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FILE NAME: Hopeman Brothers (HB) DATE: 1958 DOC#: HB031 DOCUMENT DESCRIPTION: Johns-Manville Product Use Manual for Industrial Board Products JOHN5-MANVILLE INDUSTRIAL BOARD PRODUCTS EQUIPMENT AND TECHNIQUES FOR FABRICATING TRANSITE ASBESTOCITI EBONY OHMSTONE CHEMSTONE COLORUTH MARIN1TE-23 MARINITI-36 M ARINlfl-65 I I Johfti-Monvlllo trod.mcrkj obov. o r. in vonou tountrW ol world. JO HN S MAh I N D U S T R I A L IN* I L L E C O R P O R AT l O N fl ATIONS D I V I S I O N MT-006396 Table of Contents Dust Control------- --------- -- -- ------Cutting, Straight Line------ --- *---- ----- Dry Stationary Bullard Cut-Off Saw--------------- Bench Saw------------------------- Planer Saw---------------- "-- ---- Carriage Saw------ ------- ------- Wet----------------------------------Coping Saw----- ------------------- Wheel Type9-Abrasive, Diamond, Carbide Cutting Wheel Safety------- * Shearing------------------------------- Drilling and Counter Boring----- --------- Preparation for Drilling-- -- ---- -- ----- Drilling Operation--------------------- Possible Causes of Poor Quality Work--- Drill Speeds------------------- *-- --- Grinding Twist Drills----------------- Counter Boring------------------------- Grinding Counter Bore Tools----- --- "-- - Counter Bore Speeds--- -- ----------- -- lathe-- -----------------------------Jig Saw and Band Saw-- --- -- ------- -Milling----- ------ --- ----------- ----- - Wet-----------------------------Dry-- -- ----- --- --- --- --- ----- Special Jobs, Colorlith, Chemstona--- -- ' Sink Cut-Outs-- -------------- -- ------Recesses and Rebates----- -- ----------Dry Grooves-- -- Finishing EdgesMachining and Assembling Splines-- ----- Suggested Cutting Shop Equipment-- ---------Appendix Page -- ;-------- Foreword -- -- Foreword ---------- 1 ---------- 2 ---------------------- 5 ---------- 7 ----------- 9 ----------- 9 ----------- 13 ----------- 15 ---------- 17 ----------- 17 ---------- 17 ----------- 19 ----------- 19 --------------------------------- 2200 ----------------- 20 ------------------ 20 ----------------- 21 ---------------------------------- 2212 ---------- 23 ---------- 23 ---------- 24 ---------- 26 ---------- 26 ---------- 27 ----------- 27 ----- ---- 28 ----------- 31-35 MT-006397 JOHNS-.iANVILLS INDUSTRIAL 3GA".D /TdRlALS FOREVOHD The purpose of this publication is to provide those engaged in fabrica ting Jor.ns-Manville Industrial Boards with information on equipment and techniques for cutting, drilling and machining. While the information represents many years of experience in our own plants, we recommend that before any equipment ia decided on individual requirements be discussed with equipment manufacturers. We also suggest you consider the purchase of used equipment. Often times a considerable saving can be realized if such equipment is available. We wish to caution those fabricating Johns-Manville Boards that during dry cutting, machining, drilling and sanding operations adequate pre cautions must be taken to remove dust in order to eliminate air contam ination. Proper exhaust systems should be so designed to remove dust at the point of origin. Johns-Manville recommends that you consult with firms familiar with equipment for this purpose to assure adequate protect!on. For the benefit of those requiring additional information on particular fabricating problems not covered in this manual local Johns-Manville representatives are available for consultation. J-M INDUSTRIAL INSULATIONS DIVISION M T -006398 - 1- CUTTING So/re J-M Products may be cut eitner dry or wet. The problems encounter ed in one -Method are dissimilar to those in the other. Generally speak ing wet machine cutting is somewhat slower than dry cutting but provides a smoother cut surface. The selection of equipment is therefore a matter of choice. In dry cutting proper equipment for dust removal must oe available; in wet cutting provisions for sludge disposal are necessary to prevent clogging the sewer system. DRY C U T T I N G Dry cutting may be used for all straight cutting where a very smooth cut is not essential. Both Transite, Ebony, Ohmstone, Chemstone, Asbestocite and Karinite Products are cut on similar equipment, but due to nature of the material the cutting characteristics are not essential-y the same. Ebony and Ohmstone are impregnated with organic compounds which tend to cause heating and glazing of cutting wheels if cut dry. Transite, Asbestocite and Marlnite Products have no Impregnation and may be satis factorily cut dry. EQUIPMENT USED BY JOHNS-MANVILLE: A. Portable Saw Machine Specifications Machine s Description This is primarily ulsed for field cutting by a dry method. It is only satisfactory for limited cutting operations where more substantial cutting equipment is not available. Skil Corporation $033 Elston Avenue Chicago, Illinois Model 107 {10" saw) MT-006399 - 2- Arbor Speed: Feed Speed : * Cutting Wheels: 2675 rpn. (No load) 2100 rpn. (Under load) A hard push and heavy loads reducing rpm's give best results. Skil NO. 11645 (Silicon Carbide): 8 7/8H diam. X 1/2" thick. -- -------------------------------------------------------- --------------- ----- -- -- ---- --- B. Bullard Cut-Off Saw Characteristics Machina Material Capacity Recommended thick nesses cut on machine. Tolerance Maintenance Power Cutting Wheels (Abrasive) Description Bench type design, cutting action on vertical movement of hydraulic mechanism, cut