. 62. 93. 164. 28

1-44. The strength of the bond betweenthe base metal and the thermalspray coating are greatly affectedby what conditions?

1. Humidity and roughness2. Cleanliness and roughness3. Fatigue and size4. Size and temperature

1-45. On a shaft that will be thermalsprayed, the ends of the undercutshould be cut at what angle?

1. 15° to 30°2. 15° to 45°3. 30° to 60°4. 60° to 70°

1-46. To prepare clean steel alloys forthermal spraying, you should heatthem to what maximum temperature?

1. 325°2. 425°3. 650°4. 975°

1. Cleaning and surface rougheningonly

2. Cleaning and undercoating only3. Cleaning, undercutting, and

surface roughening4. Surface roughening,

undercutting, and polishing

1-48. In abrasive blasting, which of thefollowing materials is best formasking?

1. Plastic2. Electrical tape3. Rubber4. Masking tape

1-49. When you do not want the thermalspray coating to fill areas such asholes and keyways, they should befilled with which of the followingmaterials?

1. Wood2. Plastic3. Grease4. Carbon

1-50. Hard thermal spray coating shouldbe ground with what type ofgrinding wheel?

1. Coarse grain and low bondstrength

2. Fine grain and low bondstrength

3. Coarse grain and high bondstrength

4. Fine grain and high bondstrength

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ASSIGNMENT 2

Textbook Assignment: "Repair Work," chapter 13, pages 13-8 through 13-12; "Gears and GearCutting," chapter 14, pages 14-5 through 14-30; and "Metallurgy andHeat treatment," chapter 15, pages 15-1 through 15-28.

2-1. The amount of steam admitted to apump turbine is controlled by whattype of valve?

1. Globe2. Quick-acting ball3. Constant-pressure governor4. Rising stem gate

2-2. Leakage in a constant-pressuregovernor's control valve or bushingwill cause what problem?

1. The main valve will remain open2. The auxiliary valve will stick3. Condensation will form in the

main valve4. The auxiliary valve will

override the main valve

2-3. When the lower diaphragm in aconstant-pressure governor movesdownward, which of the followingvalves will open?

1. Side port2. Auxiliary3. Main4. Lower port

2-4. Under normal operating conditions,a constant-pressure governor bypassvalve remains in what position?

1. Closed2. 1/4 open3. 1/2 open4. Fully open

2-5. When the clearance between aconstant-pressure governor'scontrol valve and diaphragm is lessthan 0.001, what problem willresult?

1. The auxiliary valve will remainopen

2. Steam will flow to the mainvalve when the throttle valveis open

3. The piston will not move4. The diaphragm will overheat

2-6. All of the seating surfaces on atop cap should be machined true tothe axis of what area?

1. The control valve seat threads2. The bottom flange3. The spring bore4. The outside diameter

2-7. Helical gears operate quieter andsmoother than spur gears for whichof the following reasons?

1. They have single teeth incontact at a given time

2. They have several teeth incontact at the same time

3. They have a sliding action4. Both 2 and 3 above

2-8. A bevel gear and a spur gear musthave what design feature in commonbefore they can mesh?

1. NT2. OD3. DP4. PD

2-9. All normal gear elements on ahelical gear are calculated andcannot be measured.

1. True2. False

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2-10. The longitudinal distance a pointon a helical gear travels duringone complete revolution of the gearis known by what term?

1. Pitch diameter2. Helix angle3. Lead4. Helix

2-11. The angle between a plane parallelto the rotational axis of a helicalgear and the helix line of the gearis known by what term?

1. The rotational angle2. The pitch cord3. The gear angle4. The helix angle

2-12. The lead of a helical gear iscomputed by multiplying thecotangent of the helix angle bywhat factor?

1. The real pitch circumference2. The pitch diameter3. The number of teeth4. The tooth thickness

QUESTIONS 2-13 AND 2-14 REFER TO A 20DP HELICAL GEAR THAT HAS 10 TEETH AND

A HELIX ANGLE OF 15 DEGREES.

2-13. What is the corrected chordaladdendum constant?

1. 1.01292 in.2. 1.03293 in.3. 1.05598 in4. 1.07598 in.

2-14. What is the corrected chordalthickness constant?

1. 1.32586 in.2. 1.56546 in.3. 1.65460 in.4. 1.82580 in

2-15. The purpose of gearing is totransmit motion between two or moreshafts.

1. True2. False

2-16.

2-17.

2-18.

2-19.

2-20.

When an index head is attached to amilling machine table through a 1:1ratio, the index head will havewhat lead?

1. 6 in.2. 8 in.3. 10 in.4. 12 in.

When manufacturing a left-handhelix, the milling machine tableshould be swiveled by using whatprocedure?

1. Face the machine table and pushit with your right hand

2. Face the machine table and pushit with your left hand

3. Set the machineto the cutter

4. Set the machinedial indicator

table parallel

table with a

The cone that forms the basis of abevel gear is known by what term?

1. The real pitch cone2. The chordal addendum3. The face angle4. The pitch cone

The dimension nomenclature of abevel gear is the same as that of aspur gear with what exception?

1. The pitch diameter2. The dedendum3. The angular addendum4. The diametral pitch

Bevel gear cutters are similar inappearance and size to spur gearcutters with what exception?

1. The outside diameter is larger2. The outside diameter is smaller3. The teeth are thinner4. The teeth are wider

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2-21. When calculating the cutting angleof a bevel gear, you shouldsubtract the dedendum angle fromwhat angle?

1. The addendum2. The helical3. The face width4. The pitch cone

2-22. After the teeth on a bevel gearhave been gashed, what is the nextoperation?

