DOCUMENT RESUME ED 401 434 CE 072 927 TITLE Machine Tool ... › fulltext › ED401434.pdf ·...

DOCUMENT RESUME

ED 401 434 CE 072 927

TITLE Machine Tool Advanced Skills Technology (MAST).Common Ground: Toward a Standards-Based TrainingSystem for the U.S. Machine Tool and Metal RelatedIndustries. Volume 4: Manufacturing EngineeringTechnology, of a 15-Volume Set of Skill Standards andCurriculum Training Materials for the PrecisionManufacturing Industry.

INSTITUTION Texas State Technical Coll., Waco.SPONS AGENCY Office of Vocational and Adult Education (ED),

Washington,, DC.

PUB DATE Sep 96CONTRACT V199J40008NOTE 300p.; For other volumes in this set, see CE 072

924-938.AVAILABLE FROM World Wide Web: http://machinetool.tstc.eduPUB TYPE Guides Classroom Use Teaching Guides (For

Teacher) (052)

EDRS PRICE MFO1 /PC12 Plus Postage.DESCRIPTORS Computer Assisted Design; Computer Assisted

Manufacturing; Course Content; CurriculumDevelopment; Electromechanical Technology;*Engineering Technicians; *Engineering Technology;*Entry Workers; Hand Tools; *Job Skills; JobTraining; Learning Modules; Machinery Industry;*Machine Tools; Manufacturing Industry; MetalWorking; Numerical Control; Postsecondary Education;Secondary Education; *Standards; Teaching Methods

ABSTRACTThis document is intended to help education and

training institutions deliver the Machine Tool Advanced SkillsTechnology (MAST) curriculum to a variety of individuals andorganizations. MAST consists of industry-specific skill standards andmodel curricula for 15 occupational specialty areas within the U.S.machine tool and metals-related industries. This volume provides theMAST standards and curriculum for the manufacturing engineeringtechnician specialty area. (A manufacturing engineering technician isa person who uses special knowledge and skills to recommend andimplement solutions for specific manufacturing applications.) Thisvolume is organized in the following sections: (1) a profile of TexasState Technical College, the development center that produced thesestandards and curriculum; (2) a manufacturing engineering techniciancompetency profile of job duties and tasks; (3) a manufacturingengineering technician duty, task, and subtask outline; (4) a coursecurriculum outline and course descriptions; (5) a technical workplacecompetencies and course crosswalk; and (6) a Secretary's Commissionon Achieving Necessary Skills (SCANS) proficiencies crosswalk.Individual syllabi for the following courses are provided: MachineTool Practices I; Drafting Principles; Machine Tool Practices II;Application Software; Engineering Materials; Safety and AccidentPrevention; Basic Fluid Power; Electrical Applications; Survey ofWelding Processes and Applications; Computer Numerical Control (CNC)Machine Programming; Statics; Manufacturing Processes; Introductionto Computer Drafting; Computer-Assisted Design/Manufacturing(CAD/CAM) I; Tool Design I; Strength of Materials; CAD/CAM II;Computer Integrated Manufacturing; Quality Assurance and StatisticalProcess Control; and Engineering Technology Project. Each coursesyllabus includes the following: course hours, course descriptions,prerequisites, required course materials, teaching and evaluationmethods, lecture and laboratory outlines, course objectives fortechnical and SCANS competencies, and suggested references. Anappendix contains industry competency profiles. (KC)

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COMMON GROUND:TOWARD A STANDARDS-BASED TRAINING

SYSTEM FOR THE U.S. MACHINE TOOLAND METAL RELATED INDUSTRIES

VOLUME 4

MANUFACTURINGENGINEERINGTECHNOLOGY

ofa 15 volume set of Skills Standards

andCurriculum Training Materials for the

PRECISION MANUFACTURING INDUSTRY

2

13fST COPY AVAILABLE

Supported bythe Office of Vocational & Adult Education

U.S. Department of Education

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AUGUSTA

TECHNICALINS TIT U T E

San Diego College

FT, ri Moraine Valley

FA A Community College

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SPRINGFIELD TECHNICALCOMMUNITY COLLEGE

Texas StateTechnical College

Waco

Machine Tool Advanced SkillsTechnology Program

VOLUME 4

MANUFACTURINGENGINEERINGTECHNOLOGY

Supported byThe Office of Vocational and Adult Education

U.S. Department of Education

September, 1996

3

Project Title:

Grant Number:

Act under whichFunds Administered:

Source of Grant:

Grantee:

Disclaimer:

Discrimination:

GRANT INFORMATION

Machine Tool Advanced Skills Technology Program

V199340008

Carl D. Perkins Vocational Education ActCooperative Demo - Manufacturing Technology, CFDA84.199J

Office of Vocational and Adult EducationU.S. Department of EducationWashington, DC 20202

Texas State Technical CollegeWaco, Texas

This publication was prepared pursuant to a grant with the Office ofVocational and Adult Education, U.S. Department of Education.Grantees undertaking such projects under government sponsorshipare encouraged to express freely their judgement in professionaland technical matters. Points of view or opinions do not, therefore,necessarily represent official U.S. Department of Educationposition or policy.

Title VI of the Civil Rights Act of 1964 states: "No person in theUnited States shall, on the ground of race, color, or national origin,be excluded from participation in, be denied the benefits of, or besubjected to discrimination under any program or activity receivingfederal financial assistance." Title IX of the EducationAmendments of 1972 states: "No person in the United States shall,on the basis of sex, be excluded from participation in, be denied thebenefits of, or be subjected to discrimination under any educationprogram or activity receiving federal financial assistance."Therefore, the Machine Tool Advanced Skills Technology (MAST)project, like every program or activity receiving financial assistancefrom the U.S. Department of Education, operated in compliancewith these laws.

ii

4

ACKNOWLEDGMENTS

This project was made possible by the cooperation and direct support of the followingorganizations:

U.S. Department of Education, Office of Vocational & Adult EducationMAST Consortia of Employers and Educators

MAST DEVELOPMENT CENTERSAugusta Technical Institute - Itawamba Community College - Moraine Valley Community College - SanDiego City College (CACT) - Springfield Technical Community College - Texas State Technical College

INDUSTRIESAB Lasers - AIRCAP/MTD - ALCOA - American Saw - AMOCO Performance Products - AutomaticSwitch Company - Bell Helicopter - Bowen Tool - Brunner - Chrysler Corp. - Chrysler Technologies -Conveyor Plus - Darr Caterpillar - Davis Technologies - Delta International - Devon - D. J. Plastics - EatonLeonard - EBTEC - Electro-Motive - Emergency One - Eureka - Foster Mold - GeoDiamond/SmithInternational - Greenfield Industries - Hunter Douglas - Industrial Laser - ITT Engineered Valve - KaiserAluminum - Krueger International. - Laser Fare - Laser Services - Lockheed Martin - McDonnell Douglas -Mercury Tool - NASSCO - NutraSweet - Rapistan DEMAG - Reed Tool - ROHR, International - Searle -Solar Turbine - Southwest Fabricators - Smith & Wesson - Standard Refrigeration - Super Sagless - TaylorGuitars - Tecumseh - Teledyne Ryan - Thermal Ceramics - Thomas Lighting - FMC, United Defense - UnitedTechnologies Hamilton Standard

COLLEGE AFFILIATESAiken Technical College - Bevil Center for Advanced Manufacturing Technology - Central FloridaCommunity College - Chicago Manufacturing Technology Extension Center - Great Lakes ManufacturingTechnology Center - Indiana Vocational Technical College - Milwaukee Area Technical College - Okaloosa-Walton Community College - Piedmont Technical College - Pueblo Community College - Salt LakeCommunity College - Spokane Community College - Texas State Technical Colleges at Harlington, Marshall,Sweetwater

FEDERAL LABSJet Propulsion Lab - Lawrence Livermore National Laboratory - L.B.J. Space Center (NASA) - Los AlamosLaboratory - Oak Ridge National Laboratory - Sandia National Laboratory - Several National Institute ofStandards and Technology Centers (NIST) - Tank Automotive Research and Development Center(TARDEC) - Wright Laboratories

SECONDARY SCHOOLSAiken Career Center - Chicopee Comprehensive High School - Community High School (Moraine, IL) -Connally ISD - Consolidated High School - Evans High - Greenwood Vocational School - Hoover Sr. High -Killeen ISD - LaVega ISD - Lincoln Sr. High - Marlin ISD - Midway ISD - Moraine Area Career Center -Morse Sr. High - Point Lamar Sr. High - Pontotoc Ridge Area Vocational Center - Putnam Vocational HighSchool - San Diego Sr. High - Tupelo-Lee Vocational Center - Waco ISD - Westfield Vocational High School

iii

ASSOCIATIONSAmerican Vocational Association (AVA) - Center for Occupational Research and Development (CORD) -CIM in Higher Education (CIMHE) - Heart of Texas Tech-Prep - Midwest (Michigan) ManufacturingTechnology Center (MMTC) - National Coalition For Advanced Manufacturing (NACFAM) - NationalCoalition of Advanced Technology Centers (NCATC) - National Skills Standards Pilot Programs - NationalTooling and Machining Association (NTMA) - New York Manufacturing Extension Partnership (NYMEP)- Precision Metalfonning Association (PMA) - Society of Manufacturing Engineers (SME) - SoutheastManufacturing Technology Center (SMTC)

MAST PROJECT EVALUATORSDr. James Hales, East Tennessee State University and William Ruxton, National Tooling and MachineAssociation (NTMA)

SPECIAL RECOGNITIONDr. Hugh Rogers recognized the need for this project, developed the baseline concepts and methodology,and pulled together industrial and academic partners from across the nation into a solid consortium. Specialthanks and singular congratulations go to Dr. Rogers for his extraordinary efforts in this endeavor.

This report is primarily based upon information provided by the above companies, schools andlabs. We sincerely thank key personnel within these organizations for their commitment anddedication to this project. Including the national survey, more than 3,000 other companies andorganizations participated in this project. We commend their efforts in our combined attempt toreach some common ground in precision manufacturing skills standards and curriculumdevelopment.

This material may be found on the Internet at http: / /machinetool.tstc.edu

iv

VOLUME 1

VOLUME 2

CATALOG OF 15 VOLUMES

EXECUTIVE SUMMARYSTATEMENT OF THE PROBLEMMACHINE TOOL ADVANCED SKILLS TECHNOLOGY

PROJECTPROJECT GOALS AND DELIVERABLESPROJECT METHODOLOGYPROJECT CONCLUSIONS AND RECOMMENDATIONSAPPENDICES

CAREER DEVELOPMENTGENERAL EDUCATIONREMEDIATION

VOLUME 3 MACHINING - CORE COURSES (MAC)

VOLUME 4 MANUFACTURING ENGINEERING TECHNOLOGY NB

VOLUME 5 MOLD MAKING (MLD)

VOLUME 6 WELDING (WLD)

VOLUME 7 INDUSTRIAL MAINTENANCE (1MM)

VOLUME 8 SHEET METAL (SML) AND COMPOSITES (COM)

VOLUME 9 TOOL AND DIE (TLD)

VOLUME 10 COMPUTER-AIDED DRAFTING AND DESIGN (CAD)

VOLUME 11 COMPUTER-AIDED MANUFACTURING ANDADVANCED CNC (CNC)

VOLUME 12 INSTRUMENTATION (INT)

VOLUME 13 LASER MACHINING (LSR)

VOLUME 14 AUTOMATED EQUIPMENT TECHNOLOGY (CIM)

VOLUME 15 ADMINISTRATIVE INFORMATION

VOLUME 4

MANUFACTURING ENGINEERINGTECHNOLOGY

Table of Contents

TAB

Foreword 1

Development Center Profile 2

Manufacturing Engineering Technician Competency Profile 3

Manufacturing Engineering Technician Duty/Task/Sub-TaskOutline 4

Course Listing/Course Descriptions 5

Technical Competency/Course Crosswalk 6

"SCANS"/Course Crosswalk 7

Individual Course Syllabi 8

Appendix A - Industry Competency Profiles 9

FOREWORD

After numerous interviews with practitioners from industry (see Appendix A), and discussionswith numerous educators, managers, supervisors, and others involved with machine relatedoccupations and specifically machining, the MAST Consortium Partners have agreed to presentour definition of a Manufacturing Engineering Technician as follows:

MANUFACTURING ENGINEERING TECHNICIAN - one who uses special knowledgeand skills to, recommend and/or implement solutions for specific manufacturing applications.

MAST has also determined that individuals working as Manufacturing Engineering Technicianswill preferably have received at least two years of training and education in both academic andtechnical courses in the areas of manufacturing methods and processes. This training may havebeen conducted in a vocational institution or college. Our research indicates that a minimum oftwo years of vocational training will prepare students with entry level skills necessary to beginwork as a Manufacturing Engineering Technician.

In this program, the students progress through a series of courses designed to both educate andtrain students with skills and knowledge in areas such as manufacturing materials and methods,conventional and CNC machining, computer-aided drafting and design, engineering mechanicsand design, computer-aided manufacturing, and robotics. Students receive a wide range oftraining which enables them to seek jobs in many different manufacturing areas. TheManufacturing Engineering Technology Program at Texas State Technical College has beentraining Manufacturing Engineering Technicians for many years and works closely with advisorycommittee members to make sure that the skills being taught are the skills needed in industry.Students who graduate from this course of study receive Associate of Applied Science degreesfrom TSTC. The MET Department worked closely with the MAST staff; made every effort toassist the MAST staff with research and seek adoption of the recommended MAST materials fortheir MET students. The MET Department at TSTC is recognized throughout Texas by large andsmall manufacturing companies as a premier source for entry-level technicians. Upon graduation,students are able to interpret complex drawings, select the correct materials and perform allnecessary machining processes. The curriculum has been designed to prepare students to enterthe workforce as entry level Manufacturing Engineering Technicians. Laboratory work isemphasized with actual industrial equipment in order to prepare students for interesting,rewarding work in a wide variety of industries. The MET department has a unique blend oftheoretical knowledge and practical application which directly corresponds to modern uses inmanufacturing. Students may choose from three options of study: Computer-AidedManufacturing, Machining and Plastics. This volume contains the justification, documentationand course syllabi for the courses which we recommend as minimum training for individualsdesiring to become Manufacturing Engineering Technicians.

PARTNER OCCUPATIONAL SPECIALITY ASSIGNMENTS

Although each of the six partner college development centers possessed detailed expertise in eachof the MAST 15 occupational specialities, a division of work was still very necessary to ensurecompletion of the project due to the enormity associated with industrial assessment and completecurriculum revision for each of the areas of investigation.

Each Collegiate Partner was responsible for development of a specialization component of theoverall model. Information for the future direction of this specialization area was obtained fromNIST Manufacturing Centers and/or national consortia, professional societies, and industrialsupport groups addressing national manufacturing needs. Each Collegiate Partner tested itsspecialization model utilizing local campus resources and local industry. Information gained fromthe local experience was utilized to make model corrections. After testing and modification,components were consolidated into a national model. These events occurred during the first yearof the Program. During the second year of the Program, the national model was piloted at eachof the Collegiate Partner institutions. Experience gained from the individual pilot programs wasconsolidated into the final national model.

What follows is a profile of the MAST development center which had primary responsibility forthe compilation and preparation of the materials for this occupational specialty area. This collegealso had the responsibility for conducting the pilot program which was used as one of the meansof validation for this program.

Dr. Cecil L. GrovesTexas State Technical College SystemDr. Frcd Williams, PresidentTexas State Technical College, WacoJoe K. Pcnick, MAST Grant DirectorTexas State Technical College, Waco

MAST DEVELOPMENT CENTERTexas State Technical College

Center for Contemporary Technology

3801 Campus DriveWaco, TX 76705

College phone: 817/799-3611 or 800-792-8784fax:817-867-3380

Center phone: 817/867-4849, fax: 817/867-3380c-mail: [email protected]

Manufacturing in TexasEconomic trends have led Texas officials to recognize the need to better prepare workers for a changing labormarket. The downturn in the oil, natural gas, ranching and farming industries during the last decade diminishedthe supply of high-paying, low-skill jobs. Growth in Texas is occurring in the low paying, low skills serviceindustry and in the high skills, high paying precision manufacturing industry. In Texas, projected increases by theyear 2000 include 4,050 jobs for machine mechanics (24% growth rate); 4,700 jobs for machinists (18% growthrate); 3,850 numeric control operators (20% growth rate); and 107,150 general maintenance repair technicians(23% growth rate). The National Center for Manufacturing Sciences (NCMS) identified that of the top twentymanufacturing states, Texas experienced the largest increase in manufacturing employment. Manufacturing willadd over 70,000 additional jobs in Texas by the year 2000 with increases in both durable and non-durable goods.

Texas State Technical College (TSTC)Texas State Technical College System (TSTC) is authorized to serve the State of Texas through excellence ininstruction, public service, research, and economic development. The system's efforts to improve thecompetitiveness of Texas business and industry include centers of excellence in technical program clusters on thesystem's campuses and support of educational research commercialization initiatives. Through closecollaboration with business, industry, governmental agencies, and communities, including public and privatesecondary and postsecondary educational institutions, the system provides an articulated and responsive technicaleducation system.

In developing and offering highly specialized technical programs and related courses, the TSTC systememphasizes the industrial and technological manpower needs of the state. Texas State Technical College isbrown for its advanced or emerging technical programs not commonly offered by community colleges.

New, high performance manufacturing firms in areas such as plastics, semiconductors and aerospace have drivendynamic change in TSTC's curriculum. Conventional metal fabrication to support oil and heavy manufacturingremains a cornerstone of the Waco campus and is a primary reason TSTC took the lead in developing newcurricula for machining and manufacturing engineering technology in the MASTprogram.

Development TeamProject Director: Joe K. Penick, Grant Director for Machine Tool Advanced Skills Technology Program(MAST); served as the primary administrator and academic coordinator for the MAST project.Subject Matter Expert: Wallace Pclton, Site Coordinator,was responsible for developing skill standardsand course/program materials for the conventional machining, mold making and manufacturing engineeringtechnology components of the MAST project.

THE MAST COMPETENCY PROFILE

Development of Competency Profiles at each of the MAST sites began with visits torepresentative companies for the purpose of surveying expert workers within the industry andoccupational areas under investigation. Each site began the survey process by asking a subjectmatter expert in the targeted technical area, generally a member of their faculty, to employ amodified version of the generally-accepted DACUM (Developing A Curriculum) method tocategorize the major skills needed to work in the selected occupation. As source materials, thecollege instructors drew on their professional knowledge and experience of current and futureindustry requirements. The initial skill standards developed by the subject matter expertsunderwent numerous internal reviews and revisions within each site, assuming final form as aseries of structured survey and interview statements designed to elicit a simple yes or no response.

To determine an appropriate survey sample, each site compiled a database of their region's smalland medium-sized manufacturers and searched for companies likely to employ workers in thetargeted occupational area. The resulting cross-industry samples were sorted further to achieve abalance of technological capability and workforce size; the sample companies within each regionwere then asked to participate in the project. Willing respondents were scheduled for interviews.

During the company interviews, MAST staff asked expert workers to identify the primary dutiesand tasks performed by a typical worker and to consider the special skills and knowledge, traitsand attitudes, and industry trends that will have an impact on worker training, employability, andperformance both now and in the future. The interview results were analyzed to create individualprofiles identifying the most common duties and skills required of workers at each company.Copies of individual company competency profiles are provided in Appendix A of this volume.These individual company Competency Profiles served two purposes. First, they showed, in aformat that could be easily understood by both industry and educators, a picture of theoccupational specialty at a given company at that particular time. Second, these individualcompany Competency Profiles furnished the company with a document for which they couldclaim ownership. This, in effect, made them "real" partners in the work of MAST.

Data for all companies were then aggregated to develop a composite Competency Profile ofindustry skill standards within the selected occupational specialty area of, as shown in thefollowing pages.

These same duties and tasks were then included in both the Texas and National Surveys forfurther validation (see Volume 1). As a result of the surveys, additional refinements were madeto the Competency Profiles. These changes were then incorporated into the individual coursesyllabi which were used for the pilot program.

The MAST Competency Profile for this occupational specialty area has been included on thefollowing pages.

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18

BE

ST C

OPY

AV

AL

AB

IT

THE MAST TECHNICAL WORKPLACECOMPETENCY OUTLINE

The Competency Profiles derived from the industry survey process were returned to industry andfaculty members at each MAST partner college for review. Reviewers were asked to identifyspecific sub-tasks within each block of Duties and Tasks in the Profile; MAST staff at eachcollege broke the sub-tasks down further into the detailed steps required to actually perform theduties and tasks of the manufacturing process. It is these detailed skill standards that were thenincorporated into development of the curriculum and piloted as a training program by each of theMAST colleges. All results for the specific occupational specialty area have been organized as anoutline of the duties, tasks, and sub-tasks required to demonstrate technical competency in theworkplace, as shown in the following pages.

As a result of the Texas and the National Surveys, additional refinements were made to theCompetency Outlines. These changes were then incorporated into the individual course syllabi.

The MAST Technical Workplace Competency Outline for this occupational specialty area hasbeen included on the following pages.

MANUFACTURING ENGINEERING TECHNICIANTECHNICAL WORKPLACE COMPETENCIES

MANUFACTURING ENGINEERING TECHNICIAN- -use special knowledge and skills torecommend and/or implement solutions for specific manufacturing applications.

A. PRACTICE SAFETYI. Follow Safety Manuals and All Safety Regulations/Requirements

a. Assume responsibility for the personal safety of oneself and othersb. Develop a personal attitude towards safetyc. Interpret safety manual directivesd. Comply with established company safety practicese. Complete forms/paperwork as required

2. Use Protective Equipmenta. Wear protective safety clothing as requiredb. Maintain and use protective guards and equipment on machineryc. Locate and properly use protective equipmentd. Use lifting aids when necessary

3. Follow Safe Operating Procedures for Hand and Machine Toolsa. Identify and understand safe machine operating proceduresb. Demonstrate safe machine operation

4. Maintain a Clean and Safe Work Environmenta. Keep work areas cleanb. Clean machine/hand tools when work is completedc. Put tools away when work is finishedd. Keep aisles clear of equipment and materialse. Perform preventative maintenance as required

5. Control Fire Hazardsa. Handle/store flammable materials appropriatelyb. Use electricity correctly (e.g., defective outlets, frayed cords, "burning"

odor)c. Prevent spontaneous ignition by practicing proper waste disposal habitsd. Keep marked aisles clear of equipment and materialse. Interpret/display MSDS sheets as requiredf. Identify fire exits and fire-fighting equipment

6. Apply American Red Cross First Aid and CPR Proceduresa. Notify appropriate personnel of injuryb. Check and evaluate life-endangering conditionsc. Determine need for CPRd. Apply appropriate first aid techniquese. Complete accident report as needed

7 Recommend Hazardous Waste Management Techniquesa. Define the types of hazards (e.g., chemical, biological, and physical)b. Understand chemical hazards and the use of Material Safety

Data Sheets ( MSDS)d. Describe the proper collection for a variety of hazardous wastese. Respond to emergencies in the appropriate manner

8. Apply Ergonomic Principles to the Workplace

a. Define ergonomicsb. Explain the characteristics and potential impact of ergonomics on design,

productivity, and safety9. Demonstrate Knowledge of State and Federal EPA Regulations

a. Meet health, safety, and legal requirements with regard to process, productand people

B. APPLY MATHEMATICAL CONCEPTS1. Perform Basic Arithmetic Functions

a. Add, subtract, multiply and divide whole numbersb. Add, subtract, multiply, and divide fractionsc. Add, subtract, multiply, and divide decimals

2. Interconvert Fractions/Decimalsa. Convert fractions to decimal equivalents .

b. Convert decimal values to nearest fractional equivalentc. Use decimal equivalent chart for conversions

3. Interconvert Metric/Inch Measurementsa. Convert inch dimensions to metricb. Convert metric dimensions to inchc. Use metric/inch conversion chart

4. Perform Basic Algebraic Operationsa. Express word statements as algebraic equationsb. Solve word statements as algebraic equations

5. Perform Basic Trigonometric Functionsa. Solve for unknown anglesb. Solve for unknown sidesc. Calculate bolt hole patterns

6. Calculate Speeds and Feeds for Machininga. Calculate RPM for various metals and various toolsb. Calculate feed for various metals, tools, and depths of cut

7 Locate Machining Points from a Datum Pointa. Identify points using the Cartesian coordinate systemb. Identify points using the absolute dimensioning systemc. Identify points using the incremental dimensioning systemd. Identify points using the polar coordinate system

8. Perform Calculations for Sine Bar and Sine Platea. Calculate gage block build up for 5" sine barb. Calculate gage block build up for 10" sine plate

9. Calculate for Direct, Simple, and Angular Indexinga. Calculate for direct indexingb. Calculate for simple indexing (plain)c. Calculate for angular indexingd. Use Machinery's Handbook for calculations

10. Perform Calculations Necessary for Turning Tapersa. Calculate tail stock offsetb. Determine unknowns (e.g., small and/or large diameters) for taper turning

11. Calculate Depth of Cut on Round Surfacesa. Calculate depth of cut for flats to be machined on cylindrical pieces

b. Calculate depth of cut for keyways which are machined on cylindricalpieces

12. Use all Functions on a Scientific Calculatora. Apply all trigonometric functionsb. Apply all algebraic functionsc. Apply all statistical functions

13. Solve Engineering Equationsa. Solve linear algebraic equations for an unknownb. Solve a system of linear equations with 2 unknownsc. Solve right triangles for unknown sides or unknown anglesd. Use law of sines and cosines to solve obtuse triangles with unknown sides

and anglese. Operate hand held electronic calculator properly (w/trigonometry keys)f. Discuss friction (e.g., coefficient, angle of friction, and angle of repose)

14. Solve Static Systems for Resultant Forcea. Solve for the following coplanar force systems: parallel, concurrent, and

nonconcurrentb. Solve for the following nonpoplanar force systems: parallel, concurrent,

and nonconcurrent15. Determine Strength of Materials for Various Applications

a. Discuss stress and deformationb. List properties of materials (e.g., strength, elasticity, stiffness, ductility,

hardness)c. Calculate stresses and designs of jointsd. Discuss advantages and disadvantages of different fastening techniquee. Discuss problems relating to torque-twisting momentsf. Discuss centroids and moments of inertia ofareas

C. INTERPRET ENGINEERING DRAWINGS AND CONTROL DOCUMENTS1. Review Blueprint Notes and Dimensions

a. Explain basic blueprint terminologyb. Identify the types of dimensionsc. Identify general note symbolsd. Locate notes on a printe. Interpret commonly used abbreviations and terminologyf. Determine tolerances associated with dimensions on a drawingg. Determine the tolerance for a reference dimensionh. Determine the surface finish for a given parti. List the essential components found in the general drawing notes

2. Identify Basic Layout of Drawingsa. Identify types of lines within a drawingb. Identify item number symbolsc. Identify general note symbolsd. List the essential components found in the title blocke. Locate bill of materials in a drawingf. List the components found in the revision block

3. Identify Basic Types of Drawingsa. Identify orthographic views

2 2

b. Identify positions of views (top, front, side, and auxiliary)c. Visualize one or more views from a given viewd. Identify isometric viewse. Identify exploded isometric drawingsf. Identify assembly drawings

4. List the Purpose of Each Type of Drawinga. Discuss purpose of orthographic (3 views) drawingsb. Discuss purpose of isometric drawingc. Discuss purpose of exploded isometric drawingd. Discuss purpose of assembly drawings

5. Verify Drawing Elementsa. Determine the scale of the view or sectionb. Check for revisionsc. Recognize out-of-date blueprints

6. Practice Geometric Dimensioning and Tolerancing (GD&T) Methodologya. Identify the purpose of GD&Tb. Identify symbols for controlling location (or true position) of part featuresc. Identify symbols for controlling form (or alignment) of part featuresd. Identify symbols for showing datums and basic dimensions on drawingse. Identify symbols for Maximum Material Size (MMS) and Regardless of

Feature Size (RFS)7 Describe the Relationship of Engineering Drawings to Planning

a. Discuss production scheduleb. Discuss Material Resource Planning (MRP)c. Discuss inventory control recordsd. Discuss shop floor routing documents

8. Use Standards to Verify Requirementsa. Discuss the purpose of standardsb. Discuss source locations for standards

9. Analyze Bill of Materials (BOM)a. Discuss components found on BOMb. Determine materials needed to produce the partc. Determine quantities necessary to produce the partd. Submit completed stock request form as requirede. Submit completed tool request form as needed

10. Understand and Use Quality Systemsa. Describe ISO 9000 quality systemb. Document paper trails for document revisions

D. RECOGNIZE DIFFERENT MANUFACTURING MATERIALS ANDPROCESSES1. Identify Materials With Desired Properties

a. Discuss classification system for metalsb. Discuss general characteristics for carbon steels, tool steels, stainless steels,

structural steels, cast irons, aluminum, and other commonly used metalsc. List advantages for considering plastic as a viable materials choiced. List the advantages and disadvantages for each of the following plastic

molding processes: blow, injection, vacuum, extrusion, etc.

e. Discuss the advantages for using composites in various manufacturingapplications

2. Identify Materials and Processes to Produce a Producta. Discuss service requirements (in strength, hardness, etc.)b. Discuss fastening processes (i.e., fasteners, welding, bonding, etc.)c. Discuss corrosion resistance methods

3. Describe Heat Treating Processesa. Discuss the reasons for heat treatingb. Discuss the time/temperature chartc. List the different quenching mediumsd. Estimate metal heat temperature by colore. List reasons for stress relieving workpiecesf. Discuss surface hardening processesPerform Heat Treating Operationsa. Harden plain carbon workpieceb. Temper plain carbon workpiecec. Anneal plain carbon workpieced. Case harden workpiece

5. Test Metal Samples for Hardnessa. Perform spark test to test for metal hardnessb. Perform Rockwell hardness testsc. Perform Brinell hardness testsd. Perform Charpy and/or Izod impact testse. Perform tensile and/or compression testsf. Prepare metal samples for viewing under a microscope

6. Describe Casting Processesa. Discuss the following casting processes: sand, evaporative, shell molding,

permanent mold, centrifugal, investment, and die castingb. Discuss pattern and mold design factors for each of the above casting

processesc. List the advantages and disadvantages of the casting processes

7. Describe Hot Working Processesa. Discuss the following hot working processes: rolling, strand casting,

forging, drawing, extrusion, spinning, and roll formingb. List the advantages and disadvantages of the hot working processes

8. Describe Cold Working Processesa. Discuss the following cold working processes: rolling, blanking, pressing,

drawing, extruding, wire and bar drawing, bending, shearing, and rollforming

b. List the advantages and disadvantages of the cold working process9. Evaluate Alternative Manufacturing Processes

a. Discuss the powder metallurgy process (PM)b. Discuss the following nontraditional machining processes: EDM, Laser

machining, Ultrasonic machining, Hydrojet machining, Electron beammachining, and plasma beam machining

E. DEMONSTRATE MEASUREMENT/INSPECTION TECHNIQUESI. Identify Types of Measurement

24

a. Discuss the use of metrology in manufacturingb. Discuss the inch system of measurementc. Discuss the metric system of measurementd. Discuss semi-precision and precision measuremente. Discuss the following: accuracy, precision, reliability, and discrimination

2. Select Proper Measurement Toolsa. Identify basic semi-precision measuring tools.b. Identify precision measuring toolsc. Justify the use of a particular measuring tool based on tool characteristicsd. Identify error possibilities in measurement tool selectione. Demonstrate proper care of precision measuring tools

3. Apply Proper Measuring Techniquesa. Discuss factors affecting accurate measurement (dirt, temperature,

improper measuring tool calibration)b. Explain calibration requirements of various precision instrumentsc. Illustrate measurement differences when taken with calibrated and

non-calibrated instrumentsd. Calibrate a micrometer type measuring tool

4. Perform Measurements With Hand Held Instrumentsa. Measure with steel rules (metric and inch)b. Measure with micrometersc. Measure with comparison measuring instruments (e.g., calipers, telescope

gages)d. Measure with direct measuring instruments (e.g., vernier, dial, and digital

instruments)e. Measure with fixed gages (go and not go gages)

5. Perform Measurements on Surface Platea. Describe care of surface plateb. Use surface plate accessories correctly (sine bar, gage blocks, etc.)c. Check for part squarenessd. Check part dimensions for accuracye. Align workpieces using height gage and dial indicators

6. Perform Inspections Using Stationary Equipmenta. Set up and use an Optical Comparatorb. Set up and use a Coordinate Measuring Machine (CMM)

F. PERFORM CONVENTIONAL MACHINING OPERATIONS1. Prepare and Plan For Machining Operations

a. Read and interpret blueprintsb. Perform basic semi-precision and precision layout as necessaryc. Plan machining operationsd. Understand machinability and chip formatione. Calculate speeds, feeds, and depth of cut for various machine applicationsf. Determine proper cutting fluids/coolants for machiningg. Use carbides and other tool materials to increase productivityh. Use the Machinery's Handbook as a reference for machine applications

2. Use Proper Hand Toolsa. Use arbor and shop presses

25

b. Select necessary work-holding devices and hand tools as neededc. Select and use hand filesd. Identify and use hand reamerse. Correctly identify and use hand taps as requiredf Follow tapping procedures to produce internal threadsg. Use thread-cutting dies to produce external threadsh. Operate bench and pedestal grinders safely

3. Operate Power Sawsa. Use reciprocating and horizontal band cutoff machinesb. Operate abrasive and cold sawsc. Prepare and use the vertical band sawd. Weld a bandsaw blade

4. Operate Drill Pressesa. Describe the different types of drill presses found in the machine shopb. Describe and use standard drilling toolsc. Sharpen a drill bit using a bench or pedestal grinderd. Setup the drill presses for drilling, countersinking, counterboring, reaming,

and tapping operationse. Drill holes using drill jigs

5. Operate Vertical Milling Machinesa. Demonstrate the use of all controls on the vertical milling machineb. Align the vertical milling machine headc. Select, align and use workholding devicesd. Select milling tool holderse. Select milling cuttersf. Perform all standard vertical milling operationsg. Bore a hole using the offset boring headh. Machine angles using sine bar and gage blocksi. Setup and use special vertical mill fixturesj. Setup and machine dovetailsk. Machine keyways

6. Operate Horizontal Milling Machinesa. Discuss the difference in plain and universal horizontal milling machinesb. Discuss the types of spindles, arbors and adaptors used on the horizontal

milling machinec. List several common work holding methodsd. Use plain milling cutterse. Use side milling cuttersf. Use face milling cuttersg. Setup and use special horizontal mill fixtures

7. Operate Metal Cutting Lathesa. Demonstrate the use of all controls on the engine latheb. Discuss standard tools and toolholders for the lathec. Face and center drill parts correctlyd. Drill, ream and bore on the lathee. Turn between centersf. Discuss alignment of lathe centers

0 p

g. Make all calculations, lathe adjustments and settings to machine UNF andUNC series threads

h. Discuss thread fit classificationsi. Describe the common tapers used in the machine shopj. Discuss taper cutting and calculations for the lathek. Setup and use the taper attachment found on most lathes1. Use follower rests and steady restsn. Use HSS cutting toolso. Use carbide cutting tools

8. Operate Grinding/Abrasive Machinesa. Discuss the selection and identification of grinding wheelsb. Inspect, mount, true, dress, and balance grinding wheelsc. Discuss the selection of grinding fluidsd. Operate horizontal spindle reciprocating table surface grinderse. Discuss common problems and solutions in surface grinding

G. PERFORM ADVANCED MACHINING PROCESSES1. Prepare and Plan For CNC Machining Operations

a. Read and interpret blueprintsb. Plan CNC machining operationsc. Calculate speeds, feeds, and depth of cut for various CNC machine

applicationsd. Determine proper cutting fluids/coolants for CNC machininge. Use the Machinery's Handbook as a reference for CNC machine

applications2. Select and Use CNC Tooling Systems

a. Understand machinability and chip formationb. Select proper insert materials and geometryc. Assemble tooling componentsd. Select correct tooling systemse. Identify tooling cost factors

3. Program CNC Machinesa. Identify CNC applicationsb. List various types of CNC machinesc. Discuss CNC machine control systemsd. Describe absolute and incremental coordinate systemse. Plan and write programs for CNC lathesf. Plan and write programs for CNC mills

4. Operate CNC Machining Centers (Mills)a. Install and align work holding devicesb. Load/align materials into the machinec. Load tools into machined. Establish tool length offset for each toole. Establish/set machine referencef. Load programs into CNC millg. Demonstrate working knowledge of all controls on the MCUh. Demonstrate proper operation of CNC machining center to include "dry

run" and final production

2?

i. Edit CNC programs for optimum part productionj. Operate machine in DNC mode if that capability exists

5. Operate CNC Turning Centers (Lathes)a. Install and bore soft jaws as requiredb. Load tools into machinec. Establish machine referenced. Set initial tool offsetse. Monitor/adjust offsets for accurate part productionf. Load programs into CNC latheg. Demonstrate working knowledge of all controls on the MCUh. Demonstrate proper operation of CNC lathe to include "dry run" and final

productioni. Edit CNC programs for optimum part productionj. Replenish stock in bar feeder as needed

6. Operate Electrical Discharge Machinesa. Discuss the EDM processb. List advantages and disadvantages of the EDM proceSsc. Identify electrode materialsd. Machine EDM electrodese. Setup and operate die sinker EDM machinesf. Calculate overburng. Identify generator setting of machineh. Choose proper techniques for flushingi. Estimate number of roughers and finishersj. Demonstrate proper electrode mounting techniquesk. Utilize 3R tooling1. Perform touch-off proceduresm. Recognize optimum machine settingsn. Perform continuity checkso. Determine R-MAX finish requiredp. Setup and operate wire cut EDM machines

7. Download Programs Via Networka. Download programs from the networkb. Upload programs to the networkc. Perform edit and print functions via network

8. Program CNC Machines Using a CAM Systema. Create Job Plan for machining operationsb. Construct part geometryc. Program tool path for roughing and finishing operationsd. Verify tool pathe. Generate CNC code

H. PERFORM DRAFTING TASKS.1. Demonstrate Traditional Mechanical Drafting Skills

a. Form freehand vertical Gothic upper-case letters and numerals ofcorrectshape and space

b. Execute the alphabet of lines correctly, producing dense black lines ofuniform thickness and spacing

c. Demonstrate proficiency with the engineers and metric scalesd. Execute geometric constructions with no mistakes in tangent points, line

quality or layout worke. Accurately draw the missing view or line in a multiview drawingf. Make or complete a sectional instrument drawing, given one or more viewsg. Develop satisfactory working drawings of simple machine components to

include all necessary views and dimensions for complete shape and sizedescription of detail parts

h. Discuss the differences in standard engineering drawings and tool drawingsi.. Develop satisfactory tool drawings for drill jigs, milling fixture, and

inspection fixtures2. Use Computer-Aided Drafting (CAD) System

a. Demonstrate the start-up and shut-down of a PC based CAD systemb. Input information through the use of various input devicesc. Use the SETTINGS menu commands to establish operating parameters in a

drawingd. Use the Cartesian coordinate system to correctly enter line and arc

elements to construct a parte. Use the DISPLAY menu to manipulate the drawing imagef. Apply basic DRAW menu and EDIT menu commands to create a drawingg. Use appropriate menu commands to manage filesh. Set up the specifications within the PLOT command for producing a hard

copy of a drawingi. Convert to accepted drawing exchanges formats (i.e., IGES, DXF, etc.)j. Convert CAD data to a CAM systemk. Use a CAD system for producing tool drawings

3. Create 3-D Solid Modelsa. Construct the required geometrical elements required for the modelb. Assign necessary properties for the creation of the solid modelc. Perform engineering tests on the solid model

