MACHINE TECHNOLOGY PROGRAM SAN DIEGO CITY COLLEGE …

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MACHINE TECHNOLOGYPROGRAM

SAN DIEGO CITY COLLEGE

COURSE SYLLABUS: MACHINE TECHNOLOGY 140BASIC PRINCIPLES OF MACHINE TECHNOLOGY

Lecture hours/week: 3 Credit hours: 4Lab hours/week: 3 Prerequisites: None

COURSE DESCRIPTION

This course offers the basic principles required in the Machine Technology field relative tomeasurements, common formulas, machining applications, safety, and interpretation of basicdrawings. (FT) Associate Degree Credit.

PREREQUISITES None

COURSE OBJECTIVES

Students who have successfully completed this course will be able to:

1. Identify and demonstrate a thorough understand of common machine safety practices.2. Identify common measuring instruments and their accessories.3. Demonstrate proper use of common measuring instruments and their accessories.4. Demonstrate proper care of common measuring instruments and their accessories.5. Identify commonly used mathematical formulas used in the machining environment.6. Demonstrate proper use of mathematical formulas used in the machining environment.7. Use mathematical calculations and reference tables to determine typical numerical results

needed in machining.8. Identify common cutting tools and their accessories.9. Demonstrate proper use and care of common cutting tools and their accessories.10. Demonstrate reading and writing skills to read and prepare required documents for course

work.11. Demonstrate communication skills to interact successfully with members of working

teams and instructor.



COURSE SYLLABUS: MACHINE TECHNOLOGY 140BASIC PRINCIPLES OF MACHINE TECHNOLOGY (CONTINUED)

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REQUIRED COURSE MATERIALS

Textbooks: Examples of appropriate textbooks include:

Technology of Machine Tools, 4th Edition, 1990.Blue Print Reading For Industry, 1986.Machinist Handbook (Current Edition).

Hand Tools/Supplies: Examples of appropriate hand tools and supplies include:

Scientific Calculator6 ruler

METHOD OF INSTRUCTION

Lecture: Presentations will include:

1. Lecture with or without, various audio-visual aids2. Discussion, debate, and/or critique3. Demonstrations4. Computer assisted or other self-paced instruction5. Field trips or field assignments6. Laboratory assignments utilizing specifically planned instructional activities or

“live” work

Laboratory: Laboratory will be a “hands-on” process

Writing Assignments: Writing assignments include:

1. Preparing process documents2. Providing written answers to assignment questions3. Maintaining a notebook of class assignments and activities




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Appropriate Outside Assignments: Students are expected to spend a minimum of twohours outside of class in practice and preparation for each hour of theory in class. Appropriateassignments include:

1. Reading appropriate references2. Preparing process documents

Appropriate Assignments That Demonstrate Critical Thinking:

1. Students will be required to demonstrate the proper use and care of commonmeasuring instruments.

2. Students will perform arithmetic calculations related to estimation of RPMS, feedrates and other common numerical values involved in producing a machined workpiece.

3. Students will interpret blueprints to produce required machine parts tospecifications within time allowed.

4. Students will be required to create a drawing of an existing object using allapplications learned in this course.

Method of Evaluation: A students grade will be based on multiple measures ofperformance. The assessment will measure development of independent critical thinking skillsand will include evaluation of the students ability to:

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

2. Apply theory to laboratory assignments3. Satisfactorily perform on written, oral, or practical examinations4. Satisfactorily perform on outside assignments including writing

assignments/processing documents5. Contribute to class discussions6. Maintain attendance per current policy7. Follow all laboratory rules and safety regulations




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SAMPLE ATTENDANCE AND CONDUCT POLICY

Attendance: Students may NOT accumulate more then 6% UNEXCUSED absences in eachclass. The Instructor has the sole responsibility of determining what is excusable. For additionaldetail, see the San Diego City College Catalog. If you have to miss a class talk to your instructor,it may be an excusable absence. If you have to miss a class, call and let the Instructor knowbefore the class. If you do miss a class, it is YOUR responsibility to find out what you missed,and to be ready for any tests, or quizzes that have been scheduled. Be in class on time. If youarrive late, it disrupts the class. Do not make a habit of being late, or you may be dropped.

EXAMPLE of 6% UNEXCUSED ABSENCES: If your class meets for 3 hours per week andlasts for 18 weeks, this equals 54 hours X 6% or 3 hours of missed class time allowable. Laboratory time will be calculated at 6% of the total time required per class. If you are droppedfrom a class, you will be dropped from it’s lab. It will be the students responsibility to log in andout of the Laboratory for each lab class. This will be confirmed by the Instructors, or their staff.