ting speeds controlled by adjustment of hydraulic valve feed, manufactured by Bullard Co., Westboro, Mass. Transits or Ebony, Asbestocite, Ohmstone, Chemstone. Widths up to 5 3 A n5 *ny length with proper support; thickneeses thru 2". Multiple thicknesses up to total of 2". + 1 /32" or equivalent. Easily maintained and adjust ed. 5 HP; 550 AC; Arbor Speed 3750 rpm; V-belt drive. Manufactured by Billard Co., Westboro, Mass., 13 7/8" x 1/8" thick x 1" arbor. Wheel NO. C20-16-B MT-006400 - 3- Cutting Speed Stock Holding Equipment Safety Crew fi. Bench Sava Characteristics Machine Material Capacity Recommended thicknesses cut on machine. Tolerance Variable by thickness of stock. Built-in hydraulic impelled clamp holds stock while cut ting. Cutting wheel enclosed in sheet steel cabinet. Very safe machine to operate. One man. Descriotion Saw designed similar to wood cutting bench saws. Machine equipped with cutting guide parallel to saw blade for ac curate cutting. Gauge move able for various dimensions. Machine has large working sur face. See Sketch, Adi endix A Method for setting gauge. Transite, Ebony, Ohmstonej Chemstone; Colorlith; Marinite 23, Marinite 36 , 65. Any length or width that is practical to handle by hand. Thicknesses up to A". Ebony thru 3/8" in sheet form, thru 2" in small pieces. Transite thru 3/4" in sheet form, thru L" in small pieces. Marinite any thickness. Fairly smooth cut edges Machine hand fed, high de eree of accuracy not expected Tolerances of + 1/32" can be maintained with careful opera tion of saw. MT-006401 Maintenance Power Easily maintained and adjusted 10 HP; 550 AC; approx: Product Transite Ebony Ohmstone Chemstone Colorlith Marinite 23 Marinite 36 Marinit'e 65 Arbor speed RFM Arbor Speed 3600 3600 3600 3600 12-1800 3600 1800 1800 Cutting Wheels (Abrasive) Product Transits Ebony & Ohmstone Chemstone Colorlith Marinite 23 Marinite 36 Marinite 65 Wheel NO. C-202-15-BS (Safety If n 11 C-202-15-BS (Safety II Wheel) Wheel) Wheel NO, or C16-222X (Steel Center) _____ II II II or CI6-IA-X (Steel Center) tt Whsels 16" X 1/4" thick l6" X 5/16" thick Wheels M anufactured by: G. H. Rillard Co., Westboro, Mass. Note: Wheel C-202-15-BS is recommended where ever possible. Cutting Speeds Stock holding equipment Variable by hand feed. Held by hand against pauge while cutting stock. Safety Wheel covered with heavy steel guard. Care must be taken not to bind wheel while cutting to cause breakage. Wheel Breaking extremely dangerous. Crew 1, 2, 3 men; depending on wgt. lifted. MT-006402 - 5- D. Johns-Manvllle Engineered Fianer Sav Characteristics Description Machine Machine converted from planer bed machine, Tvo motors placed on headder above stock. Motors adjustable laterally for various widths of cut and can be tilted to various degrees. Rate of feed governed by hydraulic system of cylinders. Feed controlled by valve. Equipment modified by Johns-Manville Eng. Dept's. See sketch in appendix, B. Material Transite, Ebony, Ohmstone, Cherastone, Marinite 23, 36, 65; Capacity Recommended thicknesses cut on machine. Tolerance Maintenance Power Cutting Wheels (Abrasive) Machine designed to strip stock on one or two edges, per machine cycle into var ious widths only. For thick nesses cut; see Cutting Speeds. Machine accommodates lengths up to 96". See Cutting Speeds + 1/32" or equivalent. Usual maintenance of equip ment designed for high speed production. 2 - 10 HP recommended; Arbor Speed (See "Cutting Speeda") 550 ACj Direct Drive. S, A. Woods Motors Manufactured by: Bullard Co., Westboro, Mass. 16" X 5/16" thick. 3 1" arbor diam. j 'Wheel No. C16-222X, steel center abrasive wheel, for Transite, Ebony, Ohmstone, Chemstone. Wheel No. C16-H-X, steel center abrasive wheel, for Marinite 23, 36, 65. MT-006403 Cutting Speeds - Planar Saw and Carriage Sau Product fCrviny and Ohms tone pnonv and Ohmstone Std. Transite 5td. Transite Std. Transite Std. Transite Std. Transite Std. Transite Std. Transite Std. Transite Std. Transite Std. Transite Std, Transite Std. Transite Std. Transite Std. Transite Std. Transite Chemstone Marinite 23 Marinite 36 Marinite 36 Marinite 36 Marinite 36 Marinite 3& Thickness 1/4" 3/8" 1/8" 3/16'' 1/4" 5/lc" 3/8 1/2" 5/8 3/4 ?/8" 1" 1 1/4 1 3/8" 1 1/2 1 3/4 2" 1 1/4" 1 1/2" 3/4" 7/8" 1" 1 1/4" No. Thicknesses Cut per Cycle 3 2 6 6 4 3 3 2 2 2 1 1 1 1 1 1 1 1 3 5 L 3 2 Feet/Min. 7.5 7.5 16.6 10.4 12.0 13.0 10.4 12.0 9.4 7.0 14.0 12.0 9.3 8.3 7.6 6.5 5.6 *10.0 17.0 15 " 17 N It It tt Cutting speeds for other thicknesses to compare with Transite RPM firhar Speed 3600 3600 3600 3600 3600 3600 3600 3600 3600 3600 3600 3600 3600 3600 3600 3600 3600 3600 3600 3600 36OO 3600 3600 3600 MT-006404 Product tarin ite 65 c r in ite 65 Karinite 65 M arinile ^5 Marini te 65 Marini te 65 TVii rlm flsa 7/16" 1/2" 3A" 7/8" 1" 1 1/A" - 7- No, Thicknesses Chit ner Cycle 5 A 3 3 2 2 Feet/Min, 12-13 n RFM ftpbor Speed 3600 3600 3600 3600 3600 3600 Stock Holding Equipment Stock Handling Equipment Safety Crew Hand pressure type clamp at each end of stock on machine bed or air clamps. Stock handled manually to machine within limits of two man lift. Vacuum handling recommended on stock tco heavy for two men. Cutting Wheels covered with steel guard. No dangerous hazards if care is taken in keeping clear of moving bed, standing clear of cutting wheels for possible breakage. Care must be taken in setting clamps and stops so as not to interfere with cutting opera tion. Two men. ....... .. ....... . v TnhnR-Manviiie -- P.hnrfl cteristics Machine Sav, or Blllerlcs_?