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ED 401 439
TITLE
INSTITUTIONSPONS AGENCY
PUB DATECONTRACTNOTE
AVAILABLE FROMPUB TYPE
EDRS PRICEDESCRIPTORS
ABSTRACT
DOCUMENT RESUME
CE 072 932
Machine Tool Advanced Skills Technology (MAST).Common Ground: Toward a Standards-Based TrainingSystem for the U.S. Machine Tool and Metal RelatedIndustries. Volume 9: Tool and Die, of a 15-VolumeSet of Skill Standards and Curriculum TrainingMaterials for the Precision ManufacturingIndustry.Texas State Technical Coll., Waco.Office of Vocational and Adult Education (ED),Washington, DC.Sep 96V199J40008317p.; For other volumes in this set, see CE 072924-938.World Wide Web: http://machinetool.tstc.eduGuides Classroom Use Teaching Guides ForTeacher) (052)
MFO1 /PC13 Plus Postage.Computer Assisted Manufacturing; Course Content;Curriculum Development; *Entry Workers; Hand Tools;*Job Skills; Job Training; Learning Modules;Machinery Industry; *Machine Tools; ManufacturingIndustry; Metal Working; Postsecondary Education;Secondary Education; *Standards; Teaching Methods;*Tool and Die Makers
This document is intended to help education andtraining 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 tool and die maker specialtyarea. (A tool and die maker is a person who produces tools, dies, andspecial guiding and holding devices that are used in machine toolsand to produce a variety of machined parts and products.) This volumeis organized in the following sections: (1) a profile of ItawambaCommunity College (Mississippi), the development center that producedthese standards and curriculum; (2) a tool and die maker competencyprofile of job duties and tasks; (3) a tool and die maker duty, task,and subtask outline; (4) a course curriculum outline and coursedescriptions; (5) a technical workplace competencies and coursecrosswalk; and (6) a Secretary's Commission on Achieving NecessarySkills (SCANS) proficiencies course crosswalk. Individual syllabi forthe following courses are provided: Machine Tool Technology;Introduction to Die Making Procedures; Fundamentals of Drafting;Introduction to Computers; Die Design I; Die Making I; ComputerNumerical Control (CNC) Operations I; Principles of Computer AssistedDesign (CAD); Die Design II; Die Making II; CNC II; Die Making III;CNC III; and Special Project. Each course syllabus includes thefollowing: course hours, course descriptions, prerequisites, requiredcourse materials, teaching and evaluation methods, lecture andlaboratory outlines, course objectives for technical and SCANScompetencies, and suggested references. Two appendixes containindustry competency profiles and the pilot program narrative. (KC)
achine Tool
dvancedkillsethnology
U.S. DEPARTMENT OF EDUCATIONOffice of Educate:maiResearch and improvement
ED CATIONAL RESOURCESINFORMATION
CENTER (ERIC/Thia document nes been reproduCed asWaived from tne person or organizationOriginating d.
C Minor changes have been made to improvereproduction oualily
Points of view or opiniOns stated in this clocument do not necessarily represent OfficialOERI position or policy
COMMON GROUND:TOWARD A STANDARDS-BASED TRAINING
SYSTEM FOR THE U.S. MACHINE TOOLAND METAL RELATED INDUSTRIES
VOLUME 9
TOOL AND DIE
ofa 15 volume set of Skills Standards
andCurriculum Training Materials for the
PRECISION MANUFACTURING INDUSTRY
2BEST COPY AVAILABLE
Supported bythe Office of Vocational & Adult Education
U.S. Department of Education
(CENTER FOR APOLISO)COMPKTITIVE THC.11.001.001
AUGUSTA
TECHNICALI N S T I T U T E
San Diego College
yr N Moraine ValleyNI .4 A Community College
SPRINGFIELD TECIINICALCOMMUNITY COLLEGE
Texas StateTechnical College
Waco
Machine Tool Advanced SkillsTechnology Program
VOLUME 9
--TOOL AND DIE --
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
V199J40008
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.
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 AFFILIATESAikcn 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 (NISI) - 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 Metalforming 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 and
. organizations 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 (MET)
VOLUME 5 MOLD MAKING (MLD)
VOLUME 6 WELDING (WLD)
VOLUME 7 INDUSTRIAL MAINTENANCE (IMM)
VOLUME 8 SHEET METAL (SML) AND COMPOSITES (COM)
VOLumz. 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
V7
VOLUME 9
TOOL AND DIE MAKER
Table of Contents
TAB
Foreword 1
Development Center Profile 2
Tool and Die Maker Competency Profile 3
Tool and Die Maker Duty/Task/Sub -Task Outline 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
Appendix B - Pilot Program Narrative 10
FOREWORD
Advanced technology has changed forever the nature of employment in modern manufacturing.Traditional assembly operations are being supplanted by automation or made redundant throughstreamlining of the manufacturing process. In most industries, fewer low-skilled workers areneeded to meet the same or higher production goals, leaving a surplus of workers to fill a smallernumber of openings. At the same time, as new employment opportunities in advancedmanufacturing begin to appear, finding qualified applicants to fill the positions is often difficult.Traditional candidates coming from crafts-based occupations often lack the education andknowledge of computers to operate modern manufacturing technology and processes.