4. Make Tool Drawingsa. Discuss the differences in tool drawings verses regular mechanical

drawingsb. Design and draw a simple drill jig using accepted practicesc. Design and draw a simple milling fixture using accepted practices

I. USE COMPUTERS1. Use Computer Operating Systems

a. Use basic computer terminology appropriately and accuratelyb. Boot the computer and recognize the basic components of DOSc. Use DOS to perform file managementd. Use DOS to perform directory managemente. Install software packages on a PC

2. Use Computer Inquiry Systemsa. Log in to a multi-user systemb. Access system for needed informationc. Print reports as necessary

3. Use Various Computer Applications 29

1a. Load word processor, create, save, edit, and print a documentb. Load spreadsheet, create, save, retrieve, erase, edit, and print a worksheetc. Load database programs, create, edit, delete, and print records in a

database file4. Recommend and Implement OM Technologies

a. Use automatic storage & retrieval systemb. Use bar coding technologyc. Understand robot applicationsd. Program robotse. Use shop floor control systemsf. Understand machine vision systems

5. Use Computer-Aided Engineering Systema. Perform structural loading testsb. Perform finite element analysis tasksc. Perform interference tests

J. PARTICIPATE IN TOTAL QUALITY, TEAMWORK, EMPOWERMENT,QUALITY PROBLEM SOLVING AND STATISTICAL PROCESS CONTROL1. Discuss the Role of Total Quality Management (TQM) in Manufacturing (TQM2)

a. Understand the history of Total Quality Management process and its majorhistorical contributors Deming, Juran, and Crosby

b. State the reason for intensive application of Total Quality Managementprinciples, concepts and constitution parts in the industrial work places ofAmerica

c. Identify the parts of the of the Total Quality Management formula (or themajor element of TQM) - TQM=(T5 + SPC) X CI + E&CS = P&S

d. Understand the vital interplay of Training, Trust, Teamwork, TotalInvolvement and Transformation (T5) to the successful implementation ofTQM2

e. Understand the need for quantitative tools to base quality decisions onobjective measurable information (Statistical Process Control - SPC)

f. Understand how Continuous Improvement (CI) is a vital philosophy withthe power to multiply quality efforts of TQM2

g. State the importance of Employee and Customer Satisfaction (E&CS) tothe successful implementation of TQM2

h. Understand how the meaning of quality is determined based on theprospective of supplier and customer

i. Understand that the quality perceptions of the customer are of primeimportance

j. Identify external and internal customers and the importance ofboth to thesuccessful implementation of TQM2

k. Know the essential importance of the Total Quality Management formulaand its constitution parts to the Profitability and Survivability ofamanufacturing enterprise

1. Understand the importance of National TQM awards2. Discuss Team Work (Teaming) Concepts

a. Understand how successful implementation of Teamwork is fundamental tothe successful implementation of TQM2

30

b. Identify the basic theories and concepts that allow for the development ofeffective teams in a manufacturing setting

c. Identify the stages in building a functioning manufacturing teamd. Identify the roes that must be fulfilled for teams to function effectivelye. Identify the responsibilities of sponsoring manager(s), team leader,

recorder, facilitator, and memberf. Be able to function in each of the roles of leader, recorder, facilitator and

memberg. Understand how team norms or guidelines are vital to an effective teamh. Identify and practice team building behaviorsi. Identify and be able to counter team subverting or destructive behaviorsj. Understand the dynamic and desirable tension between diversity and

conflict on teams1. Identify and practice methods for containing conflict with out retarding

creativity within teamsm. Understand the dynamic and desirable tension between consensus and

group thinkn. Identify the four ways to reach a decisiono. Understand the desirability of reaching a consensusq. Identify the eight factors that lead to group think and how to negate them

3. Demonstrate Empowerment Techniquesa. Understand how successful implementation of TQM2 and Teamwork in the

manufacturing environment will inevitably lead to empowermentb. List the benefits to be gained by both management and labor from the

implementation of Empowerment in a manufacturing settingc. Define Empowerment as a process that helps the right people at the right

levels make the right decisions for the right reasonsd. List and explain the two sides (facilitating empowerment in others and self

empowerment) and four dimensions of empowerment (time, alignment,capability and trust)

e. Appreciate the need to make it possible for others to be empowered byvaluing individuals, establish vision, providing tools, encouragingindependent action and building empowerment systems

f. Understand the need for delegation and the dos and don'ts of delegationg. Be able to empower themselves through recognizing and operating from

their own power, creating a personal vision, using the power tools, takingindependent action and contributing to the empowerment process

4. Demonstrate Knowledge of Quality Problem Solving (Six-Step Problem SolvingModel) Techniquesa. Understand the need in today's fast faced business environment to improve

manufacturing processes and efficiency through the diligent use of aproblem solving model

b. Be able to identify the six steps of the six-step problem solving modelc. Be able to identify each of the sub-steps of the six-step problem solving

modeld. Be able to apply the six-step problem solving model in individual and in

team situations within the manufacturing environment

31

e. Understand the "Circle of Influence" phenomenon and its impact onsuccessful problem solving in the manufacturing environment

f. Be able to use problem solving tools, e.g., brainstorming, cause and affectdiagram, paired choice matrix, and the criteria ranking form

5. Demonstrate Knowledge of Statistical Process Control (SPC) Conceptsa. Understand basic statistic for manufacturing process controlb. Be able to define variation and probabilityc. Be able to identify the difference between "natural variation" and

"unnatural variation"d. Be able to describe the difference between expected occurrence and actual

occurrences of an evente. Be able to identify a histogramf. Recognize and describe the normal distribution curveg. Understand the usefulness of the normal or. bell curve to SPCh. Be able to explain how the area under the normal curve is divided into

standard deviations, or sigma (a) unitsi. Define and calculate mean and rangej. Apply a formula to estimate standard deviationk. Describe the relationship between the distributions of individuals and

sample averages1. Be able to state the purpose of a control chartm. Identify the central line of a control chartn. Explain the difference between control limits and engineering specifications

or tolerancesp. Describe why the control chart has so much power0. Describe the purpose of a process capability studyq. Define control chart variables and explain what X "bar" and R charts

illustrate about a manufacturing processr. Explain the relationship between X "bar" (mean of sample) and R (range)

of sampless. Define attributes and explain what p charts tell about a manufacturing

processt. Be able to interpret control charts by identifying the patter of points that

shows the presence of a normal distributionu. Be able to recognize the five signs that show a process may be out of

control

K. MAINTAIN ELECTRICAL DEVICES1. Use Electrical Test Equipment

a. Measure resistance with an analog volt-ohm-milliamp meterb. Measure voltage with volt-ohm-milliamp meterc. Measure current with volt-ohm milliamp meterd. Use wattmeter to measure power in a simple DC circuite. Use oscilloscope to observe AC signals of various waveshapes and

frequencies2. Apply Specific Terms to Electrical Circuits

a. Define voltage, current, and resistanceb. Discuss power, power factor, and sine waves

32

c. Define three phase, induction, and capacitance3. Analyze Series, Parallel and Complex DC/AC Circuits

a. Define a series circuitb. Define a parallel circuitc. Define a complex DC circuitd. Define an AC circuite. Apply Ohm's law to each of the above circuitsf. Apply Kirchoffs law to each of the above circuits

4. Check AC and DC Motorsa. List types of AC and DC motorsb. List characteristics of AC motorsc. List characteristics of DC motorsd. Compare AC motors versus DC motors to job duty

5. Inspect Transformers and Generatorsa. Define transformer construction and the principle of operationb. List the different types of transformersc. Define electro-magnetic inductiond. Describe the principle of operation of AC alternators and DC generators

6. Discuss Sensors and Feedback Technologya. List the various types of feedback devices used in industrial controlsb. Apply the use of feedback systems in industrial control circuitry including

AC, DC, and servo drive systemsc. Identify, hardwire, and troubleshoot electro-mechanical devices and

electrical switching devices including proximity switches, infra-red, andmagnetic sensors

7. Set Up/Program PLCa. Describe the function and operation of three basic components of

programmable controllersb. Revise electrical ladder control diagrams as reference diagrams to be

programmed into the user memory of the programmable controllerc. Use the programming devices to program, monitor, and edit the

programmable controllerd. Design and develop programs using standard functions and special standard

functions of the programmable controllere. Troubleshoot functional circuits using reference diagram, indication lights,

and programming devices8. Troubleshoot Electrical Devices

a. Discuss common methods of troubleshooting electrical systemsb. Follow a logical troubleshooting sequence to trace a problem to its origin

L. MAINTAIN HYDRAULIC/PNEUMATIC DEVICES1. Use Test Equipment

a. Monitor hydraulic flow with flow metersb. Use temperature gauges to determine hydraulic fluid operating temperaturec. Use flow control valves, U-tube manometers and pressure gauges to

measure operating conditions for the fluid power system2. Describe Basic Principles of Hydraulic Systems

a. List advantages of hydraulic systems 3 3

b. Identify components of typical hydraulic systemc. State or describe Pascal's lawd. Analyze a hydraulic system to determine its performance

3. Identify Hydraulic Fluidsa. Name types of hydraulic fluidsb. List methods of measuring fluid viscosityc. List desirable characteristics of hydraulic fluidsd. Identify safety hazards related to hydraulic fluid usee. Discuss heat exchangers, filters, and micron rating of filters

4. Recommend Power Distribution and Sealing Devicesa. Describe proper identification and selection of lines, hoses, and fittingsb. Discuss pressure, velocity, and safety factorsc. List conditions determining selection of sealing devices

5. Recognize Pumps, Actuators, and Hydraulic Control Devicesa. Name general classifications of pumpsb. Determine overall pump efficiencyc. Name types of positive displacement pumps and give advantages and

disadvantages of eachd. Discuss types of variable delivery pumps and describe their operatione. Describe linear actuators (cylinders)f. Describe how cylinders are rated and sizedg. Describe rotary actuators and motorsh. Name two types of hydraulic motors

6. Troubleshoot Hydraulic/Pneumatic Systemsa. Discuss common methods of troubleshooting hydraulic systemsb. Follow a logical troubleshooting sequence to trace a problem to its origin

THE MAST PILOT PROGRAM CURRICULUMAND COURSE DESCRIPTIONS

Alter completing the Competency Profile and Technical Workplace Competency Outline for each1,occupational specialty area, each MAST partner reviewed their existing curricula against theindustry-verified skill standards in order to identify a suitable foundation for new pilot trainingprograms. Because each college had to comply with the requirements of its respective collegesystem and appropriate state agency, the resulting pilot curricula for occupational specialty areastended to vary in format and academic requirements (e.g., some programs were based on thesemester system, others on the quarter system). Despite differences in the curricula developed atthe partner colleges, each of the pilot programs was designed to achieve the following two goalsmandated in the MAST grant proposal:

Pilot Program: "Conduct a one year pilot program with 25 or more selected applicants ateach college or advanced technology center to evaluate laboratory content andeffectiveness, as measured by demonstrated competencies and indicators of each programarea."

Student Assessment: "Identify global skills competencies of program applicants both atpoint of entrance and point of exit for entry level and already-employed technicians."

(Note: All occupational specialty areas were not pilot tested at all Development Centers;however, all partner colleges conducted one or more pilot programs.)

Included on the following pages is the curriculum listing for the pilot program which was used tovalidate course syllabi for this occupational specialty area. This curriculum listing includedcourse names and numbers from the college which conducted the pilot program. The curriculumalso shows the number of hours assigned to each of the courses (lecture, lab and credit hours).Also included is a description of each of the courses.

I

MANUFACTURING ENGINEERING TECHNOLOGYCOMPUTER AIDED MANUFACTURING OPTION

CURRICULUM1995-96

FIRST OUARTERLEC LAB CR

PSYC 1100* College Success Skills 1 0 1

MET 100 Machine Tool Practices I 3 9 6DDT 104 Drafting Principles 2 4 3MATH 1314* College Algebra 4 0 3ENGL 1301* Composition I 4 0 3

14 13 16

SECOND QUARTERMET 200 Machine Tool Practices II 3 9 6ENGL 134* Interpersonal Communication 4 0 3MATH 1316* Plane Trigonometry 4 0 3CNS 2060 Application Software 2 4 3

13 13 15

THIRD QUARTERMET 112 Engineering Materials 2 3 3OSH 216 Safety and Accident Prevention 2 3 3PHY 114 Basic Fluid Power 3 3 4EST 120 Electrical Applications 3 3 4.WLT 105 Survey of Welding Applications and Processes 3 3 4

13 15 18

FOURTH QUARTERMET 205 CNC Machine Programming 3 3 4MET 206 Statics 3 3 4MET 301 Manufacturing Processes 3 3 4DDT 128 Introduction to Computer Drafting 1 4 2PSYC 2301* General Psychology 4 0 3

14 13 17

lel V1 OUARTERMET 302 CAD/CAM I 3 3 4MET 216 Tool Design I 2 6 4MET 312 Strength of Materials 3 3 4PHYS 1310* Elementary Physics 4 0 3

Free Elective 2 0 214 12 17

SIXTH OUARTERMET 318 CAD/CAM II 3 3 4MET 315 Computer Integrated Manufacturing 2 2 3MET 324 Quality Assurance and Statistical Process Control 2 3 3MET 322 Engineering Technology Project 4 6 6

11 14 16

Program Totals 79 80 99

* Course Syllabi in Volume 2


COURSE DESCRIPTIONS 1995-1996

MET 100 Machine Tool Practices I (3-9-6) Students will be assigned, specially designedprojects that will be machined using the engine lathe, milling, machine, drill press,and various saws. The capability and safe use of the machine tools will bestressed.

MET 112 Engineering Materials (2-3-3) A study of metallic and nonmetallic materialsused in design including properties, characteristics, and methods of conductingcommon tests and interpreting data.

MET 200 Machine Tool Practices II (3-9-6) A course designed to develop additionalmachine shop skills for those students who were successful in Machine ToolPractices I.

MET 205 CNC Machine Programming (3-3-4) A course in the programming andoperation of a computerized numerical control milling machine using manualmachine language. Included will be linear and circular interpolation, drilling cycle,and repetitive programming. Prerequisites: MET 100

MET 206 Statics (3-3-4) An introduction to the field of engineering mechanics coveringthe calculation of forces and moments acting on machine parts, frames andstructures. The equilibrium of concurrent and coplanar force systems, centroidsand friction are studied. Prerequisite: MATH 1316 or concurrent enrollment

MET 216 Tool Design 1 (2-6-4) Students will set up and machine work pieces using thelathe, vertical mill, drill press, and surface grinder. Fasteners, surface finish,machining techniques typical of tool and die making will be used. Prerequisites:MET 100 and DDT 104.

MET 301 Manufacturing Processes (3-3-4) Essential studies into the processes andmaterials for manufacturing, including metal casting, hot and cold forming of steel,powder metallurgy and plastics. Analysis of newer processes such as electricaldischarge machining, chemical machining and ultrasonic machining with anemphasis on the economical manufacturing of products.

MET 302 CAD/CAM I (3-3-4) This course will provide an introduction to "ProcessModeling" utilizing the CNC graphics programming system; "SMARTCAM".Using engineering drawings, students will program various parts for both CNCmills and CNC lathes. Related topics include: job planning, tool selection,construction of a process model, tool path verification, simulation, quality control,CAD/CAM data transfer, and CNC code generation.

oa

MET 312 Strength of Materials (3-3-4) A study of the relationship existing betweenexternally applied forces and internally induced stresses, and the resultingdeformations of structural members. Prerequisite: MET 206.

MET 315 Computer Integrated Manufacturing (2-2-3) An understanding into thefundamentals of (CIM). This includes the key elements and technologies involved,the typical applications that exist in industry today and the major trends that willaffect the future of manufacturing.

MET 318 CAD/CAM II (3-3-4) A continuation of MET 302 with advanced utilization of"SMARTCAM". Topics will include the following: 3-D Process Modeling,creation and utilization of different work planes, 4th and 5th axis programming,creation of tool path for surface primitives, swept surfaces, translated surfaces,sculpted surfaces, ruled surfaces, and coons surfaces. Additional topics include:projecting, intersecting, blending, and trimming one surface to another surface.Students will program both a simple punch and die set and a simple injection moldcavity. Prerequisite: MET 302.

MET 322 Engineering Technology Project (4-6-6) Different industrial level projectsemphasizing manufacturing applications/research in the areas of CAD/CAM, CIMor plastics will be assigned to students utilizing a team concept. Prerequisites:MET 302 and MET 312

MET 324 Ouality Assurance and Statistical Process Control (2-3-3) An introduction tothe concepts of applied quality control systems. Topics covered includ equalityresponsibility, control chart methods, samplings techniques, reliability applicationsand computer utilization/programs.


SUPPORT COURSES1995-1996

PSYC 1100* College Success Skills This course acquaints the students with the policiesof the college, services available on and off the campus, and study skillsalong with other issues that will help them through their college studies.Students are required to take this course in their first quarter at TSTC.

DDT 104 Drafting Principles A course consisting of basic exercises in lettering, useof the instruments, technical sketching, geometric construction,orthographic projection, auxiliary views, and dimensioning. Workingdrawings will be made.

MATH 1314* College Algebra A study of quadratics; polynomial, rational, logarithmicand exponential functions; systems of equations, progressions; sequencesand series; matrices and determinants. Prerequisite: MATH 104,Intermediate Algebra, or equivalent as determined by MATH placementtest.

ENGL 1301* Composition I Students study the process of composing essays, includingprewriting techniques, drafting, and revising and editing. Students writeseveral multi-paragraph essays of various types, in both in-class and out-of-class settings. Students critically analyze sample student and professionalessays. Prerequisite: ENGL 020, Writing Skills II, or equivalent asdetermined by the English placement test.

ENGL 134* Interpersonal Communication Theories and exercises in verbal andnonverbal communication with focus on interpersonal relationships.Students will study internal and external factors that impactcommunication, communication clarification, and conflict resolution.Various presentations are required. Prerequisite: ENGL 1301,Composition I.

MATH 1316* Plane Trigonometry Topics in trigonometric functions, right triangles,trigonometric identities, radian measure, graphs of periodic functions, andoblique triangles. Prerequisite: MATH 1314, College Algebra.

CNS 2060 Application Software This course includes introductory conceptscombined with an emphasis on the more predominate computer softwareincluding, but not limited to DOS, word processing, electronicspreadsheets, and databases, thus providing non-majors with computerliteracy and hands-on experience.

40,

OSH 216

PHY 114

EST 120

WLT 105

DDT 128

PSYC 2301*

PHYS 1310*

Safety and Accident Prevention A course designed to enable the studentto recognize hazards and potential hazards which may occur in theworkplace and to take corrective action. The course may be directedtoward a specific technology as required. Federal safety requirementsunder the OSHA law will be emphasized. General supervisor safetytraining course for all technologies.

Basic Fluid Power A basic study of hydraulic system components, fluidpower theory, problem solving and troubleshooting techniques.Prerequisite: MTH 109, Mathematics for Industrial Technicians, MTH 110,Basic Algebraic Concepts, or equivalent.

Electrical Applications A survey course designed to present basicconcepts in DC and AC circuits, fundamental motor design andapplications, and basic motor controls.

Survey of Welding Processes and Applications This course is a surveyof shielded metal arc, gas tungsten arc, gas metal arc, flux cored arc, andsubmerged arc welding processes. Metals weldability and weld symbolsare considered. Process safety, electrode selection, and process parametersare emphasized. Hard surfacing using shielded metal arc and oxyacetyleneprocesses and techniques are studied. It is recommended that the studenthave some knowledge of the welding processes before enrollment in thiscourse.

Introduction to Computer Drafting This course introduces the studentto Computer-Aided Drafting (CAD). This introduction involves equipmentsoftware and basic command logic. Graphic images are created usingintroductory level commands. Recommended for Non-Majors.

General Psychology A survey of the major topics in psychology,introducing the study of behavior and the factors that determine and affectbehavior.

Elementary Physics An algebra-level problem-oriented course. Presentsspecial topics in classical physics, such as basic mechanics, optics,acoustics, or electricity. Prerequisite: MATH 1314, College Algebra, orabove.

* Course syllabi in Volume 2

41

THE MAST TECHNICAL WORKPLACECOMPETENCY/COURSE CROSSWALK

Upon development of appropriate curricula for the pilot programs, each MAST college began todevelop individual course outlines for its assigned specialty area. The skill standards identified inthe Competency Profile were cross walked against the technical competencies of the courses inthe pilot curriculum. The resulting matrix provided a valuable tool for assessing whether currentcourse content was sufficient or needed to be modified to ensure mastery of entry level technicalcompetencies. Exit proficiency levels for each of the technical competencies were furthervalidated through industry wide surveys both in Texas and across the nation.

The Technical Workplace Competency/Course Crosswalk in the following pages presents thematch between industry-identified duties and tasks and the pilot curriculum for . Coursetitles are shown in columns, duties and tasks in rows. The Exit Level Proficiency Scale, anascending scale with 5 the highest level of proficiency, includes marked boxes indicating whetherthe task is covered by the instructor during the course; the numbers 1-5 indicate the degree ofattention given to the task and the corresponding proficiency expected on the part of the student.The crosswalk is intended to serve as an aide to other instructional designers and faculty incommunity college programs across the nation.

Included on the following pages is the Technical Workplace Competency/Course Crosswalk forthe pilot program curriculum. This crosswalk validates the fact that the duties and tasks whichwere identified by industry as being necessary for entry level employees have been incorporatedinto the development of the course syllabi.

",.

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A-1 Follow Safety and All Safety Regulations/Requirements X X X X X X X X 4A-2 Use Protective Equipment X X X X X X X X 4

A-3 Follow Safe Operating Procedures for Hand and Machine Tools X X X X X X X X 4

A-4 Maintain a Clean and Safe Work Environment X X X X X X X X 4

A-5 Control Fire Hazards X X X 4A-6 Apply erican Red Cross First Aid and CPR Procedures X 2

A-7 Recommend Hazardous Waste Management Techniques X 2

A-8 Apply Ergonomic Principles to the Workplace X X X 2

A-9 Demonstrate Knowledge of State and Federal EPA Regulations X 2

B. APPLY MATHEMATICAL CONCEPTS

B-1 Perform Basic Arithmetic Functions X X X X X X X X X X X X X 4

8-2 Interconvert Fractions/Decimals X X X X X X X X X X X 4

B-3 Interconvert Metric/English Measurements X X X X X 3

B-4 Perform Basic Algebraic Operations X X X 4

B-5 Perform Basic Trigonometric Functions X X X X 4

B-6 Calculate Speeds and Feeds for Machining X X X X X X X 4

8 -7 Locate Machining Points from a Datum Point X X X X X X X X X X 4

B-8 Perform Calculations for Sine Bar and Sine Plate X 2

B-9 Calculate for Direct, Simple, and Angular Indexing X 2

B-10 Perform Calculations Necessary for Turning Tapers X 2

8-11 Solve for Little II" X 2

8-12 Use all Functions on a Scientific Calculator X X X X X X 3

B-13 Solve Engineering Equations X X X 3

B-14 Solve Static Systems for Resultant Force X X 3

B-15 Determine Strength of Materials for Various Applications X X 3

C. INTERPRET ENGINEERING DRAWINGS AND CONTROL DOCUMENTS

C-1 Review Blueprint Notes and Dimensions X X X X X X X X X X 4

C-2 Identify Basic Layout of Drawings X X X

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C-3 Identify Basic Types of Drawings A q XXX X X XX X 4

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C-4 List the Purpose of Each Type of Drawing X X X X 4

C-5 Verify Drawing Elements X X X X X X X X X 43

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C-6 Practice Geometric Dimensioning and Tolerancing (GD&T) Methodol-ogy X X XX XXX

C-7 Describe the Relationship of Engineering Drawings to Planning X X X X X X X X X X

C-8 Use Standards to Verify Requirements X X X X X X X X X X X

C-9 Analyze Bill of Materials (BOM) X X X X X X X X X X X

C-10 Understand and Use Quality Systems X X X X X

D. RECOGNIZE DIFFERENT MANUFACTURING MATERIALS ANDPROCESSES

D-1 Identify Materials With Desired Properties X X X X X X X X

)III0-2 Identity Materials and Processes to Produce a Product X X X X X X X X X

D-3 Describe Heat Treating Processes X X

D-4 Perform Heat Treating Operations X

D-5 Test Metal Samples for Hardness X X

D-6 Describe Casting Processes X 2

0-7 Describe Hot Working Processes X

212D-8 Describe Cold Working Processes X

D-9 Evaluate Alternative Manufacturing Processes X X21

E. DEMONSTRATE MEASUREMENTANSPECTION TECHNIQUES

E-1 Identify Types of Measurement Used in Manufacturing X X X X

E-2 Select Proper Measurement Tools X X X X 3

31E-3 Apply Proper Measuring Techniques X X X X X

E-4 Use Metric and English Standards of Measurement X X X X 3

1E-5 Perform Measurements With Hand Held Instruments X X X X X

E-6 Perform Measurements on Surface Plate X X X X X

E-7 Perform Inspections Using Stationary Equipment X X ;I

F. PERFORM CONVENTIONAL MACHINING OPERATIONS

F-1 Prepare and Plan for Machining Operations X X X X X 3

F-2 Use Proper Hand Tools X X X X X 4

F-3 Operate Power Saws X X4. a X X 4

F-4 Operate Drill Presses X X X X 4

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F-5 Operate Vertical Milling Machines X X X X 3

F-6 Operate Horizontal Milling Machines X X X 3

F-7 Operate Metal Cutting Lathes X X X X 3

F-8 Operate Grinding/Abrasive Machines X X X X 2

G. PERFORM ADVANCED MACHINING PROCESSES

G-1 Prepare and Plan for CNC Machining Operations X X X X 3

G-2 Select and Use CNC Tooling Systems X X X X 3

G-3 Program CNC Machines X. X X X 3

G-4 Operate CNC Machining Centers (Mills) X X X X 3

G-5 Operate CNC Turning Centers (Lathes) X X 2

G-6 Operate Electrical Discharge Machines

G-7 Download Programs Via Network X X X X 2

G4 Program CNC Machines Using a CAM System X X X 3

H. PERFORM GEAR GENERATING OPERATIONS

H-1 Describe the Different Types of Gears X X 2

H-2 Understand Gear Terms X X 2

11-3 Use Rotary Tables and Dividing Heads X X 2

H-4 Discuss Gear Inspection and Measurement X X 2

I. PERFORM WELDING OPERATIONS

1-1 Weld With Shielded Metal Arc Welding (SMAW) Process X X 2

1-2 Weld/Cut With Oxyacetylene X X 2

1-3 Weld With Gas Tungsten Arc Welding (GTAW) (Heliarc) X 21-4 Weld With Gas Metal Arc Welding (GMAW)/(MIG) and Flux Core Arc

Welding (FCAW) X 2

1-5 Perform Plasma Arc Cutting (PAC) X 2

J. PERFORM DRAFTING TASKS

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J-1 Demonstrate Traditional Mechanical Drafting Skills X 3

J-2 Use Computer-Aided Drafting (CAD) System X 3

J-3 Create 3-D Solid Models X 2

J-4 Make Tool Drawings / 1-` X 2

K. USE COMPUTERS X X.. .

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K-1 Use Computer Operating Systems X X X X X X X 4

K-2 Use Computer Inquiry Systems X X X

K-3 Use Various Computer Applications X X X X X X X 3

K-4 Recommend and Implement CM Technologies X X X X

K-5 Use Computer-Aided Engineering System

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L PARTICIPATE IN TOTAL QUALITY AND SPC ACTIVITIES

L-1 Define Quality in Manufacturing and Explain Importance X X X X X

L-2 Implement Concepts of Quality in the Workplace X X X

L-3 Apply Principles and Tools of Continuous Quality Improvement...

X X

1-4 Understand and Apply SPC X

L-5 Evaluate Data to Monitor Production X X

L-6 Analyze Customer Problems and Recommend Solutions X X

L-7 Establish Methods, Plans and Procedures to Maintain Quality X X

M. MAINTAIN ELECTRICAL DEVICES

M-1 Use Electrical Test Equipment X X

M-2 Apply Specific Terms to Electrical Circuits X X 2

M-3 Analyze Series, Parallel and Complex DC/AC Circuits X X

M-4 Check AC and DC Motors X X 2

M-5 Inspect Transformers and Generators X

M-6 Discuss Sensors and Feedback Technology X X

M-7 Set Up/Program PLC X

M-8 Troubleshoot Electrical Devices X X

N. MAINTAIN HYDRAULIC/PNEUMATIC DEVICES

N-1 Use Test Equipment X X

111N-2 Describe Basic Principles of Hydraulic Systems X

N-3 Identify Hydraulic Fluids X

N-4 Recommend Paw Distribution_ and Sealing Devices X

N-5 Recognize Pumps. Actuators. and Hydraulic Control Devices X X

N-6 Troubleshoot Hydraulic/Pneumatic Systems X X 2

d C

MANUFACTURING ENGINEERING TECHNICIANTECHNICAL WORKPLACE COMPETENCIES

EXIT LEVEL PROFICIENCY MATRIX

Manufacturing Engineering Technician: use special knowledge and skills to recommendand/or implement solutions for specificmanufacturing applications.

The following matrix identifies the five exit levels of technical workplace competencies for theMachinist Certificate at Texas State Technical College Waco.

EXIT LEVEL OF PROFICIENCY

TechnicalWorkplaceCompetency

..

1 2 3 4 5

rarely routinelywithsupervision

routinelywith limitedsupervision

routinelywithoutsupervision

initiates/improves/modifies andsupervisesothers

47

THE MAST SCANS/COURSE CROSSWALK

The Secretary's Commission on Achieving Necessary Skills (SCANS), U. S. Department ofLabor, has identified in its "AMERICA 2000 REPORT' the following five competencies and athree-part foundation of skills and personal qualities that are needed for solid job performance:

COMPETENCIES:Resources:Interpersonal:Information:Systems:Technology:

FOUNDATION SKILLS:basic Skills:

Thinking Skills:

Personal Qualities:

Identifies, organizes, plans, and allocates resourcesWorks with othersAcquires and uses informationUnderstands complex inter-relationshipsWorks with a variety of technologies

Reads, writes, performs arithmetic and mathematical operations,listens and speaksThinks creatively, makes decisions, solves problems, visualizes,knows how to learn and reasonsDisplays responsibility, self-esteem, sociability, self-management,and integrity and honesty

Recognizing the value of SCANS proficiencies to job performance, as well as the growingmandate in many states to include SCANS activities in course curricula, MAST asked surveyrespondents to review the SCANS skill sets in the context of the draft skill standards for eachoccupational specialty area. MAST also incorporated evaluation of SCANS competencies andfoundation skills into its assessment of the pilot training curricula. The results were summarizedin a crosswalk that allowed MAST staff to modify course content where needed to strengthenachievement of SCANS competencies.

The following pages present the SCANS/Course Crosswalk for the pilot curriculum inCourses are listed along the top and SCANS competencies and foundations are shown along theleft side of the matrix. An exit level proficiency matrix for SCANS competencies and foundationskills is provided as well.

As "soft" skills, the SCANS competencies are inherently difficult to quantify. MAST realizesthat some faculty will emphasize the SCANS more or less than others. The SCANS/CourseCrosswalk matrix has been included with this course documentation to show the importance ofthese "soft skills" and the importance of their being addressed in the classroom (particularly intechnical classes). In time, faculty will learn to make these types of SCANS activities an integraland important part of the teaching process.

Included on the following pages is the SCANS/Course Crosswalk for the pilot programcurriculum. This crosswalk validates the fact that the "soft skills" (SCANS) which wereidentified by industry as being necessary for entry level employees have been incorporated into thedevelopment of the course syllabi. Also included is a matrix which defines the exit level ofproficiency scale (1-5).

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(RS) RESOURCES:

A. Allocates time X X X X X X X X X X X X X XXXXXX 4

B. Allocates money X X X X X XX XXX 3

C. Allocates material and facility resources XXXXXXXXXXXXX XXXXXX 3

D. Allocates human resources XXX X X XXX X XXXX X X XXXX 3

(IN) INTERPERSONAL SKILLS:

A. Participates as a member of a team X X XXXX XX X XXXXXX 4

B. Teaches others XXXXXXXXXXXXX XXXXXX 4

C. Serves clients/customers X X XX X XXXXXX 3

D. Exercises leadership XXXXXXXXXXXXX XXXXXX 4

E. Negotiates X X X 2

F. Works with cultural diversity XXXXXXXXXXXXX XXXXXX 4

(IF) INFORMATION SKILLS:

A. Acquires and evaluates information XXXXXXXXXXX XX XXXXXX 4

B. Organizes and maintains information XXXXXXXXXXX XX XXXXXX 4

C. Interprets and communicates information XXX X XXXXXXXXX XXXXXX 4

D. Uses computers to process information X X X X XX XXX,

4

(SY) SYSTEMS:

A. Understands systems XXXXXXXXXXXXX XXXXXX 4

B. Monitors and corrects performance XXXXXXXXXXXXX XXXXXX 4

C. Improves and designs systems X X X XXXXXX 3

(TE) TECHNOLOGY:

A. Selects technology XXXXXXXXXXXXX XXXXXX 4

B. Applies technology to task X X X X X X X X X X X X X XXXXXX 4

C. Maintains and troubleshoots technology X XX XXX X X X X X XXXXXX 4

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(BS) BASIC SKILLS:

A. Reading XXXXXXXXXXXXX XXXXXXB. Writing X X XXXXXXXXXXX XX XXC. Arithmetic and mathematics X X X X X X XXXXXX IID. Listening XXXXXXXXXXXXX XXXXXX a

illE. Speaking XXXXXXXXXXXXX X XXXXX

I(TS) THINKING SKILLS:

A. Creative thinking XXXXX XXXXX XXXXXX IIB. Decision making XXXXXXXXXXXXX XXXXXXC. Problem solving XXXXXXXXXXXXX XXXXXX II

4D. Seeing things in the mind's eye X X X X X XXXXXXXX XXXXXXE. Knowing how to learn XXXXXXXXXXXXX XXXXXX IIF. Reasoning XXXXXXXXXXXXX XXXXXX 4

I(PO) PERSONAL QUALITIES:

A. Responsibility XXXXXXXXXXXXX XXXXXXB. Self-esteem XXX X XXXXXXXXX XXXXXX 4

IIC. Social XXXXXXXXXXX X X X XXXD. Self-management XXXXXX XXXXXXX XXXXXXE. Integrity/honesty XXXXXXXXXXXXX XXXXXX

III

5G II

1SCANS

COMPETENCIES AND FOUNDATION SKILLSEXIT LEVEL PROFICIENCY MATRIX

The Secretary's Commission on Achieving Necessary Skills (SCANS), U. S. Department ofLabor, has identified in it's "AMERICA 2000 REPORT' the following five competencies and athree-part foundation of skills and personal qualities that are needed for solid job performance:

COMPETENCIES:Resources: Identifies, organizes, plans, and allocates resourcesInterpersonal: Works with othersInformation: Acquires and uses informationSystems: Understands complex inter-relationshipsTechnology: Works with a variety of technologies

FOUNDATION SKILLS:Basic Skills: Reads, writes, performs arithmetic and mathematical operations, listens and

speaksThinking Skills: Thinks creatively, makes decisions, solves problems, visualizes, knows how

to learn and reasonsPersonal Qualities: Displays responsibility, self-esteem, sociability, self-management, and

integrity and honesty.

The following matrix identifies the five exit levels ofproficiency that are needed for solid jobperformance.

EXIT LEVEL OF PROFICIENCY

SCANSCompetencies

and FoundationSkills

1 2 3 4 5

rarely routinelywithsupervision

routinelywith limitedsupervision

routinelywithoutsupervision

initiates/improves/modifies andsupervisesothers

MAST/01/013196

THE MAST COURSE SYLLABI"PILOT PROGRAM"

MAST has produced a very unique set of course outlines, driven and validated by industry andencompassing the broad range of technologies covered by the MAST grant. The course outlinesalso include proposed SCANS activities that will be useful to an instructor in preparing studentsto enter the workforce of the future.

Included in the following pages are final course outlines developed and refined in the process ofpiloting the MAST training programs. The outlines include a brief course description; requiredcourse materials (e.g., textbook, lab manual, and tools, if available); proposed method ofinstruction; proposed lecture and lab outlines; and detailed course objectives for both TechnicalWorkplace Competencies and SCANS Competencies.

These outlines were completed and revised during the second year of MAST, followingcompletion of the pilot phase. The outlines are intended to serve as an aide to other instructionaldesigners and faculty in community college programs across the nation.

Included on the following pages are the Course Syllabi for each of thecourses which were taughtduring the pilot program.

52


COURSE SYLLABUS

MACHINE TOOL PRACTICES I

MAST PROGRAMCOURSE SYLLABUS

MACHINE TOOL PRACTICES I

Lecture hours/week: 3

COURSE DESCRIPTION:

Lab hours/week: 9 Credit hours: 6

Students will be assigned specifically designed projects that will be machined using the enginelathe, milling machine, drill press, and various saws. The capability and safe use of machine toolswill be stressed.

PREREQUISITES: NONE

REQUIRED COURSE MATERIALS:

Textbook:Lab Manual:

Machine Tool Practices, Kibbe, Neely, and Meyer, Wiley Pub., 4th Ed.Machine Tool Practices I, Raborn, TSTC Pub., 4th Ed.

Student Tool List Qty. Req'd.Tool Box 1

Safety Glasses 1 pair6 inch Ruler 1/8, 1/16, 1/32, and 1/64 inchBall Peen Hammer 1

10 inch Adjustable Wrench 1

Center Punch 1

Magic marker, Jumbo, black. 1

Aluminum Oxide Cloth, 9" X 11", 240 Grit 2 sheetsAluminum Oxide Cloth, 9" X 11", 320 Grit 2 sheetsTool Steel, 3/8", H.S.S. 2Flat Mill Bastard File, 10 inch. 1

File Handle 1

Allen Wrench Set, Long English and Metric 1 eachCenter Drill #3 1

Scribe 1

Center Gage 1

Screw Driver, 8 inch 1

File Card Brush 1

0-6 inch Dial Calipers 1

Shop Apron (blue denim) 1

Shop Towels (1 roll) 1

METHODS OF INSTRUCTION:

Lecture: Didactic presentations will include lecture, video and demonstrations.

Laboratory: Laboratory will be a "hands-on" machining process

Method of'Evaluation: A student's grade will be based on multiple measures of performance.The assessment will measure development of independent critical thinking skills and will includeevaluation of the student's ability to:1. perform the manipulative skills of the craft as required to satisfactorily complete

laboratory assignments2. apply theory to laboratory assignments3. satisfactorily perform on written, oral, and practical examinations4. satisfactorily perform on outside assignments including writing assignments and oral

presentations5. contribute to class discussions6. maintain attendance per current policy7. follow all shop rules and safety regulations as stated in the laboratory manual

LECTURE OUTLINE:Lecture Topics

Introduction to the CourseSafetyTool GrindingThe Machine ShopThe Inch RuleThe SquareThe Inch MicrometerDrawingsLayout ToolsQUIZ I (over above lectures)Semi-precision LayoutHand ToolsHacksawsFilesVerniersVernier MicrometersThe Drill PressDrilling ToolsQUIZ 2 (over above lectures)Drilling OperationsTapsTapping ProceduresGage BlocksAngular Measuring

Text Reference Page Contact Hrs.

5-1243-45 (lab book)

1-4113-118163-166140-14528-36

249-262

262-26646-5555-5858-63

122-125151-156365-374375-384

389-40268 -7474-79

178-187187-195

1

1

1

1

1

1

1

221

1

1

1

1

1

1

1

21

21

1

1

1

Precision Layout 267-280 2QUIZ 3 (over above lectures) 1

Oral Presentations* 5

Total Lecture Hours 36

*(10-15 minute student presentations on assigned machine-related topics. These topics couldinclude future trends or special concerns of the machine tool industry.)