-'<Y Fl.ne^S TinscriDtion Machine converted from Planr machine. Four motors placed in stationary position on headder supported by t_ in floor, above material MT-006405 Material Capacity Maintenance Power Cutting Wheels (Abrasive) Stock Holding Equipment. Safety Crew Motors adjusted laterally and vertically various lengths of cuts. Rate of feed governed by hydraulic system of cylinders. Rate of feed controlled by valve on hydraulic line. Machine may be set up to cut from one to three lengths of material per cycle of machine, depending on lengths. Material cut two sides. Modified by JohnsManville Eng. Dept. See . appendix for sketc., C. The Billerica 2-way Planer Saw is basically a strip'ing and cut-off saw in one. It is designed to cut only full size sheets to size. Cutting Speed and wheel data is same as indicated under Planer Saw Page 5 Same as Planer Machine designed to cut off strips, cut on J-M Engineered Planer Saw, to various lengths. Machine set from 12" to 96" length. For thickness cuts see Cutting Speeds. Usual maintenance of equip ment designed for high speed production. it, - 10 HP Motors recommended; Arbor Speed (See "Cutting Speeds for Planer); Direct Drive. Same as J-M Eng. Planer Saw. Material held by pneumatic push type air clamp, adjust able to various positions of cutting wheel. Same as J-M Eng. Planer Saw Two men - 9- WET CUTTING Wet cutting may be used for all straight cutting where smoothness of cut is essential. The abrasive action of cut material and water flowing beck by the saw and stock results in a smooth cut edge. The water acting as a coolant reduces heat and burning of stock and cutting wheels. Water also increases the length of wheel life. There should be available a sump for collecting slurry because of danger of clogging sewer systems, EQUIPMENT USED BY JOHNS-MANVILLE A. Cooing Saw Characteristics Machine Material Capacity Recommended thicknesses cut on machine. Tolerance Description Machine has stationary bed, equipped with one V-belt driven saw mounted on over head V-rails, Rate of Feed Speed controlled by rheo stat connected to direct current generator convertor, Movement of cutting wheel by screw feed thru two speed transmission. See Appendix D for sketch. Transmission placed in high speed feed position. Cutting speeds controlled by JonesMotrola Tachometer Type "T". Machine equipped with three high pressure water jets, two directed at side of wheel one at cutting edge of cut ting wheel to reduce wheel heating at 65 lbs. pressure. Manufactured by Lincoln Iron Work, Rutland, Vt. Transite, Ebony, Colorlith and Ohmstone. Cut widths from up to 8", lengths from up to 96". For thickness see Cutting Speeds. See Cutting Speeds. Coping (Wet) + l/32" or equivalent MT-006407 Ma intonanea Power Cutting Wheels {Abrasive) Machine easily maintained and adjusted. Usual maintenance' problems of heavy equipment. 15 HP Motor; 1750 rpm; 550 AC; Sheave and V-belt driven; Arbor speed (See Cutting Speed for rpm.) 1. For cutting Ebony, Ohrastone thru 2" thick: Manufactured by Carborundum Co., Niagara Falls, N.Y.; 16" X 5/16" thick; 2 7/16" arbor diam.; 'Wheel No. C203TB-0Q-25. Bullard Co., Westboro, Mass.; 16" X 5/16" thick; 2 7/16" arbor diam; wheel No. C202.22. 2. For cutting Transits and Ebony 2 1/2" thru 4" thick; Bullard Co. - Wheel No. 16 14, 18" diameter X 5/16" thick X 2 7/16" arbor diam. 3. For cutting Colorlith: Diamond wheel No. 16932A-.093 Mfg. by: TY-SA-Man Machine Co. Knoxville, Tenn. MT-006408 Cutting Speeds - Coping (Wet) Product Ebony Ebony Ebony Ebony Ebony Ebony Ebony Ebony Ebony Ebony Ebony Ebony Ebony Ebony Ebony Ebony Ebony Transits Transite Transits Transite Colorlith Colorlith Colorlith Colorlith E <i-- I 00 3 Thickness l/A" 3/8" 3/8" 1/2" 1/2" 5/8" 3A " 1" i iA" 1 1/2" 2" 2 1/2 3" 3 1/2 A" 2 1/2 3" 3 1/2" A" 1/A" 3/8 1/2" 5/8" No, Thicknesses Cut Der Cycle 1 2 1 2 1 2 1 2 1 1 1 1 1 1 1 1 1 1 1 1 1 2 2 2 1 Feet/Min. 13-2 13.2 13.2 13.2 13.2 9.6 13.2 8.3 13.2 10.7 9.2 7.9 A.8 2.8 1.0 .75 .5 2.8 1.0 .75 .50 5.A 5.0 A.6 5.2 RPM Arbor Sneed 3600 3600 3600 3600 3600 3600 3600 3600 3600 3600 3600 3600 3600 2000 2000 2000 2000 2000 2000 2000 2000 3600 3600 3600 3600 MT-006409 Product Colorlith Colorlith Colorlith Colorlith Colorlith Colorlith Thickness 3A " 1" 1 1A" 1 1/2" 1 3A " 2" - 12 - Ho. Thicknesses Cut per Cvcle 1 1 1 1 1 1 Feet/Min, 5.0 4.6 4.2 3.8 3.3 3.0 RPM Arbor Sraed 3600 3600 3600 3600 3600 3600 Stock Holding Equipment. Stock Handling Equipment. Safety Crew Stock held by combination of C-Clarops and wooden wedges or pneumatic clamps against a guide rail on machine bed. Stock handled by hand thru 1/2" thickness on full sheets; Vacuum lift handling equipment recommended for use on 5/8" thru A" thickness on full sheets. Cutting wheel covered with heavy steel guard. Care must be taken to properly dress wheel to reduce wheel break age. Wet, slippery floor can be hazardous. One man. MT-006410 - 1J - Abrasive Cuttlnp Wheels Abrasive cutting wheels are compounded from abrasive cutting particles held together by a bonding mediur.. Abrasive wheels riv smooth, accurate ly cut surfaces together with satisfactory wheel life. Where extremely smooth surfaces are required, wet cutting ha" a decided advantage over ary cutting. The customer must decide whicn raetnod will be used to meet his specifications. To obtain smooth, accurate cut surfaces, the cutting wheel rr.ust have an accurately dressed parallel