Student Conduct: No student will interfere with the learning opportunity of another student.If anyone does they will be dropped from the roster IMMEDIATELY. I will not allow any verbalor physical abuse between students, or between students and the staff. If you have a problem getthe Instructor involved immediately. No student will copy or try to submit a project thatsomeone else has made. This is cheating, and you will both receive either a 0% for a grade, oryou may be dropped from the roster. This will also apply to all tests, quizzes and reports. Anyone who becomes a safety hazard to themselves, or others will be dropped from class.

Safety Policies: This Machine Technology course is a unique laboratory environment with it’sown Safety rules. These rules have been set by the State and Federal Government, and everyonewill be expected to follow them.

1. Safety glasses must be worn at all times in the laboratory. (Machine laboratoriesrequire special safety glasses.) Your instructor will tell you if your glasses areacceptable or not. Safety glasses can be purchased at the school bookstore, askthe instructor if you have any questions.

2. No loose fitting clothing, or long sleeves.3. No rings, necklaces, or other jewelry that could possibly get caught in the

machinery.4. No smoking in the building.5. No flip-flops, or any sandle type shoes (leather shoes only).6. No shorts, half-shirts, or sleeveless shirts. Legs and shoulders must be covered.




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7. No playing around, (people get hurt that way).8. No alcohol, or drugs, and no one under the influence of them. Some medications

warn you not to operate machinery if you are using them. Check with your Doctorif you’re not sure.

9. Be familiar with a machine BEFORE you attempt to operate it. If you have aquestion, ask the instructor.

These may seem like easy rules to follow, they are. Let’s all be careful and learn about MachineTechnology in a safe way!! These are not all the safety hazards in a machine laboratory. Youwill be advised of more safety rules as you progress with the course.

The machinery is reserved every day on a first come, first serve basis. DO NOT reservemachines for your friends. If you do, you will forfeit your own, as well as your friendsreservation. Also, only reserve one machine at a time for your use. Tools will be given out on afirst come, first serve basis. DO NOT GO INTO THE TOOL ROOM UNLESS YOU ARETOLD TO DO SO! At the end of the class make sure your machine is clean, and all the schoolstools are properly returned to the tool room.

SAMPLE GRADING POLICY

In our class the students are graded on a combination of things, these are then added together toform the overall average, to determine the final grade. In this class the variables which determinethe students grades are: Tests, Projects, Quizzes, and Attendance.

Tests: There will be approximately 3 tests per semester plus a final exam. The gradereceived on the Final exam will be doubled. Students will be given at least 1 week notice beforea test. There will be no make up tests.

Projects: Projects will be assigned by your Instructor. If you have any ideas, tell theInstructor and you may be allowed to help design your own projects.

Quizzes: Quizzes will be given when the Instructor feels they are needed, these may beannounced or unannounced. There will be no make up Quizzes.

Attendance: Attendance may account for 5% of final grade. 100% attendance may receive5 points. This will be calculated by the Instructor.

Extra Credit: You may have the option to supplement your grade by either doing extra projects,




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or extra reports. This will be determined by the Instructor.

COURSE OBJECTIVES: TECHNICAL COMPETENCIES

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

A. Demonstrate safety practices in Machining Environment

1. Use Proper Safety Equipmenta. Identify safety equipment used in the machine environmentb. State effects of proper and improper safety equipmentc. Demonstrate proper use of common safety equipment

2. Identify Proper Clothinga. Demonstrate proper dress for machining environmentb. State improper dress and its effects

3. State Proper Attitudes for Safetya. Explain responsibility for oneself and othersb. State benefits of correct safety practicesc. Explain cost of poor safety practices

4. Handle Chemicals Properlya. Interpret material safety data sheets "MSDS"b. Describe proper storage and disposal of chemicalsc. Identify labeling used for chemicalsd. Explain special precautions for handling chemicalse. Discuss OSHA's and E.P.A.'s impact on chemical handling

5. Identify Fire Hazards in Machininga. Identify fire hazards in machining environment and how to eliminateb. Identify classes of fire extinguishersc. State methods of dealing with fires

6. Demonstrate Proper Personal Hygienea. Identify hygiene as a part of personal safety b. State effect of oils, solvents, and coolants on the skin and eyesc. Exhibit proper personal hygiene




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7. Demonstrate Proper Laboratory Cleaninga. Discuss the effects of a filthy work environmentb. State impact of unclean work area on safety, machine tool accuracy and

machine tool fixtures. c. Exhibit proper cleaning of machine tools and accessories

B. Use Measuring Instruments and Their Accessories

1. Identify Applications and Limitations of Measuring Instrumentsa. Identify common measuring instruments and their applicationsb. Identify limitations of each measuring instrumentc. Explain and demonstrate methods of measuring instrument calibrationd. Demonstrate proper handling of measuring instruments.