LAB OUTLINE:Lab Topics Contact Hrs.

Shop orientation 2Use of the cut-off saw 2Grinding a lathe tool 3Grinding a mill tool 3Using the band saw 3Using the radial drill 3Using the sensitive drill 3Bench work 27Lathe work 27Mill work 27Leaving the shop in order 3Inspecting the finished work

Total Lab Hours 108

COURSE OBJECTIVES: TECHNICAL COMPETENCIES

After the successful completion of this course the student will be able to:

A. PRACTICE SAFETY1. Follow Safety Manuals and All Safety Regulations/Requirements

a. Assume responsibility for the personal safety of oneself and othersb. Develop a personal attitude towards safetyc. Comply with established safety practices


3. Follow Safe Operating Procedures for Hand and Machine Toolsa. Understand and apply safe machine operating proceduresb. Demonstrate safe machine operation

4. Maintain a Clean and Safe Work Environmenta. Keep work areas cleanb. Clean machine/hand tools when work is completedc. Put tools away when work is finished

1

d. Keep aisles clear of equipment and materialsB. APPLY MATHEMATICAL CONCEPTS



a. Explain basic blueprint terminologyb. Identify the types of dimensionsc. Identify general note symbolsd. Locate notes on a printe. Interpret commonly used abbreviations and terminologyf. Determine tolerances associated with dimensions on a drawingg. Determine the tolerance for a reference dimension

2. Identify Basic Layout of Drawingsa. Identify types of lines within a drawingb. Identify general note symbols

3. Identify Basic Types of Drawingsa. Identify orthographic viewsb. Identify positions of views (top, front, side, and auxiliary)c. Visualize one or more views from a given view

4. List the Purpose of Each Type of Drawinga. Identify the purpose of orthographic (3 views) drawings

D. PERFORM MEASUREMENT/INSPECTION1. Identify Types of Measurement

a. Discuss the use of metrology in manufacturingb. Discuss the inch system of measurementc. Discuss the metric system of measurementd. Discuss semi-precision and precision measuremente. Discuss the following: accuracy, precision, reliability, and discrimination

2. Select Proper Measurement Toolsa. Identify basic semi-precision measuring toolsb. Identify precision measuring toolsc. Justify the use of a particular measuring tool based on tool characteristicsd. Identify error possibilities in measurement tool selectione. Demonstrate proper care of precision measuring tools

3. Apply Proper Measuring Techniquesa. Discuss factors affecting accurate measurement (dirt, temperature,

improper measuring tool calibration)b. Explain calibration requirements of various precision instrumentsc. Illustrate measurement differences when taken with calibrated and

non-calibrated instrumentsd. Calibrate a micrometer type measuring tool

4. Perform Measurements With Hand Held Instrumentsa. Measure with steel rules (metric and inch)b. Measure with micrometers

57

c. Measure with comparison measuring instruments (e.g., calipers, telescopegages)

d. Measure with direct measuring instruments (e.g., vernier, dial, and digitalinstruments)

e. Measure with fixed gages (go and not go gages)5. Perform Measurements on Surface Plate

a. Describe care of surface plateb. Use surface plate accessories correctly (sine bar, gage blocks, etc.)c. Check for part squarenessd. Check part dimensions for accuracye. Align workpieces using height gage and dial indicators

E. PERFORM CONVENTIONAL MACHINING OPERATIONS1. Prepare and Plan For Machining Operations

a. Read and interpret blueprintsb. Perform basic semi-precision and precision layout as necessaryc. Plan machining operationsd. Calculate speeds, feeds, and depth of cut for various machine applicationse. Use carbides and other tool materials to increase productivity

2. Use Proper Hand Toolsa. Use arbor and shop pressesb. Select necessary work-holding devices and hand tools as neededc. Select and use hand filesd. Identify and use hand reamerse. Correctly identify and use hand taps as requiredf. Follow tapping procedures to produce internal threadsg. Use thread-cutting dies to produce external threadsh. Operate bench and pedestal grinders safely

3. Operate Power Sawsa. Use reciprocating and horizontal band cutoff machinesb. Prepare and use the vertical band saw

4. Operate Drill Pressesa. Describe the different types of drill presses found in the machine shopb. Describe and use standard drilling toolsc. Setup the drill presses for drilling, countersinking, counterboring, and

reaming operations5. Operate Vertical Milling Machines

a. Demonstrate the use of all controls on the vertical milling machineb. Align the vertical milling machine headc. Select, align and use workholding devicesd. Select milling tool holderse. Select milling cuttersf. Perform all standard vertical milling operations

6. Operate Metal Cutting Lathesa. Demonstrate the use of all controls on the engine latheb. Discuss standard tools and toolholders for the lathec. Face and center drill parts correctly

d. Drill, ream and bore on the lathee. Make all calculations, lathe adjustments and settings to machine sixty

degree external threadsf. Use HSS cutting toolsg. Use carbide cutting tools

COURSE OBJECTIVES: SCANS COMPETENCIES

The Secretary's Commission on Achieving Necessary Skills (SCANS), U.S. Department of Labor,has identified in its "AMERICA 2000 REPORT" that all students shoulddevelop a new set ofcompetencies and foundation skills if they are to enjoy a productive, full and satisfying life.These are in addition to the Technical Workplace Competencies required by industry. SCANS ismade up of five competencies and a three-part foundation of skills andpersonal qualities thatare needed for solid job performance.

The following activities will be performed by each student for successful completion of thiscourse:

I. COMPETENCIESA. Resources: Identifies, organizes, plans, and allocates resources

1. follows a schedule to complete assigned tasks on time2. follows a schedule to maximize laboratory resources3. complete a stock request form for required material

B. Interpersonal: Works with others1. complete assigned responsibilities within the shop floor serving as a

member of the team2. provide individual assistance/direction to peers as requestedInformation: Acquires and uses is ormation1. read and interpret blueprints2. organize and apply theories of machine tool operation3. perform basic semi-precision and precision layout as necessary

D. Systems: Understands complex inter-relationships1. demonstrate knowledge of the following systems:

a. organization of personnel and facilities on the shop floorb. systematic approach to the metal removal processc. dimensioning and measurement systems

2. monitors and corrects performance duringa. the machining processb. adjustments of individual laboratory work schedulec. constantly evaluating the quality of work to achieve acceptable

standardsE. Technology: Works with a variety of technologies

1. chooses procedure, tools and equipment required to produce a part

ao

2. applies appropriate procedures and uses appropriate tools and equipmentto produce a machined part to acceptable standards

II. FOUNDATION SKILLSA. Basic Skills: Reads, writes, performs arithmetic and mathematical operations,

listens and speaks.1. Reading: Locates, understands, and interprets written information in

prose and in documents such as manuals, graphs, and schedulesa. read/studies textbookb. studies student laboratory manualc. interprets blueprints and technical drawingsd. follow a daily laboratory schedule to maintain appropriate time-line

and product completion2. Writing: Communicates thoughts, ideas, information, and messages in

writing; and creates documents such as letters, directions, manuals,reports, graphs, and flow chartsa. outline the steps necessary to produce a simple machine partb. maintain a lecture notebookc. submit written responses to chapter question assignments

3. Arithmetic/Mathematics: Perform basic computations and approachespractical problems by choosing appropriately from a variety ofmathematical techniquesa. determines optimum machining speeds, feeds, and depth of cutb. interconverts fractions to decimal expressionsc. keeps a running computation of individual graded. calculate tap drill size

4. Listening: Receives, attends to, interprets, and responds to verbalmessages and other cuesa. assimilate classroom instructionb. interpret and assimilate video instructionc. observe and assimilate laboratory demonstrationsd. seek and receive individualized instruction in the laboratorye. practices active listening by affirming understanding of verbal

instructions, asking questions for clarification and probing forspecifics

5. Speaking: Organizes ideas and communicates orallya. participates in classroom discussionsb. organize ideas and communicate specific questions to the instructorc. verbally affirms understanding of a concept, procedure, or required

skilld. communicate with peers, instructors and supervisors to ensure the

smooth and safe operation of the laboratorye. plan and deliver a 10-15 minute oral presentation on an assigned

machine-related topicB. Thinking Skills: Thinks creatively, makes decisions, solves problems, visualizes,

knows how to learn and reasons.

60

1. Decision Making: Specifies goals and constraints, generates alternatives,considers risks, and evaluates and chooses best alternativea. decides upon a job process plan to produce a part to specifications,

given constraints of available time, equipment and other resourcesb. prioritizes activities for effective use of time

2. Problem Solving: Recognizes problems and devises and implements planof actiona. makes daily accommodations to stay on scheduleb. seeks additional instruction/clarification for assignment completionc. troubleshoots machining processes and equipmentd. recognize problems in machining and selects appropriate corrective

or preventive action3. Seeing Things In the Mind's Eye: Organizes, andprocesses symbols,

pictures, graphs, objects, and other informationa. visualize objects in three dimensions from engineering drawingsb. visualize process during instructor lecturec. visualize the relative motions between tool and workpiece to

generate desired features in raw stock in order to plan machinesetups and sequence of machining operations

4. Knowing How to Learn:. Use efficient learning techniques to acquire andapply new knowledge and skillsa. understand that practice will improve skillb. asks questions or seeks help when uncertain about new skills or

knowledge5. Reasoning: Discovers a rule or principle underlying the relationship

between two or more objects and applies it when solving a problema. applies knowledge of principles of machining to troubleshoot

process problemsb. applies knowledge of machining process to develop a logical,

sequential process planc. applies knowledge of workpiece machinability, cutter

characteristics and machine tool characteristics to adjust speeds andfeeds

Personal Qualities: Displays responsibility, self-esteem, sociability, self-management, and integrity and honesty.1. Responsibility: Exerts a high level of effort andperseveres towards goal

attainmenta. displays promptness and preparation for the day's workb. plans work to use time efficientlyc. accepts responsibility for mistakes, and takes corrective and

preventive actionsd. takes initiative when needed to gain resources or assistance to

complete assignments2. Self-Esteem: Believes in own self-worth and maintains a positive view of

selfa. takes pride in work through positive reinforcement

61

b. sees self as a valued member of the group through continuedcontributions toward common goals

3. Sociability: Demonstrates understanding, friendliness, adaptability,empathy, and politeness in group settingsa. assist classmates in improving technical skillsb. share laboratory resources (machines, tools and instructor's

individual attention)4. Self-Management: Assesses self accurately, sets personal goals,

monitors progress, and exhibits self-controla. perform in-process quality checks on machined partsb. maintain a record of academic achievement (individual gradebook)c. accept responsibility for mistakes and infractions, and take steps to

resolve or eliminate themIntegrity/Honesty: Chooses ethical courses of actiona. accept the responsibility for own actionsb. exhibit personal honesty at all timesc. accept the challenge of doing your own work in the laboratory,

during examination, and on outside assignmentsd. understand the consequences of unethical behaviors

Appropriate Reference Materials:

1. Machinery's Handbook, Industrial Press2. Technology of Machine Tools, 4th Ed. McGraw Hill Publishers

MET10001/072296


COURSE SYLLABUS

DRAFTING PRINCIPLES

63


DRAFTING PRINCIPLES

ILecture hours/week: 2 Lab hours/week: 4 Credit hours: 3

COURSE DESCRIPTION:II

Students will be assigned basic exercises in lettering, use of instruments, technical sketching,geometric construction, orthographic projection, auxiliary views and dimensioning. Working Idrawings will be made.

PREREQUISITES: NONE


Textbook: Technical Drawing, Spencer, Giesecke, Mitchell, HillWorkbook: Technical Drawing Problems, Spencer, Giesecke, Mitchell, Hill

Materials:Drafting Kit No. 1 or the equivalent:

10" Triangles:1 -45°1- 300/60°

Engineer's ScaleMetric ScaleAmes Lettering GuideEraser Holder with erasersDrafting DotsCircle Template (Combination Imperial and Metric)Sandpaper PointerErasing ShieldBow CompassDusting BrushLead PointerIrregular CurveMechanical Pencils with refills:

.5mm

.7mm.9mm

Lead Holder - 2mmLeads:

.5mm - HB

.7mm - H, HB6 4.9mm - FIB

2mm 4H, H, FHard Carrying Case8 V2" x 11" vellum (10 sheets)

Additional items not included in kit:4 - 17 x 22 (C size) vellum1 - Preprinted 22 x 34 (D size) vellum


Lecture:

Laboratory:

Classroom presentations will include lecture, video and demonstrations. Computeraided instruction may be used.

Laboratory will be a "hands-on" drawing process using appropriate tools andmedia.

Method of Evaluation: A student's grade will be based on multiple measures of performance.The assessment will measure development of independent critical thinking skills and will includeevaluation of the student's ability to:1. perform the manipulative skills of the craft as required to satisfactorily complete

laboratory assignments2. apply theory to laboratory assignments3. satisfactorily perform on written, oral, and practical examinations4. satisfactorily perform on outside assignments including writing assignments5. contribute to class discussions6. maintain attendance per current policy7. follow all safety regulations as stated in the class policies


Introduction to CourseRequired Materials and TestsClass Policies and Safety ConcernsFunction of Drafting in Design and

ProductionDrafting Instruments, Material and

EquipmentLetteringQuizAlphabet of LinesTypes of Pencils and LeadsScales - Engineering and MetricQuizGeometric ConstructionsAngle MeasurementsTheory of Third Angle Orthographic

ProjectionTheory of First Angle Orthographic


HandoutHandout

1

23

21

2

44

6

65

Projection 6Arrangement of Views 6Common Dimensions Between Views 6 /11QuizFunction of Sectional Views 7Cutting Planes 7Conventional Representations 7Classifications of Sections 7QuizDimensioning Concepts 11

Dimensioning Techniques 11

Selection and Placement of Dimensions 11Metric Dimensioning 11Final Exam



Using Drafting Instruments, Materials and Equipment 2Applying Lettering 2Delineating Alphabet of Lines 2Selecting and Using Pencils and Leads 1

Using Scales 2Developing Geometric Constructions 12Using Angle Measurement 1

Using Third Angle Orthographic Projection 6Using First Angle Orthographic Projection 6Arranging Views and Common Dimensions 2Creating Sectional Planes 2Applying Cutting Planes 2Determine and Use Conventional Representations 1

Using Classifications of Sections 1

Applying Dimensioning 4Applying Metric Dimensioning 1

Final Exam 1

Total Lab Hours 48


After the successful completion of this course the student will be able to:

A. PERFORM DRAFTING TASKS.1. Demonstrate Traditional Mechanical Drafting Skills

a. Form freehand vertical Gothic upper-case letters and numerals of correctshape and space


c. Demonstrate proficiency with the engineers and metric scales

1

d. Execute geometric constructions with no mistakes in tangent points, linequality or layout work

e. Accurately draw the missing view or line in a multiview drawingf. Make or complete a sectional instrument drawing, given one or more viewsg. Develop satisfactory working drawings of simple machine components to


h. Discuss the differences in standard engineering drawings and tool drawings


The Secretary's Commission on Achieving Necessary Skills (SCANS), U.S. Department ofLabor,has identified in its "AMERICA 2000 REPORT" that all students should develop a new set ofcompetencies and foundation skills if they are to enjoy a productive, full and satisfying life.These are in addition to the Technical Workplace Competencies required by industry. SCANS ismade up of five competencies and a three-part foundation of skills and personal qualities thatare needed for solid job performance.



1. follows a schedule to complete assigned tasks on time2. determine the appropriate media and instruments to complete assignments3. provide a self-evaluation of performance based on the time and quality of

workB. Interpersonal: Works with others

1. complete assigned responsibilities within the course serving as a member ofthe team

2. provide individual assistance/direction to peers as requested3. produce drawings to acceptable levels of quality as required4. works well with all members of the classInformation: Acquires and uses information1. read and interpret text and handouts2. organize and apply theories of drafting and design3. apply lecture concepts to lab techniques


a. laboratory organization structure: physical and socialb. organization of personnel and facilities in the drafting labc. systematic approach to the drafting and design processd. dimensioning and measurement systemse. systematic organization of training materials

2. monitors and corrects performancea. during the drawing processb. making adjustments tolindividual laboratory work schedules

67

c. while constantly evaluating the quality of work to achieveacceptable standards

d. though maintaining a record of evaluationse. to meet individual goals

E. Technology: Works with a variety of technologies1. chooses procedure, tools and equipment required to produce a drawing2. applies appropriate procedures and uses appropriate tools and equipment

to produce a drawing to acceptable standards3. maintains and troubleshoots equipment and tools

a. applies appropriate preventative maintenanceb. reports all malfunctions of equipment to supervisor/instructorc. performs clean-up assignments of lab



prose and in documents such as manuals, graphs, and schedulesa. studies student laboratory manual and textb. interprets blueprints and technical drawingsc. reads/studies concepts in textbookd. follows a daily laboratory schedule to maintain appropriate time-

line to meet scheduled deadlinese. interprets concepts in lab manual drawings and texts to develop

accurate drawings2. Writing: Communicates thoughts, ideas, information, andmessages in

writing; and creates documents such as letters, directions, manuals,reports, graphs, and flow chartsa. outlines the steps necessary to produce.a simple drawingb. sketches object to produce a final drawingc. maintains a schedule of assignments and deadlines (these may take

the form of a chart, graph, etc.)d. maintains a lecture notebooke. submits written responses to chapter question assignmentsf. completes all written assignments

3. Arithmetic/Mathematics: Perform basic computations and approachespractical problems by choosing appropriately from a variety ofmathematical techniquesa. bisects lines, circles, arcs and anglesb. divides objects into equal partsc. applies tolerancesd. applies and verify dimensionse. uses fraction and decimal valuesf. applies principles of trigonometry and geometry to solve angle

calculations, tangencies and to define points4. Listening: Receives, attends to, interprets, and responds to verbal

messages and other cues

a. assimilates concepts presented by lecture, video or any multimediamethods

b. observes laboratory demonstrations for technique and safetyinstructions

c. seeks and receive individualized instruction in the laboratoryd. actively listens and participates in discussions and question/answer

sessions5. Speaking: Organizes ideas and communicates orally

a. participates in classroom discussionsb. organizes ideas and communicates specific questions to the

instructorc. verbally affirms understanding of a concept, procedure, or required

skilld. communicates with peers to ensure the efficient and safe

completion of assignmentsB. Thinking Skills: Thinks creatively, makes decisions, solves problems, visualizes,

knows how to learn and reason.1. Decision Making: Specifies goals and constraints, generates alternatives,

considers risks, and evaluates and chooses best alternativea. identifies personal goalsb. prioritizes goalsc. identifies specific actions required to accomplish personal goalsd. allows for flexibility in meeting goals as circumstances change

2. Problem Solving: Recognizes problems and devises and implements planof actiona. makes daily accommodations to stay on scheduleb. seeks additional instruction/clarification for assignment completionc. balances social and academic life/responsibilitiesd. accepts responsibility

3. Seeing Things In the Mind's Eye: Organizes, andprocesses symbols,pictures, graphs, objects, and other informationa. understands both written and verbal instructionsb. assimilates process during instructor demonstrationsc. interprets technical drawingsd. interprets technical illustrations and symbolse. interprets and applies geometric construction conceptsf. completes missing orthographic viewsg. creates multiview projections from pictorial drawingsh. identifies missing lines in multiview drawings

4. Knowing How to Learn: Use efficient learning techniques to acquire andapply new knowledge and skillsa. demonstrates mastery of the basic skills and techniquesb. uses these sequential skills to support mastery of new skillsc. consistently applies the sequential nature of acquired skills to the

subsequent knowledge application of new skills and techniques5. Reasoning: Discovers a rule or principle underlying the relationship

between two or more objects and applies it when solving a problema. understands that practice will improve the skill of the technician

6.9

b. understands that the quality of the product is a function of timespent and the attitude and skill of the technician


attainmenta. attends class as scheduled and is well prepared for the day's workb. completes assignments independently and on timec. works well within a team while completing individual assignmentsd. plans and organizes so time may be used wisely

2. Self-Esteem: Believes in own self-worth and maintains a positive view ofselfa. learns to take pride in his or her work through positive

reinforcementb. sees himself or herself as an asset to the class through continued

contributions to the group and a shared common goalc. understands that an individual with a positive attitude and the belief

in their own abilities will systematically seek solutions and be avaluable employee

3. Sociability: Demonstrates understanding, friendliness, adaptability,empathy, and politeness in group settingsa. assists classmates in improving technical skillsb. assists students with special needs as a peer mentorc. shares laboratory resources (machines, tools and instructor's


monitors progress, and exhibits self-controla. performs in-process quality checks on technical drawingsb. maintains a record of academic achievement (individual gradebook)c. maintains a schedule of deadlines, due dates, and other important

dates (calendar)d. adjusts calendar to accommodate unexpected circumstancese. accepts the responsibility for self management

5. Integrity/Honesty: Chooses ethical courses of actiona. accepts the responsibility for own actionsb. exhibits personal honesty at all timesc. accepts the challenge of doing your own work in the laboratory,

during examination, and on outside assignmentsd. understands the consequences of unethical behaviors

DDT104MAST/01/0722%

a


COURSE SYLLABUS

MACHINE TOOL PRACTICES IIPrerequisite: MACHINE TOOL PRACTICES I


MACHINE TOOL PRACTICES II


COURSE DESCRIPTION:


This course is designed to develop additional machining skills for those students who have thebasic skills that were developed in Machine Tool Practices I.

The student will work from more complex engineering drawings and use the engine lathe andmilling machines to produce parts that will assemble into a functioning machine. Precision workand the control of surface finishes will be stressed. The engine lathe will be used to turn, taper,thread, bore, ream and knurl several parts. The milling machine will be used to cut keyways, millprecise angles and bore holes. The safe operation and maintenance of the machine shop will alsobe an important objective.

PREREQUISITES: Machine Tool Practices I


Textbook: Machine Tool Practices, Kibbe, Neely, and Meyer, Wiley Pub., 4th Ed.Lab Manual: Machine Tool Practices II, Raborn, TSTC Pub., 4th Ed.

Student Tool List/Qty. Req'd: The same hand tools required in Machine Tool Practices I arealso required for Machine Tool Practices II.



Laboratory: Laboratory will be a "hands-on" machining process.


laboratory assignments2. apply theory to laboratory assignments3. perform on written, oral, or practical examinations4. perform on outside assignments including writing assignments

72

1

5. contribute to class discussions6. maintain attendance per current policy7. follow all shop rules and safety regulations as stated in the laboratory manual

LECTURE OUTLINE:Lecture Topics Text Reference Page Contact Hrs.

Introduction to the Course 1

Safety in the Machine Shop 5 1

Gages 88 1Lathe Parts 414 1

Lathe Accessories 394 1

Cutting Speeds and Feeds 270 1

Aligning Centers 440 1

Machining Between Centers 428 1

Knurling and Grooving 452 1

QUIZ I (over the above units)1

Tapers 477 2Threads 457 3Using Chucks 408 1

Drilling and Boring 443 1

Milling Machines 502 1

QUIZ 2 (over the above units)1

Milling Cutters 507 1

Cutting Speeds 522 1

Milling Operations 526 1

Indexing 592 2Gears 607 1

Gear Cutting 611 1

Assembly of Jig Saw 3QUIZ 3 (over the above units) 1

Oral Presentations* 6Total Lecture Hours 36

*(15-20 minute student presentations on assigned machine-related topics. These topics couldinclude future trends or special concerns of the machine tool industry.)


Shop orientation and safety 1

Precision layout 4Precision measuring with gage blocks and sine bar 8Lathe work 27Vertical milling machine work 18Horizontal milling machine 6

7 3

Bench work 27Assembly of machined parts 6Testing of completed machine 6Leaving the shop in order 5

Total Lab Hours 108


After the successful completion of this course the student will be able to:A. PRACTICE SAFETY

1. Follow Safe Operating Procedures for Hand and Machine Toolsa. Identify and understand lathe operating proceduresb. Demonstrate safe lathe operationc. Identify and understand milling machine operating proceduresd. Demonstrate safe milling machine operation

B. APPLY MATHEMATICAL CONCEPTS1 Perform Basic Trigonometric Functions

a. Solve for unknown anglesb. Calculate bolt hole patterns


3. Locate Machining Points from a Datum Pointa. Identify points using the absolute dimensioning systemb. Identify points using the incremental dimensioning system

4. Perform Calculations for Sine Bar and Sine Platea. Calculate gage block build up for 5" sine bar

5. Calculate for Direct, Simple, and Angular Indexinga. Calculate for direct indexingb. Calculate for simple indexing (plain)c. Calculate for angular indexingd. Use Machinery's Handbook for calculations

6. Perform Calculations Necessary for Turning Tapersa. Calculate tail stock offsetb. Determine unknowns (e.g., small and/or large diameters) for taper turning

7. Calculate Depth of Cut on Round Surfacesa. Calculate depth of cut for flats to be machined on cylindrical piecesb. Calculate depth of cut for keyways which are machined on cylindrical

piecesC. PERFORM CONVENTIONAL MACHINING OPERATIONS

1. Operate Vertical Milling Machinesa. Demonstrate the use of all controls on the vertical milling machineb. Align the vertical milling machine headc. Select, align and use workholding devicesd. Select milling tool holders

74

e. Select milling cuttersf. Perform all standard vertical milling operationsg. Bore a hole using the offset boring headh. Machine angles using sine bar and gage blocksi. Setup and use special vertical mill fixturesj. Setup and machine dovetailsk. Machine keyways


milling machinec. List several common work holding methodsd. Use plain milling cutterse. Use side milling cuttersf. Use face milling cutters

3. Operate Metal Cutting Lathesa. Demonstrate the use of all controls on the engine latheb. Discuss standard tools and toolholders for the lathec. Face and center drill parts correctlyd. Drill, ream and bore on the lathee. Turn between centersf. Discuss alignment of lathe centersg. Make all calculations, lathe adjustments and settings to machine UNF and

UNC series threadsh. Discuss thread fit classificationsi. Describe the common tapers used in the machine shopj. Discuss taper cutting and calculations for the lathek. Use HSS cutting tools1. Use carbide cutting tools


The Secretary's Commission on Achieving Necessary Skills (SCANS), U.S. Department of Labor,has identified in its "AMERICA 2000 REPORT" that all students should develop a new set ofcompetencies and foundation skills if they are to enjoy a productive, full and satisfying life.These are in addition to the Technical Workplace Competencies required by industry. SCANS ismade up of five competencies and a three-part foundation of skills and personal qualities thatare needed for solid job performance.



1. follows a schedule to complete assigned tasks on time2. follows a schedule to maximize laboratory resources3. complete a stock request form for required material


member of the team2. provide individual assistance/direction to peers as requestedInformation: Acquires and uses information1. read and interpret blueprints2. organize and apply theories of machine tool operation3. perform basic semi-precision and precision layout as necessary


a. organization of personnel and facilities on the shop floorb. systematic approach to the metal removal processc. dimensioning and measurement systems



1. chooses procedure, tools and equipment required to produce a part2. applies appropriate procedures and uses appropriate tools and equipment

to produce a machined part to acceptable standards


listens and speaks.I. Reading: Locates, understands, and interprets written information in

prose and in documents such as manuals, graphs, and schedulesa. read/studies textbookb. studies student laboratory manualc. interprets blueprints and technical drawingsd. follow a daily laboratory schedule to maintain appropriate time-line


writing; and creates documents such as letters, directions, manuals,reports, graphs, and flow chartsa. outline the steps necessary to produce a simple machine partb. maintain a lecture notebookc. submit written responses to chapter question assignmentsd. prepare job process for lathe and mill assignments

3. Arithmetic/Mathematics: Perform basic computations and approachespractical problems by choosing appropriatelyfrom a variety ofmathematical techniques

a. determines optimum machining speeds, feeds, and depth of cutb. interconverts fractions to decimal expressionsc. keeps a running computation of individual graded. calculate gage block buildupe. calculate for turning tapersf. calculate for indexing problems





smooth and safe operation of the laboratorye. plan and deliver a 15-20 minute oral presentation on an assigned

machine-related topicB. Thinking Skills: Thinks creatively, makes decisions, solves problems, visualizes,

knows how to learn and reasons.1. Decision Making: Specifies goals and constraints, generates alternatives,

considers risks, and evaluates and chooses best alternativea. decides upon a job process plan to produce a part to specifications,

given constraints of available time, equipment and other resourcesb. prioritizes activities for effective use of time

2. Problem Solving: Recognizes problems and devises and implements planof actiona. makes daily accommodations to stay on scheduleb. seeks additional instruction/clarification for assignment completionc. troubleshoots machining processes and equipmentd. recognize problems in machining and selects appropriate corrective

or preventive action3. Seeing Things In the Mind's Eye: Organizes, and processes symbols,

pictures, graphs, objects, and other informationa. visualize objects in three dimensions from engineering drawingsb. visualize process during instructor lecturec. visualize the relative motions between tool and workpiece to

generate desired features in raw stock in order to plan machinesetups and sequence of machining operations

77

4. Knowing How to Learn: Use efficient learning techniques to acquire andapply new knowledge and skillsa. understand that practice will improve skillb. asks questions or seeks help when uncertain about new skills or


between two or more objects and applies it when solving a problema. applies knowledge of principles of machining to troubleshoot

process problemsb. applies knowledge of machining process to develop a logical,

sequential process planc. applies knowledge of workpiece machinability, cutter

characteristics and machine tool characteristics to adjust speeds andfeeds





selfa. takes pride in work through positive reinforcementb. sees self as a valued member of the group through continued

contributions toward common goals3. Sociability: Demonstrates understanding, friendliness, adaptability,

empathy, and politeness in group settingsa. assist classmates in improving technical skillsb. share laboratory resources (machines, tools and instructor's


monitors progress, and exhibits self-controla. perform in-process quality checks on machined partsb. maintain a record of academic achievement (individual grade book)c. accept responsibility for mistakes and infractions, and take steps to

resolve or eliminate them5. Integrity/Honesty: Chooses ethical courses of action

a. accept the responsibility for own actionsb. exhibit personal honesty at all timesc. accept the challenge of doing your own work in the laboratory,



1. Machinery's Handbook, Industrial Press2. Technology of Machine Tools, 4th Ed., McGraw Hill Publishers

MET20001/072396

6 9


COURSE SYLLABUS

APPLICATION SOFTWARE


APPLICATION SOFTWARE


COURSE DESCRIPTION:


This course covers introductory computer concepts combined with an emphasis on the morepredominate computer software including, but not limited to DOS, word processing, electronicspreadsheets, and data bases thus providing non-majors with computer literacy and hands-onexperience.

PREREQUISITES: NONE


Textbook: Microsoft Office Professional for Windows (Illustrated); by Halvorson,Swanson, Reding, Beskeen, and Johnson. Latest edition.

Lab Manual: None

Supplies/Quantity Required:2 High density disks (3 1/2")6 Scantron test forms



Laboratory: Laboratory will be a "hands-on" application of computer software.

Method of Evaluation: A student's grade will be based on multiple measures of performance.The assessment will measure development of independent critical thinking skills and will includeevaluation of the student's ability to:1. perform the computer skills as required to satisfactorily complete laboratory assignments2. apply theory to laboratory assignments3. satisfactorily perform on written, oral, and practical examinations4. satisfactorily perform on outside assignments including writing assignments5. contribute to class discussions6. maintain attendance per current policy

81


DOS Commands 2Review & Test - DOS Commands 1

Microsoft Windows 3.1 2a. Getting started with Windows 3.1b. Creating and managing files

Review & Test - Microsoft Windows 3.1 1

Microsoft Word 6.0 1

a. Getting started with Microsoft Word 6.0b. Creating and editing a documentc. Formatting a documentd. Arranging text and graphics

Review & Test - Microsoft Word 6.0 1

Microsoft Excel 5.0 1

a. Getting started with Microsoft Excel 5.0b. Creating a worksheetc. Modifying a worksheetd. Working with chartse. Integrating Word and Excel

Review & Test - Microsoft Excel 5.0 1

Microsoft Access 2.0 1

a. Getting started with Microsoft Access 2.0b. Creating a databasec. Manipulating datad. Creating forms and reports

Review & Test Access 2.0 for Windows 1


LAB OUTLINE:Lab Topics

Work with DOS Tutor (Sections 2, 4, 5, 6, and 7)Microsoft Windows 3.1 (Units 1 and 2)Microsoft Word 6.0 (Units 1, 2, 3, and 4)Microsoft Excel 5.0 (Units 1, 2, 3, and 4)Microsoft Access 2.0 (Units 1, 2, 3, and 4)

Total Lab Hours


Contact Hrs.12101088

48

After the successful completion of this course the student will be able to:A. USE COMPUTERS

1. Use Computer Operating Systemsa. Use basic computer terminology appropriately and accuratelyb. Boot the computer and recognize the basic components of DOSc. Use DOS to perform file managementd. Use DOS to perform directory management

82

e. Install software packages on a PC2. Use Computer Inquiry Systems

a. Log in to a multi-user systemb. Access system for needed informationc. Print reports as necessary

3. Use Various Computer Applicationsa. Load word processor, create, save, edit, and print a documentb. Load spreadsheet, create, save, retrieve, erase, edit, and print a worksheetc. Load database programs, create, edit, delete, and print records in a

database file


The Secretary's Commission on Achieving Necessary Skills (SCANS), U.S. Department of Labor,has identified in its "AMERICA 2000 REPORT" that all students should develop a new set ofcompetencies and foundation skills if they are to enjoy a productive, full and satisfying life.These are in addition to the Technical Workplace Competencies requfred by industry. SCANS ismade up of five competencies and a three-part foundation of skills and personal qualities thatare needed for solid job performance.



1. follows a schedule to complete assigned tasks on timeB. Interpersonal: Works with others

1. provide individual assistance/direction to peers as requested2. works well with all members of the classInformation: Acquires and uses information1. read and interpret textbooks

D. Systems: Understands complex inter-relationships1 demonstrate knowledge of the following systems:

a. laboratory organization structure: physical and socialb. systematic organization of training materials

2. monitors and corrects performance duringa. operation of computer hardware and softwareb. adjustments of individual laboratory work schedulec. constantly evaluating the quality of work to achieve acceptable

standardsd. maintains record of evaluations and sets individual goals

E. Technology: Works with a variety of technologies1. chooses procedure to successfully complete assignments

IL FOUNDATION SKILLSA. Basic Skills: Reads, writes, performs arithmetic andmathematical operations,


prose and in documents such as manuals, graphs, and schedulesa. studies student laboratory manualb. read/studies textbookc. follow a daily laboratory schedule to maintain appropriate time-line

2. Writing: Communicates thoughts, ideas, information, andmessages inwriting; and creates documents such as letters, directions, manuals,reports, graphs, andflow chartsa. maintain a lecture notebookb. submit written responses to chapter question assignmentsc. complete all written assignments

3. Listening: Receives, attends to, interprets, and responds to verbalmessages and other cuesa. assimilate classroom instructionb. interpret and assimilate video instructionc. observe classroom demonstrationsd. seek and receive individualized instruction in the laboratory


skillB. Thinking Skills: Thinks creatively; makes decisions, solves problems, visualizes,


considers risks, and evaluates and chooses best alternativea. identifies personal goalsb. identifies actions required to accomplish personal goals


3. Seeing Things In the Mind's Eye: Organizes, andprocesses symbols,pictures, graphs, objects, and other informationa. interprets technical manualsb. interprets technical illustrations and symbolsc. understands both written and verbal instructionsd. assimilates process during instructor demonstrations

4. Knowing How to Learn: Use efficient learning techniques to acquire andapply new knowledge and skillsa. demonstrate mastery of the basic skills and techniquesb. use these sequential skills to support mastery of new skills

84

c. understand the sequential nature of acquired skills and thesubsequent knowledge application ofnew skills and techniques

5. Reasoning: Discovers a rule or principle underlying the relationshipbetween two or more objects and applies it when solving a problema. understands that practice may not make it perfect but it certainly

will improve the skill of the operatorPersonal Qualities: Displays responsibility, self-esteem, sociability, self-management, and integrity and honesty.1. Responsibility: Exerts a high level of effort andperseveres towards goal

attainmenta. develops an understanding that in order to be successful you must

be a "good" studentb. develops an understanding that a "good" student is the one who is

prompt to every class and has prepared for the day's workc. develops an understanding good students know what they are going

to do in class and does not waste timed. develops a fine work-ethic





3. Sociability: Demonstrates understanding, friendliness, adaptability,empathy, and politeness in group settingsa. assist classmates in improving computer skillsb. assist students with special needs as a peer mentor

4. Self-Management: Assesses self accurately, sets personal goals,monitors progress, and exhibits self-controla. perform in-process checks of workb. maintain a record of academic achievement (individual gradebook)c. accept the responsibility for self-management

5. Integrity/Honesty: Chooses ethical courses of actiona. accept the responsibility for own actionsb. exhibit personal honesty at all timesc. accept the challenge of doing your own work in the laboratory,


CNS206001/072396


COURSE SYLLABUS

ENGINEERING MATERIALSPrerequisite: MACHINE TOOL PRACTICES II


ENGINEERING MATERIALS


COURSE DESCRIPTION:


Engineering Materials is the study of materials used in the manufacture of products produced by avariety of manufacturing processes. Topics will include the characteristics and properties of bothmetallic and nonmetallic materials used in the design of products. Students will conduct tests onmaterials, collect data and interpreting that data.

PREREQUISITES: Machine Tool Practices IMachine Tool Practices IICollege Algebra


Textbook: Practical Metallurgy and Materials of Industry, John Neely, WileyPub., 3rd Ed.

Lab Manual: NONE

Tools and Equipment/Quantity Required:Safety GlassesScientific Calculator


1

1


Laboratory: Laboratory will be "hands-on" activities.


laboratory assignments2. apply theory to laboratory assignments3. satisfactorily perform on written, oral, and practical examinations4. satisfactorily perform on outside assignments including writing assignments5. contribute to class discussions6. maintain attendance per current policy7. follow all shop rules and safety regulations as stated in the laboratory manual

LECTURE OUTLINE:Lecture Topic Text Reference Page Contact Hrs.