edge. A wheel that is not dressed properly, or has a beveled eage dressing nas a tendency to give wavy cuts, and cause roughing of cu; edges of material. It is important that the wheel is properly dressed from the standpoint of smoothness of cut and efficiency obtained from electric motors, as more power is required to operate a dull saw. Tne modern cutting wheel possesses an interesting characteristic, peculiar to itself - that of sharpening itself, in effect, while it works. The grains on the surface of the wheel are either broken or pulled out under the stress of the work as they become dulled. This characteristic is not entirely true, nowever, in the cutt.ng of J-M Products. The wheel, after several cuts, may become clogged with stock particles causing the wheel to lose its efficiency, therefore, frequent uneel dressings are necessary. Care should be taken not to dress wheels too often which results in excessive wheel usage. It is important in wet cutting that sufficient water is available for best results. The water not only acts as a cooling agsnt but removal of waste material as well. The abrasive action of cut material and polishing action of side rub of wheel along edge of cut piece leaves a very smooth cut, which is not possible in dry cutting. Diamond Wheels Diamond wheels may be used for wet cutting on the same equipment but smoothness of cut will not be quite as good as with abrasive wheels. Rate of cut is somewhat greater and saw kerf is less. Both important advantages in use of diamond wheels. Carbide Wheels From experience at J--M Nashua plant, the company h^s found that Carbide Tipped Wheels have not proved satisfactory in cutting J-M Froducts. Mechanical Condition of Equipment The quality of work produced Is dependent on the mechanical condition of the cutting equipment. To cut material at close tolerances all bearings, arbors, feeds, clamping arrangement, mounting of machine must be in good condition to reduce variances in the mechanism as undue vibration will cause rough edges, chipped edges, wavy cuts, and unsafe conditions. MT-006411 -K Cutting Wheel Safety To assure proper handling and use of cutting wheels, your attention is cabled to the booklet issued by the American Standards Association entitled "American Engineering Standards Safety Coda for the Use, Care and Protection of Abrasive Wheels" - ASA - B7 - 19A3, ^ e 6 p C u t t i n g Wheel s p r o p e r l y g u a r d e d a t all times. MT-0064J2 - 15 - SHEARING Asbestocite or Marine Veneer may be sheared very satisfactorily where specifications do not require a smooth edge. Shearing produces an irregular roughly cut surface which is caused by the fibers pulling and breaking apart at the cutting point, ^ome installations of wet machine products do not require a smooth edge and shearing is an economical means to cut stock to a rough dimension for use or further maching. A , Shear Characteristics Machine Mat srial Capacity Recommended thick nesses cut on machine Tolerances Maintenance Power Cutting speed Stock holding equipment Safety Crew Description Scissor type action, one move able blade for cutting. Mach ine made by the Peck, Stow and Wilcox Co. Southington, Conn. See Appendix E for sketch. Asbestocite, Marine Veneer Machines available for cutting 1 ft. or 8 ft. lengths 1/8" and 3/16" thicknesses. + 1/16" or equivalent. Easily maintained and adjusted. 5 HP Motor: 550 AC; 1 H 0 rpm full load. Constant Pressure plate holds stock on downward movement of cutting action. Blade guarded but caution should be used in operating machine. One and 2 men. MT-006413 - 16 - Shear Blade Since there is a certain amount of abrasive action on the heJr in cutting Asbestocite and Marine Veneer products, a very hard steel is used to reduce aorasive wear, increase life of shear blade and produce a more sharply cut edPe. The blades used on machines at Johns-Manville are manufactured by Peck, Stow and Wilcox Co. of special steels. Tne cuttine ed*e on the shear blade must be sharpened correctly for / ng results, otherwise, instead of a cutting action being S h o w e d an faoropcrly sharpen.*! bl.d. ca..a a > action at the cutting point. See Appendix F, Crinaing Shear Blade. The shear blade is set into the machine at a slight difference in plane to the lower shear knife, this difference is approximately 1/2" in four feet. MT-006414 17 - D R I L L I N G & C O U N T E R B O R I N G A L L__F_ R O D U,,c J_s There are no special techniques required in drilling J-M Froducts other than equipment should be of proper design to handle the operation for maximum efficiency. The equipment should be in good mecrsnical condition which is required if quality work is to be produced at close tolerance. All drilling should be done dry, with provisions for adequate dust collection. . .. ,, , +<1 Any standard make of twist drill can be used m drilling J-M Products. Either Carbon, or High Speed Steel Drills up to 2" diameter are used. High speed steel drills give better service than Carbon steel from the standpoint of long life and frequency of sharpening. Carbide tip.ed drills perform well on Colorlith. A . Preparation for Drilling Have drill press firm on its base. Be sure chuck is tight, both vertical and hori zontal . Be sure drill ie sharpened correctly and that it is not worn tapered. Have stock on firm bed. Reason If separate bed is used to hold work, the drill and work will not be lined up at all times, thus enlarging and burring hole. Vertical play makes