94-Fundamentals Machine Tools

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V TC 9-524 i 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 publicati
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  V TC 9-524 i  TC 9-524 Preface The purpose of this training circular is to provide a better understanding of power-driven machine tools. It alsosupplements 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 thispublication 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 formulasfor machining different materials.The proponent of this publication is HQ TRADOC. Send comments and recommendations on DA Form 2028directly 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. i i  TC 9-524 Chapter 1 INTRODUCTION TO THE MACHINE SHOP GENERAL INFORMATION 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. FIELD REPORT OF ACCIDENTS 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. Any deficiencies detected in the equipment covered hereinshould be immediately reported in accordance with DA Pam 738-750. These reports will be submitted as an Equipment Improvement Recommendation on SF 368. DEFINITION OF MACHINE TOOLS Machine tools are power-driven equipment designed to drill, bore, grind, or cut metal or other material. LISTING OF MACHINE TOOLS A complete list of machine tools including specialized machine tools currently authorized for issue is in ComponentList C 3405/70-lL. SPECIALIZED MACHINE TOOLS In view of the different design and operating features incorporated in specialized machine tools (cylinder boringmachines, 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 completeinformation on these tools, see pertinent TM 9-3400-, TM 9-5100-, and TM 9-9000-series technical manuals covering the specific machines. RISK-MANAGEMENT To assure a high degree of safety, no machine -tool is to beused unless the risk management process as outlined below is understood and applied by the user and the supervisor: 1. Identify the potential hazard(s) that the machine tool can generate. 2. Assess the probability and severity of the hazard(s) byutilizing the Risk Assessment Matrix infigure 1-1.Risk acceptance decision authority for the risk levels is as follows: 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. c. Moderate and low - Delegated to the appropriate level in your unit chain of command. 3. Determine the risk control measures that will eliminate the hazard(s) or reduce the risk. 4. Implement the risk control measures before and during operation of the machine tool to eliminate the hazards or reduce their risks.5. Supervise and evaluate the process. Enforce theestablished standards and risk control measures. Evaluate the effectiveness of the control measures and adjust/update themas necessary. 1-1  TC 9-524 A.B.C. D . E. PROBABILITY FREQUENT - Individual soldier/item - Occurs often in the career/equipment service life. All soldiers or iteminventory exposed - Continuously experienced during operation/mission. LIKELY - Individual soldier/item - Occurs several times in career/equipment service life. - All soldiers or item inventory exposed. - Occurs frequently during operator/mission. OCCASIONAL - Individual soldier/item. - Occurssometimes in career/equipment service life. All soldiers or item inventory exposed. Occurs sporadically, or several times in inventory service or operations/mission. 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. UNLIKELY - Individual soldier/item - Can assume willnot occur in career/equipment/service life. All soldiers or item inventory exposed. - Possible, but improbable; occurs only very rarely during operation/mission. SEVERITYI. 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. III. MARGINAL - Minor injury. Lost workday accident with compensable injury/illness. Mirror system damage. Minor property damage. IV. NEGLIGIBLE - First aid or minor treatment. Minor system impairment. RISK LEVELS supportive medical EXTREMELY HIGH - Loss of ability to accomplish mission. HIGH - Significantly degrades mission capabilities in terms of required mission standards. MODERATE- Degrades mission capabilities in terms of  required missions standards. LOW - Little or no impact on accomplishment of mission. 1-2
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