2. Demonstrate Use of Measuring Instrumentsa. Rulers (scales)b. Outside micrometersc. Vernier calipersd. Dial caliperse. Depth micrometersf. Inside micrometersg. Telescoping gaugesh. Edge finders

C Test and dial indicatorsC Gauge blocksC Coordinate Measuring Machine (CMM)

i. Height gaugesj. Protractorsk. Bore gauges




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C. Demonstrate Use of Mathematical Formulas in Machining

1. Perform Mathematical Computations with Calculator a. Explain need of using mathematics in machiningb. Explain the benefits of a scientific pocket calculatorc. Demonstrate ability to add, subtract, multiply and divide whole numbers

2. Calculate Fractions and Decimals with Calculatora. Demonstrate the ability to add, subtract, multiply and divide fractionsb. Demonstrate the ability to convert fractions to decimalsc. Demonstrate the ability to add, subtract, multiply and divide decimalsd. Demonstrate the ability to round off numbers and state limitationse. Demonstrate the ability to convert decimals to base fractions

3. Convert Metric and US Standard Units of Measurea. Explain use of metric systemb. Convert U.S. system units to metric system unitsc. Convert metric system units to U.S. system units

4. Perform RPM Calculationsa. Explain the need to properly calculate RPM'sb. Describe implications of changing variables in formulasc. Explain effect of different alloys and cutting tools on RPM'sd. Demonstrate correct use of formulas to achieve proper RPM

5. Perform Feed Calculationsa. State the need for proper feed calculationsb. Explain meaning of each variable in feed equationsc. Explain position and negative effects of RPM, feed, and depth of cut on

tool life, production and profitabilityd. List benefits of increased production related to increased profite. State differences between inch per revolution (IPR) and inch per minute

(IPM)f. State proper application of IPR and IPM.g. Explain chip load per tooth for roughing verses finishing of different

materials




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h. Explain effects of set-up rigidly, tool diameter, length and horsepower onfeed

I. Explain step over distances involved in millingj. Establish proper roughing and finishing feed rates for:

C Face millingC Slot millingC DrillingC ReamingC TappingC TurningC BoringC Single point turningC ReamingC Facing

6. Perform Depth of Cut Calculationsa. State depth of cut calculationsb. Demonstrate ability to calculate RPM, feed and depth of cut

7. Perform Thread Cutting Calculationsa. State uses of thread calculationsb. Describe equations to identify thread depth and measure thread sizes

c. Demonstrate proper use of thread calculations

8. Perform Tap Drill Calculationsa. State uses of tap drill calculations

b. Explain tap size verses drill sizes c. Describe equation to calculate tap drill sizes for fractional taps d. List equation converting tap size number to decimal e. Demonstrate use of tap drill calculations

9. Interpret Reference Tables Related to Machininga. Identify commonly used reference tablesb. Locate specific reference tables in various support documentationc. Extract and apply reference information




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D. Apply Trigonometric Calculations in Machine Technology

1. Apply Cartesian Coordinate System in Machininga. Explain Cartesian Coordinate systemb. Explain + and - number lines and use to represent Cartesian Coordinate

Systemc. Explain use of Cartesian Coordinate system in machiningd. Explain different quadrants & their values of x, y, & z.e. Show location of rectangular coordinates and axesf. Explain integration of polar coordinates onto the rectangular coordinate

system and the degree value of each quadrantg. Place specific x, y and z locations on the Cartesian Coordinate systemh. Explain placement of rotational degrees on coordinate systemI. Place various angular locations on coordinate system

2. Perform Trigonometric Calculationsa. Explain the need for calculating length and angles in CAD/CAM and CNC

Programmingb. Explain degrees, minutes and seconds of anglesc. Explain decimal representation for anglesd. Convert degrees, minutes and seconds to decimal format using calculatore. Convert decimal format to degrees, minutes and seconds using calculatorf. State and explain equations for finding angles and sides

C Sine of Angle = Opposite Side / HypotenuseC Cosine of Angle = Adjacent Side / HypotenuseC Tangent of Angle = Opposite Side / Adjacent Side

g. Convert sine, cosine and tangent to angle using natural trigonometrictables and calculator

h. Convert angle to sine, cosine and tangent using natural trigonometrictables and calculator

3. Perform Pythagorean Theorem Calculationsa. Explain Pythagorean Theorem strengths and limitationsb. List and explain the equations for the Pythagorean Theorem:

C c2 = a

2 + b

2

C b2 = c

2 - a

2

C a2 = c

2 - b

2

c. Demonstrate use of Pythagorean equations to find sides of triangles




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d. Combine sine, cosine, and tangent equations with Pythagorean equationsto solve missing sides and angles

e. Demonstrate use of combined methods to solve missing lengths and angles

4. Perform Polar Trigonometry Calculationsa. Explain trigonometry using polar coordinatesb. Explain sine = opposite side / hypotenuse and cosine = adjacent side /

hypotenuse relative to polar trigonometryc. Explain comparison and application of sine bar and sine functiond. Apply benefits of not being limited to 90°e. Describe calculator equation using "Casio" type scientific calculationsf. Describe time benefit to using Polar coordinates to calculate locationsg. Demonstrate proper use of Polar trigonometry to calculate locations on a

bolt hole circleh. Explain translation of center reference relative to a known point to give

absolute location of new coordinates to a X , Y reference used in CNCProgramming

i. Demonstrate the ability to translate locations from a center referenceposition to a absolute position

E. Demonstrate Cutting Tool Identification and Application

1. Identify Cutting Tools and Describe Tool Nomenclaturea. Identify different types of end mills, center drills, drills, reamers, tapsb. Explain cost differences for types of tooling within same tool

classification, including:•End mills•Face mills•Center drills•Drills•Reamers•Single point boring head•Single point threading tools•Counter boring tools•Spot facing tools•Taps

2. Identify and Explain Application of Machine Toolsa. List different applications requiring proper selections of each tool




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b. Identify proper cutting tool for specified applicationc. Demonstrate ability to identify cutting tools defined by blueprint, process

documentation and verbal instructiond. Demonstrate ability to give written or verbal justification of tool selection

to include cost differential

F. Identify and Describe Machine Operation Nomenclature

1. Identify and Describe Types of Millinga. Explain climb millingb. Explain conventional millingc. Describe benefits and draw backs of each applicationd. Explain contouring operationse. Explain pocketing operations

2. Describe Drilling / Boring Operations and Their Applicationsa. Describe applications for center drillingb. List and explain the different accuracies achieved from drilling, reaming

and single point boringc. List and explain reasons to use single point boringd. Describe the difference between spot facing and counter boring operations

3. Identify and Describe Threading Operationsa. Identify and describe common single point threading tool set-upsb. Describe the reasons for choosing single point threading tools instead of

taps and diesc. Identify and describe various taping operations and accessories

G. Apply Elements of Blueprint Reading to Machining Technology

1. Describe Types of Blueprint Drawingsa. Describe and create common line types used in engineering drawings.




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b. Identify and describe reasons for the following drawing types:C Orthographic projectionsC Pictorial drawingsC Detail drawingsC Sectional viewsC Assembly drawings

2. Describe Blueprint Dimensionsa. Identify types of dimensions found on blueprintsb. Interpret, describe and create dimensions as found on blueprintsc. Interpret, describe and create tolerances found on blueprintsd. Explain effects of tolerances on machining operations and coste. Identify and interpret geometric dimensioning and tolerancing symbols.

3. Interpret Title, Notes, Revision and Material Informationa. Identify and explain difference between general and local drawing notesb. Describe information contained in title blocksc. Locate and interpret various call outs in material listings

4. Interpret Blueprint Drawingsa. Identify various surface finish symbolsb. Interpret and discuss various call outs of a surface finish symbolc. Identify need for various process documentationd. Interpret and create process documentation, including:

C Planning documentationC Inspection documentationC Engineering changesC Set-up documentation

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MACHINE TECHNOLOGY PROGRAMSAN DIEGO CITY COLLEGE


SCANS SKILLS

Five Competencies Three Part Foundation Skills

Resources Basic SkillsInterpersonal Skills Thinking SkillsInformation Skills Personal QualitiesSystemsTechnology

SCANS COMPETENCIES

The following competencies will be achieved by each student for successful completion of thiscourse.

1. Resources: Identifies, organizes, plans, and allocates resources

• Follow a schedule to complete assigned tasks on time.• Determine initial cost of materials and “value added” as a result of

machining.• Complete a stock request form for required material.• Provide a self-evaluation of performance based on the time and quality

of work.

2. Interpersonal: Works with others

• Complete assigned responsibilities within the shop floor serving as amember of the team.

• Provide individual assistance/direction to peers as requested.• Produce machine parts to acceptable levels of quality as required.• Work well with all members of you class.

3. Information: Acquired and uses information

• Read and interpret blueprints.• Organize and practically apply theories of machine tool operation.• Perform basic semi-precision and precision layout as necessary.