it diffi cult to "feel" drill and will allow it to punch thru the bot tom of work. Horizontal play allows the drill to run out, making it inaccurate and bur ring the edges. A dull drill causes punching, rough holes, and excessive time for drilling. A tapered drill causes burring on top edge of hole. A loo se bed allows stock to move, throwing load on drill, thus reaming and burring the hole. R . Drilling Operation The drill should be hand fed. Reason In stock over half inch thick the drill should be raised to free its flutes of chips, other wise it will heat, bind and cut a ragged, uneven hole. MT-006415 - 18 - Release pressure on drill for last eighth inch stock. For very clean cut holes, use a piece of natural wood, Iransite, or Metal lic template under stock being drilled. Drilling holes from 2" to 3" in diameter, use an insert tooth counter bore with an Armstrong Self Hardening steel cutter. Drilling holes from 3" to 22" in diameter, use a trepanning tool or fly cutter bar. Small holes in small pieces are drilled on sensitive bench drills. Drills up to 5/8" dia meter may have to have the shanks cut off and turned down to fit small cnucks. Faster rpm's are best in drilling - See data on drill rpm's. Drill three quarters way thru stock with boring tool, turn piece over and finish drilling from other side, Drilling with counter bore, have lead guide hole large enough to fit freely and drill clear thru. Frevents punching ana tear ing edge of nole. Allows drill to cut thru stock Best method. Best method. Better control and "feel" of drill. Better results and less wear on drill. Cleaner holes. Prevents binding and move ment of stock. tor-006416 - 19 - scitle Causes nf Poor Cuality Work Causes Holes run cut of line and burr raised on top edge, Reason Drill press loose on base. Chuck loose in press. _ Drill sharpened too pointed. Drill worn tapered. v,'ork not '.eld ste .dy. Scribe marljs for hole to deep. Holes not clean on bottom Drills get hot and gummed up. Excessive Drilling Time. Vertical play.in chuck and drill. Drill too pointed. Forcing drill near end of cut. Speed too slow. Dull drill. Drill worn tapered. Speed toe great. Crowding drill. Drill not free of cuttings. Drills not sharpened correctly. Speed to slow. Drill fed too slow. Drill not free of chips, .nnroximate Speeds of Drills Diameter of Drill rpm Up thru 3/8" 850 7/16" thru 9/16" 6CC 5/8" thru 7/8" 50 1" thru 1 1/l" 250 1 3/3" thru 1 1/2" 170 1 5/8" thru 2" 70 ^ T - 0 0 6417 - 20 - Grinding Twist Drills Twist drills should be ground, preferably on an automatic drill grinder, so that the cutting edge is a straight line on a 59 angle with the center line of the drill. The heels of the lips should be bached off 1 or 5 less than the cutting edges. See sketc'j showing grinding features. Appendix G . Counter Bering On holes from 2" to 6C" in diameter, a trepanning tool or fly cutter b r is used with good results. The size of hole is reg ulated by moving the cutter in and cut of the spindle. When using these bars it is necessary to reauce the speed. The pro blems encountered in the drilling section are applicable to counter boring. Grirkiing Counter Bore Tools Steel cutters in boring tools should be ground so that the tool edge is not at right angles to the spindles but so its extrem ity touches the work first. The heel of the tool is backed off about 5 to 10 from the cutting edge. See sketch showing grind ing features - Appendix G . Approximate Speed of Counter Bore. Rate of Feed Ranee R.F.H. " - 6" 260 6" - 10" 162 10" - U " 102 U " - 20" 10 20" - 60" AO - 29 Feed/R.F.M. .029 .OU -,0U .Old (Depending on) (Hand, feed ) M T-006418 - 21 " M A C H I N I N G ALL P R O D U C T S J-M Products may be machined by various methods. Care should be taken to select the proper method of machining as much depends on selection of method in producing a quality piece at a reasonable cost. gJUIPilhNT USED BY JOHNS-MANVILIE Lathe J-M Products can be lathe worked to capacity procedure can be used as turning soft metals rate of cut is possible. Rate of out should should leave a clean cut surface. Range of Sizes Type RFW of machine. Same except that a faster not tear work but Feeds/ Min. Depth of Cut 0 thru 3 l/2" rods, discs or rings 235 4 5/8" 1/4" 3 1/2" thru A" rods, discs or rings 135 2 3/4" 1/4" ln thru 6" -- discs or rings 135 2 3/4" 1/4" 6" thru 10" -- discs or rings 40 7/8" 1/4" 10" thru 14" .-- discs or rings 26 Note: Last cut of Lathe reduced to l/l6" 9/16" 1/4" Jig Saw & Band Saw Curves and irregular cuts can be made with a jig saw (bow type, reciprocating action) or a band saw. Holes over 22" in diameter or cut-outs can be cut on a jig saw or band saw. Since the saw cut is fairly rough the saw cut must be smoothed with a sanding device. For an outside cut the saw cut may be sanded on a sand wheel. For an inside cut a sand wheel placed on an upright spindle works satisfactorily. A coarse tooth blade of 5 teeth to the inch should be used on jig and band saw machines for best results. Care must^ be taken not to put too much pressure on the saws in cutting for safety against breakage. A heavy duty jig saw or band saw with deep throat to allow turning and handling the work should be used. Machine Specificationa Jig Strokesi 820/min. Band Saw: 2900 S.F.M. Power Supply: 2 hp ' _ ,, __ ,. v v Blade Data: Mfg. by OlsonBros. Machine & Tool Co., Brooklyn, N.Y. Jig blade - 1/2" wide, 15 gauge, 5 points per inch. Band saw blade - l/2" wide, 21 gauge, 5 points