Extracting Metals from Ores 12-28The Manufacture of Steel Products 32-41Identification and Selection of Iron

& Steels 44-50Identification on Nonferrous Metals 52-64Identification and Selection of

Nonmetallic MaterialsThe Mechanical and Physical Properties

of Materials 70-86Rockwell and Brinell Hardness Testers 92-98The Crystalline Structure of Materials 102-123Phase Diagrams and the Iron-Carbon

Diagram 127-142Hardening and Tempering of Carbon Steels 145-151Annealing, Normalizing and Stress Relieving 155-163I-T Diagrams and Cooling Curves 165-173Harden ability of Steels and Tempered

Martensite 175-183Heat-Treatment Equipment and Procedures 185-206Heat Treatment of Nonferrous Metals 207-207



Using Hardness Testers 6a) Standard Rockwell Hardness Testerb) Superficial Rockwell Testerc) Automatic Rockwell Hardness Testerd) Shores Testere) Brinell Testerf) Vickers Tester

Microscopic Examination of Specimens 12Determination of Critical Temperature of Steels 6Tempering of Hardened Materials 4Impact Testing 4Determining the Harden ability of Steels 4

Total Lab Hours 36



1. Follow Safety Manuals and All Safety Regulations/Requirementsa. Assume responsibility for the personal safety of oneself and others

b. Develop a personal attitude towards safetyc. Interpret safety manual directivesd. Comply with established company safety practices

2. Use Protective Equipmenta. Wear protective safety clothing as requiredb. Maintain and use protective guards and equipment on machineryc. Locate and properly use protective equipmentd. Use lifting aids when necessarye. Know the location(s) and type of fire extinguishersf. Review procedures for using emergency eye-wash station


4. Maintain a Clean and Safe Work Environmenta. Keep work areas cleanb. Clean machine/hand tools when work is completedc. Put tools away when work is finishedd. Keep aisles clear of equipment and materials



2. Interconvert Fractions/Decimalsa. Convert fractions to decimal equivalentsb. Convert decimal values to nearest fractional equivalentc. Use Decimal Equivalent Chart for conversions

3. Interconvert Metric/English Measurementsa. Convert English dimensions to Metricb. Convert Metric dimensions to Englishc. Use Metric/English conversion chart

4. Perform Basic Trigonometric Functionsa. Solve for unknown anglesb. Solve for unknown sides




89

D. RECOGNIZE DIFFERENT MANUFACTURING MATERIALS ANDPROCESSES1. Identify Materials With Desired Properties

a. Discuss classification system for metalsb. Discuss general characteristics for carbon steels, stainless steels, structural

steels, cast irons, aluminum, and other commonly used metalsc. List advantages for considering plastic as a viable materials choiced. List the advantages and disadvantages for each of the following plastic

molding processes: blow, injection, vacuum, and extrusione. Discuss the advantages for using composites in various manufacturing

applications2. Describe Heat Treating Processes

a. Discuss the reasons for heat treatingb. Discuss the time/temperature chartc. List the different quenching mediumsd. Estimate metal temperature by colore. List reasons for stress relieving work piecef. Discuss surface hardening processes

3. Perform Heat Treating Operationsa. Harden plain carbon steel work piecesb. Temper plain carbon steel work piecesc. Anneal plain carbon steel work piecesd. Case harden mild steel work pieces

4. Test Metal Samples for Hardnessa. Perform spark test on carbon steelsb. Perform Rockwell hardness testsc. Perform Brinell hardness tests


The Secretary's Commission on Achieving Necessary Skills (SCANS), U.S. Department of Labor,has identified in its "AMERICA 2000 REPORT" that all students should develop a new set ofcompetencies and foundation skills if they are to enjoy a productive, full and satisfying life.These are in addition to the Technical Workplace Competencies required by industry. SCANS ismade up of five competencies and a three-part foundation ofskills and personal qualities thatare needed for solid job performance.



1. follows a schedule to complete assigned tasks on time2. determine the initial cost of materials and "value added" as result of

machining3. complete a stock request form for required material

90

4. provide a self-evaluation of performance based on the time and quality ofwork


member of the team2. provide individual assistance/direction to peers as requested3. produce machine parts to acceptable levels of quality as required4. works well with all members of the classInformation: Acquires and uses information1. read and interpret blueprints2. organize and apply theories of machine tool operation3. perform basic semi-precision and precision layout as necessary


a. laboratory organization structure: physical and socialb. organization of personnel and facilities on the shop floorc. systematic approach to the metal removal processd. dimensioning and measurement systemse. systematic organization of training materials



E. Technology: Works with a variety of technologies1. chooses procedure, tools and equipment required to produce a part2. applies appropriate procedures and uses appropriate tools and equipment

to produce a machined part to acceptable standards3. maintains and troubleshoots equipment

a. applies appropriate preventative maintenanceb. when operating machinesc. reports all malfunctions of equipment to supervisor/instructord. perform clean-up assignments of machine and shop floor at the end

of the laboratory



prose and in documents such as manuals, graphs, and schedulesa. studies student laboratory manualb. interprets blueprints and technical drawingsc. read/studies textbookd. follow a daily laboratory schedule to maintain appropriate time-line

and product completion

91

2. Writing: Communicates thoughts, ideas, information, and messages inwriting; and creates documents such as letters, directions, manuals,reports, graphs, and flow chartsa.. outline the steps necessary to produce a simple machine partb. maintain a lecture notebookc. submit written responses to chapter question assignmentsd. complete all written assignments

3. Arithmetic/Mathematics: Perform basic computations and approachespractical problems by choosing appropriately from a variety ofmathematical techniquesa. determines optimum machining speeds, feeds, and depth of cutb. calculates "value added to the part"c. aligns machine and/or work holding deviced. taps and threadse. keeps a running computation of individual gradef. interconverts fractions to decimal expressionsg. use protractors to lay-out angle machiningh. use trigonometry to solve angle and taper calculations

4. Listening: Receives, attends to, interprets, and responds to verbalmessages and other cuesa. assimilate classroom instructionb. interpret and assimilate video instructionc. observe laboratory demonstrationsd. seek and receive individualized instruction in the laboratory


skilld. communicates with peers to ensure the smooth and safe operation

of the laboratoryB. Thinking Skills: Thinks creatively, makes decisions, solves problems, visualizes,




3. Seeing Things In the Mind's Eye: Organizes, and processes symbols,pictures, graphs, objects, and other informationa. interprets technical drawingsb. interprets technical illustrations and symbolsc. understands both written and verbal instructions

92

d. assimilates process during instructor demonstrations4. Knowing How to Learn: Use efficient learning techniques to acquire and

apply new knowledge and skillsa. demonstrate mastery of the basic skills and techniquesb. use these sequential skills to support mastery of new skillsc. understand the sequential nature of acquired skills and the

subsequent knowledge application of new skills and techniquesS. Reasoning: Discovers a rule or principle underlying the relationship

between two or more objects and applies it when solving a problema. understands that practice may not make it perfect but it certainly

will improve the skill of the operatorb. understands that the quality of the product is a function of the time

of the operation and the attitude and skill of the machinistc. understands the relationship between different metals and the tool

applied to the metal surface and adjusts machining parametersaccordingly

Personal Qualities: Displays responsibility, self-esteem, sociability, self-management, and integrity and honesty.1. Responsibility: Exerts a high level of effort and perseveres towards goal









3. Sociability: Demonstrates understanding, friendliness, adaptability,empathy, and politeness in group settingsa. assist classmates in improving technical skillsb. assist students with special needs as a peer mentorc. share laboratory resources (machines, tools and instructor's


monitors progress, and exhibits self-controla. perform in-process quality checks on machined partsb. maintain a record of academic achievement (individual grade book)c. make accommodations to laboratory schedules due to broken

machines/tools

d. accept the responsibility for self-management5. Integrity/Honesty: Chooses ethical courses of action





METI1201/072396


COURSE SYLLABUS

SAFETY AND ACCIDENT PREVENTION

95


SAFETY AND ACCIDENT PREVENTION


COURSE DESCRIPTION:


A course designed to enable the student to recognize hazards and potential hazards which mayoccur in the workplace and to take corrective action. The course may be directed toward aspecific technology as required. Federal safety requirements under the OSHA law will beemphasized. General supervisor safety training course for all technologies.

PREREQUISITES: NONE


Textbook: Supervisor's Safety Manual, National Safety Council, 8th EditionLab Manual: NONE

Hand Tools/Quantity Required:Notebook paperNotebookPencils or pens


Lecture: Didactic presentations will include lecture, demonstrations, and the followingtraining materials and visual aids (OSH Film Library):"The Convincer" - 45 min. color slide"Safety and the Supervisor - 16 mm - color film"All About OSHA" - 16 mm - color film"Search for Safety" - 16 mm - color film"In Search of the Facts" - 16 mm - color film"Color of Danger" - 16 mm - color film"Six Ways to Lift" - 16 mm - color film"MGM Grand Hotel Fire" - 16 mm - color film

Laboratory: Laboratory assignments will require students to recognize hazards and potentialhazards which may occur in the workplace and to take corrective action.

Method of Evaluation: A student's grade will be based on multiple measures of performance.The assessment will measure development of independent critical thinking skills and will includeevaluation of the student's ability to:

96

1. perform the manipulative skills of the craft as required to satisfactorily completelaboratory assignments

2. satisfactorily perform on written, oral, and practical examinations3. explain all the elements of good communication as it relates to safety4. apply several human relations concepts as a supervisor to ensure safety in the work place5. discuss the importance of industrial hygiene and noise control6. correctly fill out an accident investigation report and a safety inspection form7. discuss and/or demonstrate the use of personal protective equipment8. apply the principles of and discuss the benefits of machine safeguarding9. explain and/or demonstrate the use and safe handling of hand and portable power tools10. discuss safe electrical procedures11. discuss the basic principles and causes of fire12. explain the need for safety training of workers13. satisfactorily perform on outside assignments including writing assignments14. contribute to class discussions15. maintain attendance per current policy16. follow all shop rules and safety regulations as stated in the laboratory manual


Introduction 1

Course content and textAttendance and gradingTesting proceduresThe origin of the safety movementThe Williams-Steiger ActOSHAct applied to technologySafety Management 1Definition of termsAreas of responsibilityThe "old" approach to safety performanceA better approach to safety performanceSummary of Key PointsCommunications 1Elements of communicationMethods of communicationEffective listeningSummary of key pointsHuman Relations 1

Human relations conceptsLeadershipCoping with difficult problemsShift work and shift changesStress managementAlcohol and drug problemsEmployee assistance programsSummary of key pointsEmployee Safety Training 97

Orientation trainingJob instruction trainingOther methods of instructionJob safety analysisSummary of key pointsEmployee ImprovementPromoting safety among workersOff-the-job accident problemsSummary of key pointsEXAM #1Safety InspectionsFormal inspectionsInspection planning and proceduresInspecting work practicesInspection reportsSummary of key pointsAccident InvestigationAccident reportingFinding causesEmergency proceduresEffective use of witnessesAccident investigation reportsSummary of key pointsEXAM #2Industrial HygieneChemical stressesPhysical stressesErgonomic stressesBiological stressesThreshold limit valuesStandard Operating Procedures (SOP)Summary of key pointsEXAM #3Personal Protective EquipmentControlling hazardsHead protectionFace protectionEye protectionEar protectionRespiratory protectionBody protectionProtecting extremitiesSummary of key pointsEXAM #4ErgonomicsWhat are ergonomic problems?Understanding ergonomicsMaterials movement 98

Work space and body characteristicsHand work and use of toolsWhole-body vibrationVideo display terminalsLighting, noise, and heatSummary of key pointsEXAM #5Machine SafeguardingPrinciples of guardingSafeguard designSafeguarding mechanismsAutomationMaintenance of safeguardsSummary of key pointsHand Tools and Portable Power ToolsSafe work practicesUse of hand toolsPortable power toolsSupervisory considerationsMaintenance and repairSummary of key pointsMaterials Handling and StorageMaterials handling problemsManual handling methodsMaterials handling equipmentRopes, chains, and slingsMaterials storageSummary of key pointsEXAM #6Electrical SafetyMyths and misconception about electricityElectrical fundamentals reviewBranch circuits and grounding conceptsPlug and cord connected equipment

and extension cordsBranch circuit and equipment testing methodsGround-fault circuit interruptersHazardous locationsElectrical standards most often violatedInspection guidelines and checklistSafeguards for portable home electrical

appliancesSafety program policy and proceduresElectrical distribution system reviewSummary of key pointsFire SafetyBasic principlesCauses of fire 99

Other hazardous materialsEffective housekeeping for fire safetyFire prevention inspectionsAlarms, equipment, and evacuationFire protection educationProtective insurance requirementsSummary of key pointsEXAM #7


ILAB OUTLINE:

Lab Topics Contact Hrs.Students will research each chapter of the Supervisor's

Safety Manual and answer questions which cover the mainpoints of the chapter 16

Students will demonstrate the six steps in proper lifting 4Students will demonstrate the proper use of powered hand tools 6Students will demonstrate the use of different types of fire

extinguishers 6Students will explain the importance of inspecting electricalextension cords, plugs and cord-connected equipment 4

Total Lab Hours 36

ICOURSE OBJECTIVES: TECHNICAL COMPETENCIES

After the successful completion of this course the student will be able to: IA. PRACTICE SAFETY

1. Follow Safety Manuals and All Safety Regulations/Requirements Ia. Assume responsibility for the personal safety of oneself and othersb. Develop a personal attitude towards safetyc. Interpret safety manual directivesd. Comply with established company safety practicese. Complete forms/paperwork as required


3. Follow Safe Operating Procedures for Hand and Machine Tools Ia. Identify and understand safe machine operating proceduresb. Demonstrate safe machine operation

4. Maintain a Clean and Safe Work Environmenta. Keep work areas cleanb. Clean machine/hand tools when work is completedc. Put tools away when work is finished Id. Keep aisles clear of equipment and materials

roc 0. .

e. Perform preventative maintenance as required5. Control Fire Hazards

a. Handle/store flammable materials appropriatelyb. Use electricity correctly (e.g., defective outlets, frayed cords, "burning"

odor)c. Prevent spontaneous ignition by practicing proper waste disposal habitsd. Keep marked aisles clear of equipment and materialse. Interpret/display MSDS sheets as requiredf. Identify fire exits and fire-fighting equipment

6. Apply American Red Cross First Aid and CPR Proceduresa. Notify appropriate personnel of injuryb. Check and evaluate life-endangering conditionsc. Determine need for CPRd. Apply appropriate first aid techniquese. Complete accident report as needed

7. Recommend Hazardous Waste Management Techniquesa. Define the types of hazards (e.g., chemical, biological, and physical)b. Evaluate and determine hazardsc. Interpret MSDS sheetsd. Describe the proper collection for a variety of hazardous wastese. Respond to emergencies in the appropriate manner

8. Apply Ergonomic Principles to the Workplacea. Define ergonomicsb. Explain the characteristics and potential impact of ergonomics on design,

productivity, and safety9. Demonstrate Knowledge of State and Federal EPA Regulations

a. Meet health, safety, and legal requirements with regard to process, productand people


The Secretary's Commission on Achieving Necessary Skills (SCANS), U.S. Department of Labor,has identified in its "AMERICA 2000 REPORT" that all students should develop a new set ofcompetencies and founndation skills if they are to enjoy a productive, full and satisfying life.These are in addition to the Technical Workplace Competencies required by industry. SCANS ismade up of five competencies and a three-part foundation of skillsand personal qualities thatare needed for solid job performance.


I. COMPETENCIESA. Resources: Identifies, organizes, plans, and allocatesresources

1. follows a schedule to complete assigned tasks on time2. provide a self-evaluation of performance based on the time and quality of

work

101

B. Interpersonal: Works with others1. provide individual assistance/direction to peers as requested2. works well with all members of the classInformation: Acquires and uses information1. studies safety materials and completes assignments2. makes safety recommendations based on classroom instruction

D. Systems: Understands complex inter-relationships1. demonstrate knowledge of the following systems

a. laboratory organization structure: physical and socialb. organization of personnel and facilities in the labc. systematic organization of training materials

2. monitors and corrects performance duringa. adjustments of individual laboratory work scheduleb. maintains record of evaluations and sets individual goals

E. Technology: Works with a variety of technologies1. apply fire safety principles2. apply hazardous material handling principles3. apply ergonomic principles to the workplace

U. FOUNDATION SKILLSA. Basic Skills: Reads, writes, performs arithmetic and mathematical operations,


prose and in documents such as manuals, graphs, and schedulesa. studies student laboratory manualb. read/studies textbookc. follow a daily laboratory schedule to maintain appropriate time-line


writing; and creates documents such as letters, directions, manuals,reports, graphs, and flow chartsa. maintain a lecture notebookb. submit written responses to chapter question assignmentsc. complete all written assignments




of the laboratory

B. Thinking Skills: Thinks creatively, makes decisions, solves problems, visualizes,knows how to learn and reasons.1. Decision Making: Specifies goals and constraints, generates alternatives,


2. Problem Solving: Recognizes problems and devises and implementsplanof actiona. makes daily accommodations to stay on scheduleb. seeks additional instruction/clarification for assignment completionc. balances social and academic life/responsibilitiesd. accepts responsibility

3. Seeing Things In the Mind's Eye: Organizes, andprocesses symbols,pictures, graphs, objects, and other informationa. understands both written and verbal instructionsb. assimilates process during instructor demonstrations

4. Knowing How to Learn: Use efficient learning techniques to acquire andapply new knowledge and skillsa. demonstrate mastery of the basic skills and techniquesb. use these sequential skills to support mastery of new skillsc. understand the sequential nature of acquired skills and the

subsequent knowledge application ofnew skills and techniques5. Reasoning: Discovers a rule or principle underlying the relationship


will improve the skill of the studentPersonal Qualities: Displays responsibility, self-esteem, sociability, self-management, and integrity and honesty.1. Responsibility: Exerts a high level of effort andperseveres towards goal









3. Sociability: Demonstrates understanding, friendliness, adaptability,empathy, and politeness in group settings

1_03

a. assist classmates in improving technical skillsb. assist students with special needs as a peer mentorc. share laboratory resources (machines, tools and instructor's

individual attention)4. Self-Management: Assesses self accurately, sets personalgoals,

monitors progress, and exhibits self-controla. maintain a record of academic achievement (individual grade book)b. make accommodations to laboratory schedules due to broken

machines/toolsc. accept the responsibility for self-management




OSH21601/072396


COURSE SYLLABUS

BASIC FLUID POWERPrerequisites: MATHEMATICS FOR INDUSTRIAL TECHNICIANS,

BASIC ALGEBRAIC CONCEPTS, OR EQUIVALENT


BASIC FLUID POWER

Lecture hours/week: 3 Lab hours/week: 3 Credit hours: 4

COURSE DESCRIPTION:

A basic study of hydraulic system components, fluid power theory, problem solving andtroubleshooting techniques.

PREREQUISITES: Mathematics for Industrial Technicians, Basic AlgebraicConcepts, or equivalent


Textbook: Industrial Hydraulic Technology, Parker Hannifin Corp.Lab Manual: NONE

Supplies Required:Electronic Pocket Calculator (Texas Instruments Model No. TI-35 or equivalentRuler-plastic, 12-inch, graduated in inches and centimetersNotebookBallpoint pen#2 Pencil (6)


Lecture: Didactic prenntations will include lecture, video and demonstrations.




106

LECTURE OUTLINE:Lecture Topics Text Reference Page Contact Firs.

Introduction 1A. Historical backgroundB. Advantages and application of

hydraulic power1) List five advantages of

hydraulic power2) List five examples of

the application ofhydraulic power

C. Overview of a typical hydraulicsystem1) Identify by name and

describe the function ofthe major componentsof a basic hydraulicsystem

2) Sketch or identify theANSI standard symbolfor each major component

Basic Principles of Hydraulics 8A. Pressure and force relationships

1) State or describe theconsequences of Pascal'slaw

2) Knowing the basicmathematical relationshipof pressure, force, andarea, solve for any onegiven the other two

B. Principles and Concepts of FluidPressure and Flow1) Given the density or specific

gravity of a fluid, calculatethe pressure head for agiven fluid height

2) State Bernoulli's Theory interms of velocity and pressure

3) Using the Continuity Equation,solve for hydraulic line sizegiven the flow rate andvelocity parameters; determinecylinder extension speed(or time) given flow rate andcylinder size; determine flow

velocity in various sized linesgiven flow rate

4) State the results of Torricelli'sTheories in terms of pressurehead and velocity

5) Use the Reynolds Number todetermine laminar or turbulentflow

6) Given the movement of a loadin a given time interval,calculate work, power, andhorsepower

7) Analyze a hydraulic system todetermine its performancegiven the specifications of thepump and various actuators(cylinders, hydraulic motors,rotary actuators)

Hydraulic FluidsA. Types, properties, and safety

1) Name three types of hydraulicfluid

2) List two methods of measuringfluid viscosity

3) List four desirable characteristicsof a hydraulic fluid

4) Given a hypothetical hydraulicsystem configuration, identifythe safety hazards and meansof correction

B. Fluid storage and conditioning1) List five features of a well-

designed hydraulic reservoir2) Name two types of heat

exchangers3) Name two basic types of filter

elements4) Explain what is meant by the

micron rating of filters5) List three benefits derived

from proper conditioning ofhydraulic fluid

Power, Distribution and Sealing DevicesA. Lines, hoses and fittings

1) Given the pressures and flowrates of a system, select thecorrect tubing size for a 108

properly designed hydraulicsystem

2) Show actual or illustrated hoseinstallations, identify improperinstallation and recommend anacceptable configuration

3) Show actual or illustrated tubingconnectors, properly identifythem within the two mainclassifications

B. Pressure, velocity, and safety factors1) Using Barlow's Formula, or

a proper reference chart,determine the allowablemaximum pressure of agiven conductor

2) Determine working pressureof a system given the safetyfactor

3) Using Darcy's Formula,calculate the pressure dropof a given length of conductor

4) Given the Reynold's Number,determine whether the flowis laminar or turbulent

5) Using a nomograph, determinethe flow rate, conductor size,or flow velocity given any twoparameters

6) Determine hydraulic pumpinlet and discharge line sizegiven the flow rate, using theContinuity Equation andaccepted industrial velocityparameters

C. Sealing devices1) List three conditions affecting

the selection of sealing devices2) Name the three general

categories Of sealing materialsPumpsA. Types and operation

1) Name the two generalclassifications of pumps

2) List the design features, mainuses, and describe theoperation of each of the two

109

types of pumps3) Know why positive displace-

ment pumps are preferred forfluid power systems

Theory and calculations1) Calculate the theoretical

output flow and inputtorque of a positivedisplacement pump

2) Determine overall pumpefficiency

3) Determine the volumetricefficiency of a pump

4) Determine the mechanicalefficiency of a pump

5) Calculate the hydraulichorsepower output of a pump

C. Design and selection factors1) Name three types of

positive displacementpumps; list the advantages/disadvantages of each

2) Name two types of variabledelivery pumps and describetheir operation

3) Using catalog or advertisingdata, evaluate various pumpsfor use in specific applications

Hydraulic ActuatorsA. Linear actuators (cylinders)

1) Name two of the mostcommon types of cylinders

2) Describe how cylinders arerated and sized

3) Using an illustration oractual cylinder, name andidentify the parts

4) Given the size of a cylinderand the system flow rate,calculate the cylinderextension speed orextension time

5) Given system flow andpressure, or load, stroke,and extension time,calculate the poweroutput of a cylinder 1.10 0

B. Rotary actuators and motors1) Name the two general

types of hydraulic motors2) Name the three principle

elements of motor ratings3) Given displacement and

flow rate, calculate motorspeed (rpm)

4) Given the torque and rpmof a motor, calculate thehydraulic horsepower

Hydraulic ControlsA. Control of hydraulic power

1) Name the three primaryways of controllingpressurized hydraulic fluid

2) Name five types of pressurecontrol valves and describetheir use and operation

3) Name at least four typesor designs ofdirectional control valvesand describe their use

4) Describe the function offlow control valves andname three types or designs

B. Hydraulic circuits1) Describe the function of

pressure controls forsequencing actuators,counterbalances or brakingapplications, safety or reliefoperations, pressurereducing and unloadingfunctions

2) Explain the function andproper application ofmeter-in, meter-out, andbleed-off circuits

3) Explain the function of athree-position directionalcontrol valve and name fourcommon center designs

4) Describe the use andlimitations of a regenerativecircuit

5) Describe the difference

1 11

between a hydrostatictransmission and a hydro-static drive and givethree applications

Hydraulic System TroubleshootingA. Define component relationships

1) Given a real orhypothetical hydraulicsystem, trace the flowthrough the entiresystem, state thepurpose of eachcomponent, anddescribe the action oroperation of eachcomponent at eachcontrol setting

B. Analyze pressure and flow1) Name the three common

terms used when referringto pressure within ahydraulic system

2) Describe the causes ofeach of the three kinds ofsystem pressure

3) Describe the effect ofincreased or decreased flowon actuator operation

4) Describe the effect ofincreased or decreasedpressure on actuator operation

C. Troubleshooting sequence1) Describe two ways of

determining the problem witha malfunctioning hydraulicsystem

2) Given the fault in amalfunctioning hydraulicsystem, describe the componentrelationships

3) Make a list of possible causesfor the malfunctioning of thegiven system

4) Given the specifications of ahydraulic system, comparethem to actual or hypotheticalmeasurements 112

5) Given a malfunctioninghydraulic system, following alogical troubleshootingsequence, trace the problemto its origin

Fluid Power System Maintenance andSafetyA. Maintenance

1) List three general require-ments for a good maintenanceprogram

2) In addition to a proper setof mechanics tools andgauges, list two other factorswhich are considered "tools"for good maintenance

3) List at least three types ofrecords used to insureproper preventive maintenance

1

B. Safety1) List five safety rules for the

operator of fluid power machinery2) List five safety rules for the

fluid power mechanicMajor Exams and Critiques 6



The Fundamental Hydraulic Circuit 3This exercise establishes a common base for discussionof hydraulic systems by providing the student theopportunity to:A. Identify hydraulic componentsB. Assemble components into a hydraulic circuitC. Adjust valve settingsD. Operate a basic circuitE. Test circuit operationBasic Physical Laws 3Pressure and flow relationships are introduced anddemonstrated under flow and non-flow (Pascal'sLaw) conditionsPressure and Force 3Pressure and force relationships are illustrated by:A. Demonstration of pressure, force, area

relationships

B. Causes of pressure, units of measurement,measuring instruments

C. Concept of the "hydraulic leverD. Cylinder load and working pressure

relationshipsFlow Rate and VelocityRelationships between flow rate and actuator speed,creation of flow in the system, calculation andmeasurement of flow, actuator speed, and cylinderextension times are examined and demonstratedWork, Power and HorsepowerDefinitions of work and power, relationshipsbetween pressure and flow to produce power,demonstration and calculations using formulas,and concepts of efficiency are examinedProperties of Hydraulic Fluids and Fluid StorageConditioningA combined lab exercise of activity 6 and 9 toillustrate:A. Effect of temperature change on viscosityB. Relationship of viscosity and resistance to

flow through hydraulic lines, valves, andfitting

C. Characteristics of a well designed reservoirD. Importance of proper fluid conditioningFluid Power SymbolsThe introduction of graphic symbols used inindustrial diagrams. (Previous introductory labs usedpictorial symbols as a training aid.) Basic symbolsfor components are studied and practiced byinterpreting and sketching simple hydraulic circuitsHydraulic PumpsThe concept of pumps displacement and itsrelationship to output flow, volumetric efficiency,and the effects of temperature are demonstratedFluid Transmission and Introduction to ControlValvesA combined lab of Activity 10 and 11 to illustrate:A. Hydraulic conductors, terminology, design

features, sizing, and selection aredemonstrated

B. Pressure, flow, and directional controls areintroduced and demonstrated

Pressure Control ValvesDesign features and function of pressure controlsare discussed. Definition of terms and testing of apilot-operated relief valve, to include plotting of

1 14

test results, demonstrates valve operation(Activity 12)Directional Control ValvesDesign features, terminology, and valveconfigurations are demonstrated and discussed(Activity 13)Flow Control ValvesValve ratings and concepts of compensation arediscussed and pressure compensation isdemonstrated in the lab exercise (Activity 14)

3

3

Total Lab Hours 36



1. Follow Safety Manuals and All Safety Regulations/Requirementsa. Assume responsibility for the personal safety of oneself and othersb. Develop a personal attitude towards safetyc. Interpret safety manual directivesd. Comply with established company safety practicese. Complete forms/paperwork as required

2. Use Protective Equipmenta. Wear protective safety clothing as requiredb. Maintain and use protective guards and equipment on machineryc. Locate and properly us% protective equipmentd. Use lifting aids when necessary




odor)c. Prevent spontaneous ignition by practicing proper waste disposal habitsd. Keep marked aisles clear of equipment and materialse. Interpret/display MSDS sheets as .requiredf. Identify fire exits and fire-fighting equipment



2. Interconvert Fractions/Decimalsa. Convert fractions to decimal equivalentsb. Convert decimal values to nearest fractional equivalent

3. Interconvert Metric/English Measurementsa. Convert English dimensions to Metricb. Convert Metric dimensions to English


C. MAINTAIN HYDRAULIC/PNEUMATIC DEVICES1. Use Test Equipment

a. Monitor hydraulic flow with flow metersb. Use temperature gauges to determine hydraulic fluid operating temperaturec. Use flow control valves, U-tube manometers and pressure gauges to

measure operating conditions for the fluid power system2. Describe Basic Principles of Hydraulic Systems

a. List advantages of hydraulic systemsb. Identify components of typical hydraulic systemc. State or describe Pascal's lawd. Analyze a hydraulic system to determine its performance

3. Identify Hydraulic Fluidsa. Name types of hydraulic fluidsb. List methods of measuringfluid viscosityc. List desirable characteristics of hydraulic fluidsd. Identify safety hazards related to hydraulic fluid usee. Discuss heat exchangers, filters, and micron rating of filters

4. Recommend Power Distribution and Sealing Devicesa. Describe proper identification and selection of lines, hoses, and fittingsb. Discuss pressure, velocity, and safety factorsc. List conditions determining selection of sealing devices

5. Recognize Pumps, Actuators, and Hydraulic Control Devicesa. Name general classifications of pumpsb. Determine overall pump efficiencyc. Name types of positive displacement pumps and give advantages and

disadvantages of eachd. Discuss types of variable delivery pumps and describe their operatione. Describe linear actuators (cylinders)f. Describe how cylinders are rated and sizedg. Describe rotary actuators and motorsh. Name two types of hydraulic motors

6. Troubleshoot Hydraulic/Pneumatic Systemsa. Discuss common methods of troubleshooting hydraulic systemsb. Follow a logical troubleshooting sequence to trace a problem to its origin

116.


The Secretary's Commission on Achieving Necessary Skills (SCANS), U.S. Department of Labor,has identified in its "AMERICA 2000 REPORT" that all students should developa new set ofcompetencies and foundation skills if they are to enjoy a productive, full and satisfying life.These are in addition to the Technical Workplace Competencies required by industry. SCANS ismade up of five competencies and a three-part foundation of skills and personal qualities thatare needed for solid job performance.





1. complete assigned responsibilities within the lab serving as a member of theteam

2. provide individual assistance/direction to peers as requested3. works well with all members of the classInformation: Acquires and uses information1. read and interpret schematics and flowcharts


a. laboratory organization structure: physical and socialb. organization of personnel and facilities in the labc. systematic organization of training materials

2. monitors and corrects performance duringa. adjustments of individual laboratory work scheduleb. constantly evaluating the quality of work to achieve acceptable

standardsc. maintains record of evaluations and sets individual goals

E. Technology: Works with a variety of technologies1. maintains and troubleshoots equipment

a. applies appropriate preventative maintenanceb. when operating equipmentc. reports all malfunctions of equipment to supervisor/instructord. perform clean-up assignments of lab at the end of the class


listens and speaks.

117

1. Reading: Locates, understands, and interprets written information inprose and in documents such as manuals, graphs, and schedulesa. studies student laboratory manualb. interprets blueprints and technical drawingsc. read/studies textbookd. follow a daily laboratory schedule to maintain appropriate time-line

and product completion2. Writing: Communicates thoughts, ideas, information, andmessages in


3. Arithmetic/Mathematics: Perform basic computations and approachespractical problems by choosing appropriately from a variety ofmathematical techniquesa. keeps a running computation of individual gradeb. interconverts fractions to decimal expressions








3. Seeing Things In the Mind's Eye: Organizes, andprocesses symbols,pictures, graphs, objects, and other informationa. interprets technical drawingsb. interprets technical illustrations and symbols

118

c. understands both written and verbal instructionsd. assimilates process during instructor demonstrations




will improve the skill of the technicianPersonal Qualities: Displays responsibility, self-esteem, sociability, self-management, and integrity and honesty.1. Responsibility: Exerts a high level of effort andperseveres towards goal











monitors progress, and exhibits self-controla. maintain a record of academic achievement (individual gradebook)b. make accommodations to laboratory schedules due to broken


5. Integrity/Honesty: Chooses ethical courses of actiona. accept the responsibility for own actionsb. exhibit personal honesty at all times

1

c. accept the challenge of doing your own work in the laboratory,during examination, and on outside assignments

d. understand the consequences of unethical behaviors


PHYI 1401/072396


1 COURSE SYLLABUS

ELECTRICAL APPLICATIONS121


ELECTRICAL APPLICATIONS


COURSE DESCRIPTION:


A survey course designed to present basic concepts in DC and AC circuits, fundamental motordesign and applications, and basic motor controls, including analyzing, calculating, and measuringDC and AC voltage, current, and resistance.

PREREQUISITES: NONE


Textbook: Delmar's Standard Textbook of Electricity, Stephen L. Herman, DelmarPublishers, Inc., latest edition.

Lab Manual: NONE

Hand Tools/Quantity Required:Notebook paper (50 sheets)BinderScientific calculatorTest leads with alligator clips (12 minimum)Screwdriver - 6 inch long, 3/16 inch straight bladeScrewdriver - #2 PhillipsSafety glasses



Laboratory: Laboratory will include presentation of basic concepts in DC and AC circuits,including analyzing, calculating, and measuring DC and AC voltage, current, andresistance, as well as fundamental motor design, applications and controls.


laboratory assignments

1.22

2. satisfactorily perform on written, oral, and practical examinations3. follow safe practices in using electricity4. analyze atomic structure and the proportionalism that makes an atom a good conductor5. analyze electrical quantities in circuits, including voltage, current, resistance, and power6. analyze series and parallel DC circuits using Ohm's law and Kirchoff s voltage and current

laws7. analyze complex DC circuits using Ohm's law and Kirchoffs voltage and current laws8. relate the principles of magnetism and inductance to electrical circuits9. satisfactorily perform on outside assignments including writing assignments10. contribute to class discussions11. maintain attendance per current policy12. follow all shop rules and safety regulations as stated in the laboratory manual


Unit 1 Introduction to Electricity 41.01 Define atoms, protons,

electrons, charge, voltage,current, resistance, power,electricity, etc.

1.02 Decode the colors of a carbonresistor

1.03 Apply Ohm's lawUnit 2 Series Circuits 4

2.01 Define a series circuit2.02 Apply Ohm's law and Kirchoff s

voltage law to a series circuit2.03 Evaluate a simple circuit to

determine if it is a seriescircuit

Unit 3 Parallel Circuits 43.01 Define a parallel circuit3.02 Apply Ohm's law and Kirchoff s

law to a parallel circuit3.03 Evaluate a simple circuit to

determine if it is a parallel circuitUnit 4 Complex DC Circuits 4

4.01 Analyze a circuit to establish acircuit arrangement

4.01a What is series?4.01b What is parallel?4.02 Apply series/parallel parameters

to circuit4.03 Apply Ohm's law and Kirchoff s

current voltage law to the circuit

123

UNIT 5 Magnetism and Inductance5.01 Define magnetism and inductance5.02 Relate the effects of magnetism

and inductance to AC devices5.03 Define impedance, inductive

reactance and capacitivereactance

UNIT 6 AC Circuits6.01 Define alternating current6.02 List examples of AC signals6.03 Illustrate the generation of a

sinewave6.04 Define terms relating to AC

signals6.04a Peak values6.04b RMS values6.04c Instantaneous values6.04d Frequency6.04e Period6.04f Cycle6.04g Hertz

UNIT 7 Inductance and Capacitance7.01 Define inductance and

capacitance7.02 Relate the effects of inductance

and capacitance to AC circuitsand motors

UNIT 8 Relays8.01 Define relay construction and

the principle of operation8.02 List the different types of relays

UNIT 9 Transformers9.01 Define transformer construction

and the principle of operation9.02 List the different types of transformers

LAB OUTLINE:

4

4

4

4

4


Lab Topics Contact Hrs.Unit 1 Safety and Orientation 2

1.01 Review lab safety1.02 Demonstrate uses of analog volt-ohm-milliamp meter

Unit 2 Resistance 32.01 Practice decoding color bands of a carbon resistor2.02 Demonstrate resistance measuring function of analog

1

I

I 1125

meter2.03 Measure carbon resistors2.04 Calculate percent error of resistor; coded value versus

measured valueUnit 3 Voltage 4

3.01 Demonstrate voltage measuring function of analog meter3.02 Measure voltage output of series-aiding, series-opposing,

parallel and series-parallel battery groupings3.03 Compare the advantages and disadvantages ofpower

supplies and battery sourcesUnit 4 Current 3

4.01 Demonstrate the current measuring function ofan analogmeter

4.02 Measure current in a variety of simple circuitsUnit 5 Power 3

5.01 Demonstrate the use of a wattmeter to measure powerin a simple DC circuit

5.02 Measure power in a circuit5.03 Confirm the validity of power formulas by measurements

of power in a circuitUnit 6 Series Circuits 4

6.01 Build a simple series circuit6.02 Analyze a series circuit

Unit 7 Parallel Circuits 47.01 Build a simple parallel circuit7.02 Confirm the four parameters that govern a parallel circuit7.03 Troubleshoot a parallel circuit

Unit 8 Complex (Series/Parallel) Circuits 48.01 Build a complex circuit8.02 Analyze a complex circuit

Unit 9 Magnetism 39.01 Analyze the properties of permanent magnets9.02 Observe and analyze the operation and properties

of electromagnetsUnit 10 Magnetic Induction 310.01 Analyze the properties of magnetic induction10.02 Observe magnetic induction in operation

Unit 11 AC Signals 311.01 Observe AC signals of various waveshapes and

frequencies on an oscilloscope11.02 Compare peak values on oscilloscope with RMS

values of analog meter11.03 Measure voltage with analog volt-ohm-milliamp meter

Total Lab Hours 36



1. Follow Safety Manuals and All. Safety Regulations/Requirementsa. Assume responsibility for the personal safety of oneself and othersb. Develop a personal attitude towards safetyc. Interpret safety manual directivesd. Comply with established company safety practicese. Complete forms/paperwork as required


3 Maintain a Clean and Safe Work Environmenta. Keep work areas cleanb. Clean machine/hand tools when work is completedc. Put tools away when work is finishedd. Keep aisles clear of equipment and materialse. Perform preventative maintenance as required


odor)c. Keep marked aisles clear of equipment and materialsd. Interpret/display MSDS sheets as required

B. MAINTAIN ELECTRICAL DEVICES1. Use Electrical Test Equipment

a. Measure resistance with an analog volt-ohm-milliamp meterb. Measure voltage with volt-ohm-milliamp meterc. Measure current with volt-ohm milliamp meterd. Use wattmeter to measure power in a simple DC circuite. Use oscilloscope to observe AC signals of various waveshapes and

frequencies2. Apply Specific Terms to Electrical Circuits

a. Define voltage, current, and resistanceb. Discuss power, power factor, and sine wavesc. Define three phase, induction, and capacitance

3. Analyze Series, Parallel and Complex DC/AC Circuitsa. Define a series circuitb. Define a parallel circuitc. Define a complex DC circuitd. Define an AC circuite. Apply Ohm's law to each of the above circuitsf. Apply Kirchoffs law to each of the above circuits

4. Check AC and DC Motorsa. List types of AC and DC motorsb. List characteristics of AC motorsc. List characteristics of DC motorsd. Compare AC motors versus DC motors to job duty

5. Inspect Transformers and Generatorsa. Define transformer construction and the principle of operationb. List the different types of transformersc. Define electro-magnetic inductiond. Describe the principle of operation of AC alternators and DC generators

6. Troubleshoot Electrical Devicesa. Discuss common methods of troubleshooting electrical systemsb. Follow a logical troubleshooting sequence to trace a problem to its origin


The Secretary's Commission on Achieving Necessary Skills (SCANS), U.S. Department of Labor,has identified in its "AMERICA 2000 REPORT" that all students shoulddevelop a new set ofcompetencies and foundation skills if they are to enjoy a productive, full and satisfying life.These are in addition to the Technical Workplace Competencies required by industry. SCANS ismade up of five competencies and a three-part foundation of skills andpersonal qualities thatare needed for solid job performance.