1. Remove the gear2. Offset and roll the gear3. Swivel the milling machine

table4. Swivel the dividing head

2-23. What tool is used to profile abevel gear?

1. A grinder2. A drill3. A file4. A hacksaw

2-24. A triple-threaded worm has adistance of 0.625 inch between twoadjacent threads. One thread willadvance what distance in onerevolution of the worm?

1. 1.875 in.2. 2.850 in.3. 3.825 in.4. 4.500 in.

2-25. To machine the throat radius of aworm wheel, you should use which ofthe following cutters?

1. A fly cutter2. A two-lip end mill3. A ball end mill4. A shell end mill

2-26. When cutting the teeth on a wormwheel, you should perform whatoperation first?

2-27. Stub tooth gears are widely used intransmissions and high-torqueequipment for what reason?

1. They are compact2. They run quieter3. They generate less heat4. They have great strength

2-28. Splines with involute teeth aremore common than splines withstraight teeth for which of thefollowing reasons?

1. They have greater torque-transmitting power

2. They can be produced by usingthe same techniques andequipment used to cut gears

3. They have self-centering actionunder load

4. All of the above

2-29. The process by which metals aremachined, cast, or forged dealswith what branch of metallurgy?

1. Chemical2. Physical3. Mechanical4. Electrical

2-30. Crystals in solid metal are knownby what term?

1. Grains2. Lattice3. Carbon4. Pearlite

2-31. The line-shaped areas betweenadjacent grains are known by whatterm?

1. Body-centered lattice2. Iron-carbon phase lines3. Grain boundaries4. Face-centered lattice

1. Hob the teeth2. Gash the teeth3. Offset the teeth4. Roll the teeth

8

IN ANSWERING QUESTIONS 2-32 THROUGH 2-35, IN ANSWERING QUESTIONS 2-38 THROUGH 2-40,SELECT THE SPACE LATTICE IN COLUMN B THAT SELECT FROM COLUMN B THE DESCRIPTION OFMATCHES THE DESCRIPTION IN COLUMN A. THE FURNACE ATMOSPHERE GIVEN IN COLUMN A.

A. DESCRIPTIONS B. TYPES OF LATTICE

2-32. Hard to work 1. Face-centeredwhen cold but cubicstrong innature 2. Body-centered

2-33. Contains 14atoms and tends 3. Body-centeredto be soft cubic

2-34. Contains nine 4. Hexagonalatoms and looks close packedlike abody-centeredcubic latticestretched inone dimension

2-35. Structure haslittle plasticityand is verydifficult towork cold

2-36. The combination of three atoms oriron carbide and one atom of carboncreates what intermetallic compound?

1. Ferrite2. Austenite3. Cementite4. Pearlite

2-37. As a lattice changes from onestructure to another, it goesthrough what type of phase change?

1. Allotropic2. Amorphous3. Caustic4. Eutectic

A. FURNACE B. DESCRIPTIONSATMOSPHERES

2-38. Neutralatmosphere

2-39. Oxidizingatmosphere

2-40. Reducingatmosphere

1. Contains neitheran oxidizingnor a reducdingagent

2. Occurs whenexcess air iscirculatedthrough thefurnace

3. Tends to removeoxygen from themetal's surface

2-41. Metal parts with cavities arenormally cooled by the flushquenching method to minimize whateffect?

1. Contraction2. Expansion3. Distortion4. Erosion

2-42. What is the correct temperaturerange for a brine quench?

1. 30° to 65°F2. 65° to 100°F3. 100° to 135°F4. 135° to 170°F

2-43. When compared to water and brine,what is the relative quenching rateof a 10 percent solution of causticsoda?

1. Slower than water or brine2. Faster than water or brine3. Faster than brine, but slower

than water4. Slower than brine, but faster

than water

9

2-44. When iron is cooling, it undergoesan allotropic transformation at2,550 degrees Farenheit. What isthe new crystal structure called?

1. Body-centered cubic2. Body-centered tetragonal3. Face-centered cubic4. Hexagonal close-packed

2-45. The complete iron-carbon phaserepresents the relationship betweentemperatures, compositions, andstructures of all phases that may beformed by iron and carbon under anequilibrium condition.

1. True2. False

2-46. Which of the following is NOT amajor factor in all heat treatingprocesses?

1. Rate of heating2. Holding time at a specific

temperature3. The transformation range4. The rate of cooling

2-47. What phase diagram is a map thatcharts the transformation ofaustenite as a function oftemperature and time, showing how asteel will respond to any rate ofslow or rapid cooling?

1. Type V iron-carbon2. Bain S-curve3. Type I iron-carbon4. Iron-carbon

2-48. Carbon steels are usually quenchedin which of the following mediums?

1. Brine2. Oil3. Freon4. Compressed air

2-49. Tempering is always done attemperatures below what point?

1. Upper transformation2. Upper equilibrium3. Lower transformation4. Lower equilibrium

2-50. The hardening of metals thatinvolves quenching the metal in abath of molten salt maintained abovethe start of the martensitetemperature and holding it untiltransformation is complete is knownas what treatment?

1. Annealing2. Normalizing3. Spheroidizing4. Austempering

2-51. Which of the following is NOT a casehardening process?

1. Carburizing2. Tempering3. Cyaniding4. Nitriding

2-52. Nonferrous alloys are heat treatedby using which of the followingmethods?

1. Normalizing2. Spheroidizing3. Solution4. Freezing

2-53. Shrinkage resulting from atemperature differential between theouter and inner areas of a metalpart is prevented by using whatquenching method?

1. Flush2. Stabilizing3. Normalizing4. Tank

10

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