per inch. MT-006419 v'ming Machine Characteristic Machine Material Capacity Recommended thick nesses to be cut on machine Tolerance Maintenance Power Cutter data - 22 Description Standard Horizontal Milling Machine Table Working surface 68" X 19" Size overall 72" X 1911 T- slots 3 - 13/16" Distance between T-slots - L 1/4" 0 Swing of table 4? Ranee Longitudinal travel 35" Cross travel 14" Vertical travel 14" Manufactured by Cincinnati Milling Machine Co., Cincinnati? Ohio, Mach. No. 4 High Power Horizontal,* Model No. HO. Transits, Ebony, Ohmstone, Chemstone, Colorlith, and Marinite Products. Accommodates stock 35" lQ.g3 32" wide between hub and cut ter; all thicknesses of stock? all depths cut up to 4", all widths of cut. l/8" thickness thru 4". + 1/32" or equivalent Usual maintenance character istic to milling equipment. 10 hp Motor; Speed full lead 1140 rpm; 550 volts; multiple V-belt driven. Standard high-speed steel cutters similar to equipment used on metal. Mfg. by 0. iw Tool Co., Milford, M, H,; Morse Twist Drill i<aoh< Co, New Bedford., xiaes. Browne 6: Sharpe Co,, Providence, h .1 MT-006420 ' 23 ' Milling Speeds Stock Holding Equi rraent Safety Feed rate from 3/8" thru 1$"/ min. Milling speed varies by depth and width of cut. Adjustable flat steel flange bolted to bed and wedpes. Keep clear 'f revolvinp cut ter and moving table. Belts, pulleys, pears enclosed, Cut ter shaft unguarded. No dust problem. Vertical shifting of table by automatic drive is hazardous due to hand adjust ment handle revolving at high speed. MACHINE B VtLING ALL PRODUCTS Some installations require the edpes of the panel or sheet to be beveled. Ebony, Ohmstone, Chemstone, Colorlith are beveled wet due to impregnation, Trapsite and Marinite Products are beveled dry. Panel to be beveled should be placed on table face down, and clamped in that position so that face of beveling wheel is in same plane as edge of panel. Positioning ranel in this manner on machine tends to eliminate variances in width of bevel cn edge of panel. A. Wet Beveling Characteristics Machine Material Capacity Description Modified Coping Saw. Machine has stationery bed equipped with direct drive beveling wheel, mounted'on over-head V-rails, Rate of feed control lable by rheostate connected to direct current generator convertor. Movement of cutting wheel by screw feed thru trans mission. Manufactured by Lincoln Iron Works, Rutland, Vt. Modi fied by Johns-Manville Enr, Dept. Ebony, Obmstone, Chemstone, Colo-iiih. Any length bevelled desired thru v6"; Widths of Devels from 1/16 thru 1/2", on 45 angles. MT-006421 - 2A l0-commceuntdedon tmhiacckhni en se ses Tnlc'tnce *; ntenance ro r Beveling Wheel ! . Beveling Speeas I Stock Holding Equipment t i ! Safety B. i>v Beveling Characteristics Machine Material Capacity 3/8" thru l" + l/32" or equivalent Usual maintenance problems of heavy equipment. 15 hp Motor; Arbor Speed 1750 rpm; direct drive; 550 volts. Manufactured by Bullard Co., Westboro, Mass. ; Wheel No. U0l 6 x - 3" thick - 10" cup diam., Tested speed 6700 rpm; Recom-nended Speed 500 rpm. 13,2 feet/min. Eight air cylinders placed in a vertical position which hold panels being machined. Air cylinders adjustable to any size panel. Cutting wheel positioned at back of machine, does not en danger operator. Wet sur roundings can be hazardous. Description J-M DESIGNED; Working Surface 32 1/2" X 102" ; Beveling wheel attached to solid-rails, screw feed, beveling action forward and reverse - feed, constan beveling speed. Transite, Marinite Products Any length bevel thru 96 long, width of bevel from 1/16" thru 1/2" on 15 angles. Thickness up to 3A'1 MT-006422 - 25 - Recommended thicknesses to be beveled on machine Tolerance Maintenance Power Beveling Wheel Beveling Speed Stock Holding Equipment Safety Hand Beveling Equipment Procedure l A " thru 3A " + 1 /32" or equivalent Usual maintenance problems of heavy equipment. Special c re in cleaning and greasing of rails is pood preventative maintenance due to dust problem, 7 l/2hp Motor; 3600 rpm: Direct Drive. Manufactured by Bullard Co., Westboro, Mass., Wheel No. 016X - 3" thick - 10" cup diam. Tested speed 6700 rpm; Recommended spe^d 500 rnm, 30.75 feet/min. Concentric action air clamps, rubber cushioned, adaptable to all length stock. Cutting wheel positioned at back of machine, does not en danger operator. Bevels may be put on panels by han; or to touch-up machine bevels. 1. Flat bastard fil 1 3/8" x li" double cut, 17 teeth per inch (Nicholson file). 1. Hold file at 5 angle and use a stiff wrist motion to hold constant angle the length of the panel. 2 Smooth the formed bevel with a sand block and 120 grit pacer. Hand Toole All J-M Products may be machined with common hand tools - hand drills hand saws, etc. If sawing is done by hand, a very coarse tooth hand st^ used with 5 points to the incn, with a great deal of setin the teeth. Same care should be taken in drilling with hand drill with power drills as same problems are likely to occur. MT-006423 - 26 - Spgnial Jobs - Colorllth. Chemstone Considerable technique is required in fabrication of the various aaterials for special application. Some of the techniques for fabrication of jobs more commonly encountered in the field are listed below: A, Sink Cut-Outs The method used for sink cut-outs is as follows: 1. Steps in ope-atlon for square corner sinks a. Lay out dimension of sink hole to be cut on panel. t>. Drill 3/A" hole in all four corners of lay-out to allow for 1/2" wide jig saw blade to pass through. c. Saw out opening on bench saw. * Note: The saw used in this operation is hydraulically- lifted and lowered by cylinder. The stock is placed on bench table and saw raised through stock. The stock is pushed by the saw for cut-out. See picture of bench saw and controls and bench saw with round cornered sink in cut position. d. After sawing, stock is removed from bench saw and corners are cut out with l/2" jig saw. e. Corners are filed bv hand with coarse file to smooth corners. 