1. complete assigned responsibilities within the lab serving as a member of theteam

2. provide individual assistance/direction to peers as requested3. works well with all members of the classInformation: Acquires and uses information1. read and interpret schematics2. organize and apply theories of electrical applications


a. laboratory organization structure: physical and socialb. organization of personnel and facilities on the shop floorc. systematic organization of training materials

127



E. Technology: Works with a variety of technologies1. chooses procedure, tools and equipment required to prepare/check a circuit2. maintains and troubleshoots equipment

a. applies appropriate preventative maintenanceb. reports all malfunctions of equipment to supervisor/instructorc. perform clean-up assignments of laboratory at the end of the class

period



prose and in documents such as manuals, graphs, and schedulesa. studies student laboratory assignment sheetsb. read/studies textbookc. follow a daily laboratory schedule to maintain appropriate time-line

and project completion2. Writing: Communicates thoughts, ideas, information, and messages in

writing; and creates documents such as letters, directions, manuals,reports, graphs, and flow chartsa. outline the steps necessary to produce a build/test a simple circuitb. maintain a lecture notebookc. submit written responses to chapter question assignmentsd. complete all written assignments

3. Arithmetic./Mathematics: Perform basic computations and approachespractical problems by choosing appropriately from a variety ofmathematical techniquesa. determines appropriate test parameters and variablesb. calculates voltage, current and resistance



skill

12

d. communicates with peers to ensure the smooth and safe operationof the laboratory

Thinking Skills: Thinks creatively, makes decisions, solves problems, visualizes,knows how to learn and reasons.1. Decision Making: Specifies goals and constraints, generates alternatives,



3. Seeing Things In the Mind's Eye: Organizes, andprocesses .symbols,pictures, graphs, objects, and other informationa. interprets technical drawingsb. interprets technical illustrations and symbolsc. understands both written and verbal instructionsd. assimilates process during instructor demonstrations




will improve the skill of the technicianb. understands that the quality of the product is a function of the time

of the operation and the attitude and skill of the technicianPersonal Qualities: Displays responsibility, self-esteem, sociability, self-management, and integrity and honesty.1. Responsibility: Exerts a high level of effort andperseveres towards goal





2. Self-Esteem: Believes in own self-worth and maintains a positive view ofself

129

a. learns to take pride in his or her work through positivereinforcement

b. sees himself or herself as an asset to the class through continuedcontributions to the group and a shared common goal

c. understands that an individual with a positive attitude and the beliefin their own abilities will systematically seek solutions and be avaluable employee

3. Sociability: Demonstrates understanding, friendliness, adaptability,empathy, and politeness in group settingsa. assist classmates in improving technical skillsb. assist students with special needs as a peer mentorc. share laboratory resources (test equipment, tools and instructor's


monitors progress, and exhibits self-controla. maintain a record of academic achievement (individual grade book)b. accept the responsibility for self-management




EST12001/072396


COURSE SYLLABUS

SURVEY OF WELDING PROCESSES ANDAPPLICATIONS

131


SURVEY OF WELDING PROCESSES ANDAPPLICATIONS


COURSE DESCRIPTION:


This course is a survey of shielded metal arc, gas tungsten arc, gas metal arc, flux cored arc, andsubmerged arc welding processes. Metal weldability and weld symbols are considered. Processsafety, electrode selection, and process parameters are emphasized. Hard surfacing, usingshielded metal arc and oxyacetylene processes and techniques are studied.

PREREQUISITES: NONE


Textbook: Oxy-Acetylene Handbook, by Linde, Union Carbide Publisher, LatestEditionNew Lessons in Arc Welding, by Lincoln Electric, Lincoln ElectricPublisher, Latest Edition

Lab Manual: None Required

Student Tool List Qty. Req'd.Oxy-acetylene cutting and welding goggles (mono)

with #5 filter lens and one clear plastic lens 1 pairFriction lighter 1

Wire brush 1" wide with long handle 1

Soap stone 2 piecesWelder's cap 1

Welding gloves, long gauntlet 1 pairChipping hammer 1

Safety glasses 1 pairSlip joint pliers 1 pair


Lecture: Didactic presentations will include lecture, video, and demonstrations.

Laboratory: Hands on laboratory activities to enable the students to learn the various aspects ofthe welding process.


laboratory assignments2. apply theory to laboratory assignments3. perform on written, oral, or practical examinations4. perform on outside assignments including writing assignments5. contribute to class discussions6. maintain attendance per current policy7. follow all shop rules and safety regulations as stated in the laboratory manual


Introduction to the course1

Introduction to oxy-acetylene fusion 1 1

Oxy-acetylene welding and cutting 9 2Introduction to mechanical and physicalproperties 77 1

Non-fusion welding1

Introduction to the oxy-acetylene cuttingprocesses

1

Test #11

The shielded metal arc welding process 1-7 1

Running a good quality bead in the flat position 1-21 1

Introduction to shielded metal arc weldingelectrodes 3-3 2Shielded metal arc power sources 2-3 1

Test #21

Weld joints, weld types and weld positions 1-54 2Introduction to fillet welds 1-56 1

Test #31

Introduction to gas metal arc welding and fluxcore arc welding 7-37 2

Short circuiting metal transfer1

Test #41

Power sources for GMAW and FCAW1

SMAW and FCAW filler metal transfer modes1

Test #51

Shielding gases used with the GMAW process 7-37 1

Shielding gases used with the FCAW process 1Test #6

1

133

Introduction to gas tungsten arc weldingPower sources for GTAWGTAW electrodesTest #7Introduction to submerged arc welding andtechniquesSubmerged arc welding processesTest #8

7-69

Total Lecture Hours

21

I

1

1

1

36


1 The Oxy-Acetylene Welding and Cutting Process 9Demonstration of setting up and break down of equipmentA. Welding beads on plate

(1) Flat position(2) Without and with filler

B. Square butt joints(1) Flat and vertical position(2) With filler material

C. Brazing beads on plate(1) Flat position(2) With filler material

D. Brazing square butt joint(1) Flat and vertical position(2) With filler

E. Oxy-acetylene cutting(1) Cutting to a straight line

2 The Shielded Metal Arc Welding Process (SMAW) 9A. Welding beads on plate

(1) E6010, E6011 and/or E7018 dependent on availability(2) Flat, horizontal and vertical

B. Welding tee joint(1) E6010, E6011 and/or E7018 dependent on availability(2) Flat, horizontal and vertical

3 The Gas Metal Arc Welding and Flux Core Welding Processes (GMAW) 6A. Set up 3 machines each processB. Welding beads on plate, both processes

(1) Have hands on with observers at each stationC. Demonstration of GMAW spot welder

4 The Gas Tungsten Arc Welding Process (GTAW) 6A. Set up machines for welding steel and aluminum (2 or 3 each)B. Welding beads on plate steel

(1) Have hands on with observersC. Welding bead on plate aluminum

-134

(2) Have hands on with observers5 The Submerged Arc Welding Process

A. Demonstrate beads on plateB. Demonstrate running beads roll positionC. Let students have hands on and observation

Total Lab Hours


6

36


1. Use Protective Equipmenta. Wear protective safety clothing as required when welding

2. Follow Safe Operating Procedures for Welding/Cutting Machinesa. Identify and understand safe welding proceduresb. Demonstrate safe welding procedures

B. PERFORM WELDING OPERATIONS1. Weld With Shielded Metal Arc Welding (SMAW) Process

a. Identify factors for welding electrode selectionb. Adjust welding amperage setting for each applicationc. Demonstrate proper use of safety equipmentd. Weld beads on plate (flat and horizontal)e. Weld tee joints (flat and horizontal)f. Identify weld inspection factors and techniques

2. Weld/Cut With Oxy-acetylenea. Setup and break down the oxy-acetylene welding/cutting stationb. Properly adjust oxy-acetylene regulatorsc. Identify factors that determine torch welding and cutting tip selectiond. Demonstrate routine torch maintenance procedurese. Weld beads on plate (with and without filler) in the flat and horizontal

positionsf. Weld square groove butt joints in the flat and horizontal positionsg. Braze weld beads on plate in the flat positionh. Make square cuts to a straight line with the cutting torchi. Demonstrate proper use of safety equipment

3. Weld With Gas Tungsten Arc Welding (GTAW) (Heliarc)a. Set up GTAW welder for welding steelb. Set up GTAW welder for welding aluminumc. Weld beads on plate (steel) with appropriate filler rod in the flat positiond. Weld beads on plate (aluminum) with appropriate filler rod in the flat

positione. Weld lap joints in the horizontal position on steel platef. Weld lap joints in the horizontal position on aluminum plate

4. Weld With Gas Metal Arc Welding (GMAW)/(MIG)a. Set up machine for gas metal arc welding

135

b. Set up machine for flux cored arc weldingc. Weld beads on plate with gas metal arc welding system in the flat positiond. Weld beads on plate with flux cored welding system in the flat positione. Weld lap joints on steel plate with the gas metal arc welding system in the

horizontal positionf. Weld lap joints on steel plate with the flux cored arc welding system in the

horizontal position


The Secretary's Commission on Achieving Necessary Skills (SCANS), U.S. Department of Labor,has identified in its "AMERICA 2000 REPORT" that all students shoulddevelop a new set ofcompetencies and foundation skills if they are to enjoya productive, full and satisfying life.These are in addition to the Technical Workplace Competencies required by industry. SCANS ismade up of five competencies and a three-part foundation of skills and personal qualities thatare needed for solid job performance.



1. follows a schedule to complete assigned tasks on time2. follows a schedule to maximize laboratory resources3. complete a tool crib request form for required materials and suppliesInterpersonal: Works with others1. complete assigned responsibilities within the welding lab serving as a

member of the team2. provide individual assistance/direction to peers as requested3. works well with all members of the classInformation: Acquires and uses information1. read and interpret weld symbols2. organize and apply theories of welding and cutting


a. organization of personnel and facilities on the shop floorb. systematic approach to the cutting and welding processesc. welding rod classification and match to various metalsd. systematic organization of training materials

2. monitors and corrects performance duringa. the welding processb. adjustments of individual laboratory work schedulec. constantly evaluating the quality of work to achieve acceptable

standards

E. Technology: Works with a variety of technologies1. chooses procedure, tools and equipment required to perform the welding

process2. applies appropriate procedures and uses appropriate tools and equipment

to produce a weld to acceptable standards3. maintains and troubleshoots equipment

a. applies appropriate preventative maintenanceb. when using equipmentc. reports all malfunctions of equipment to supervisor/instructor



prose and in documents such as manuals, graphs, and schedulesa. read/studies textbookb. studies student laboratory manualc. interprets welding symbolsd. follow a daily laboratory schedule to maintain appropriate time-line


writing; and creates documents such as letters, directions, manuals,reports, graphs, and flow chartsa. outline the steps necessary to set up, properly adjust and weld/cut

using different types of welding equipmentb. maintain a lecture notebook

3. Arithmetic/Mathematics: Perform basic computations and approachespractical problems by choosing appropriately from a variety ofmathematical techniquesa. keeps a running computation of individual grade



5. Speaking: Organizes ideas and communicates orallya. participates in classroom discussionsb. organize ideas and communicate specific questions to the instructorc. verbally affirms understanding ofa concept, procedure, or required


smooth and safe operation of the laboratory

137

Thinking Skills: Thinks creatively, makes decisions, solves problems, visualizes,knows how to learn and reasons.1. Decision Making: Specifies goals and constraints, generates alternatives,

considers risks, and evaluates and chooses best alternativea. analyzes requirements and makes decisions to select appropriate

welding process, equipment, materials, fixturing, and protectiveequipment

b. prioritizes activities for effective use of time2. Problem Solving: Recognizes problems and devises and implements plan

of actiona. makes daily accommodations to stay on scheduleb. seeks additional instruction/clarification for assignment completionc. troubleshoots welding problems and makes process adjustments to

correct3. Seeing Things In the Mind's Eye: Organizes, and processes .symbols,

pictures, graphs, objects, and other informationa. visualize process during instructor lectureb. visualize the relative motions between welding rod and workpiece

to generate desired weld patterns and weld strength as required4. Knowing How to Learn: Use efficient learning techniques to acquire and

apply new knowledge and skillsa. understand that practice will improve skillb. asks questions or seeks help when uncertain about new skills or


between two or more objects and applies it when solving a problema. applies knowledge of material characteristics, job requirements, and

welding processes to perform assignmentsb. applies knowledge of material characteristics, job requirements, and

welding processes to troubleshoot and/or imporve the weldingprocess






contributions toward common goals

3. Sociability: Demonstrates understanding, friendliness, adaptability,empathy, and politeness in group settingsa. assist classmates in improving technical skillsb. share laboratory resources (welding machines, tools and instructor's


monitors progress, and exhibits self-controla. perform in-process quality checks on weldmentsb. maintain a record of academic achievement (individual grade book)c. accept responsibility for mistakes and infractions, and take steps to





1. Machinery's Handbook, Industrial Press2. Welding Technology Today_ Principles and Practices, Stinchcomb, Craig;: Prentice Hall

Inc., New Jersey 19893. Welder Handbook. W-100 E-1 Corp., Publication #51077, Nov., 19954. Hobart Audio - Visual Training Program5. Miller Audio - Visual Training Program

WLT 10501/060696

1

1


1

COURSE SYLLABUS

CNC MACHINE PROGRAMMING

140


CNC MACHINE PROGRAMMING


COURSE DESCRIPTION:


This course is designed to provide the student with a basic understanding of the programming ofCNC machine tools using machine languages to describe machining operations/processes. Thecourse describes the relationship between conventional and CNC machining operations and safetyconsiderations for CNC machining centers. Principles of programming, tooling, setup andmachine operations, the Cartesian coordinates system, absolute/incremental modes, wordaddresses, G & M codes, as well as fixed and canned cycles will be discussed.

PREREQUISITES: Machine Tool Practices I


Textbook: Machine Tool Practices, Kibbe, Neely, and Meyer, Wiley Pub., 4th Ed.Lab Manual: NONE

Hand Tools/Quantity Required: Basic tool list for Machine Tool Practices I



Laboratory: Laboratory will include computer based exercises as well as "hands-on"programming of machining processes and setups on the Fadal milling machinecenter and the Okuma turning center and other machine control simulators.


laboratory assignments2. apply theory to laboratory assignments involving cnc machine codes, Cartesian coordinate

system, G & M codes, fixed and canned cycles, and the basic skills used to produce a cncprogram with SMARTCAM's Job Plan and Edit Plus module

3. satisfactorily perform on written, oral, and practical examinations4. satisfactorily perform on outside assignments including writing assignments5. contribute to class discussions6. maintain attendance per current policy

1

7. follow all shop rules and safety regulations as stated in the laboratory manual

LECTURE OUTLINE:Lecture TopicS Text Reference Page Contact Hrs.

Unit 1 CNC Overview 31.01 Description of CNC1.02 Job Opportunities in the

CNC field1.03 Employability Skills in CNC1.04 Working Safely with CNC

machinesUnit 2 The Structure of a CNC

System 32.01 CNC vs. conventional

machining terminology2.02 5 Considerations before

programming begins2.03 Cartesian Coordinate System

Unit 3 Process Planning (Mill) 33.01 Interpreting a part print3.02 Creating a Job Sheet from a part

print3.03 Introduction to SMARTCAM's

Job Plan module3.04 Entering information into a Job Plan

Unit 4 Programming Format (Mill) 34.01 Basic CNC code structure for the

FADAL mill4.02 Starting a CNC Program4.03 Machining examples4.04 Ending a CNC program4.05 An introduction to SMARTCAM's Edit

Plus module and Tape-to Shape4.06 Using SMARTCAM to simulate machine

tool movementsUNIT 5 Programming CNC Machining

Operations (Mill) 185.01 Straight milling5.02 Drilling operations5.03 Circular milling

UNIT 6 Process Planning (Lathe) 36.01 CNC lathe coordinate systems6.02 Carbide tooling for CNC lathes6.03 Process planning for the CNC lathe6.04 Entering tool information into the

Job PlanUNIT 7 Programming the CNC Lathe 142 3

7.01 Basic program structure7.02 Turning, Facing, Boring, Drilling

and Threading



1 CNC Lab Organization and Safety 32 Identification of Major CNC Components 33 CNC (Mill) Tooling Systems 34 Introduction to SMARTCAM's Programming 6

Softwarea) Job Planb) Applicationsc) Edit Plus Modules

5 Programming CNC Mills 9a) Basic Program Structureb) Linear Milling, Drilling, Circular Milling

and Canned Cycles6 CNC Lathe Tooling Systems 37 Programming CNC Lathes 38 Final Project 6

Total Lab Hours 36



1. Follow Safety Manuals and All Safety Regulations/Requirementsa. Assume responsibility for the personal safety of oneself and othersb. Develop a personal attitude towards safetyc. Interpret safety manual directivesd. Comply with established company safety practices


3. Follow Safe Operating Procedures for CNC Machine Toolsa. Identify and understand safe machine operating proceduresb. Demonstrate safe machine operation


143


1. Perform Basic Arithmetic Functionsa. Add, subtract, multiply and divide whole numbersb. Add, subtract, multiply, and divide decimals



4. Calculate Speeds and Feeds for Machininga. Calculate RPM for various metals and various toolsb. Calculate feed for various metals, tools, and depths ofcut

5. Locate Machining Points from a Datum Pointa. Identify points using the Cartesian coordinate systemb. Identify points using the absolute dimensioning systemc. Identify points using the incremental dimensioning system




3. Identify Basic Types of Drawingsa. Identify orthographic viewsb. Identify positions of views (top, front, side, and auxiliary)c. Visualize one or more views from a given viewd. Identify isometric viewse. Identify exploded isometric drawingsf. Identify assembly drawings

4. List the Purpose of Each Type of Drawinga. Identify the purpose of orthographic (3 views) drawingsb. Identify the purpose of isometric drawing

144

c. Identify the purpose of exploded isometric drawingd. Identify the purpose of assembly drawings



Feature Size (RFS)7. Describe the Relationship of Engineering Drawings to Planning

a. Discuss production scheduleb. Discuss Material Resource Planning (MRP)c. . Discuss inventory control records


D. PERFORM MEASUREMENT/INSPECTION1. Select Proper Measurement Tools

a. Match appropriate measurement tools with various types of measurementrequirements

b. Demonstrate proper measurement tool usage2. Perform Measurements With Hand Held Instruments

a. Measure with steel rules (metric and inch)b. Measure with micrometersc. Measure with direct measuring instruments (i.e., vernier, dial, and digital

instruments)E. PERFORM ADVANCED MACHINING PROCESSES

1. Prepare and Plan For CNC Machining Operationsa. Read and interpret blueprintsb. Plan CNC machining operationsc. Calculate speeds, feeds, and depth of cut for various CNC machine



a. Understand machinability and chip formationb. Select proper carbide insert material and geometry neededc. Assemble tooling componentsd. Select correct tooling systemse. Identify tooling cost factors

3. Program CNC Machinesa. Identify CNC Applications

145

b. List various types of CNC machinesc. Discuss CNC machine control systemsd. Describe absolute and incremental coordinate systemse. Plan and write program for CNC mills and lathesf Edit CNC programs


The Secretary's Commission on Achieving Necessary Skills (SCANS), U.S. Department of Labor,has identified in its "AMERICA 2000 REPORT" that all students should develop a new set ofcompetencies and foundation skills if they are to enjoy a productive, full and satisfying life.These are in addition to the Technical Workplace Competencies required by industry. SCANS ismade up of five competencies and a three-part foundation of skills andpersonal qualities thatare needed for solid job performance.





1. complete assigned responsibilities within the shop floor serving as amember of the team

2. provide individual assistance/direction to peers as requested3. produce machine parts to acceptable levels of quality as required4. works well with all members of the classInformation: Acquires and uses information1. read and interpret blueprints2. organize and apply theories of machine tool operation





146

E. Technology: Works with a variety of technologies1. chooses procedure, tools and equipment required to produce a part using

CNC2. applies appropriate procedures and uses appropriate tools and equipment



of the laboratory


listens and speaks.I. Reading: Locates, understands, and interprets written information in



writing; and creates documents such as letters, directions, manuals,reports, graphs, and flow chartsa. outline the steps necessary to produce a simple machine partb. maintain a lecture notebookc. submit written responses to chapter question assignmentsd. complete all written assignments

3. Arithmetic/Mathematics: Perform basic computations and approachespractical problems by choosing appropriately from a variety ofmathematical techniquesa. determines optimum machining speeds, feeds, and depth of cutb. calculates "value added to the part"c. aligns machine and/or work holding deviced. taps and threadse. keeps a running computation of individual gradef. use trigonometry to solve angle and taper calculations


5. Speaking: Organizes ideas and communicates orallya. participates in classroom discussionsb. organize ideas and communicate specific questions to the instructor

147

c. verbally affirms understanding of a concept, procedure, or requiredskill


B. Thinking Skills: Thinks creatively, makes decisions, solves problems, visualizes,knows how to learn and reasons.I. Decision Making: Specifies goals and constraints, generates alternatives,



3. Seeing Things In the Mind's Eye: Organizes, and processes symbols,pictures, graphs, objects, and other informationa. interprets technical drawingsb. interprets technical illustrations and symbolsc. understands both written and verbal instructionsd. assimilates process during instructor demonstrations











to do in class and does not waste time

148

d. develops a fine work-ethic2. Self-Esteem: Believes in own self-worth and maintains a positive view of

selfa. learns to take pride in his or her work through positive







machines/toolsd. accept the responsibility for self-management





MET20501/072396


COURSE SYLLABUS

STATICS

150


STATICS


COURSE DESCRIPTION:


This is a basic course in applied Statics and Mechanics and will prepare the student for courses inStrength of Materials and Machine Design. The student will acquire a fundamental understandingof concepts and principles which apply in the calculations of such things as: levers, structuralmembers, inclined planes, sheaves, machined parts and structural joints. Other topics will include:coplanar forces, equilibrium of forces, structural analysis, free-body diagrams, laws of friction andthe calculation of centroids and centers of gravity.

PREREQUISITES: Plane Trigonometry


Textbook:

Lab Manual:

Applied Statics and Strength of Materials, Spiegel and Limbunner,Merrill PublishersNONE

Required Materials:Engineering paper, greenScientific Calculator



Laboratory: Laboratory assignments will require student to solve appropriate static problems.


laboratory assignments2. apply theory to laboratory assignments3. satisfactorily perform on written, oral, and practical examinations4. satisfactorily perform on outside assignments including writing assignments5. contribute to class discussions6. maintain attendance per current policy

15i

LECTURE OUTLINE:Lecture Topics Text Reference Page

Unit 1 Introduction to Mechanics 1-161.01 Definition of Mechanics 1

1.02 Problem in Applied Mechanics 1-21.03 Procedures in the Solution on

Mechanics Problems 3-51.04 Standards of Workmanship in

Problem Solutions 9-12Unit 2 Basic Principles of Statics 17-71

2.01 Force 172.02 Types of Force 172.03 Characteristics and Units of a

Force 172.04 Vector and Scalar Quantities 192.05 Transmissibility of Force 182.06 Types of Force Systems 212.07 Components of a Force 222.08 Resultant of Two Concurrent Forces 362.09 Moments of a Force 472.10 The Principles of Moments

Viraginous Theorem 512.11 Couples 592.12 Resultant of Parallel Forces 532.13 Resolution of a Force into Parallel 532.14 Equilibrium of Force Systems

Components 752.15 Principles of Force Equilibrium 752.16 Supports and Support Reactions2.17 Free-body Diagrams 762.18 Problems in Equilibrium of

Coplanar Force SystemsUnit 3 Coplanar, Parallel Force Systems 36-91

3.01 Resultant of Coplanar, ParallelForces 36-71

3.02 Resultants of Distributed Loads 36-713.03 Equilibrium of Coplanar, Parallel

Force Systems 75-91Unit 4 Coplanar, Concurrent Force

Systems 53-1124.01 Resultants of Coplanar, Concurrent

Force Systems 36-714.02 Equilibrium of Coplanar,

Concurrent Force Systems 5-91.4.03 Trusses 1094.04 Stresses in Members of Trusses 1114.05 Ropes over Sheaves and Pulleys4.06 Stresses in Trusses; Analytical 152

Contact Hrs.

Method of Joints 112-1184.07 Stresses in Trusses; the Graphical

Method of Joints 112-1184.08 Stresses in Trusses; the Graphical

Method of Combined Diagrams 112-1184.09 Three-force Members4.10 Graphical Determination of

Reactions Using Three-forcePrinciple

Unit 5 Coplanar, Nonconcurrent ForceSystems 62-119

5.01 Resultant of Coplanar,Nonconcurrent Force Systems 62

5.02 Equilibrium of Coplanar,Nonconcurrent force Systems 93

5.03 Determination of Reactions;Graphical String-polygon Method

5.04 Determination of Reactions;Analytical Method 112-118

5.05 Pin Reactions; the Method ofMembers

5.06 Stresses in Trusses; the Methodof Sections 119

5.07 Counter Diagonals in TrussesUnit 6 Noncoplanar, Parallel Force

Systems 75-1056.01 Resultant of a Noncoplanar,

Parallel Force Systems6.02 Equilibrium of Noncoplanar,

Parallel Force SystemUnit 7 Noncoplanar, Concurrent

Force Systems 75-1057.01 Components of a Force in Space7.02 Equilibrium of Noncoplanar,

Concurrent Force SystemsUnit 8 Noncoplanar, Nonconcurrent

Force Systems 75-1058.01 Equilibrium of Noncoplanar,

Nonconcurrent Force Systems 93Unit 9 Friction 143-165

9.01 Coefficient of Friction, Angle ofFriction, and Angle of Repose 143-146

9.02 Laws of Friction 1449.03 Friction Problems 1479.04 Belt Friction 1659.05 Rolling Resistance



Introduction to MechanicsBasic Principles of StaticsCoplanar, Parallel Force SystemsCoplanar, Concurrent Force SystemsCoplanar, Nonconcurrent Force SystemsNoncoplanar, Parallel Force SystemsNoncoplanar, Concurrent Force SystemsNoncoplanar, Nonconcurrent Force SystemsFriction

Total Lab Hours


Contact Hrs.263

643

3

3

636

After the successful completion of this course the student will be able to:A. APPLY MATHEMATICAL CONCEPTS

1. Perform Basic Arithmetic Functionsa. Add, subtract, multiply and divide whole numbersb. Add, subtract, multiply, and divide fractionsc. Add, subtract, multiply, and divide decimals


3. Interconvert Metric/English measurementsa. Convert English dimensions to Metricb. Convert Metric dimensions to Englishc. Use Metric/English conversion chart


5. Solve Static Systems for Resultant Forcesa. Solve for the following coplanar force systems: parallel, concurrent and

nonconcurrentb. Solve for the following Noncoplanar force systems: parallel, concurrent

and nonconcurrent6. Solve Engineering Equations

a. Solve linear algebraic equations for an unknownb. Solve a system of linear equations with 2 unknownsc. Solve right triangles for unknown sides or anglesd. Use the law of sines and cosines to solve obtuse triangles with unknown

sides and anglese. Calculate factors of Friction

7. Use all Functions of a Scientific Calculatora. Apply all trigonometric functionsb. Apply all algebraic functions

154

c. Apply all statistical functions


The Secretary's Commission on Achieving Necessary Skills (SCANS), U.S. Department of Labor,has identified in its "AMERICA 2000 REPORT" that all students should develop a new set ofcompetencies and foundation skills if they are to enjoy a productive, full and satisfyingThese are in addition to the Technical Workplace Competencies required by industry. SCANS ismade up of five competencies and a three-part foundation of skills and personal qualities thatare needed for solid job performance.





1. complete assigned responsibilities within the class serving as a member ofthe team

2. provide individual assistance/direction to peers as requestedInformation: Acquires and uses information1. read and interpret blueprints2. organize and apply theories of mechanics, forces and friction


a. laboratory organization structure: physical and socialb. systematic organization of training materials



E. Technology: Works with a variety of technologies1. chooses procedure and formulas necessary for problem solving.



prose and in documents such as manuals, graphs, and schedulesa. studies student laboratory manualb. interprets diagrams and technical drawingsc. read/studies textbook

155

2. Writing: Communicates thoughts, ideas, information, and messages inwriting; and creates documents such as letters, directions, manuals,reports, graphs, and flow chartsa. outline the steps necessary for problem solvingb. maintain a lecture notebookc. submit written responses to chapter question assignmentsd. complete all written assignments

3. Arithmetic/Mathematics: Perform basic computations and approachespractical problems by choosing appropriately from a variety ofmathematical techniquesa. add, subtract, multiply and divide whole numbersb. add, subtract, multiply, and divide fractionsc. add, subtract, multiply, and divide decimalsd. convert fractions to decimal equivalentse. convert decimal values to nearest fractional equivalentf. use Decimal Equivalent Chart for conversionsg. convert English dimensions to Metrich. convert Metric dimensions to Englishi. use Metric/English conversion chartj. solve for unknown anglesk. solve for unknown sides1. solve for the following coplanar force systems: parallel, concurrent

and nonconcurrentm. solve for the following noncoplanar force systems: parallel,

concurrent and nonconcurrentn. solve linear algebraic equations for an unknowno. solve a system of linear equations with 2 unknownsP. solve right triangles for unknown sides or anglesq. use the law of sines and cosines to solve obtuse triangles with

unknown sides and anglesr. calculate factors of frictions. apply all trigonometric calculator functionst. apply all algebraic calculator functionsu. apply all statistical calculator functionsv. calculates coplanar, parallel force systems

4. Listening: Receives, attends to, interprets, and responds to verbalmessages and other cuesa. assimilate classroom instructionb. observe laboratory demonstrationsc. seek and receive individualized instruction in the laboratory


skillB. Thinking Skills: Thinks creatively, makes decisions, solves problems, visualizes,

knows how to learn and reasons.

156

1. Decision Making: Specifies goals and constraints, generates alternatives,considers risks, and evaluates and chooses best alternativea. identifies personal goalsb. identifies actions required to accomplish personal goals


3. Seeing Things In the Mind's Eye: Organizes, andprocesses symbols,pictures, graphs, objects, and other informationa. interprets technical drawingsb. interprets technical illustrations and symbolsc. understands both written and verbal instructionsd. assimilates process during instructor demonstrations




will improve the skill of the technicianPersonal Qualities: Displays responsibility, self-esteem, sociability, self-management, and integrity and honesty.1. Responsibility: Exerts a high level of effort andperseveres towards goal









3. Sociability: Demonstrates understanding, friendliness, adaptability,empathy, and politeness in group settings

157

a. assist classmates in improving technical skillsb. assist students with special needs as a peer mentor

4. Self-Management: Assesses self accurately, sets personal goals,monitors progress, and exhibits self-controla. perform in-process checks on calculationsb. maintain a record of academic achievement (individual gradebook)c. accept the responsibility for self-management




1. Machinery's Handbook, Industrial Press2. Applied Statics and Strength of Material, Spiegel and Limbunner

MET20601/072396


COURSE SYLLABUS

MANUFACTURING PROCESSES

159


MANUFACTURING PROCESSES


COURSE DESCRIPTION:


Essential studies into the processes and materials for manufacturing, including metal casting, hotand cold forming of steel, powder metallurgy and plastics. Analysis of newer processes such aselectrical discharge machining, chemical machining, and ultra-sonic machining; with a emphasis onthe economical manufacturing of products.

PREREQUISITES: NONE


Textbook: Modern Materials and Manufacturing Processes, John E. Neeley &Richard R. Kibbe, Prentice Hall Career & Technology, Englewood Cliffs,N.J., 1987

Lab Manual: None Required

Student Tool List: Safety glasses



Laboratory: Laboratory will consist of "hands-on" activities. Students will operate variousconventional metalworking machines to manufacture a product.


laboratory assignments2. apply theory to laboratory assignments3. perform on written, oral, or practical examinations4. perform on outside assignments including writing assignments5. contribute to class discussions6. maintain attendance per current policy7. follow all shop rules and safety regulations as stated in the laboratory manual


Introduction to the Course1

The Manufacturing Industry 2F 3Material Resource Planning ('MRP) 25 2Processing of Metals: Casting 7 3Processing of Metals: Hot Working 8 3Processing of Metals: Cold Working 9 3QUIZ I

1Powder Metallurgy 10 2Non-traditional Machining Processes 13 3Plastics & Composite Processes 15 4QUIZ II

1

Joining Processes 14 3Corrosion & Protection for Materials 16 1

Design, Tooling & Production Lines 18 5QUIZ III



Lab Orientation and Safety 2Lab Sheet #1 - Stock preparation; measure (semi-precision), shear and debur 3Lab Sheet #2 - Layout, drill, ream and debur holes 3Lab Sheet #3 - Metal forming (bending) and countersinking holes 3Lab Sheet #4 - Metal joining (welding), stress relieving and sawing 3Mid-term project evaluation and rework 2Lab Sheet #5 - Surface preparation (sand blast) and surface finish (paint) 3CNC stock preparation 2CNC Machining Demonstration and CIM Lab Demonstration 3Lab Sheet #6 - Component sub-assembly and precision machining activity 3Lab Sheet #7 - Sub-assembly manufacture (handle) 3Lab Sheet #8 - Final assembly and test (final project evaluation) 3Lab clean-up 3

Total Lab Hours 36




B. INTERPRET ENGINEERING DRAWINGS AND CONTROL DOCUMENTS1. Describe the Relationship of Engineering Drawings to Planning




C. RECOGNIZE Dlk .t.LRENT MANUFACTURING MATERIALS ANDPROCESSES1. Identify Materials With Desired Properties

a. Discuss classification system for metalsb. Describe general characteristics for carbon steels, tool steels, stainless

steels, structural steels, cast irons, aluminum, and other commonly usedmetals





1. follows a schedule to complete assigned tasks on time2. follows a schedule to maximize laboratory resources3. determine the initial cost of materials and "value added" as result of

processingB. Interpersonal: Works with others

1. complete assigned responsibilities within the manufacturing lab serving as amember of the team

2. provide individual assistance/direction to peers as requestedInformation: Acquires and uses information1. read and interpret blueprints2. organize and apply theories of manufacturing processes

1 6 2

3. perform basic semi-precision and precision layout as necessaryD. Systems: Understands complex inter-relationships

1. demonstrate knowledge of the folloWing systems:a. organization of personnel and facilities in the manufacturing labb. systematic approach to the production processc. dimensioning and measurement systems

2. monitors and corrects performance duringa. the manufacturing processb. adjustments of individual laboratory work schedulec. constantly evaluating the quality of work to achieve acceptable


1. ,chooses procedure, tools and equipment required to fabricate a product2. applies appropriate procedures and uses appropriate tools and equipment

to fabricate a part to referenced engineering standards



prose and in documents such as manuals, graphs, and schedulesa. read/studies textbookb. studies student laboratory exercisesc. interprets blueprints and technical drawingsd. follow a daily laboratory schedule to maintain appropriate time-line


writing; and creates documents such as letters, directions, manuals,reports, graphs, and flow chartsa. outline the steps necessary to produce simple productb. maintain a lecture notebookc. submit written responses to chapter question assignments

3. Arithmetic/Mathematics: Perform basic computations andapproachespractical problems by choosing appropriately from a variety ofmathematical techniquesa. calculate bend allowances for sheet metal and metal plateb. keeps a running computation of individual grade


instructions, asking questiOns for clarification and probing forspecifics

5. Speaking: Organizes ideas and communicates orallya. participates in classroom discussions

1 P1

b. organize ideas and communicate specific questions to the instructorc. verbally affirms understanding of a concept, procedure, or required


smooth and safe operation of the laboratoryB. Thinking Skills: Thinks creatively, makes decisions, solves problems, visualizes,


considers risks, and evaluates and chooses best alternativea. applies knowledge of process and materials to select appropriate

material and process for safe and economical service in a givenapplication

b. prioritizes activities for effective use of time2. Problem Solving: Recognizes problems and devises and implements plan

of actiona. makes daily accommodations to stay on scheduleb. seeks additional instruction/clarification for assignment completionc. troubleshoots manufacturing processes and equipmentd. recognize problems in manufacturing and selects appropriate

corrective or preventive action3. Seeing Things In the Mind's Eye: Organizes, and processes symbols,

pictures, graphs, objects, and other informationa. visualize objects in three dimensions from engineering drawingsb. visualize process during instructor lecturec. visualize the capabilities of various manufacturing processes and

machine tools to generate desired features in raw stock in order tomanufacture a simple product

4. Knowing How to Learn: Use efficient learning techniques to acquire andapply new knowledge and skillsa. understand that practice will improve skillb. asks questions or seeks help when uncertain about new skills or


between two or more objects and applies it when solving a problema. apply general understanding of process and material characteristics

to determine the process by which a part or piece of stock has beenmade

b. applies knowledge of manufacturing materials and processes todevelop a logical, sequential process plan

c. apply broad understanding of processes, materials, productrequirements, and manufacturing economics to consider and applynew or alternative techniques to reduce costs, save time andimprove quality


attainmenta. displays promptness and preparation for the day's work

b. plans work to use time efficientlyc. accepts responsibility for mistakes, and takes corrective and




contributions toward common goals3. Sociability: Demonstrates understanding, friendliness, adaptability,

empathy, and politeness in group settingsa. assist classmates in improving technical skillsb. share laboratory resources (machines, tools and instructor's


monitors progress, and exhibits self-controla. perform in-process quality checks on manufactured component

partsb. maintain a record of academic achievement (individual grade book)c. accept responsibility for mistakes and infractions, and take steps to





1. Machinery's Handbook, Industrial Press2. Technology of Machine Tools, 4th Ed. McGraw Hill Publishers

MEMO'01/060196


COURSE SYLLABUS

INTRODUCTION TO COMPUTERDRAFTING

166


INTRODUCTION TO COMPUTER DRAFTING


COURSE DESCRIPTION:


This course introduces the student to computer-aided drafting (CAD). This introduction involvesequipment, software, and basic command logic. Graphic images are created using introductorylevel commands.

PREREQUISITES: NONE


Textbook: AutoCAD and Its Applications Terence Shumaker/David A. Madsen

Materials: 2 - HEMS 3 1/2" diskettes1 Ream of plain bond paper (201b)Notebook PaperFelt tip pen1 Pkg Calcomp Plotter Pens - Assorted Colors


Lecture: Classroom presentations will include lecture, video and demonstrations. Computerassisted instruction will be used.

Laboratory: Laboratory will be a "hands-on" drawing process using computer hardware,software, plotters and printers.



7. follow all safety regulations as stated in the class policies


Introduction to CourseRequired Materials and TestsClass Policies and Safety ConcernsSystem OrientationOperating Parameters and Drawing AidsCartesian CoordinatesDisplay CommandsDraw CommandsEdit CommandsText CommandsInquiry CommandsDOS/Utility CommandsPlot SpecificationsLayer CommandBlocksDimensioningManufacturing/CAD Project



System OrientationOperating ParametersCartesian CoordinatesDisplaying Different ViewsDrawing EntitiesEditing Existing EntitiesText on the DrawingsInquiry - Obtaining Database InformationDOS/Utility CommandsPlottingUsing LayersCreating BlocksDimensioning DrawingsProject

HandoutHandoutAppendix B, 1Chapters 2, 3, 4, 5Chapter 6Chapter 9Chapters 6, 7, 8, 13Chapters 11, 12Chapter 10Chapter 14Chapters 15, 35Chapter 27Chapter 17Chapter 21Chapter 18


Contact Hrs.

Total Lab Hours

2241

4221

1

1

244

18

48



1.

2.

Follow Safety Requirementsa. Assume responsibility for the personal safety of oneselfand othersb. Develop a personal attitude towards safetyc. Comply with established safety practicesd. Use special caution with magnetic mediaMaintain a Clean and Safe Work Environment

Observe computer lab hygienePut equipment and supplies away when work is finished

a.b.