4. Systems: Understands complex inter-relationships



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• 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 systemse. systematic organization of training materials

• Monitors and corrects performance duringa. the machining processb. adjustments of individual laboratory work schedulec. constantly evaluating the quality of work to achieve acceptable standardsd. Maintains record of evaluations and sets individual goals

5. Technology: Works with a variety of technologies

• Chooses procedure, tools and equipment required to produce a part• Applies appropriate procedures and uses appropriate tools and equipment to

produce a machined part to acceptable standards • 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



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FOUNDATION SKILLS

The following skills will be achieved by each student for successful completion of this course.

1. Basic Skills: Reads, writes, performs arithmetic and mathematical operations, listensand speaks.

• Reading: Locates, understands, and interprets written information in prose and in documents such as manuals, graphs, and schedules

a. 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

• Writing: Communicates thoughts, ideas, information, and messages inwriting; and creates documents such as letters, directions,manuals, reports, graphs, and flow charts

a. outline the steps necessary to produce a simple machinepart

b. maintain a lecture notebookc. submit written responses to chapter question assignmentsd. complete all written assignments

• Arithmetic/ Perform basic computations and approaches practical problems Mathematics: by choosing appropriately from a variety of mathematical techniques.

a. determines optimum machining speeds, feeds, and depth ofcut

b. calculates “value added to the part”c. aligns machine and/or work holding deviced. taps and threadse. keeps a running computation of individual gradef. intraconverts fractions to decimal expressionsg. use protractors to lay-out angle machiningh. use trigonometry to solve angle and taper calculations



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• Listening: Receives, attends to, interprets, and responds to verbal messagesand other cues

a. assimilate classroom instructionb. interpret and assimilate video instructionc. observe laboratory demonstrationsd. seek and receive individualized instruction in the laboratory

• Speaking: Organizes ideas and communicates orally

a. participates in classroom discussionsb. organize ideas and communicate specific questions to the

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

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

operation of the laboratory

2. Thinking Skills: Thinks creatively, makes decisions, solves problems, visualizes,knows how to learn and reasons.

• Decision Making: Specifies goals and constraints, generates alternatives,considers risks, and evaluates and chooses best alternative

a. identifies personal goalsb. identifies actions required to accomplish personal

goals

• Problem Solving: Recognizes problems and devises and implements plan ofaction

a. makes daily accommodations to stay on scheduleb. Seeks additional instruction/clarification for

assignment completionc. balances social and academic life/responsibilitiesd. accepts responsibility



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• Seeing Things Organizes, and processes symbols, pictures, graphs,In the Mind’s Eye: objects, and other information

a. interprets technical drawingsb. interprets technical illustrations and symbolsc. understands both written and verbal instructionsd. assimilates process during instructor demonstrations

• Knowing How Use efficient learning techniques to acquire and apply new to Learn: knowledge and skills

a. demonstrate mastery of the basic skills andtechniques

b. use these sequential skills to support mastery of newskills

c. understand the sequential nature of acquired skillsand the subsequent knowledge application of newskills and techniques

• Reasoning: Discovers a rule or principle underlying the relationshipbetween two or more objects and applies it when solving aproblem.

a. understands that practice may not make it perfectbut it certainly will improve the skill of the operator

b. understands that the quality of the product is afunction of the time of the operation and the attitudeand skill of the machinist

c. understands the relationship between differentmetals and the tool applied to the metal surface andadjusts machining parameters accordingly.

3. Personal Qualities: Displays responsibility, self-esteem, sociability, self-management,and integrity and honesty.

• Responsibility: Exerts a high level of effort and perseveres towards goalattainment

a. develops an understanding that in order to besuccessful you must be a “good” student

b. develops an understanding that a “good” student is



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the one who is prompt to every class and hasprepared for the day’s work

c. develops an understanding good students knowwhat they are going to do in class and does notwaste time

d. develops a fine work-ethic

• Self-Esteem: Believes in own self-worth and maintains a positive view ofself

a. learns to take pride in his or her work throughpositive reinforcement

b. sees himself or herself as an asset to the classthrough continued contributions to the group and ashared common goal

c. understands that an individual with a positiveattitude and the belief in their own abilities willsystematically seek solutions and be a valuableemployee

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

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)

• Self-Management: Assesses self accurately, sets personal goals, monitorsprogress, and exhibits self-control

a. perform in-progress quality checks on machinedparts

b. maintain a record of academic achievement(individual grade book)

c. make accommodations to laboratory schedules dueto broken machines/tools

d. accept the responsibility for self-management

• Integrity/Honesty: Chooses ethical courses of action



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a. 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 outsideassignments

d. understand the consequences of unethical behaviors

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