2. Steps in operation for Round Corner Sinks a. Layout dimension of sink hole to be cut on panel. b. Cut out round corners of sink hole. * Note: Up to and including 3/4" radius corners, a drill is used in making round corners. Over 3/l * radius corners, a fly-bar and cutter are used. If fly-bar is used, a guide hole ia drilled for proper radius and hole is cut with fly-bar. c. After making round corners with drill or fly-bar, the sink opening 1b cut on bench saw by same method as for square corner sinks. " d. After saving, stock is removed from bench saw and where corners are filed with a area saw and round coarse file to corners meet. smooth No jig is used in the layout or cutting of sink out-outs by the Nashua Method. B. Recesses and Rebates Nashua uses several methods for making recesses, depending on the dimension of recess and size of panel. M T -006424 - 27 - 1. On round sink holes a fly-bar cutter is used, and material left between holes not cut is chiseled out by hand. 2 . On square sink holes, the recess is made on a rlilling machine and the corners chiseled out by hand. The machine Is limited to uh.t else p.nel sen be oorked on, , On long recesses along edges of panels, the recess is made 3 - the^coping saw with a wide wheel set at the proper depth. C. Drip Grooves Ua ,,on Skil Saw at Nashua for making drip grooves. 9 l A " Sd. h l 1. set et the proper depth end dlstence rom the eage of opening, and the cut is made. Unf^ s^ ^ f the groove are chiseled out with a round, pointed chisel. D. Finishing ages General; Edges of panels may be finished to match the top surface by polishing the edge to a soft sheen. Procedure; 1. Use a portable belt sender with 70 grit paper to remove deep scratches and saw marks* 2. With a portable sander and 120 grit paper, hand buff to a polished finish. Notes Hold portable sander vertical to the edge in a tight grip to prevent rounding edges. MT-006425 28 - spaiai Jobs Continued ) , inching and Assembling Splines 1, Machining Splines : a . Operation ' The machining operation consists of cutting a l A " wide by 2 1 /1 6 " deep groove with a resinoid abrasive wheel along the edge of panels to accommodate a 2" wide by 7/32" thick spline strip. b, Description of Equipment! Machining of splines is done on a Johns-Manville Engineered Plane/saw? t L s nach-ns is . regular production -achi. for stripping 8" x 96" sheets to various widths. *or spiining^a special honor oust is inst.ll.d to brine cutting S t i r t^desied cutting position cn Mtsrl. . Th. otor Is rotated so that the abrasive heel is horizontal to th tlblo surfsce for splin. cut. See sketch for details. c . Power Requirements : 7 1/2 H. P. S. A. woods arbor type motor; arbor speed 3600 rpm; 550 volts AC; direct drive. d. Abrasive Cutting Wheel: Hanufactured by Ceo. H. Bullard Co., Westboro, ss. 16" * l A " thick k 1" arbor hole! wheal So. C202-15-BS (Safety Wheel) e . S to ck H o li n g E q u ip m en t* Stock held by air clamps or hand pressure type clamps. f . nutting Method': Dry method; dust collection required. g. Cutting Speed: 4 - 8 ft./min. h. Tolerances: + 1/32" i. Safety; Keep cutting wheel covered with steel taken in setting clamps and stops so as ^ to i with cutting operation. Caution ;a*en area guarded against possible wheel breakage. MT-006426 - 29 - 2 Assembling Sp IIm Strips in Groove; Altar spline M t 1 . i . , the 8 TM TM " fTM t " lea f tt* ,>`"',1 ^ is plugged to fill spline groove. Steps for Plugging Bid of Groove) 1. Cot plug to dimension. Sh""S T 2 . Cement ple Into spline groove pith j o t a - i w v i n . 06-1 t b e r fee. cement SKETCH OF TWO PANELS WITH INSTALLED SPLINE SHOWING CLEARANCES MT-006427 - 30 J o h n s E n g i n e e r e dSkpeintncherof for M&ehiiiijig Spiihes^ Side Vie-w MT-006428 - 31 - Suggested Cutting Shop Equipment We have listed below and on the following pages equipment we feel essen tial for a fabricator handling all board materials if 'he is to properly service his accounts, .-e v/isn to emphasis again that by "shopping arounc" bargains can be found in good used equipment. Machinery provid ing tolerances t 1/32" is for the most part aderuate. Again remember that dry fabricating must have adequate means for dust removal while wet operations require sludge removal facilities. A. Most Important Equipment for a Cutting Shop Cutting and Sizing Saw Ty-Sa-Man Machine Co., Knoxville, Tenn.; Saw Model III Series, Suggested Machine Require ments : HP Min. 20. Max. 