B. APPLY MATHEMATICAL CONCEPTS1. Use Inquiry Commands to Perform Basic Addition and Subtraction2. Use Inquiry Commands to Find Area, Length and Distance3. Apply Basic Concepts of Geometry Using CAD Software4. Convert English Dimensions to Metric

C. APPLY DRAFTING CONCEPTS TO COMPUTER AIDED DRAFTING1. Identify the Equipment Used in Computer Aided Drafting2. Describe the Methods and Procedures Used to Produce Cad DrawingsESTABLISH AND USE OPERATING PARAMETERS1. Use Dos Commands to Manage Drawing Files2. Describe and Use Menus and Screen Prompts3. Set UNITS4. Set LIMITS5. Set GRID6. Set SNAP7. Establish a Prototype Drawing8. Open, Close and Save Files9. Use ORTHO to Create Lines at Right Angles

E. USE CARTESIAN COORDINATE POINT ENTRY SYSTEMS1. Create Drawings Using Absolute Coordinates2. Create Drawings Using Relative Coordinates3. Create Drawings Using Polar Coordinates4. Determine Which System Is Most Efficient for Each Application

F. USE DISPLAY COMMANDS TO VIEW DRAWINGS1. Enlarge or Reduce the Amount of Drawing Displayed on the Monitor Using Zoom

Options2. Redraw the Screen to Clean up Clutter3. Specify and Save Certain Views on a Drawing4. Manipulate Your View of the Drawing Without Changing the Magnification

G. USE CAD COMMANDS TO CREATE DRAWINGS1. Determine Most Efficient Sequence of Commands to Produce Required Object2. Use Standard Line Types to Indicate Drawing Features3. Use POLYLINES to Show Width And/or Taper

D.

4. Draw Circles Using the CIRCLE Command Options5 Draw Arcs Using the ARC Command Options6. Use Ellipses, Polygons and Doughnuts to Represent Drawing Features7. Use OSNAPS to Create Accurate Geometry8. Use ARRAY to Create Rectangular and Circular Repetitions

H. USE CAD COMMANDS TO EDIT DRAWINGS1. Create Angled Corners Using the CHAMFER Command2. Create Rounded Corners Using the FILLET Command3. Remove Portions of Entities Using the BREAK Command4. Change the Location of an Entity5. Use TRIM and EXTEND to Shorten or Lengthen an Object6. Use COPY to Create Duplicates of Existing Objects7. Change Angular Position of Objects8. Use the STRETCH and SCALE Commands to Change to Size Length and Height

of an ObjectI. PLACE TEXT ON A DRAWING

1. Use the Text Command to Add Notes and Callouts to a Drawing2. Set Text Style3. Draw Special Symbols Using Control Characters4. Underscore and Overscore Text5. Edit Existing Text

J. OBTAIN INFORMATION ABOUT A DRAWING1. Determine the Area of an Object by Adding and Subtracting Entities2. List Database Information Related to Entities and Drawings3. Track Time Spent in a Drawing Session

K. USE DOS/UTILITY COMMANDS TO MANAGE FILES1. Explain the Meaning and Use of DOS File Extensions2. List Files Using FILE UTILITIES3. Copy, Rename and Delete Files Using FILE UTILITIES4. Format, Label and List Contents of Disks Using DOS Commands5. Copy, Rename, and Delete Files Using DOS Commands

L. PRODUCE PLOTTED COPIES OF DRAWINGS1. Set up Plotter

a. Load mediab. Load pens

2. Set up Parameters Within a Drawing File for PlottingM. USE LAYERS TO SEPARATE DETAILS OF A DESIGN

1. Name and Create Layersa. Select colorsb. Set linetypes

2. Set Layers3. Control Visibility of Layers4. Lock Layers5. Freeze Layers6. Rename Layer

170

7. Edit Layer PropertiesN. CREATE AND STORE SYMBOLS

1. Create and Save Blocks2. Insert Blocks into a Drawing3. Edit Blocks and Update Existing Insertions

0. DESCRIBE SIZE, SHAPE AND LOCATION OF DRAWING FEATURES WITHDIMENSIONS1. Dimension Objects According to ANSI Standards2. Identify and Set Variables to Control the Appearance of Dimensions3. Add Linear, Angular, Diameter and Radius Dimensions to a Drawing4. Set Units and Decimal Places5. Apply Tolerances as Required

P. USE CAD SKILLS TO CREATE A DRAWING PROJECT RELATED TOSTUDENT'S MAJOR





1. follows a schedule to complete assigned tasks on time2. determine the appropriate media and instruments to complete assignments3. provide a self-evaluation of performance based on the time and quality of


1. complete assigned responsibilities within the course serving as a member ofthe team

2. provide individual assistance/direction to peers as requested3. produce drawings to acceptable levels of quality as required4. works well with all members of the classInformation: Acquires and uses information1. reads and interprets text and handouts2. organizes and applies theories of drafting and design3. applies lecture concepts to lab techniques

171

D. Systems: Understands complex inter-relationships1. demonstrates knowledge of the following systems:

a. laboratory organization structure: physical and socialb. organization of personnel and facilities in the computer drafting labc. systematic approach to the drafting and design processd. dimensioning and measurement systemse. systematic organization of training materials

2. monitors and corrects performancea. during the drawing processb. making adjustments to individual laboratory work schedulesc. while constantly evaluating the quality of work to achieve

acceptable standardsd. though maintaining a record of evaluationse. to meet individual goals

E. Technology: Works with a variety of technologies1. chooses, procedures media and supplies required to produce a drawing2. applies appropriate procedures and uses appropriate tools and equipment

to produce a drawing to acceptable standards3. maintains and troubleshoots equipment and tools

a. applies appropriate preventative maintenanceb. reports all malfunctions of equipment to supervisor/instructorc. performs clean-up assignments of lab



prose and in documents such as manuals, graphs, and schedulesa. interprets technical drawingsb. reads/studies concepts in textbookc. follows a daily laboratory schedule to maintain appropriate time-

line to meet scheduled deadlinesd. interprets concepts in texts to develop accurate drawings

2. Writing: Communicates thoughts, ideas, information, andmessages inwriting; and creates documents such as letters, directions, manuals,reports, graphs, and flow chartsa. outlines the steps necessary to produce a simple drawingb. sketches object to produce a final drawingc. maintains a schedule of assignments and deadlines (these may take

the form of a chart, graph, etc.)d. maintains a lecture notebooke. submits written responses to chapter question assignmentsf. completes all written assignments

172

3. Arithmetic/Mathematics: Perform basic computations and approachespractical problems by choosing appropriately from a variety ofmathematical techniquesa. bisects lines, circles, arcs and anglesb. divides objects into equal partsc. applies tolerancesd. applies and verify dimensionse. uses fraction and decimal valuesf. applies principles of trigonometry and geometry to solve angle

calculations and tangencies and to define points4. Listening: Receives, attends to, interprets, and responds to verbal

messages and other cuesa. assimilates concepts presented by lecture, video or any multimedia

methodsb. observes laboratory demonstrations for technique and safety

instructionsc. seeks and receive individualized instruction in the laboratoryd. actively listens and participates in discussions and question/answer

sessions5. Speaking: Organizes ideas and communicates orally

a. participates in classroom discussionsb. organizes ideas and communicates specific questions to the

instructorc. verbally affirms understanding ofa concept, procedure, or required

skilld. communicates with peers to ensure the efficient and safe

completion of assignmentsB. Thinking Skills: Thinks creatively, makes decisions, solves problems, visualizes,

knows how to learn andreason.I. Decision Making: Specifies goals and constraints, generates alternatives,

considers risks, and evaluates and chooses best alternativea. identifies personal goalsb. prioritizes goalsc. identifies specific actions required to accomplish personal goalsd. allows for flexibility in meeting goals as circumstances change


3. Seeing Things In the Mind's Eye: Organizes, andprocesses symbols,pictures, graphs, objects, and other informationa. understands both written and verbal instructionsb. assimilates process during instructor demonstrations

c. interprets technical drawingsd. interprets technical illustrations and symbolse. interprets and applies geometric construction concepts

4. Knowing How to Learn: Use efficient learning techniques to acquire andapply new knowledge and skillsa. demonstrates mastery of the basic skills and techniquesb. uses these sequential skills to support mastery of new skillsc. consistently applies the sequential nature of acquired skills to the


between two or more objects and applies it when solving a problema. understands that practice will improve the skill of the technicianb. understands that the quality of the product is a function of time

spent and the attitude and skill of the technicianPersonal Qualities: Displays responsibility, self-esteem, sociability, self-management, and integrity and honesty.1. Responsibility: Exerts a high level of effort andperseveres towards goal

attainmenta. attends class as scheduled and is well prepared for the day's workb. completes assignments independently and on timec. works well within a team while completing individual assignments





3. Sociability: Demonstrates understanding, friendliness, adaptability,empathy, and politeness in group settingsa. assists classmates in improving technical skillsb. assists students with special needs as a peer mentorc. shares laboratory resources (computers, plotters and instructor's


monitors progress, and exhibits self-controla. performs in-process quality checks on CAD drawingsb. maintains a record of academic achievement (individual gradebook)c. maintains a schedule of deadlines, due dates, and other important

dates (calendar)d. adjusts calendar to accommodate unexpected circumstancese. accepts the responsibility for self management

174

5. Integrity/Honesty: Chooses ethical courses of actiona. accepts responsibility for own actionsb. exhibits personal honesty at all timesc. accepts the challenge of doing his/her own work in the laboratory,

during examination and on outside assignmentsd. understands the consequences of unethical behaviors

DDT 12801/072396

IMachine Tool Advanced Skills

Technology Program

1

1

COURSE SYLLABUS

a

CAD/CAM I

176


CAD/CAM I


COURSE DESCRIPTION:


Student will introduced to "Process Modeling" utilizing a CNC graphics programming systemcalled "SMARTCAM". Using engineering drawings, students will program various parts for bothCNC mills and CNC lathes. Related topics include: job planning, tool selection, process modelconstruction, tool path verification, machine simulation, quality control, CAD/CAM transfer andCNC code generation.

PREREQUISITES: NONE


Textbook: SMARTCAM -2D, Pe lton, TSTC Pub., 2nd Ed.Lab Manual: NONE

Materials and/or Supplies: 2 - double sided, high density 3 1/2" floppy diskettes


Lecture: Didactic presentations will include lecture, overheads and SMARTCAM andrelated software demonstrations.

Laboratory: Laboratory will be a "hands-on" (computer based) process modeling using theSMARTCAM System.

Method of Evaluation: A student's grade will be based on multiple measures of performance.The assessment will measure development of independent critical thinking skills and will includeevaluation of the student's ability to:1. demonstrate the ability to use DOS commands2. create a basic procedure for machining a part on a machine center and a turning center,

including: machine tool selection, tool selection and application, operational sequences,speeds, feeds and depth of cuts and tool length offsets

3. develop job plans using SMARTCAM4. demonstrate the ability to develop a SHAPE file in the SMARTCAM graphics system5. demonstrate the ability to manipulate files to successfully complete a graphics project

within a CAM system6. create part profiles and part geometry to produce accurately coded information for both

CNC lathes and mills7. utilize plotters and printers to produce accurate documents

1

8. perform and demonstrate the ability to transfer CAD files to CAM files and CAM files toCAD files

9. generate a tool path from CAD to CAM files10. edit a tool path from a CAD file and proof the tool path from a CAD file.11. satisfactorily perform on written, oral, and practical examinations12. satisfactorily perform on outside assignments including writing assignments13. contribute to class discussions14. maintain attendance per current policy

LECTURE OUTLINE:Lecture Topic Text Reference Page Contact Hrs.

Unit 1 CNC/CAD/CAM Overview1.01 Description of CNC handouts1.02 Computer Systems Review and1.03 Job Opportunities in the CAM

Field overheads1.04 Employability Skills in CAM

Unit 2 The Structure of a CAM System2.01 From Print to Part 5-62.02 The Graphical User Interface 11-182.03 Working with SMARTCAM's

Display Areas 37-41Unit 3 Process Planning (Mill)

3.01 Interpreting a Part Print handouts3.02 Creating a Job Sheet from a

Part Print overheads3.03 Entering Tool Information into

the Job Plan 28-29Review for Quiz 1Quiz 1Return and Discuss Quiz 1

Unit 4 Working with a CNC ProcessModel (Mill)

4.01 Starting a CNC Process Model 19-24; 37-424.02 Roughing and Finishing an Existing

Process Model and4.03 Modifying Existing Geometry handouts4.04 Methods for Creating Geometry

for the Process ModelUnit 5 Generating CNC Code with a

CAM System5.01 Basic NC Code Structure overheads5.02 Locating the Data Source for

Code Generation5.03 How a CAM System Generates

CNC CodeReview for Quiz 2

178

Unit 6QUIZ 2Additional Modeling Practices

6.01 Pocketing and Facing withIslands/Notches, etc. 21-22

6.02 Re-sequencing MachiningOperations

6.03 Rotate, Move, Copy, Mirrorand Scale Commands overheads

Unit 7 Process Planning (Lathe)7.01 CNC Lathe Coordinate Systems overheads7.02 Carbide Tooling for CNC Lathes overheads7.03 Entering Tool Information into

the Job Plan overheadsUnit 8 Working with a CNC Process

Model (Lathe)8.01 Turning, Facing, Boring and

Drilling overheadsReview for Quiz 3Quiz 3

Unit 9 Additional Modeling Practices9.01 Threading Cycles and Grooving

Cycle overheads9.02 Roughing for Turning and Facing

OperationsUnit 10 Working with CAD Geometry

10.01 Conventions of CAD Geometry overheads10.02 Using a CAM System to Transfer

CAD Geometry10.03 Working with CAD Geometry in

a CAM System10.04 Transferring a CNC Process

Model to a CAD SystemQuiz 4 ReviewQuiz 4


LAB OUTLINE:Lab Topics Contact Firs.

Job Plan 2"Tryit" Exercises 1 thru 5 2Simple Part Profile (Mill 1) 2Simple Part Profile (Mill 2) 2Profile with Roughing (Mill 3) 2Using Multiple Tools (Mill 4) 2Using Multiple Tools and Roughing (Mill 5) 2Using Layers, Islands and Rough Facing (Mill 6) 3Rough Processing (Mill 7) 2

179

Converting Geometry to Profiles, Using Copy (Mill 8)Complex Part Geometry With Multiple Tools (Mill 9)Using Rotate and Move Commands (Mill 10)Roughing, Pocketing Drilling and Tapping (Mill 11)Complex Modeling, Rotating, Moving Scaling (Mill 12)Turning Lengths and Diameters (Lathe 1)O.D. and I.D. Contour Turning (Lathe 2)Multiple Tool with Roughing (Lathe 3)

Total Lab Hours


22223

222

36


1. Perform Basic Arithmetic FunctionsAdd, subtract, multiply and divide whole numbersAdd, subtract, multiply, and divide fractionsAdd, subtract, multiply, and divide decimals

a.b.c.



4. Utilize Trigonometric Functionsa. Solve for unknown anglesb. Solve for unknown sides

5. Calculate Speeds and Feeds for Machining Using SMARTCAM's Job Plan Modulea. Calculate RPM for various metals and various toolsb. Calculate feed for various metals, tools, and depths ofcut

6. Locate Machining Points from a Datum Pointa. Identify points using the Cartesian coordinate systemb. Identify points using the absolute dimensioning systemc. Identify points using the incremental dimensioning system

B. INTERPRET ENGINEERING DRAWINGS AND CONTROL DOCUMENTS1. Review Blueprint Notes and Dimensions

a. Interpret basic blueprint terminologyb. Identify the types of dimensionsc. Identify general note symbolsd. Locate notes on a printe. Interpret commonly used abbreviations and terminologyf. Determine tolerances associated with dimensions on a drawingg. Determine the tolerance for a reference dimensionh. Determine the surface finish for a given parti. List the essential components found in the general drawing notes

180

2. Identify Basic Layout of Drawingsa. Interpret the meaning of lines used within a drawingb. Identify item number symbolsc. Identify general note symbolsd. List the essential components found in the title blocke. Locate bill of materials in a drawingf. Identify the components found in the revision block

3. Identify Basic Types of Drawingsa. Interpret information found in orthographic viewsb. Identify positions of views (top, front, side, and auxiliary)c. Visualize one or more views from a given viewd. Identify isometric viewse. Identify exploded isometric drawingsf. Identify assembly drawings




a. Discuss production scheduleb. Discuss Material Resource Planning (MRP)c. Discuss inventory control records


C. RECOGNIZE DIFFERENT MANUFACTURING MATERIALS & PROCESSES1. Identify Materials With Desired Properties

a. Discuss classification system for metalsD. PERFORM ADVANCED MACHINING PROCESSES

1. Prepare and Plan For CNC Machining Operationsa. Read and interpret blueprintsb. Plan CNC machining operationsc. Calculate speeds, feeds, and depth of cut for various CNC machine



a. Understand machinability and chip formationb. Select proper insert materials and geometryc. Assemble tooling componentsd. Select correct tooling systemse. Identify tooling cost factors

3. Program CNC Machinesa. Identify CNC applicationsb. List various types of CNC machinesc. Discuss CNC machine control systemsd. Describe absolute and incremental coordinate systemse. Plan and write programs for CNC lathesf. Plan and write programs for CNC mills

4. Operate CNC Machining Centers (Mills)a. Install and align work holding devicesb. Load/align materials into the machinec. Load tools into machined. Establish tool length offset for each toole. Establish/set machine referencef. Load programs into CNC millg. Demonstrate working knowledge of all controls on the MCUh. Demonstrate proper operation of CNC machining center to include "dry

run" and final productioni. Edit CNC programs for optimum part productionj. Operate machine in DNC mode if that capability exists

5. Download Programs Via Networka. Download programs from the networkb. Upload programs to the networkc. Perform edit and print functions via network

6. Program CNC Machines using a CAM systema. Create Job Plan for machining operationsb. Construct part geometryc. Program tool path for roughing and finishing operationsd. Verify tool pathe. Generate CNC code

E. USE COMPUTERS1. Use Computer Operating Systems

a. Use basic computer terminology appropriately and accuratelyb. Boot the computer and recognize the basic components of DOSc. Use DOS to perform file managementd. Use DOS to perform directory management


The Secretary's Commission on Achieving Necessary Skills (SCANS), U.S. Department ofLabor,has identified in its "AMERICA 2000 REPORT" that all students should develop a new set ofcompetencies and foundation skills if they are to enjoy a productive, full and satisfying life.These are in addition to the'Technical Workplace Competencies required by industry. SCANS is

182

made up of five competencies and a three-part foundation of skills and personal qualities thatare needed for solid job performance.




machining3. provide a self-evaluation of performance based on the time and quality of



2. provide individual assistance/direction to peers as requested3. produce machine parts to acceptable levels of quality as required4. works well with all members of the classInformation: Acquires and uses information1. read and interpret blueprints2. organize and apply theories of machine tool operation







a. applies appropriate preventative maintenanceb. when operating machines


listens and speaks.63

1. Reading: Locates, understands, and interprets written information inprose and in documents such as manuals, graphs, and schedulesa. studies student laboratory manualb. interprets blueprints and technical drawingsc. read/studies textbookd. follow a daily laboratory schedule to maintain appropriate time-line



3. Arithmetic/Mathematics: Perform basic computations andapproachespractical problems by choosing appropriately from a variety ofmathematical techniquesa. determines optimum machining speeds, feeds, and depth ofcutb. calculates "value added to the part"c. taps and threadsd. keeps a running computation of individual gradee. interconverts fractions to decimal expressions








184

3. Seeing Things In the Mind's Eye: Organizes, andprocesses .symbols,pictures, graphs, objects, and other informationa. interprets technical drawingsb. interprets technical illustrations and symbolsc. understands both written and verbal instructionsd. assimilates process during instructor demonstrations







Personal Qualities: Displays responsibility, self-esteem, sociability, self-management, and integrity and honesty.I. Responsibility: Exerts a high level of effort andperseveres towards goal










individual attention)

1.85

4. Self-Management: Assesses self accurately, sets personal goals,monitors progress, and exhibits self-controla. perform in-process quality checks on machined partsb. maintain a record of academic achievement (individual gradebook)c. make accommodations to laboratory schedules due to broken


S. Integrity/Honesty: Chooses ethical courses of actiona. accept the responsibility for own actionsb. exhibit personal honesty at all timesc. accept the challenge of doing your own work in the laboratory,



1. SMARTCAM Advanced 3-D Machining Reference Manual2. Technology of Machine Tools, 4th Ed. McGraw Hill Publishers3. Machine Tool Catalogs

MET30201/072396

186


COURSE SYLLABUS

TOOL DESIGN IPrerequisite: MACHINE TOOL PRACTICES I

187


TOOL DESIGN I


COURSE DESCRIPTION:


Students will be assigned specific machining problems involving tool and die design concepts.These projects will be machined using the engine lathe, milling machine, drill press, band saws,surface grinders and various hand tools. Design simplification thru utilization of commerciallyavailable hardware vs. special non 'standard items and the safe use of machine tools will bestressed.

PREREQUISITES: Machine Tool Practices I and Drafting Principles


Textbook: Machine Tool Practices, Kibbe, Neely, and Meyer, Wiley Pub., 4th Ed.Tool Design, LeCain & Goold, published by McGraw-Hill Pub., 4th Ed.

Hand Tools/Quantity Required:Tool Box 1

Safety Glasses 1 pair6 inch Ruler 1/8, 1/16, 1/32, and 1/64 inchBall Peen Hammer 1

10 inch Adjustable Wrench 1

Center Punch 1

Magic marker, Jumbo, black. 1

Aluminum Oxide Cloth, 9" X 11", 240 Grit 2 sheetsAluminum Oxide Cloth, 9" X 11", 320 Grit 2 sheetsTool Steel, 3/8", H.S.S. 2Flat Mill Bastard File, 10 inch. 1

File Handle 1

Allen Wrench Set, Long English and Metric 1 eachCenter Drill #3 1

Scribe 1

Center Gage 1

Screw Driver, 8 inch 1

File Card Brush 1

0-6 inch Dial Calipers 1

Shop Apron (blue denim) 1

Shop Towels (1 roll) 1

le$





laboratory assignments2. apply theories of design considerations to laboratory assignments involving design and

production of jigs, fixtures and other production tooling3. demonstrate a knowledge of alternate manufacturing processes by selecting processes that

reduce or eliminate primary and/or secondary machining operations4. satisfactorily perform on written, oral, and practical examinations5. satisfactorily perform on outside assignments including writing assignments6. contribute to class discussions7. maintain attendance per current policy8. follow all shop rules and safety regulations as stated in the laboratory manual

LECTURE OUTLINE:

Unit 1Unit 2Unit 3Unit 4Unit 5

5.015.025.03

Unit 6Unit 7Unit 8Unit 9Unit 10

Unit 11Unit 12Unit 13Unit 14

Lecture TopicsIntroduction to Tool DesignSafetyTool GrindingReview Measuring ToolsReview Machine Tools andOperationsThe Drill PressEngine LathesVertical Milling MachinesIntroduction to Surface GrindingSpecial ToolingProblems Resulting from DesignToolmaker PracticesTooling Materials and HeatTreatmentLocation and Clamping MethodsDesign of Drill JigsDesign of FixturesUsing Standard vs. Non-StandardParts

Text Reference Page1-5 TD1-13MTP436-443MTP113-186MTP

189

365-402MTP429-535MTP553-577MTP671 -719MTP26-112TD3-6TD26-128TD

162-202TD493-515TD540 -564TD573-604TD

Contact Hrs.



Identifying Design Problems 10Solving Manufacturing Problems 24Evaluating the Design Considerations 2

Total Lab Hours 36



1 Follow Safety Manuals and All Safety Regulations/Requirementsa. Assume responsibility for the personal safety of oneself and othersb. Develop a personal attitude towards safetyc. Interpret safety manual directivesd. Comply with established company safety practicese. Complete forms/paperwork as required


3. Follow Safe Operating Procedures for Hand and Machine Toolsa. Identify and understand safe machine operating procedures.b. Demonstrate safe machine operation


5. Apply Ergonomic Principles to the Workplacea. Define ergonomicsb. Explain the characteristics and potential impact ofergonomics on design,

productivity, and safetyB. INTERPRET ENGINEERING DRAWINGS AND CONTROL DOCUMENTS

Review Blueprint Notes and Dimensionsa. Explain basic blueprint terminologyb. Identify the types of dimensionsc. Identify general note symbolsd. Locate notes on a printe. Interpret commonly used abbreviations and terminologyf. Determine tolerances associated with dimensions on a drawingg. Determine the tolerance for a reference dimensionh. Determine the surface finish for a given parti. List the essential components found in the general drawing notes

190



4. List the Purpose of Each Type of Drawinga. Discuss purpose of orthographic (3 views) drawingsb. Discuss purpose of isometric drawingc. Discuss purpose of exploded isometric drawingd. Discuss purpose of assembly drawings








191

C. RECOGNIZE DIFFERENT MANUFACTURING MATERIALS ANDPROCESSES1. Identify Materials With Desired Properties

a. Discuss classification system for metalsb. Discuss general characteristics for carbon steels, tool steels, stainless steels,

structural steels, cast irons, aluminum, and other commonly used metalsc. List advantages for considering plastic as a viable materials choiced. List the advantages and disadvantages for each of the following plastic

molding processes: blow, injection, vacuum, extrusion, etc.e. Discuss the advantages for using composites in various manufacturing

applications2. Identify Materials and Processes to Produce a Product

a. Discuss service requirements (in strength, hardness, etc.)b. Discuss fastening processes (i.e., fasteners, welding, bonding, etc.)c. Discuss corrosion resistance methods

3. Describe Heat Treating Processesa. Discuss the reasons for heat treatingb. Discuss the time/temperature chartc. List the different quenching mediumsd. Estimate metal heat temperature by colore. List reasons for stress relieving workpiecesf. Discuss surface hardening processes

4. Perform Heat Treating Operationsa. Harden plain carbon workpieceb. Temper plain carbon workpiecec. Anneal plain carbon workpieced. Case harden workpiece

5. Test Metal Samples for Hardnessa. Perform spark test to test for metal hardnessb. Perform Rockwell hardness tests

D. DEMONSTRATE MEASUREMENT/INSPECTION TECHNIQUES1. Identify Types of Measurement Used in Manufacturing

a. Distinguish between direct and calculated measurementsb. Compute calculated measurementsc. Justify the use of precision measurements in manufacturingd. Discuss the following: precision, reliability and accuracye. Demonstrate general measurement techniquesf. Demonstrate semi-precision measurement techniquesg. Demonstrate precision measurement techniquesh. Document results of measurement activities and calculations

2. Select Proper Measurement Toolsa. Match appropriate measurement tools with various types of measurement

requirementsb. Demonstrate proper measurement tool usagec. List steps of proper measurementd. Explain rationale for each stepe. Identify error possibilities in measurement tool selection

192

f. Identify error possibilities within measurement proceduresg. Identify common conversion error possibilitiesh. Discriminate between accepted measurement procedures and improper

measurement procedures3. Apply Proper Measuring Techniques

a. Explain calibration requirements ofvarious precision instrumentsb. Illustrate measurement differences when taken with calibrated and

non-calibrated instrumentsc. Justify use of particular measurement tools based on tool characteristicsd. Discuss factors affecting accurate measurement (e.g., dirt, temperature)

4. Perform Measurements With Hand Held Instrumentsa. Measure with steel rules (metric and inch)b. Measure with micrometersc. Measure with comparison measuring instruments (e.g., calipers, telescope

gages)d. Measure with direct measuring instruments (e.g., vernier, dial, and digital

instruments)5. Perform Measurements on Surface Plate

a. Describe care of surface plateb. Use surface plate accessories correctly (sine bar, gage blocks, etc.)c. Check for part squarenessd. Check part dimensions for accuracye. Align workpieces using height gage and dial indicators

E. PERFORM CONVENTIONAL MACHINING OPERATIONS1. Prepare and Plan For Machining Operations

a. Read and interpret blueprintsb. Perform basic semi-precision and precision layout as necessaryc. Plan machining operationsd. Understand machinability and chip formatione. Calculate speeds, feeds, and depth ofcut for various machine applicationsf. Determine proper cutting fluids/coolants for machiningg. Use carbides and other tool materials to increase productivityh. Use the Machinery's Handbook as a reference for machine applications

2. Use Proper Hand Toolsa. Use arbor and shop pressesb. Select necessary work-holding devices and hand tools as neededc. Select and use hand filesd. Identify and use hand reamerse. Correctly identify and use hand taps as requiredf Follow tapping procedures to produce internal threadsg. Use thread-cutting dies to produce external threadsh. Operate bench and pedestal grinders safely

3. Operate Power Sawsa. Use reciprocating and horizontal band cutoff machinesb. Operate abrasive and cold sawsc. Prepare and use the vertical band sawd. Weld a bandsaw blade

193

4. Operate Drill Pressesa. Describe the different types of drill presses found in the machine shopb. Describe and use standard drilling toolsc. Sharpen a drill bit using a bench or pedestal grinderd. Setup the drill presses for drilling, countersinking, counterboring, reaming,

and tapping operationse. Drill holes using drill jigs

5. Operate Vertical Milling Machinesa. Demonstrate the use of all controls on the vertical milling machineb. Align the vertical milling machine headc. Select, align and use workholding devicesd. Select milling tool holderse. Select milling cuttersf. Perform all standard vertical milling operationsg. Bore a hole using the offset boring headh. Machine angles using sine bar and gage blocksi. Setup and use special vertical mill fixturesj. Setup and machine dovetailsk. Machine keyways


milling machinec. List several common work holding methodsd. Use plain milling cutterse. Use side milling cuttersf. Use face milling cuttersg. Setup and use special horizontal mill fixtures

7. Operate Metal Cutting Lathesa. Demonstrate the use of all controls on the engine latheb. Discuss standard tools and toolholders for the lathec. Face and center drill parts correctlyd. Drill, ream and bore on the lathee. Turn between centersf. Discuss alignment of lathe centersg. Make all calculations, lathe adjustments and settings to machine

sixty-degree internal and external threadsh. Discuss thread fit classificationsi. Make all calculations, lathe adjustments and settings to machine an Acme

threadj. Describe the common tapers used in the machine shopk. Discuss taper cutting and calculations for the lathe1. Setup and use the taper attachment found on most lathesm. Use follower rests and steady restsn. Use HSS cutting toolso. Use carbide cutting toolsp. Setup and operate tracer lathes

194

q. Setup and operate turret lathes8. Operate Grinding/Abrasive Machines

a. Discuss the selection and identification of grinding wheelsb. Inspect, mount, true, dress, and balance grinding wheelsc. Discuss the selection of grinding fluidsd. Operate horizontal spindle reciprocating table surface grinderse. Operate cylindrical grindersf. Operate ID and OD grindersg. Setup and operate tool and cutter grindersh. Discuss common problems and solutions in surface grindingi. Operate honing machinej. Operate lapping machines

F. PERFORM WELDING OPERATIONS1. Weld With Shielded Metal Arc Welding (SMAW) Process

a. Discuss factors for welding electrode selectionb. Adjust welding amperage setting for each applicationc. Demonstrate proper use of safety equipmentd. Weld beads on plate (flat, horizontal, and vertical)e. Weld tee joints (flat, horizontal, and vertical)f. Weld pipe jointsg. Discuss weld inspection factors and techniques

2. Weld/Cut With Oxyacetylenea. Setup and break down the oxyacetylene welding/cutting stationb. Discuss proper settings for oxyacetylene regulatorsc. Discuss factors that determine torch welding and cutting tip selectiond. Demonstrate routine torch maintenance procedurese. Weld beads on plate (with and without filler) in the flat and horizontal

positionsf. Weld square groove butt joints in the flat and horizontal positionsg. Braze weld beads on plate in the flat positionh. Make square cuts to a straight line with the cutting torchi. Demonstrate proper use of safety equipment

G. PERFORM DRAFTING TASKS.1. Demonstrate Traditional Mechanical Drafting Skills

a. Form freehand vertical Gothic upper-case letters and numerals of correctshape and space


c. Demonstrate proficiency with the engineers and metric scalesd. Execute geometric constructions with no mistakes in tangent points, line

quality or layout worke. Accurately draw the missing view or line in a multiview drawingf. Make or complete a sectional instrument drawing, given one or more viewsg. Develop satisfactory working drawings of simple machine components to


h. Discuss the differences in standard engineering drawings and tool drawings

195

i. Develop satisfactory tool drawings for drill jigs, milling fixture, andinspection fixtures

2. Make Tool Drawingsa. Discuss the differences in tool drawings verses regular mechanical

drawingsb. Design and draw a simple drill jig using accepted practicesc. Design and draw a simple milling fixture using accepted practices






machining3. complete a stock request form for required material4. provide a self-evaluation of performance based on the time and quality of



2. provide individual assistance/direction to peers as requested3. produce tools and fixtures to acceptable levels of quality as required4. works well with all members of the classInformation: Acquires and uses information1. read and interpret blueprints2. organize and apply theories of tool design3. perform basic semi-precision and precision layout as necessary

D. Systems: Understands complex inter- relationships1. demonstrate knowledge of the following systems:

a. laboratory organization structure: physical and socialb. organization of personnel and facilities on the shop floorc. systematic approach to the metal removal processd. dimensioning and measurement systems

196

e. systematic organization of training materials2. monitors and corrects performance during

a. the machining processb. adjustments of individual laboratory work schedulec. constantly evaluating the quality of work to achieve acceptable





of the laboratory




and product completion2. Writing: Communicates thoughts, ideas, information, andmessages in


3. Arithmetic/Mathematics: Perform basic computations and approachespractical problems by choosing appropriately from a variety ofmathematical techniquesa. determines optimum machining speeds, feeds, and depth of cutb. calculates "value added to the part"c. aligns machine and/or work holding deviced. taps and threadse. keeps a running computation of individual gradef. interconverts fractions to decimal expressionsg. use protractors to lay-out angle machiningh. use trigonometry to solve angle and taper calculations


S. Speaking: Organizes ideas and communicates orallya. participates in classroom discussionsb. organize ideas and communicate specific questions to the instructorc. verbally affirms understanding of a concept, procedure, or required





2. Problem Solving: Recognizes problems and devises and implementsplanof actiona. use tool design concepts to design a tool which will work

acceptablyb. seeks additional instruction/clarification for assignment completionc. balances social and academic life/responsibilitiesd. accepts responsibility

3. Seeing Things In the Mind's Eye: Organizes, andprocesses symbols,pictures, graphs, objects, and other informationa. interprets technical drawingsb. interprets technical illustrations and symbolsc. understands both written and verbal instructionsd. assimilates process during instructor demonstrations







I n

















1. Tool Design, 4th Edition, Donaldson, Lecain, and Gold. McGraw Hill Pub.2. Technology of Machine Tools, 4th Ed. McGraw Hill Publishers3. Machinery's Handbook, Industrial Press

1.4E7216

01/072396

199


COURSE SYLLABUS

STRENGTH OF MATERIALS200


STRENGTH OF MATERIALS


COURSE DESCRIPTION:


This is a course designed to give the student a basic understanding of the internal stresses anddeformation of elastic bodies resulting from the action of external forces. The student should beable to: determine internal stresses due to external loads, make calculations for riveted joints withspecified loads, analyze welded joints, determine the centroid and moment of inertia of a built-upsection.

PREREQUISITES: Statics


Textbook: Applied Statics and Strength of Materials, Spiegel and Limbunner,Merrill Publishers

Lab Manual: NONE

Required Materials: Engineering paper, greenScientific Calculator



Laboratory: Laboratory assignments will require student to solve appropriate problemsinvolving the mechanical and physical properties ofvarious materials.



201

LECTURE OUTLINE:Lecture Topics Text Reference Page

1 Centroids and Centers of Gravity(Review from MET 205)

.01 Center of Gravity 1821.02 Centroids and Centroidal Axes 1851.03 Centroids and Centodial Axes of

Composite Areas 1862 Area Moments of Inertia2.01 Terms and Definitions 2012.02 Moments of Inertia 2032.03 The Transfer Formula 2072.04 Moments of Inertia of Composite Areas 2082.05 Radius of Gyration 2162.06 Polar Moment of Inertia 2182.07 Chapter Review 2213 Stresses and Strains3.01 Tensile and Compressive Stresses 2273.02 Shear Stresses 2343.03 Tensile and Compressive Strain and

Deformation 2393.04 Shear Strain 2413.05 The Relationship Between Stress and

Strain (Hooke's Law) 2423.06 Chapter 9 Summary 2494 Torsion in Circular Sections4.01 Introduction 3164.02 Torsional Shear Stress 3204.03 Angle of Twist 3284.04 The Transmission of Power by Shafts 3324.05 Chapter 12 Summary 3365 Shear and Bending Moments in Beams5.01 Types of Beams and Supports 3435.02 Types of Loads on Beams 3465.03 Beam Reactions 3475.04 Shear Force and Bending Moments 3525.05 Shear Diagrams 3605.06 Moment Diagrams 3715.07 Sections of Maximum Moment 3775.08 Moving Loads 3815.09 Chapter 13 Summary 3856 Stresses in Beams6.01 Tensile and Compressive Stresses Due

to Bending 3956.02 The Flexure Formula 3976.03 Computation of Bending Stresses 4016.04 Shear Stresses 407

202

Contact Hrs.