'Wheel diam, 18". Max, Straight Cutting Capacity - To accommodate longest cuts 8 1 for Nashua products or 10' for Billerica products. Max. Cross Trav'elMin. of S'. Max. Vert. Adjust ment - 12". Carriage Feed Screw feed. Controls Electronic variable speed to J>" per min. Cutting Method Equipped for cutting wet or dry. Clamping - Recommended Ty-Sa-Man clamping mechanism. Variable arbor speed from 1600 to 3600 rpm. Bench Saw: Suggested Machine Require ments! MT-006429 I^rge Radial Drill: Manufactured by American #1. Model #6 or equivalent make. HP 15, Variable arbor speed 1200 to 3600 rpm. Tilting table top - To 45 for making angle cuts and bevels. Saw Mechanism - Raising and lowering mechanism of cutting wheel for cutting sink cut-outs and radiator grills, etc. Saw Guide - Heavy saw guide for accuracy. Cutting method - Dry. Size - Heavy cast frame for rough usage. Manufactured by Cincinnati Bickford Tool Co., Cincinnati, Ohio; Model AD-166; A' radial - 32 - Cutters : Clamps : R-.a11-Breed Lathe: Suggested ilachine Requirerne ri". s : Pest Drill; Suggested lachine Require ments : Small Belt Sander - 6" Suggested Machine Require ments: Large Post Drill: Suggested liachine Require ments : Electric Band Drill with 1/2" Chuck: High-speed steel cutters or carbine-tipped similar to those used cn metal. Adequate clamping. Manufacturer - any standard make, To have chuck capacity of 8", To be useu for small rods and tubes net adaptable to large lathe operation. Manufactured by Walker-Turnsr, Plainfield, N.J.J Serial no. 52E3B3. Have at least 10" swing. One HP motor; adjustable table height and swing; wide range of feed speeds and chuck speeds. Manufactured by Delta Power _ Tool Div., Rockwell Manufacturing Co., 1ittsburgh, Pa. Have 6" belt, 1 HP motor, table adjustable from horizontal through 90 vertical. To be used for surface and edge ^ sanding of small pieces, making small bevels, etc. Manufactured by Prentice Bros., Worcester, Mas:.; Serial No. *1-12 1 HP motor; adjustable table height and swing; broad range of drill speeds and feed speeds; at least 13-inch swing. Manufacturer - Any standard make. MT-006430 - 33 - Large Radial Drill (Continued.) Suggested Machine require ments; Bench Radial Drill: Suggested Machine Require ments ; Lathe; Suggested Machine Require ments; Jig Saw; drill, 11" column, quick change gear box, :IT in spir.ule, reverse in head, auxiliary box table, 5 HP motor at 12CC rpm or equivalent make. Machine to be rugged for drilling large diameter holes up to 2" ar.d for use with fly-bar cutters for circle cutting of large radii, etc. Manufactured by .-.alker-Turner, E, Plainfield, N.J.; 1/2 HP motor; Serial No. 7-624.8, To be well supported on a steel table to minimize vibration. Have a wide range of drill speeds for various materials and drill sizes. To be used for drilling small holes not adaptable for large radial drill. . Manufactured by South Bend 16 inch x 10 feet. Precision Lathe cr equivalent make. To be equipped with chuck capacity to 16 inch diameter stock for rings, discs, rods, etc., with center-rest attach ment, follower rest, taper attachment, reversing 2 HP motor. Manufactured by American Wood Working Mach. Co. or equivalent make, Williamsport, Pa, MT-006431 - 34 - Suggested Machine Require ments; Band Saw; Suggested Machine Require ments; Drill Grinder; Dust Collector for Dry Cutting; Sump Basins for Collecting Sludge from Wet Cutting; 1 To be a "bow-type", spring reciprocating action machine for small square and round cut-outs, finishing up corners left by saws, and large circles or irregular cutting. Saw blades should be 5 points to the inch and resharpenable by 15 gauge X l/2" wide. Machine should accommodate all size panels to 48" x 96"* Manufactured by S. A. Woods Co, or equivalent make, Should be 36" throat for cutting large size circles and radii. Speed of blade should be approx imately 2900 surface feet per minute. Blade; 1/2 vide x 21 gauge x 5 points to the inch and resharpenable. Capacity to 2 1/2 drill diameter. Manufactured by Black Diamond Saw ani Machine Works, Inc., Natick, liass.; Model OEM, Cap. 1/2 - 2 1/2" (Worcester drill grinder). B. Next moat important for a cutting shop; Milling Machine; Manufactured by Cincinnati Milling Mach. Co., Cincinnati, Ohio, Mach. No. 4 High power horizontal; Model No. HO or equivalent make. Suggested Machine Require ments; To be used for special grooves, slots, rabbets, adaptable to multiple operation. Capacity; tutors Accommodate stock 8" long, 32" wide between hub and cutter, all thicknesses of stock. 10 HP. MT-006432 - 35 - C. Other Essential Equipment; Small Tools: Cutting Wheels: Band Saw & Jig Saw Blades: Sanding Belts: Work Tables: Box Shop Equipment: Handling Equipment: Hammers, chisels, jibs of various sizes, squares, punches, wrenches drills, etc. Abrasive and diamond cutting wheels for various materials. Several replacements, Abrasives for small belt sander and hand finishing of various grits. Various sizes. Small swing saw for cutting crating lumber; supply 7/8" lumber; supply 7-d nails; banding equipment. Skids - U x 8 and A x A; hand push trucks; hand lift truck; fork truck; , MT-006433 APPENOIX A METHOD OF SETTING GAUGE TO PREVENT STOCK BINDING OR SAW HEATING, MT-006434 APPFTm B Vertical Adjuatment Lateral Adjuatraent Sketch of JOHNS-MANVILLE ENGINEERED PLANER SAW -j^y-006435 APPiNDrX c Lateral Adjustment A --------------- ^ Sketch of OOHNS-MANVILLE ENGINEERED CARRIAGE SAW MT-006436 J.J.A . 4 -2904 APPENDI! D Feed Motor Sketch of COPING SAW MADE B LINCOLN IBON WORKS MT-006437 APPENDIX E Cutting blade set at angle of approx. 1/2" to horizontal in h1 FRONT VIEW 07 SHEAR FOR COTTINO ASEESTOCITE AND MARINE VENEER. Prur. Plata for holding atoek vhlle baing cut - not ehom ^T-006438 APPENDI! F 9A6" SKETCH OP CROSS SECTION OF S EAR CUTTING FULDE SHOWING METHOD OF GRINDING MT-006439 BACKED OFF APPENDIX Q END OF CUTnNO EDGE ORINDING TWIST DRILLS LEAD GUIDE GRINDING BORING TOOLS MT-006440