6,05 The General Shear Formula 4086.06 Shear Stresses in Structural Members 4116.07 Beam Analysis 4216.08 Chapter 14 Summary 4267 Design of Beams7.01 The Design Process 4377.02 The Design of Steel Beams 4407.03 The Design of Timber Beams 4507.04 Chapter 15 Summary 4598 Review and Testing



Area Moments of Inertia (Chapter 8, Problems 1, 2, 7, 9, and 22) 4Stresses and Strains (Chapter 9, Problems 2, 4, 7, 8, 12, 13, 14, 16, 25,

and 28) 8Torsion in Circular Sections (Chapter 12, Problems 1-6, 11, 12, 14, and 24) 8Shear and Bending Moments in Beams (Chapter 13, Problems 2, 4, 6, 10, 12,

13, 15, 16, 17, and 18) 8Stresses in Beams (Chapter 14, Problems 3, 5, 8, 9, 11, 15, and 32) 4Design of Beams (Chapter 15, Problems 2, 4, 5, 6, and 12) 4

Total Lab Hours 36












5. Solve Static Systems for Resultant Forcesa. Solve for the following coplanar force systems: parallel, concurrent and

nonconcurrentb. Solve for the following noncoplanar force systems: parallel, concurrent

and nonconcurrent6. Solve Engineering Equations

a. Solve linear algebraic equations for an unknownb. Solve a system of linear equations with two unknownsc. Solve right triangles for unknown sides or anglesd. Use the law of sines and cosines to solve obtuse triangles with unknown

sides and anglese. Calculate factors of friction

7. Use All Functions of a Scientific Calculatora. Apply all trigonometric functionsb. Apply all algebraic functionsc. Apply all statistical functions

8. Determine Strengths of Materials for Various Applicationsa. Discuss stress and deformationb. List properties of materials (e.g., strength, elasticity, stiffness, ductility,

hardness)c. Calculate stresses and design of jointsd. Discuss advantages and disadvantages of different fastening techniquee. Discuss problems related to torque-twisting momentsf. Discuss centroids and moments of inertia ofareas


a. Explain basic blueprint terminologyb. Identify the types of dimensionsc. Identify general note symbolsd. Locate notes on a print

204

e. Interpret commonly used abbreviations and terminologyf. Determine tolerances associated with dimensions on a drawingg. Determine the tolerance for a reference dimensionh. Determine the surface finish for a given parti. List the essential components found in the general drawing notes






machining3. complete a stock request form for required material4. provide a self-evaluation of performance based on the time and quality of



2. provide individual assistance/direction to peers as requested3. works well with all members of the classInformation: Acquires and uses information1. read and interpret blueprints2. organize and apply theories of machine tool operation



2. monitors and corrects performance duringa. application of statics principles and structural analysisb. adjustments of individual laboratory work schedule

.05

c. constantly evaluating the quality of work to achieve acceptablestandards

d. maintains record of evaluations and sets individual goalsE. Technology: Works with a variety of technologies

1. uses a scientific calculator2. applies appropriate procedures and uses appropriate hardware and

software

II. FOUNDATION SKILLSA. Basic Skills: Reads, writes, performs arithmetic andmathematical operations,



and product completion2 Writing: Communicates thoughts, ideas, information, and messages in


3. Arithmetic/Mathematics: Perform basic computations and approachespractical problems by choosing appropriately from a variety ofmathematical techniquesa. determines optimum machining speeds, feeds, and depth ofcutb. calculates "value added to the part"c. aligns machine and/or work holding deviced. taps and threadse. keeps a running computation of individual gradef. interconverts fractions to decimal expressionsg. use protractors to lay-out angle machiningh. use trigonometry to solve angle and taper calculations


5. Speaking: Organizes ideas and communicates orallya. participates in classroom discussionsb. organize ideas and communicate specific questions to the instructorc. verbally affirms understanding ofa concept, procedure, or required

skill


B. Thinking Skills: Thinks creatively, makes decisions, solves problems, visualizes,knows how to learn and reasons.1. Decision Making: Specifies goals and constraints, generates alternatives,



3. Seeing Things In the Mind's Eye: Organizes, andprocesses symbols,pictures, graphs, objects, and other informationa. . interprets technical drawingsb. interprets technical illustrations and symbolsc. understands both written and verbal instructionsd. assimilates process during instructor demonstrations





of the operation and the attitude and skill of the machinistc. understands the relationship between different materials and the

principles of statics and mechanics applied to these materialsPersonal Qualities: Displays responsibility, self-esteem, sociability, self-management, and integrity and honesty.1. Responsibility: Exerts a high level of effort and perseveres towards goal





2. Self-Esteem: Believes in own self-worth and maintains a positive view ofself

a. learns to take pride in his or her work through positivereinforcement

b. sees himself or herself as an asset to the class through continuedcontributions to the group and a shared common goal

c. understands that an individual with a positive attitude and the beliefin their own abilities will systematically seek solutions and be avaluable employee








1. Machinery's Handbook, Industrial Press2. Applied Statics and Strength of aterials, Spiegel and Limbunner, Merrill Publishers

ME731201/072396

208

IIIIIIII

I

I

I

I

1

1

I

III

I


COURSE SYLLABUS

CAD/CAM IIPrerequisite: CAD/CAM I

209


CAD/CAM II


COURSE DESCRIPTION:


A continuation of CAD/CAM I with advanced utilization of "SMARTCAM". Topics will includethe following: 3-D Process Modeling, creation and utilization of different work planes, 4th and5th axis programming, creation of tool path for surface primitives, swept surfaces, translatedsurfaces,' sculpted surfaces, ruled surfaces, and coons surfaces. Additional topics include:projecting, intersecting, blending, and trimming one'surface to another surface. Students willprogram both a simple punch and die set and a simple injection mold cavity.

PREREQUISITES: CAD/CAM I


Textbook: SMARTCAM-3D, Pelton, TSTC Pub., 2nd Ed.Lab Manual: NONE

Materials and/or Supplies: 2 - double sided, high density 3 1/2" floppy diskettes


Lecture: Didactic presentations will include lecture, overheads and SMARTCAM andsoftware demonstrations.

Laboratory: Laboratory will be a "hands-on" (computer based) process modeling"SMARTCAM" System.

Method of Evaluation: A student's grade will be based on multiple measures of performance.The assessment will measure development of independent critical thinking skills and will includeevaluation of the student's ability to:1. demonstrate the comprehension of Work Plane and Plane Coordinates and the ability to

change from one work plane to another work plane to perform work2. demonstrate the ability to construct surface boundaries on various work planes3. demonstrate the ability to both identify and create various surfaces which are available in

the SMARTCAM 3-D system to include:Surface Primitives: Plane, Cone, Cylinder, Sphere, TonsComposite Surfaces: Spun, Translated, Ruled, Lofted, Form Patch, Coons

4. generate tool path in both the generator, radial and planar directions5. develop tool path geometry and part geometry to produce accurately coded information

for 3-D CNC mill parts

1

1

6. demonstrate the 3-D techniques of projection, intersection, surface trim and blend7. utilize plotters and printers to produce accurate documents8. perform and demonstrate the ability to transfer CAD files to CAM files and CAM files to

CAD files9. generate a tool path from CAD to CAM files10. edit a tool path from a CAD file and proof the tool path from a CAD file11. satisfactorily perform on written, oral, and practical examinations12. satisfactorily perform on outside assignments including writing assignments13. contribute to class discussions14. maintain attendance per current policy


Unit 1 Understanding 3-D Parts 1-91.01 Coordinate Systems in

SMARTCAM's Advanced3-D Machining 1

1.02 Choosing Active Work Planes 41.03 World vs. Local Coordinate

Inputs 41.04 Working with Geometry on

Work Planes 61.05 Planning and Creating the

3-D Model 7Unit 2 Surface Primitives 9-11

2.01 Understanding Surfaces 92.02 Types of Surfaces 10-112.02.1 Plane 10-112.02.2 Cone 10-112.02.3 Cylinder 10-112.02.4 Sphere 10-112.02.5 Tons 10-11

Unit 3 Composite Surfaces 123.01 Spun Surfaces 123.02 Translated Surfaces 123.03 Ruled Surfaces 12

Review for Quiz 1QUIZ 1

Unit 4 Sculpted Surfaces 13-144.01 Lofted Surfaces 134.02 Form Patch Surfaces 13-144.03 Coons Surfaces 14

Unit 5 Modeling 3-D Surface Toolpaths5.01 Expert Tipscfor Model Construction5.02 Using Wireframe Geometry for

Surface E Definition5.03 Creating 3-D Surface Tool Paths 211

5.04 Creating a Blend Surface5.05 Planar Cuts


Unit 6 Additional Modeling Practices6.01 Projection6.02 Intersection6.03 Surface Trim and Blend6.04 Editing Surfaces




Understanding Work Planes 2Surface Primitives 3Composites Surfaces 2Sculpted Surfaces 2Process Modeling (Drawing) 24a. Wax Blockb. Pyramidc. Palaced. Round Punche. Ruled Blockf. Crossg. Round Dieh. Shift Booti. Finj. KnobmoldFinal Project 3

Total Lab Hours 36





3. Interconvert Metric/English measurements

212

a. Convert English dimensions to Metricb. Convert Metric dimensions to Englishc. Use Metric/English conversion chart

4. Utilize Trigonometric Functionsa. Solve for unknown anglesb. Solve for unknown sides

5. Calculate Speeds and Feeds for Machining Using SMARTCAM's Job Plan Modulea. Calculate RPM for various metals and various toolsb. Calculate feed for various metals, tools, and depths of cut

6. Locate Machining Points from a Datum Pointa. Identify points using the Cartesian coordinate systemb. Identify points using the absolute dimensioning systemc. Identify points using the incremental dimensioning systemd. Identify points using both world and local coordinate values

B. INTERPRET ENGINEERING DRAWINGS AND CONTROL DOCUMENTS1. Review Blueprint Notes and Dimensions


2. Identify Basic Layout of Drawingsa. Identify types of lines within a drawingb. Identify item number symbolsc. Identify general note symbolsd. List the essential components found in the title blocke. Locate bill of materials in a drawingf. Identify the components found in the revision block



5. Practice Geometric Dimensioning and Tolerancing (GD&T) Methodologya. Identify the purpose of GD&Tb. Identify symbols for controlling location (or true position) of part featuresc. Identify symbols for controlling form (or alignment) of part featuresd. Identify symbols for showing datums and basic dimensions on drawings

213

e. Identify symbols for Maximum Material Size (MMS) and Regardless ofFeature Size (RFS)

6. Describe the Relationship of Engineering Drawings to Planninga. Discuss production scheduleb. Discuss Material Resource Planning (MRP)c. Discuss inventory control recordsd. Utilize "SMARTCAM's" Job Plan to determine machine operations

sequences7. Analyze Bill of Materials (BOM)

a. Discuss components found on BOMb. Determine materials needed to produce the partc. Determine quantities necessary to produce the partd. Submit completed stock request form as requirede. Submit completed tool request form as needed

C. RECOGNIZE DIFFERENT MANUFACTURING MATERIALS ANDPROCESSES1. Determine Operations to be performed

a. Identify workpiece material requirementsb. Identify cutting tool material requirements speeds, feeds, depth of cutsc. Identify setup parameters, strength and ridigity of setup, strength and

ridigity of the workpiece, power requirements, finish and tolerances, use ofcoolants

2. Sequence Machine Operationsa. Utilize "SMARTCAM's" 3-D Modeling Toolb. Verify toolpath


The Secretary's Commission on Achieving Necessary Skills (SCANS), U.S. Department of Labor,has identified in its "AMERICA 2000 REPORT" that all students should developa new set ofcompetencies and foundation skills if they are to enjoy a productive, full and satisfying life.These are in addition to the Technical Workplace Competencies required by industry. SCANS ismade up of five competencies and a three-part foundation of skills and personal qualities thatare needed for solid job performance.





1. complete assigned responsibilities within the laboratory serving as amember of the team

2. provide individual assistance/direction to peers as requested3. works well with all members of the classInformation: Acquires and uses information1. read and interpret blueprints2. organize and apply theories of machine tool operation


a. laboratory organization structure: physical and socialb. systematic approach to the metal removal processc. dimensioning and measurement systemsd. systematic organization of training materials




to produce a machined part to acceptable standards

II. FOUNDATION SKILLSA. Basic Skills: Reads, writes, performs arithmetic andmathematical operations,





3. Arithmetic/Mathematics: Perform basic computations and approachespractical problems by choosing appropriately from a variety ofmathematical techniquesa. determines optimum machining speeds, feeds, and depth of cutb. calculates "value added to the part"

4. Listening: Receives, attends to, interprets, and responds to verbalmessages and other cuesa. assimilate classroom instructionb. interpret and assimilate video instruction

21.

c. observe laboratory demonstrationsd. seek and receive individualized instruction in the laboratory



of the laboratoryThinking Skills: Thinks creatively, makes decisions, solves problems, visualizes,knows how to learn and reasons.1. Decision Making: Specifies goals and constraints, generates alternatives,







will improve the skill of the technicianb. understands the relationship between different metals and the tool





prompt to every class and has prepared for the day's work

216

c. develops an understanding good students know what they are goingto do in class and does not waste time

d. develops a fine work-ethic2. Self-Esteem: Believes in own self-worth and maintains a positive view of

selfa. learns to take pride in his or her work through positive






monitors progress, and exhibits self-controla. perform in-process quality checks on machined partsb. maintain a record of academic achievement (individual gradebook)c. make accommodations to laboratory schedules due to broken





1. SMARTCAM Advanced 3-D Machining Reference Manual2. Technology of Machine Tools, 4th Ed. McGraw Hill Publishers3. Machine Tool Catalogs

MET31801/072496


COURSE SYLLABUS

COMPUTER INTEGRATEDMANUFACTURING

218


COMPUTER INTEGRATED MANUFACTURING


COURSE DESCRIPTION:


An introduction to fundamentals of Computer Integrated Manufacturing (CIM). This include thekey elements and technologies involved, the typical applications that exist in industry today andthe major trends that will affect the future of manufacturing.

PREREQUISITES: NONE


Textbook:

Lab Manual:

Computer-Automated Manufacturing, John H. Powers Jr., McGraw-Hill Publishers, 1987NONE

Hand Tools/Quantity Required:Safety Glasses6 inch Ruler0-6 inch Dial CalipersPencilScientific Calculator31/2 high density disk





laboratory assignments2. apply theory to laboratory assignments3. satisfactorily perform on written, oral, and practical examinations4. satisfactorily perform on outside assignments including writing assignments5. contribute to class discussions6. maintain attendance per current policy7. follow all shop rules and safety regulations as stated in the laboratory manual219


Introduction to Computer-AutomatedManufacturingWhat is Computer-Automated

4

Manufacturing 2Why Do We Use Computers in

Manufacturing 10Computer Control 18Computer Applications in Manufacturing 28Trends in the Use of Computers in

Manufacturing 38Computer Technologies 4Computer Hardware 48Computer Software 63Micro and Minicomputers 77Artificial Intelligence 92Computer Automated Engineering 4Computer Graphics Technology 112Computer Automated Design 132Computer Tools for Engineering Analysis 148Robotics 4Basic Robotic Technology 164Intelligent Robotics Systems 176Robot Application 195Implementing Robotics in Manufacturing 207Manufacturing Systems 4System Architecture 218Management Systems 234Integrated Manufacturing Systems 254Computer Automated Manufacturing 4Automated Manufacturing 274Implementing CAM 290



CIM Lab Safety 2CIM System Components 6a) Conveyor Systemsb) Automated Storage and Retrieval Systemsc) PUMA 562 Robotd) IBM 7576 Robote) CNC Vertical Milling Centerf) CNC Turning Centerg) Vision Systems

220

h) Barcode SystemsCIM Software 4Robot Programming 4Programming CNC Machining Centers 4Manufacturing Cells/System Integration 4

Total Lab Hours 24



1. Follow Safety Manuals and All Safety Regulations/Requirementsa. Assume responsibility for the personal safety of oneself and othersb. Develop a personal attitude towards safetyc. Interpret safety manual directivesd. Comply with established company safety practicese. Complete forms/paperwork as required




5. Apply Ergonomic Principles to the Workplacea. Define ergonomicsb. Explain the characteristics and potential impact of ergonomics on design,

productivity, and safetyB. INTERPRET ENGINEERING DRAWINGS AND CONTROL DOCUMENTS

1. Describe the Relationship of Engineering Drawings to Planninga. Discuss production scheduleb. Discuss Material Resource Planning (MRP)c. Discuss inventory control recordsd. Discuss shop floor routing documents


221


C. USE COMPUTERS1. Use Computer Operating Systems


2. Use Computer Inquiry Systemsa. Log in to a multi-user systemb. Access system for needed informationc. Print reports as necessary

3. Use Various Computer Applicationsa. Load word processor, create, save, edit, and print a documentb. Load spreadsheet, create, save, retrieve, erase, edit, and print a worksheetc. Load database programs, create, edit, delete, and print records in a

database file4. Recommend and Implement CIM Technologies

a. Use automatic storage & retrieval systemb. Use bar coding technologyc. Understand robot applicationsd. Program robotse. Use shop floor control systemsf. Understand machine vision systems







work

272


member of the team2. provide individual assistance/direction to peers as requested3. works well with all members of the classInformation: Acquires and uses information1. understand and recommend CIM related technologies


a. laboratory organization structure: physical and socialb. organization of personnel and facilities on the shop floorc. systematic organization of training materials






of the laboratory






3. Arithmetic/Mathematics: Perform basic computations and approachespractical problems by choosing appropriately from a variety ofmathematical techniquesa. calculates "value added to the part"

b. keeps a running computation of individual grade4. Listening: Receives, attends to, interprets, and responds to verbal

messages and other cuesa. assimilate classroom instructionb. interpret and assimilate video instructionc. observe laboratory demonstrationsd. seek and receive individualized instruction in the laboratory














224












monitors progress, and exhibits self-controla. maintain a record of acadeniic achievement (individual grade book)b. make accommodations to laboratory schedules due to broken





1. Machinery's Handbook, Industrial Press2. Computer-Automated Manufacturing, John H. Powers Jr., McGraw-Hill Pub., 1987

ME731501/072496


COURSE SYLLABUS

QUALITY ASSURANCE ANDSTATISTICAL PROCESS CONTROL

226


QUALITY ASSURANCE ANDSTATISTICAL PROCESS CONTROL


COURSE DESCRIPTION:


An introduction to the concepts of applied quality control systems. Topics covered include:quality responsibility, control chart methods, sampling techniques, reliability applications andcomputer utilization/programs.

PREREQUISITES: NONE


Textbook: Statistical Process Control and Quality Improvement, Gerald Smith,Macmillan Pub., 2nd Ed.

Lab Manual: Quality Control Laboratory Manual, TSTC

Hand Tools/Quantity Required:Safety Glasses6 inch Ruler0-6 inch Dial CalipersPencilScientific Calculator with statistical functions to solve for: means and standard deviation31/2" high density disk





laboratory assignments2. apply theory to laboratory assignments3. satisfactorily perform on written, oral, and practical examinations4. satisfactorily perform on outside assignments including writing assignments

227'41

5. contribute to class discussions6. maintain attendance per current policy7. follow all shop rules and safety regulations as stated in the laboratory manual


Introduction to Statistical ProcessControl1.1 Prevention vs. Detection 21.2 SPC Goals 41.3 Basic Tools of SPC 51.4 Statistical Process Control

Techniques 61.5 The Problem-Solving Model for

an Existing Process 71.6 Designed Experiments 91.7 What is Quality? 10Striving for Quality2.1 Management's Dilemma 142.2 Leadership by Management 152.3 Deming's Way 152.4 Deming's 14 Points for Management 162.5 Crosby's Approach 212.6 A Comparison; Deming vs. Crosby 262.7 Which Way to Top Quality? 262.8 Avoid the Pitfalls in thee Quest for

Quality 272.9 Total Quality Management 29Introduction to Variation an Statistics3.1 Measurement Concepts 373.2 Special-Cause and Common-Cause

Variation 403.3 The Variation Concepts 413.4 Distributions and SPC Goals 433.5 Basic Algebraic Concepts 443.6 Basic Statistical Concepts 50Introduction to The Control ChartConcept4.1 Variables and Attributes 654.2 Preparation for Control Charting 674.3 The General Procedure for an

X-Bar and R Chart 70The Normal Probability Distribution5.1 The Frequency Distribution 855.2 Histograms 895.3 Probability Distribution 97

228

5.4 The Normal Distribution 100Variable Control Charts6.1 X-bar and R Charts 1226.2 The Capability Analysis 1376.3 The Median and Range Charts 1576.4 X-Bar and S Charts 173Variables Charts for Limited Data7.1 Precontrol or Rainbow Charts 2007.2 Compound Probability 2047.3 Modified Precontrol for Tight

Control 2077.4 Charts for Individual Measurements 2137.5 The Modified X-Bar and R Chart

for Small Sets of Data 2297.6 The Nominal X-Bar and R Chart 2337.7 The Transformation X-Bar and

R Chart 237Attributes Control Charts8.1 The Four Types of Attributes

Charts 2528.2 The P Chart 2538.3 The NP Chart 2658.4 The C Chart 2698.5 The U Chart 2738.6 SPC Applied to the Learning

Process 275Interpreting Control Chart9.1 The Random Distribution of Points 2869.2 Freaks 2889.3 Binomial Distribution Applications 2929.4 Freak Patterns 2969.5 Shifts 3029.6 Runs and Trends 3089.7 Cycles 3129.8 Grouping 313Problem Solving10.1 The Problem-solving Sequence 33310.2 Teamwork and Tools for Problem

Solving 33510.3 Brainstorming 33610.4 Flowcharts 33910.5 Story Boards 34210.6 The Cause-and Effect Diagram 34310.7 Pareto Charts 34710.8 Other Graphs for Problem Solving 354Acceptance Sampling11.1 The Sampling Dilemma 420

?29

11.2 Random Sampling 42711.3 Operating Characteristic Curve 42811.4 The Average Outgoing Quality

Curve 44111.5 MLT STD 105D for Inspection

by Attributes 44411.6 The Average Proportion Defective 45711.7 Vendor Certification and Control

Chart Monitoring 462Total Lecture Hours 24


Introduction to SPCVariations, Statistics and HistogramsIntroduction to Control ChartsProbability DistributionVariables Control ChartsPrecontrol ChartsAttribute Control ChartsInterpreting Control ChartsProblem SolvingAcceptance Sampling

Total Lab Hours


Contact Hrs.3

3

3

3

3

3

3

3

3

3

36





4. Maintain a Clean and Safe Work Environmenta. Keep work areas cleanb. Clean machine/hand tools when work is completed

c. Put tools away when work is finishedd. Keep aisles clear of equipment and materials




3. Interconvert Metric/English Measurementsa. Convert English dimensions to Metricb. Convert Metric dimensions to Englishc. Use Metric/English conversion chart

4. Perform Basic Algebraic Operationsa. Express word statements as algebraic equationsb. Solve word statements ass algebraic equations






3. Identify Basic Types of Drawingsa. Identify orthographic viewsb. Identify positions of views (top, front, side, and auxiliary)c. Visualize one or more views from a given view

d. Identify isometric viewse. Identify exploded isometric drawingsf. Identify assembly drawings




a. Discuss production scheduleb. Discuss Material Resource Planning (MRP)c. Discuss inventory control records



'D. RECOGNIZE DIFFERENT MANUFACTURING MATERIALS ANDPROCESSES1. Identify Materials With Desired Properties

a. Discuss classification system for metalsb. Discuss classification systems for non-metals

E. PERFORM MEASUREMENT/INSPECTION1. Identify Types of Measurement Used in the Machine Shop

a. Distinguish between direct and calculated measurementsb. Compute calculated measurementsc. Justify the use of precision measurements in manufacturingd. Discuss the following: precision, reliability , and accuracye. Demonstrate general measurement techniquesf. Demonstrate semi-precision measurement techniquesg. Demonstrate precision measurement techniquesh. Document results of measurement activities and calculations

2. Select Proper Measurement Toolsa. Match appropriate measurement tools with various types of measurement

requirementsb. Demonstrate proper measurement tool usagec. List steps of proper measurement

d. Explain rationale for each stepe. Identify error possibilities in measurement tool selectionf. Identify error possibilities within measurement proceduresg. Identify common conversion error possibilitiesh. Discriminate between accepted measurement procedures and improper

measurement procedures3. Apply Proper Measuring Techniques

a. Explain calibration requirements of various precision instrumentsb. Illustrate measurement differences when taken with calibrated and

non-calibrated instrumentsc. Justify use of particular measurement tools based on tool characteristicsd. Discuss factors affecting accurate measurement (dirt, temperature, etc.)

4. Perform Measurements With Hand Held Instrumentsa. Measure with steel rules (metric and inch)b. Measure with micrometersc. Measure with comparison measuring instruments (i.e., calipers, telescope

gages)d. Measure with direct measuring instruments (i.e., vernier, dial, and digital

instruments)e. Measure with fixed gages (go and not go gages)

5. Perform Measurements on Surface Platea. Describe care of surface plateb. Use surface plate accessories correctly (sine bar, gage blocks, etc.)c. Check for part squarenessd. Check part dimensions for accuracye. Align workpieces using height gage and dial indicators

F. USE COMPUTERS1. Use Computer Operating Systems


2. Use Computer Inquiry Systemsa. Login to a multi-user systemb. Access system for needed informationc. Print reports as necessary

3. Use Various Computer Applicationsa. Load word processor, create, save, edit and print a documentb. Load spreadsheet, create, save, retrieve, erase, edit and print a worksheetc. Load database programs, create, edit, delete, and print. records in a

database fileG. PARTICIPATE IN TOTAL QUALITY AND SPC ACTIVITIES

1. Define Quality in Manufacturing and Explain Importancea. Justify the use of quality in manufacturing systemsb. Identify impact of quality on specific manufacturing processes

2. Implement Concepts of Quality in the Workplace

233

a. Explain how profit is generatedb. Explain how manufacturing costs are determinedc. Explain the effect of quality in profitd. Explain the cost incurred by scrapping parts or correcting parts with

defects3. Apply Principles and Tools of Continuous Quality Improvement

a. Identify the effect of continuous quality improvementb. Demonstrate the ability to apply continuous quality

improvement to the manufacturing process4. Understand and Apply SPC

a. Define SPCb. Identify the relationship between SPC steps and specific

productionc. Apply SPC to specific production processesd. Recognize a standard deviation

5. Evaluate Data to Monitor Productiona. Understand process variationb. Understand probabilityc. Create a Histogramd. Set up and use X-bar, R Chartse. Calculate process capability indexf. Calculate gauge capability

6. Analyze Customer Problems and Recommend Solutionsa. Analyze production specific processesb. Analyze and interpret test data for compliance to specificationsc. Correct production process(if indicated by data)d. Maintain production according to instructions

7. Establish Methods, Plans and Procedures to Maintain Qualitya. Develop a plan utilizing a selected quality control systemb. Evaluate a process selected verse desired goals





234



workInterpersonal: Works with others1. complete assigned responsibilities within the shop floor serving as a

member of the team2. provide individual assistance/direction to peers as requested3. works well with all members of the classInformation: Acquires and uses information1. read and interpret blueprints2. organize and apply theories of machine tool operation








of the laboratory




and product completion

235'

2. Writing: Communicates thoughts, ideas, information, and messages inwriting; and creates documents such as letters, directions, manuals,reports, graphs, and flow chartsa. outline the steps necessary to produce a simple machine partb. maintain a lecture notebookc. submit written responses to chapter question assignmentsd. complete all written assignments

3. Arithmetic./Mathematics: Perform basic computations and approachespractical problems by choosing appropriately from a variety ofmathematical techniquesa. determines optimum machining speeds, feeds, and depth of cutb. calculates "value added to the part"c. aligns machine and/or work holding deviced. keeps a running computation of individual gradee. interconverts fractions to decimal expressions









236


















monitors progress, and exhibits self-controla. perform in-process quality checks on machined partsb. maintain a record of academic achievement (individual gradebook)c. make accommodations to laboratory schedules due to broken

machines/tools

23 7

d. accept the responsibility for self-management5. Integrity/Honesty: Chooses ethical courses of action




1. Machinery's Handbook, Industrial Press2. Statistical Process Control and Quality Improvement, by Gerald Smith, Macmillan

Publishing Company, 1991

64E732401/072496


COURSE SYLLABUS

ENGINEERING TECHNOLOGYPROJECT

239


ENGINEERING TECHNOLOGY PROJECT


COURSE DESCRIPTION:


Different industrial level projects emphasizing manufacturing applications/research in the areas ofCNC, CAD/CAM, CIM, or Plastic Mold Making will be assigned to students utilizing a teamconcept.

PREREQUISITES: NONE


Textbook: NONELab Manual: NONE

Hand Tools/Quantity Required: See basic tool list for Machine Tool Practices I



Laboratory: Laboratory will be a "hands-on" manufacturing assignments which will require theuse of problem solving skills by the students.



LECTURE OUTLINE:

Lecture content will be determined by the instructor based on the manufacturing-relatedexercise(s) which have been selected for the students.

Total Lecture Hours

LAB OUTLINE:

48

Lab activities will be determined by the instructor based on the manufacturing-related exercise(s)which have been selected for the students.

Total Lab Hours 72


Technical competencies will be determined for each individual class. The instructor will selectcertain manufacturing-related problem solving/troubleshooting exercises which will simulateproblems in "the real world." Students will work in teams to solve these problems. This mayrequire machine maintenance, tool/fixture building, or any other activities which will lead to thesuccessful completion of the required assignment. Technical competencies will be covered whichwill reinforce or strengthen the training/education the students have received in prior courses.



--*** THIS COURSE CAN BE CONSIDERED TO BE SCANS INTENSIVE DUE TOTHE NATURE AND STRUCTURE OF THE COURSE.



Students will draw from information learned in their other classes to identifyproblems, organize and plan work, and allocate resources necessary to solveassigned manufacturing-related problems.

241

B. Interpersonal: Works with othersEmphasis will be on working in teams to identify, solve and document solutions toassigned manufacturing-related problems.Information: Acquires and uses informationStudents will draw from information learned in their other classes to identifyproblems, organize and plan work, and allocate resources necessary to solveassigned manufacturing-related problems.

D. Systems: Understands complex inter-relationshipsStudents will draw from information learned in their other classes to identifyproblems, organize and plan work, and allocate resources necessary to solveassigned manufacturing-related problems.

E. Technology: Works with a variety of technologiesStudents will draw from information learned in their other classes to identifyproblems, organize and plan work, and allocate resources necessary to solveassigned manufacturing-related problems. Students will be teamed up withstudents from other disciplines and expected to communicate and work with avariety of technologies to complete the course assignments.



prose and in documents such as manuals, graphs, and schedulesStudents will be expected to use research techniques to find solutions toassigned work. This may include using machinery manuals and charts totroubleshoot equipment.

2. Writing: Communicates thoughts, ideas, information, and messages inwriting; and creates documents such as letters, directions, manuals,reports, graphs, and flow chartsStudents will be expected to document the steps required to complete theassigned work. Students will also be expected to write a final summary ofthe work performed in class.

3. Arithmetic/Mathematics: Perform basic computations and approachespractical problems by choosing appropriately from a variety ofmathematical techniquesStudents may be expected to perform any computations necessary for thecompletion of their tasks.

4. Listening: Receives, attends to, interprets, and responds to verbalmessages and other cuesStudents will have to communicate with the instructor and the other teammembers to successfully complete their tasks. Listening skills will be ofparamount importance in this class.

S. Speaking: Organizes ideas and communicates orallyStudents will be expected to communicate effectively with the instructorand the other team members to successfully complete their tasks. Each

student will be required to give a short (5-10 minute) final oral presentationof their findings/observations taken from the course.

E. Thinking Skills: Thinks creatively, makes decisions, solvesproblems, visualizes,knows how to learn and reasons.1. Decision Making: Specifies goals and constraints, generates alternatives,

considers risks, and evaluates and chooses best alternativeStudents will be required to determine goals and constraints, generatealternative solutions, consider risks/costs, and evaluate and choose the bestalternative to satisfy the requirements of the course.

2. Problem Solving: Recognizes problems and devises and implements planof actionStudents will be expected to recognize problems, devise, and implement aplan of action.

3. Seeing Things In the Mind's Eye: Organizes, andprocesses symbols,pictures, graphs, objects, and other informationStudents will be encouraged to organize, and process symbols, pictures,graphs, objects, and other information in order to solve specificmanufacturing-related problems.

4. Knowing How to Learn: Use efficient learning techniques to acquire andapply new knowledge and skillsStudent learning will be accomplished through problem solving techniquesand team learning.

5. Reasoning: Discovers a rule or principle underlying the relationshipbetween two or more objects and applies it when solving a problemThe format of this class is such that students will be working more withabstract concepts rather than absolute facts. This will help students todevelop thinking and reasoning skills.

C Personal Qualities: Displays responsibility, self-esteem, sociability, self-management, and integrity and honesty.1. Responsibility: Exerts a high level of effort andperseveres towards goal

attainmentSuccessful completion of the course will come only after students havespent sufficient time and efforts in identifying problems, organizing andplanning work, and allocating resources necessary to solve assignedmanufacturing-related problems.

2. Self-Esteem: Believes in own self-worth and maintains a positive view ofselfStudents will be encouraged to use the information learned in their otherclasses to solve practical assignments. Successful completion of thiscourse helps students achieve more of a positive view of their self.

3. Sociability: Demonstrates understanding, friendliness, adaptability,empathy, and politeness in group settingsGroup problem solving activities will develop understanding, friendliness,adaptability, empathy, and politeness towards other team members.

243

MM2201/072496

4. Self-Management: Assesses self accurately, sets personal goals,monitors progress, and exhibits self-controlEach team will be self managed. Team members will be expected to setgoals, assess progress accurately, monitor their progress, and exhibit self-control.

5. Integrity/Honesty: Chooses ethical courses of actionStudents will be expected to make reasonable contributions to team effortsand choose to do things the "right" way.

?44

APPENDIX A - INDUSTRY COMPETENCY PROFILES

The following pages contain the individual Competency Profiles for each of the companiessurveyed by the MAST development center for the occupational specialty area of . TheseCompetency Profiles/skill standards were used to develop the curriculum for the pilot program.

The participation of the companies as partners in the MAST effort is greatly appreciated. Eachcompany has approved the use of its logo in MAST materials. None of the participatingcompanies shall be held responsible or liable for any of the findings of the project.

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rC

oord

inat

e M

easu

rem

ent M

achi

neH

ydra

ulic

/Pne

umat

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rain

ing

Equ

ipm

ent

Ele

ctri

cal T

rain

ing

Equ

ipm

ent

Safe

ty T

rain

ing

Equ

ipm

ent

FUT

UR

E T

RE

ND

S A

ND

CO

NC

ER

NS

Stat

istic

al P

roce

ss C

ontr

olC

ompo

site

sL

aser

Mac

hini

ngA

dvan

ced

Com

pute

r A

pplic

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nsR

obot

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Env

iron

men

tal C

once

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Fibe

r O

ptic

Con

trol

sA

utom

ated

Mat

eria

l Han

dlin

g E

quip

men

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ter

Inte

grat

ed M

anuf

actu

ring

CO

MPE

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RO

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Man

ufac

turi

ngE

ngin

eeri

ng T

echn

icia

n

BE

ST C

OPY

VA

ILA

BL

E

Prep

ared

By

M.A

.S.T

.M

achi

ne T

ool A

dvan

ced

Skill

sT

echn

olog

y Pr

ogra

man

dC

onso

rtia

Par

tner

s(V

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!°11

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1Im

o

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ITY

CO

LL

EG

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r CM

®

247

MA

NU

FAC

TU

RIN

G E

NG

INE

ER

ING

TE

CH

NIC

IAN

.... u

se s

peci

al k

now

ledg

e an

d sk

ills

to r

ecom

men

d an

d/or

impl

emen

t sol

utio

ns f

or s

peci

fic

man

ufac

turi

ng a

pplic

atio

ns.

Dut

ies

A B

248H

moarrvs

ICL

IT/0

1/10

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9

Perf

orm

Mea

sure

men

t&

Ins

pect

ion

4T

asks

A-I

Fol

low

safe

ty m

anua

lsan

d al

l saf

ety

regu

latio

ns/

requ

irem

ents

A-2

Use

prot

ectiv

eeq

uipm

ent

A-3

Fol

low

saae

cmat

ingfor

and

mac

hine

tool

s

A-4

Mai

ntai

n a

clea

n en

d sa

few

ork

envi

ron-

men

t

A-5

Con

trol

fire

haz

ards

A4

App

lyar

nom

icpi

mpl

es to

the

wor

kpla

ce

B-1

Per

form

basi

car

itlun

etic

func

tions

B-2

Int

er-

conv

ert

fiac

tiora

/de

cim

als

B-3

Int

er-

conv

ert M

etri

c/E

nglis

hm

easu

rem

ents

13-4

Per

form

basi

c al

gebr

aic

oper

atio

ns

13-5

Per

form

basi

ctr

igon

omet

ric

func

tions

B.6

spee

ds a

ndfe

eds

for

mac

hini

ng

B-7

Loc

ate

mac

hini

ngpo

ints

fro

mda

tum

poi

nt

134

Perf

orm

calc

ulat

ions

for

sine

bar

and

sine

pla

te

13-9

Cal

cula

tefo

r di

rect

.si

mpl

e, a

ndan

gula

rin

dexi

ng

B-I

0 P

erfo

rmca

lcul

atio

nsne

cess

ary

for

tuni

ng ta

ct*,

B-1

1 So

lve

for

little

`h"

B-1

2 U

se a

llfu

nctio

ns o

n a

scie

ntif

icca

lcul

ator

-,13

-13

Solv

een

gine

erin

geq

uatio

ns

B-1

4 So

lve

stat

ic s

yste

ms

for

resu

ltant

fore

C-I

Und

er-

stan

d PC

be-

sics

C-2

Dis

cuss

CA

D b

asic

san

d fi

lem

anag

emen

t

C-3

Use

draw

ing

setti

ngs

C-4

Per

form

basi

c ed

iting

com

man

ds

C-5

Cre

ate

draw

ings

with

accu

racy

C-6

Org

aniz

edr

awin

g in

fer-

mar

ker

C-7

Con

trol

the

disp

lay

ofdr

awin

gs.

C-8

Use

inte

rmed

iate

draw

ing

com

man

ds

C-9

Per

form

in-

tenn

edat

e ed

it-co

g co

mm

ands

C-I

0 C

ame

mul

tivie

wdr

awin

gs

C-1

1 C

reat

ese

ctio

ned

draw

ings

C-1

2 In

vest

i-ga

te b

asic

pens

ioni

ng

GI3

Per

form

adva

nced

dim

ensi

onin

g

C -

14 U

se a

ndm

anip

ulat

ebl

ocks

C-1

5 U

sebl

ocks

to a

uto-

mat

e th

e dr

aw-

big

proc

ess

D-I

Ide

ntif

ym

ater

ials

with

desi

red

prop

ertie

s

D-2

Des

crib

ehe

n tr

eatin

gpr

oces

ses

D-3

Per

form

heat

trea

ting

oper

atio

ns

D-4

Tes

t met

alsa

mpl

e fo

rha

rdne

ss

13-5

Des

crib

eca

stin

gpr

oces

ses

D-6

Des

crib

eho

t wor

king

proc

esse

s

D-7

Des

crib

eco

ld w

orki

ngpr

oces

ses

D-8

Eva

luat

eal

tern

ativ

em

anuf

actu

ring

proc

esse

s

11-1

Stu

dyba

sics

of

met

rolo

gy

8-2

Sele

ctin

stru

men

tsus

ed f

orm

easu

rem

ent

8-3

bite

rpre

t!k

nits

and

tole

ranc

es

8-4

Sele

ctga

ggin

g to

ols

E-5

Use

CM

Mfo

r lo

catio

n of

feat

ures

,

8-6

Perf

orm

surf

aoe

men

et-

ogy

8-7

Perf

orm

mea

sure

men

tby

com

pari

son

EA

Per

fort

ncir

-cu

lari

ty,

cyfi

ndri

city

, pro

-fi

le o

f a

line,

and

nmou

t mea

sure

-tu

ns.

8-8

Inve

stig

ate

adva

nced

met

rolo

gyto

pics

F-I

Prep

are

and

plan

for

mac

hini

ngop

erat

ions

F-2

Use

pro

per

hand

tool

sF-

3 O

pera

tepo

wer

saw

sF-

4 O

pera

tedr

ill p

ress

esF-

5 O

pera

teve

rtic

al m

illin

gm

achi

nes

,F-

6 O

pera

teho

rizo

ntal

mill

ing

mac

hine

s

F-7

Ope

rate

met

al c

uttin

gla

thes

F4 O

pera

tegr

indi

ng/

abra

sive

mac

hine

s

0.1

App

ly M

S-ch

ine

spec

ific

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ing

end

la-

seri

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men

-cl

atur

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r-m

inol

ogy

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Inve

stig

ate

the

Car

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anco

ordi

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eye

-te

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s ap

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r m

achi

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0-3

App

ly C

NC

lang

uage

0-4

Perf

orm

star

t up,

tool

chan

ging

. and

endi

ng o

fpr

ogra

ms

0-5

Perf

orm

posi

tioni

ng a

nddu

o dr

illin

g

0-6

Cre

ate

asu

b -

prog

ram

0-7

Use

pos

i-lio

n an

d fi

xed

cycl

es

0-8

Perf

orm

cont

ouri

ng0-

9 A

pply

tool

radi

us c

oven

-sa

tion

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ter

com

p)

0-10

Per

i=pr

cgra

mnt

ing

prep

arat

ion

0-11

App

lysp

ecia

l las

erco

ders

per

m-

eter

s

H-I

Und

er-

stan

d th

eba

sics

of

a PC

base

d C

AM

syst

em

H-2

Dis

cuss

basi

c C

AM

oper

atio

ns

H-3

Set

up

cutti

ng to

ols

H-4

Cre

ate

part

pro

file

sH

-5 E

dit p

art

prof

iles

11-4

5 Pe

rfor

mad

vanc

eded

iting

of

part

prof

iles

H-7

Edi

t too

lpa

ths

H4

Perf

orm

drill

ing

rod

corm

tabo

ring

H-9

Use

cons

truc

tion

laye

rs in

Smea

tCA

M

H -

10 P

erfo

rmus

es c

omm

ands

and

mac

hine

even

ts

H-1

1 C

reat

efa

mili

es o

f pa

rts

H-I

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erfo

rmC

AD

/CA

Min

tegr

atio

n

14-1

3 Pa

lo%

code

3-j

gene

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n

BE

ST

CO

PY

AV

AIL

AB

LE

MI I

=M

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I=O

M N

M I=

MIS

ME

IIN

IIII=

I= N

MI

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.111

1=11

.111

111

MIN

IM =

I M

1111

1111

1111

1111

1111

1111

1111

MM

IIII

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ies

I J

AS

WIE

ITIP

W5

MA

JT/M

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Part

icip

ate

laT

otal

Qua

lity

sod

SPC

Act

iviti

es

Tas

ks1-

1 D

efin

equ

ality

its

man

ufac

turin

gan

d ex

plai

nim

port

ance

1-2

Impl

emen

tco

ncep

ts o

fqu

ality

in th

ew

orkp

lace

1-3

App

ly p

rin.

eipl

es a

nd to

ols

of c

ontin

uous

qual

ity in

-pr

over

nent

1-4

Und

erst

and

and

appl

y S

PC

1-5

Eva

luat

eda

ta to

mon

itor

prod

uctio

n

1-6

Ana

lyze

cust

omer

pro

b.1-

7 E

stab

lish

met

hods

, pla

nsan

d pr

oced

ures

to m

aint

ain

qual

ity

tern

s an

d re

com

men

d so

lutio

ns

1.1

Use

elec

tric

al te

st

equi

pmen

t

1-2

App

lysp

ecifi

c te

rms

to e

lect

rical

circ

uits

1.3

Ana

lyze

serie

s, p

aral

lel

and

com

plex

DC

/AC

circ

uits

1-4

Che

ck A

Can

d D

C m

otor

s1-

5 In

spec

ttr

ansf

orm

ers

and

gene

rato

rs

1-6

Dis

cuss

sens

ors

and

feed

back

tedm

olog

y

1-7

Set

up/

prog

ram

PLC

1-8

Tro

uble

-sh

oot e

lect

rical

devi

ces

K-I

Use

test

equi

pmen

tK

-2 D

escr

ibe

basi

c pr

inci

ples

of h

ydra

ulic

syst

ems

K-3

Iden

tify

hydr

aulic

flui

dsK

-4 R

ecom

men

dpo

wer

dist

ribut

ion

and

seal

ing

devi

ces

K-5

Rec

ogni

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utilP

s,ac

tuat

ors,

and

hydr

aulic

cont

rol d

evic

es

K-6

Tro

uble

-sh

oot h

ydra

u-lie

/pne

umat

icsy

stem

s

L-I I

nves

tigat

eth

e co

ncep

ts o

fpr

oduc

t des

ign

..

M-I

Stu

dym

anuf

actu

ring

cells

M-2

Iden

tify

auto

mat

ion

sens

ors

M-3

per

form

robo

tP

rugt

atar

aill8

M-4

Use

vis

ion

syst

ems

250

BE

ST

CO

PY

AV

AIL

AB

LE

MI E

MI N

M Il

iN

MI

IliI M

IM

INM

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I MN

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LS

AN

D K

NO

WL

ED

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Com

mun

icat

ion

Skill

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se M

easu

rem

ent T

ools

Use

Ins

pect

ion

Dev

ices

Mat

hem

atic

al S

kills

Ree

ding

/Wri

ting

Skill

sK

now

ledg

e of

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ety

Reg

ulat

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Prac

tice

Safe

ty in

the

Wor

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rgan

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l Ski

llsK

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pany

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icie

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oced

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ptitu

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bilit

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Com

preh

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tten/

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bel I

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uctio

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now

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ting

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ds/L

ubri

cant

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asic

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aste

ners

Abi

lity

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ork

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art o

f a

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mC

onve

rse

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e T

echn

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Lan

guag

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Tra

deK

now

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Occ

upat

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l Opp

ortu

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sK

now

ledg

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Em

ploy

ee/E

mpl

oyer

Res

pons

ibili

ties

Kno

wle

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ompa

ny Q

ualit

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ssur

ance

Act

iviti

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actic

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onsc

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ness

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CO

MA

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vece

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Inte

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Prof

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mag

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easu

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Too

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quip

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AW

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C M

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Cen

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Gea

r Pr

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Bor

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Too

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Equ

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Wor

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Vis

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Aut

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ater

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Equ

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Com

pute

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tegr

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Man

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MPE

TE

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RO

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Man

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Con

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Mac

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Too

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RIN

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NG

INE

ER

ING

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CH

NIC

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se s

peci

al k

now

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e an

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ills

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ecom

men

d an

d/or

impl

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t sol

utio

ns f

or s

peci

fic

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ufac

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pplic

atio

ns.

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form

Gea

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atin

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eldi

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254

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IT/0

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form

Dra

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Tas

ks

Tas

ks

A-1

Rev

iew

blue

prin

t not

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d di

men

-si

ons

A-2

Iden

tify

basi

c la

yout

of

draw

ings

A-3

Iden

tify

basi

c ty

pes

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awin

gs

A-4

Lis

t the

purp

ose

of e

ach

type

of d

raw

ing

A-5

Ver

ifydr

awin

gel

emen

ts

A-6

Iden

tify

lines

and

syr

n-bo

ll (O

D&

I)

A-7

Und

er-

stan

d th

e re

la-

6ons

hip

of e

n-gi

neen

ng d

raw

-m

g; to

pla

nnin

g

A-8

Use

stan

dard

s to

verif

yre

quae

inen

ts

A-9

Ana

lyze

IA 1

ofm

ater

ials

B-1

Sel

ect

mat

eria

ls w

ithde

sire

dpr

oper

ties

B-2

Iden

tify

mat

eria

ls a

ndpr

oces

ses

topr

oduc

e a

prod

uct

B-3

Iden

tify

heat

trea

ting

proc

esse

s

B-4

Tha

mal

proc

ess

wor

kpie

ces

B-5

Tea

t met

alsa

mpl

es

B-6

Dis

cuss

cast

ing

proc

esse

s

B-7

Dis

cuss

hot w

orki

ngpr

oces

ses

B-8

Dis

cuss

cold

wor

king

proc

esse

s

9-9

Eva

luat

eal

tern

ativ

em

anuf

actu

ring

proc

esse

s

C-I

Iden

tify

type

s of

mea

sure

men

ts

C-2

Pra

ctis

epr

oper

mea

surin

g sk

ills

C-3

Sel

ect

prop

erm

easu

rem

ent

tool

s

C-4

Use

Met

rican

d E

nglis

hst

anda

rds

ofm

easu

rem

ent

C-5

Paf

onn

mea

sure

men

tsw

ith h

and

held

inst

rum

ents

C-6

Per

form

mea

sure

men

tson

sur

face

pla

te

C-7

Per

form

insp

ectio

nsus

ing

stat

iona

ryeq

uipm

ent

D-I

Pre

pare

and

plan

for

mac

hini

ngop

erat

ions

D-2

the

prop

erha

nd to

ols

D-3

Ope

rate

pow

er s

aws

D-4

Ope

rate

drill

pre

sses

13-5

Ope

rate

vert

ical

mill

ing

mac

hine

s

D-6

Ope

rate

horiz

onta

lm

illin

gm

achi

nes

13-7

Ope

rate

met

al c

uttin

gla

thes

as O

pera

tegr

indi

ngm

achi

nes

E-1

Prc

gran

CN

C m

achi

neE

-2 O

pera

teC

NC

mac

hini

ngan

tes

and

tinni

ng c

ente

rs

E-3

Ope

rate

elec

tric

aldi

scha

rge

mac

hine

s

E-4

Ope

rate

CN

C g

rinde

rsE

.-5

Ope

rate

CN

Cpg

bai

ngm

achi

nes

E6

Dow

nloa

dpr

ogra

ms

via

netw

ork

F-I

Des

crib

eth

e di

ffere

ntty

pes

of g

ears

F-2

Und

erst

and

gear

term

s an

dca

lcul

atio

ns

F-3

Cal

cula

tefo

r di

rect

,si

mpl

e, a

nd e

n-gu

ise

inde

xing

F-4

Use

rot

ary

tabl

es a

nddi

vidi

ng h

eads

F-5

Mak

e ca

l-ci

liatio

n fo

rge

ar c

uttin

g

F-6

Dis

cuss

gear

insp

ectio

n

0-1

Wel

d w

ithgM

AW

pro

-C

C=

0-2

Wel

dkut

with

oxy

acet

y-le

ns

0-3

Wel

d vr

ithO

TA

W(H

ehar

c)

0-4

Wel

d w

ithO

MA

W (

Mig

)/F

CA

W

0-5

Per

tain

Pla

sma

Arc

Cut

ting

(PA

C)

H-1

Dem

on-

stra

tatr

aditi

onal

draf

ting

skill

s

H-2

Inte

rpre

tan

d ap

ply

OD

&T

met

hod-

olog

y

H-3

Use

CA

Dsy

stem

s

11-4

Cre

ate

3-D

solid

mod

els

H-5

Mak

e to

oldr

awin

gs

I-1

Use

com

pute

rop

erat

ing

syst

ems

1-2

Use

com

pute

rm

qutr

y sy

stem

s

1-3

Use

var

ious

case

ter

appl

icat

ions

1-4

Rec

.:am

end

and

impl

emen

tC

1M te

chno

lo-

gins

1-1

Def

ilequ

ality

inm

anuf

actu

ring

and

expl

ain

impo

rtan

ce

1-2

knpl

arne

ntco

ncep

ts o

fqu

ality

in th

ew

orkp

lace

1-3

App

lypr

inci

ples

and

tool

s of

cont

inuo

usim

prov

emen

t

1-4

Und

erst

and

and

appl

y S

PC

1-5

Eva

luat

eda

ta to

mon

itor

prod

uctio

n

1-6

Ana

lyze

cust

omer

prob

lem

s an

dre

com

men

dso

lutio

u

1-7

Est

ablis

hm

etho

ds, p

lans

and

proc

edur

esto

mai

ntai

nqu

ality

.

25

BE

ST C

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AIL

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Mai

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K-I

Use

elec

tric

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steq

uipm

ent

K-2

App

lysp

ecif

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rms

to e

lect

rica

lci

rcui

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Ana

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Dis

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K-7

Set

up/

pprr Prag

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eble

Log

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ontr

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r

K-8

Tro

uble

-sh

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lect

rica

lde

vice

s

L-I

Che

sil

func

tions

on

scie

ntif

icca

lcul

ator

I.-2

Per

form

basi

c al

gebr

aic

oper

atio

ns

L-3

Per

form

trig

onom

etri

cfu

nctio

ns

L-4

Sol

veen

gine

erin

geq

uatio

ns

L-5

Sol

ve s

tatic

syst

ems

for

resu

ltant

for

ce

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eter

min

est

reng

th o

fm

ater

ials

L-7

the

Com

pute

rA

ided

Eng

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ring

syst

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se te

steq

uipm

ent

M-2

Des

gib

eba

sic

prin

cipl

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hyd

raul

ic/

pneu

mat

icsy

stem

s

M-3

Ide

ntif

yhy

drau

lic f

luid

sM

-4 R

ecom

-m

end

pow

erdi

stri

butio

n an

dse

alin

g de

vice

s

M-5

Rec

ogni

zepu

mps

.ac

tuat

ors.

and

cont

rol d

evic

es

M-6

Tro

uble

-sh

oot h

ydra

u-lia

pneu

rnat

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stem

s

N-I

App

lysa

fety

man

ual

dire

ctiv

es

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fir

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zard

sN

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pply

Am

eric

an R

edC

ross

fir

st a

idan

d C

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ures

N-4

Rec

omm

end

haza

rdou

s w

aste

man

agem

ent

tech

niqu

es

N-5

App

lyer

gono

mic

pnnc

ples

toth

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orkp

lace

N-6

Dem

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Org

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Pow

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Pow

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Hyd

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Pre

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Im

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A-1

Fol

low

safe

ty m

anua

lsan

d al

l saf

ety

regu

latio

n/re

quir

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ts

A-2

Use

prot

ectiv

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uipm

ent

A-3

Fol

low

safe

ope

ratin

gpr

oced

ures

for

hand

and

mac

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tool

s

A-4

Mai

ntai

n a

clea

n an

d sa

few

ork

envi

ron-

men

t

A-5

Con

trol

fire

haz

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A-6

App

lyA

mer

ican

Red

Cro

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irst

Aid

and

CPR

proc

edur

es

A-7

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oon-

men

d ha

zard

-ou

s w

aste

mac

arm

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tech

niqu

es

A-8

App

lyer

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mic

prin

cipl

es to

the

wor

kpla

ce

A-9

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ar-

met

e IM

OW

1-ed

ge o

f st

ate

an f

eder

al E

PAre

gula

tions

B-I

Per

form

basi

car

ithm

etic

func

tions

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Int

er-

conv

ert

&ac

tions

/de

cim

als

B-3

Int

er-

conv

ert M

etri

c/E

nglis

hm

easu

rem

ents

B-4

Per

form

basi

c al

gebr

aic

oper

atio

ns

B-5

Per

form

basi

ctr

igon

omet

ric

func

tions

B-6

Cal

cula

tesp

eeds

and

feed

s fo

rm

achi

ning

13-7

Loc

ate

mac

hini

ngpo

ints

fro

m a

datu

m p

oint

13-8

Per

form

calc

ulat

ions

for

sine

bar

and

sine

pla

te

13-9

Cal

cula

tefo

r di

rect

,si

mpl

e, a

ndan

gula

rin

dexi

ng

B-I

0 Pe

rfor

mca

lcul

atio

nsne

cess

ary

for

turn

ing

tape

rs

B.I

1So

lve

for

little

"V

13-1

2 U

se a

llfu

nctio

ns o

n a

scie

ntif

icca

lcul

ator

13-1

3 So

lve

engi

neer

ing

equa

tion

8-14

Sol

vest

atic

sys

tem

sfo

r re

sulta

ntfo

rce

B-1

5 D

eter

-m

ine

stre

ngth

of m

ater

ials

for

vari

ous

appl

i-ca

tions

C-I

Rev

iew

blue

prin

t not

esan

d di

men

-si

ons

C-2

Ide

ntif

yba

sic

layo

ut o

fdr

awin

gs

C-3

Ide

ntif

yba

sic

type

s of

draw

ings

C-4

Lis

t the

purp

ose

of e

ach

type

of

draw

ing

C-5

Ver

ify

draw

ing

elem

ents

C-6

Pra

ctic

eO

eom

etri

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men

nicr

ing

and

Tol

eren

cul8

(OD

&T

)met

hod

olog

y

C-7

Des

crib

eth

e re

latio

nshi

pof

eng

inee

ring

draw

ings

topl

anni

ng

C-8

Use

stan

dard

s to

veri

fyre

quir

emen

ts

C-9

Ana

lyze

bill

of m

ater

ials

(BO

M)

C-I

0 U

nder

-st

and

and

use

qual

ity s

yste

ms

D-I

Ide

ntif

ym

ater

ials

with

desi

red

prop

ane,

D-2

Ide

ntif

ym

ater

ials

and

proc

esse

s to

prod

uce

apr

oduc

t

D-3

Des

crib

ehe

at tr

eatin

gpr

oces

ses

D-4

Per

form

heat

trea

ting

oper

atio

ns

D-5

Tes

t met

alsa

mpl

es f

orha

rdne

ss

D-6

Des

crib

eca

stin

gpr

oces

ses

D-7

Des

crib

eho

t wor

king

proc

esse

s

D-8

Des

crib

eco

ld w

orki

ngpr

oces

sor

D-9

Eva

luat

eal

tern

ativ

em

anuf

actu

ring

proc

esse

s

E-1

Ide

ntif

yty

pes

ofm

easu

rem

ent

used

inm

anuf

actu

ring

E-2

Sel

ect

prop

erm

easu

rem

ent

tool

s

B-3

App

lypr

oper

mea

suri

ngte

chni

ques

E-4

Use

Met

ric

and

Eng

lish

stan

dard

s of

mea

sure

men

t

E-5

Per

form

mea

sure

men

tsw

ith h

and

held

insM

unen

ts

E-6

Per

form

mea

sure

men

tson

sur

face

pla

te

E-7

Per

form

impa

ctio

nsus

ing

stat

iona

ryeq

uipm

ent

F-1

Prep

are

and

plan

for

mac

hini

ngop

erat

ions

F-2

Use

pro

per

hand

tool

sF-

3 O

pera

tepo

wer

saw

sF-

4 O

pera

tedr

ill p

ress

esF-

5 O

pera

teve

rtic

al m

illin

gm

achi

nes

F-6

Ope

rate

hori

zont

alm

illin

gm

achi

nes

F-7

Ope

rate

met

al c

uttin

gla

thes

F-8

Ope

rate

grin

ding

/ab

rasi

vem

achi

nes

0-1

Prep

are

and

plan

for

CN

C g

rem

lin-

ing

oper

atio

ns

0-2

Sele

ct a

ndus

e C

NC

tool

ing

syst

ems

0-3

Prog

ram

CN

C m

achi

nes

0-4

Ope

rate

CN

Cm

achi

ning

cent

ers

(mill

s)

0-5

Ope

rate

CN

C tu

ning

cent

ers

(lat

hes)

0-6

Ope

rate

elec

tric

aldi

scha

rge

mac

hine

s

0-7

Dow

nloa

dpr

ogra

ms

via

netw

ork

H-1

Des

crib

eth

e di

ffer

ent

type

s of

gea

rs

H-2

Und

er-

stan

d ge

arte

rms

H-3

Use

rot

ary

tabl

es a

nddi

vidi

ng h

eeds

/1-4

Dis

cuss

gets

insp

ectio

nan

d m

easu

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men

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I-1

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1-3

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KIM

AW

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Cor

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1111

1111

1111

1111

1111

1111

1111

1111

1111

1111

1111

1111

1211

1111

1111

1111

1111

1111

1110

1111

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I

Tas

ks1-

1 D

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-st

rata

trad

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alm

echa

nica

ldr

aftin

g sk

ills

1-2

Use

Com

pute

r-A

ided

Dra

fting

(CA

D)

syst

em

1-3

Cre

ate

3-D

solid

mod

els

1-4

Mak

e to

oldr

awin

gs1

-S R

ecom

men

dto

ol d

esig

n

K-I

Use

com

plie

rop

erat

ing

syst

ems

K-2

Use

com

pile

rin

quiry

sys

tem

s

K-3

Use

vario

usco

mpu

ter

appl

icat

ions

K-4

Rea

m-

men

d an

dim

plem

ent C

IMte

chno

logi

es

K-5

Use

com

pute

r-ai

ded

engi

neer

ing

syst

em

L-I P

ecan

-m

end

tool

ing

for

spec

ific

mac

hine

s

L-2

Soh

'epr

oduc

tion

set-

up p

robl

ems

L-3

Pec

an-

men

d sh

op fl

oor

layo

ut a

ndro

utin

g

L-4

Pro

vide

cost

info

rmat

ion

need

ed fo

rqu

otes

or

cost

anal

ysis

M-I

Def

ine

qual

ity in

man

ufac

turin

gan

d ex

plai

nim

port

ance

M-2

Impl

emen

tco

ncep

ts o

fqu

ality

in th

ew

orkp

lace

M-3

App

lypr

inci

ples

and

tool

s of

con

-tin

uous

qua

lity

impr

ovem

ent

M-4

Und

er-

stan

d an

d ap

ply

SP

C

M-5

Eva

luat

eda

ta to

mon

itor

prod

uctio

n

M-6

Ana

lyze

cust

omer

prob

lem

s an

dre

com

men

dso

lutio

ro

M-7

Est

ablis

hm

etho

ds, p

lans

and

proc

edur

esto

mai

ntai

nqu

ality

N-I

Use

elec

tric

al te

steq

uipm

ent

N-2

App

lysp

ecifi

c ta

ms

to e

lect

rical

circ

uits

N-3

Ana

lyze

serie

s, p

aral

lel

and

com

plex

DC

/AC

circ

uits

N-4

Che

ck A

Can

d D

C m

otor

sN

-5 In

spec

ttr

ansf

orm

ers

and

gene

rato

rs

N-6

Dis

cuss

sens

ors

and

feed

back

tech

nolo

gy

N-7

Set

up/

prog

ram

PLC

N-8

Tro

uble

-sh

oot e

lect

rical

devi

ces

0-1

Use

test

equi

pmen

t0-

2 D

escr

ibe

basi

c pr

inci

ples

of h

ydra

ulic

syst

ems

0-3

Iden

tify

hydr

aulic

flui

ds0-

4 R

econ

men

dipo

wer

dis

trib

u-lio

n an

d se

alin

gde

vice

s

0-5

Rec

ogni

zepu

mps

,ac

tuat

ors,

and

hydr

aulic

cont

rol d

evic

es

04 T

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ems

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I IR

SKIL

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AN

D K

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WL

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Com

tnic

atio

nU

se M

easu

rem

ent T

ools

Use

Ins

pect

ion

Dev

ices

Mat

hem

atic

al S

kills

Rea

ding

/Wri

ting

Skill

sK

now

ledg

e of

Saf

ety

Reg

ulat

ions

Prac

tice

Safe

ty in

the

Wor

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ceO

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isat

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aste

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ork

as P

art o

f a

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onve

ne in

the

Tec

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angu

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atio

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uran

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e.g.

cal

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Mea

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Pow

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Met

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Dri

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ente

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Com

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afet

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men

ts

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Use

prot

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A-3

Fol

low

safe

otin

sfo

ran

dm

achi

ne to

ols

A-4

Mai

ntai

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ork

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App

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Dam

n-st

rata

kno

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of s

tate

and

fede

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regu

latio

ns

B-I

Per

form

basi

car

ithm

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func

tions

B-2

Inte

r-co

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tfr

actio

ns/

deci

mal

s

B-3

Inte

r-co

nver

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ric/

Eng

lish

mea

sure

men

ts

B-4

Per

form

basi

c al

gebr

aic

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atio

ns

B-5

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form

basi

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omet

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ns

13-6

Cal

cula

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eeds

and

feed

s fo

rm

achi

ning

B-7

Loc

ate

mac

hini

ngpo

ints

from

ada

tum

poi

nt

13-8

Per

form

calc

ulat

ions

for

sine

bar

and

sine

pla

te

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Cal

cula

tefo

r di

rect

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mpl

e, a

ndan

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dexi

ng

11-1

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rmca

lcul

atio

nsne

cess

ary

for

turn

ing

tape

rs

13-1

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olve

for

little

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Use

all

emot

ions

on

asc

ient

ific

calc

ulat

or

13-1

3 S

olve

engi

neer

ing

equa

tions

13-1

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olve

stat

ic s

yste

ms

for

resu

ltant

forc

e

B-1

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eter

min

e st

reng

thof

mat

eria

ls fo

rva

rious

app

li-ca

tions

C-1

Und

er-

stan

d P

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e-s

ics

C-2

Dis

cuss

CA

D b

asic

san

d fil

em

anag

emen

t

C-3

the

draw

ing

setti

ngs

C-4

Per

form

basi

c ed

iting

com

man

ds

C-5

Cre

ate

draw

ings

with

accu

racy

C-6

Org

aniz

edr

awin

g in

for-

min

ion

C-7

Con

trol

the

disp

lay

ofdr

awin

gs

C-8

the

inte

rmed

iate

draw

ing

com

man

ds

C-9

Per

form

irten

nedi

ate

editi

ngco

mm

ands

C-1

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vate

mul

tivie

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awin

gs

C-I

I C

reat

ese

ctio

ned

draw

ings

C-1

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vest

i-ga

te b

asic

dim

ensi

onin

g

C-I

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rmad

vanc

eddi

men

sion

ing

C-1

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se a

ndm

anip

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ocks

C-I

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ocks

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tom

ate

the

draw

ing

proc

ess

D-1

Iden

tify

mat

eria

ls w

ithde

sire

dpr

oper

ties

D-2

Des

crib

ehe

at tr

eatin

gpr

oces

ses

D-3

Per

form

heat

trea

ting

oper

atio

ns

D-4

Tes

t met

alsa

mpl

es fo

rlu

rdne

ss

0-S

Des

crib

eca

stin

gpr

oces

ses

D-6

Des

crib

eho

t wor

king

mor

asse

s

D-7

Des

crib

eco

ld w

orki

ngpr

oces

ses

0-8

Eva

luat

eal

tern

ativ

em

anuf

actu

ring

proc

esse

s

E-1

Stu

dyba

sics

of

met

rolo

gy

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Sel

ect

inst

rum

ents

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for

mea

sure

men

t

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rpre

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ndto

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Sel

ect

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tool

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Impl

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fqu

ality

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ew

orkp

lace

K-3

App

lypr

inci

ples

and

tool

s of

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uous

qua

lity

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ovem

ent

K-4

Und

er-

stan

d an

d ap

ply

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C

K-5

Eva

luat

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ta to

mon

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prod

uctio

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com

men

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K-7

Est

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hm

etho

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lans

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test

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App

lysp

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ical

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L-3

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circ

uits

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spec

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tech

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Set

up/

prog

ram

PLC

L-8

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uble

-sh

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lect

rical

devi

ces

.

M-I

Use

test

equi

pmen

t'

M-2

Des

crib

eba

sic

prin

cipl

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hyd

raul

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stem

s

M-3

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hydr

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flui

dsM

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end

pow

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dse

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drau

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M-6

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s.

280

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281

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CN

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and

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ING

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se s

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now

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to r

ecom

men

d an

d/or

Im

plem

ent s

olut

ions

for

spe

cifi

c m

anuf

actu

ring

app

licat

ions

.

Dut

ies

A

Per

form

Adv

ance

dM

achi

ning

Pro

cess

es

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form

HW

eldi

ngO

pera

tions

284

JIM

OS

ICIT

lags

MA

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VO

illt1

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ksA

-I F

ollo

wsa

fety

man

uals

end

insa

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regu

latio

ns/

requ

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A-2

Use

prot

ectiv

eeq

uipm

ent

A-3

Ree

onen

end

and

unde

rsta

ndsa

feop

era

tins for

hard

and

ma-

chin

e to

ols

A-4

Mai

ntai

n a

clea

n an

d sa

few

ade

arrin

in-

mea

t

A-5

Con

trol

fire

haza

rds

A-6

App

lyA

mer

ican

Red

Cro

n F

ilet A

idan

d C

PR

proc

edur

es

A-7

Fol

low

haza

rdou

sw

aste

man

agem

ent

tech

niqu

es

A-8

App

lyer

gono

mic

prm

aple

s to

the

wor

kpla

ce

A-9

Dan

on-

stat

e !m

ow!.

edge

of s

tate

and

fede

ral E

PA

regu

latio

ns

B-1

Per

form

basi

car

ithm

etic

func

tions

B-2

Inte

r-co

nver

tfr

actio

ns/

deci

mal

s

B-3

Inte

r-co

nver

t Met

ric/

Eng

lish

mea

sure

men

ts

B-4

Per

form

basi

c al

gebr

aic

oper

atio

ns

B-5

Per

form

basi

ctr

igon

omet

ricfu

nctio

ns

13-6

Cal

cula

tesp

eeds

and

feed

s fo

rm

achi

ning

8-7

Loca

tem

achi

ning

poin

ts fr

om a

datu

m p

oint

B-8

Per

form

calc

ulat

ions

for

sine

bar

and

sine

pla

te

13.9

Cal

cula

tefo

r di

rect

,si

mpl

e. a

ndan

gula

rin

dexi

ng

13-1

0 P

erfo

rmca

lcul

atio

nsne

cess

ary

for

turn

ing

tape

r,

B11

Use

all

func

tions

on

asc

ient

ific

calc

ulat

or

8-I2

Sol

veen

gine

erin

geq

uatio

ns

8-I3

Det

euni

nest

reng

th o

f ma-

teria

ls fo

r va

n-ow

app

lies-

lions

C-I

Rev

iew

blue

prin

t not

esan

d di

men

-si

ons

C-2

Iden

tify

basi

c la

yout

of

draw

ings

C-3

Iden

tify

basi

c ty

pes

ofdr

awin

gs

C-4

Lis

t the

purp

ose

of e

ach

type

of d

raw

ing

C-5

Ver

ifydr

awin

gel

emen

ts

C-6

Pra

ctic

eO

eom

euic

Di-

mai

nlin

ing

and

Tol

eran

ang

(OD

&T

) m

eth-

odol

ogy

C-7

Des

crib

eth

e re

latio

nshi

pof

eng

inee

ring

draw

ings

topl

ann

ing

C-8

Use

stan

dard

s to

verif

yre

quire

men

ts

C-9

Use

Aut

o-m

ated

Dra

win

gP

arts

Lis

t(A

DP

LS)

C-1

0 U

nder

-st

and

and

use

qual

ity s

yste

ms

D-1

Iden

tify

mat

eria

ls w

ithde

sire

dpr

oper

ties

D-2

Iden

tify

mat

eria

ls a

ndpr

oces

ses

topr

oduc

e a

prod

uct

D-3

Des

crib

ehe

at tr

eatin

gpr

oces

ses

D-4

Set

up

heat

trea

ting

oper

a-lio

ns

D-5

Tes

t met

alsa

mpl

es fo

rbe

am

D-6

Des

cnbe

tast

ing

proc

esse

s

D-7

Des

crib

eho

t won

ting

proc

esse

s

D-8

Des

crib

eco

ld w

orki

ngpr

oces

ses

D-9

Eva

luat

eal

tern

ativ

em

anuf

actu

ring

proc

esse

s

E-I

Iden

tify

type

s of

mea

sure

men

tus

ed in

man

ufac

turin

g

5-2

Sel

ect

prop

erm

easu

rem

ent

tool

s

E-3

App

lypr

oper

mea

surin

gte

chni

ques

E-4

Use

Met

rican

d E

nglis

hst

anda

rds

ofm

easu

rem

ent

5-5

Per

form

mea

sure

men

tsw

ith h

and

held

inst

rum

ents

5-6

Und

er-

stan

d m

easu

re-

men

ts o

n si

r-fa

ce p

late

5-7

Uni

tast

and

insp

ec-

lions

usi

ngst

atio

nary

equi

pmen

t

F-I

Pre

pare

end

plan

for

mac

hini

ngop

erat

ions

F-2

Ope

rate

pow

er s

aws

F-3

Ope

rate

drill

pre

sses

F-4

Ope

rate

vert

ical

mill

ing

mac

hine

s

F-5

Ope

rate

horiz

onta

lm

illin

gm

achi

nes

F6

Ope

rate

met

al c

uttin

gla

thes

F-7

Ope

rate

grin

ding

/ab

rasi

vem

achi

nes

0 -I

Pre

pare

end

plan

for

CN

C m

achi

n-M

g op

erat

ions

0-2

Sel

ect,

reco

mm

end

and

me

CN

Cto

olin

g sy

stem

s

0-3

Pro

gram

CN

C m

achi

ne0-

4 O

pera

teC

NC

mac

hini

ngce

nter

s (m

ills)

0-5

Ope

rate

CN

C tu

rnin

gce

nter

s (la

thes

)

0-6

Ope

rate

elec

tric

aldi

scha

rge

mac

hine

s

0-7

Dow

nloa

dpr

ogra

ms

via

netw

ork

0.8

Und

erst

and

DN

C n

estin

gsy

stem

H-1

Wel

d w

ithS

hiel

ded

Met

al A

roW

eldi

ng(S

MA

W)

pro-

au

H2

Wel

d/cu

tw

ith o

xyao

ety.

len.

11-3

Wel

d w

ith(le

a T

ungs

ten

Arc

wet

(OT

AW

)(H

elle

n)

H-4

Wel

d w

ithG

as M

etal

Arc

Wel

ding

(OM

AW

Y(v

fig)

&F

het C

cre

Arc

Wel

ding

(F

CA

W)

H.5

Per

form

Pla

sma

Arc

Cut

ting

(PA

C)

11-6

Per

form

elec

tron

beam

wel

ding

H-7

Und

er-

stan

d w

eldi

ngin

spec

tion

tech

niqu

es

1-1

Dem

onst

rate

trad

ition

alm

echa

nica

ldr

aftin

g sk

ills

1-2

Use

Com

pute

r-A

ided

Dra

fting

(CA

D)

syst

em

1-3

Cre

ate

3-D

solid

mod

els

1-4

Mak

e to

oldr

awin

gsI-

5 D

igiti

zedr

awin

gs1-

6 U

nder

stan

dsc

anni

ngpr

oces

ses

for

draw

ings

1-1

Use

com

pute

rop

erat

ing

syst

ems

1-2

Use

com

pute

rin

quiry

sys

tem

s

1-3

Use

var

ious

callP

tIler

appl

icat

ions

1-4

Rec

onen

end

and

inpl

emm

tC

lMte

chno

lo-

gies

1 -S

Use

com

pute

r -a

ided

engi

neer

ing

syst

em28

5

BE

ST C

OPY

AV

AIL

AB

LE

- M

D N

O il

lM

BN

M M

I MS

IMP

MIS

NM

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M

4111

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MO

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MD

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1111

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ies

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Tas

ksK

-I D

efin

equ

ality

inm

anuf

actu

ring

and

expl

ain

impo

rtan

ce

K-2

hup

lem

ent

conc

epts

of

qual

ity in

the

wor

kpla

ce

K-3

App

lypr

inci

ples

and

tool

s of

con

-tin

uous

qua

lity

impr

ovem

ent

K-4

Und

er-

stan

d an

d ap

ply

SP

C

K-.

5 E

valu

ate

data

to m

onito

rpr

oduc

tion

K.4

Ana

lyze

cust

omer

prob

lem

s an

dre

com

men

dso

lutio

ns

K-7

Est

ablis

hm

etho

ds, p

lans

and

proc

edur

esto

mai

ntai

nqu

ality

K-8

Und

erst

and

varia

bilit

yre

duct

ion/

valu

een

gine

erin

g

L-I U

nder

stan

del

ectr

ical

test

equi

pmen

t

L-2

App

lysp

ecifi

c te

rms

to e

lect

rical

circ

uits

L-3

Ana

lyze

serie

s, p

aral

lel

and

com

plex

DC

/AC

circ

uits

L-4

Che

ck A

Can

d D

C m

otor

sL-

5 In

spec

ttr

ansf

orm

ers

and

gene

rato

rs

L-6

Dis

cuss

sens

ors

and

feed

back

tech

nolo

gy

L-7

Set

up /

prog

ram

PLC

L-8

Tro

uble

-sh

oot e

lect

rical

devi

ces

M-I

Use

test

equi

pmen

tM

-2 D

escr

ibe

basi

c pr

inci

ples

of h

ydra

ulic

syst

ems

M-3

Iden

tify

hydr

aulic

flui

dsM

-4 R

eoom

-m

end

pow

erdi

strib

utio

n an

dse

alin

g de

vice

s

M-5

Rec

ogni

zepu

mps

,ac

tuat

or, a

ndhy

drau

licco

ntro

l dev

ices

M-6

Tro

uble

-sh

oot h

ydra

u-lie

/pne

umat

icsy

stem

s

N-I

Ana

lyze

stan

dard

tool

-in

g an

d w

ork

orde

r re

pair

sche

dule

s

N-2

For

ecas

tw

orko

rder

repa

ir tin

esan

d m

etho

ds

N-3

Exp

edite

repa

ir pr

oces

ses

N-4

Ana

lyze

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ols

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on-

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s

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lish

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sure

men

ts

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form

basi

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aic

oper

atio

ns

B-5

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form

basi

ctr

igon

omet

ricfu

nctio

ns

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cula

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rm

achi

ning

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Loc

ate

mac

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ngpo

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from

ada

tum

poi

nt

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form

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bar

and

sine

pla

te

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mpl

e, a

nd

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atio

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cess

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rs

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olve

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se a

llfu

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olve

engi

neer

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tions

8-14

Sol

vest

atic

sys

tem

sfo

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eter

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stre

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ater

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for

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asic

san

d fil

em

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the

draw

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com

man

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ate

draw

ings

with

accu

racy

C-6

Org

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for-

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Com

o! th

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spla

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draw

ings

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Use

inte

rmed

iate

draw

ing

com

man

ds

C-9

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form

inte

rmed

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editi

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mm

ands

010

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ate

mul

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at tr

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hard

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proc

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valu

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Stu

dyba

sics

of

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Sel

ect

inst

rum

ents

used

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mea

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men

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rpre

tlim

its a

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ect

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se C

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Per

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com

paris

on

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form

oncu

larit

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lindr

icilY

ipr

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of a

lire

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mea

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pics

.F

-I P

repa

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an fo

rm

achi

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oper

atio

ns

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per

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tool

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pera

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wer

saw

sF

-4 O

pera

tedr

ill p

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esF

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pera

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gm

achi

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F-6

Ope

rate

horiz

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gm

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F-7

Ope

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met

al c

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rasi

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0-1

App

ly m

a-ch

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spec

ific

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ing

and

la-

sal)

mum

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NC

lang

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prop

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posi

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ly to

olra

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com

pens

atio

n(c

utte

r co

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0-10

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form

prog

ram

min

gpr

epar

atio

n

0-11

App

lysp

ecia

l las

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ding

para

met

ers

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Und

er-

stan

d th

e be

-si

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f a P

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stem

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Dis

cuss

basi

c C

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oper

atio

ns

H-3

Set

up

cutti

ng to

ols

H-4

Cre

ate

put p

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esH

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d/ p

ert

prof

iles

11-6

Per

form

adva

nced

editi

ng o

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prof

iles

H-7

Edi

t too

lpa

ths

H-8

Per

form

drill

ing

and

eoun

tabo

ring

H-9

Use

cons

truc

tion

laye

rs in

Sm

artC

AM

II-10

Per

form

user

com

man

dsan

d m

achi

neev

ents

H-1

1 C

ream

fam

ilies

of p

arts

H-I

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atio

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ew

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App

ly p

an-

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ols

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ontin

uous

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-pr

ovem

ent

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Und

erst

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and

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5 E

valu

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onito

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Ana

lyze

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prob

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dre

com

men

dso

lutio

ns

1-7

Est

ablis

hm

etho

ds, p

lans

end

proc

edur

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mai

ntai

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ality

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Use

elec

tric

al te

steq

uipm

ent

1.2

App

lysp

ecif

ic ta

ms

to e

lect

rica

lci

rcui

ts

1-3

Ana

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seri

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aral

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and

com

plex

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cir

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1-4

Che

ck A

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d D

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otor

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5 In

spec

ttr

ansf

onne

raan

d ge

nera

tor

1-6

Dis

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sens

ors

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tech

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1-7

Setu

p/pr

ogra

m P

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1-8

Tro

uble

-sh

oot e

lect

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lde

vice

s

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Use

test

equi

pmen

tK

-2 D

escr

ibe

basi

c pr

inci

ples

of h

ydra

ulic

syst

ems

K-3

Ide

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luid

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unen

dpo

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dist

ribu

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seal

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mps

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tuat

ors,

and

hydr

aulic

cont

rol d

evic

es

K-6

Tro

uble

-sh

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ydra

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lidpn

eum

atic

syst

ems

L4

Inve

stig

ate

the

conc

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of

prod

uct d

esig

n

L-2

Per

form

prod

uctio

n an

din

vent

ory

plan

ning

and

cont

rol (

PIPC

)

L-3

Per

form

fore

cast

ing

de-

min

d fo

r fi

n-fi

shed

pro

duct

san

d se

ams

L4

Perf

orm

ca-

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, req

uire

-m

elds

pla

nnin

gan

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r Pr

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Per

form

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Stu

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Stu

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job

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sche

dulin

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L-8

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Des

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lm

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For more information:

MAST Program DirectorTexas State Technical College3801 Campus DriveWaco, TX 76705

(817) 867-4849FAX (817) 867-33801-800-792-8784http://machinetool.tstc.edu

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