The occupation of Tool and Die Maker epitomizes the state of transition in modern Americanmanufacturing. Tool and Die Makers stand with one foot on the cutting edge of technology andthe other in the craftsmanship of the previous era. They must be adept at computer programmingand computer-aided drafting, understand computerized numerically controlled machining, stayabreast of the most recent innovations in manufacturing materials. At the same time, they mustpossess knowledge and expertise in conventional areas of machining, such as grinding, milling,welding, and turning, and be skilled in the use of various hand held instruments.
Recognizing the need to increase the supply of new skilled workers in this and otheroccupations for the metal and metals-related industries, the U.S. Department of Educationlaunched the Cooperative Demonstration Program (Manufacturing Technologies) as partof the National Skills Standards Act of 1994. The goal of the Department initiative was tofoster the development and implementation of national skill standards and a training modelfor certificate and Associate of Science degree programs. In July 1994, a multi-stateconsortium of community colleges led by Texas State Technical College received a grantawarded by the Department under the initiative. The Machine Tool Advanced SkillsTechnology (MAST) consortium, which includes six of the nation's leading AdvancedTechnology Centers (ATCs), was formed to develop, test and disseminate industry-specificskill standards and model curricula for the U.S. machine tool industry over a two yearperiod. As part of the MAST consortium, Texas State Technical College was tasked withdeveloping and piloting skill standards and model curricula in the technical area of Tool &Die Maker.
The diversity of knowledge and skills required by the Tool and Die Maker occupation complicatesidentification of entry-level Tool and Die Maker skills. While a broad background in metal-working and machining is ideal, and knowledge of metallurgy is vital, manufacturers continue toinsist that the best Tool and Die Makers have the manual dexterity and hand-eye coordination ofOld World craftsmen. The skill standards and curriculum presented here are the result ofnumerous interviews with practitioners from industry (see Appendix A) and discussions witheducators, managers, supervisors, and others involved with tool and die making. Based ondiscussion with the other MAST consortia partners, the project presents the following definitionof the new occupation:
9
TOOL AND DIE MAKER: The Tool and Die Maker produces tools, dies, and special guidingand holding devices that are used in machine tools and to produce a variety of machined partsand products.
Itawamba Community College's tool and die making curriculum is a 20-course, two year programencompassing manufacturing technology and methods and laboratory work using equipment andmaterial standard across various industries. The present volume provides the occupational skillstandards, project documentation, and course syllabi for education and training recommended asminimum preparation for an individual desiring to enter the field of Tool and Die Maker.
PARTNER OCCUPATIONAL SPECIALITY ASSIGNMENTS
111 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.
1
MAST DEVELOPMENT CENTER, TUPELO, MSItawamba Community College
Tupelo Campus
David Cole, PresidentItawamba Community CollegeCharles Chrestman, DeanCareer Education and Community ServicesDon Benjamin, Associate DeanCareer Education
653 Eason BoulevardTupelo, MS 38801
College phone: 601/842-5621, fax: 601/680-8423
Manufacturing in MississippiEvolving from a previously agrarian economy, the region served by Itawamba Community College now contains asignificant industrial base. Approximately 45% of employed adults in the surrounding area work inmanufacturing, with the predominant industries including metal-working, machinery, paper products,rubber/plastics, electrical components, furniture, apparel, and wood products. About 35-40% of all manufacturingemployees work in the furniture industry. After World War II, several major metal-working companiesestablished branch plants in the Tupelo area, a trend that has continued into the 1990's. Between 1975 and 1980,pressures of competition and technology caused a number of these companies to reconsider their continuedpresence in northern Mississippi, spurring action by regional economic development organizations to preserve anemployment and tax base essential to the community. Many of their economic development initiatives involvedthe community college, leading directly to the establishment of its Tool and Die Making Technology program andintroduction of training in CAD, CNC, robotics, and lasers.
Itawamba Community CollegeItawamba Community College (ICC) provides university transfer programs, associate degree career programs,non-credit customized industry training, and continuing education to a rural five-county area in northeastMississippi. Of the local population of approximately 170,000 persons, 79% are white and 19% black; thestudent profile at the College roughly mirrors the racial composition of the general population, and a highpercentage of students are from low-income households. The mission of the College includes the mandate toprovide "educational services which contribute to the needs of new, expanding, or existing businesses andindustries and to the training needs of the people." Accordingly, the College's instructional programs are designedwith national trends and the needs of business and industry in mind, and the objective of all courses and trainingis to provide both students and companies with what they need to succeed. The main campus is in Fulton and thevocational-technical campus in Tupelo.
Development TeamProject Director: Don Benjamin, Associate Dean of Career Education, served as program manager andacademic coordinator for the MAST project.Site Coordinator: Barry Emison was responsible for industrial assessment and skills validation, as well asdevelopment of skill standards and course/program materials for the Tool and Die Technology component ofthe MAST project. Barry worked closely with Steve Zimmer of Syzygy, Inc., who conducted task analysissessions with teams of expert workers.Subject Matter Experts: Pat Masur, Basic Skills/Related Studies Instructor, served as advisor for basicacademic competencies, sharing responsibility with Mr. Emison for compiling data from industry surveys andinterviews during the skill standards development process. Donald Taylor and Terry Kitchens, Tool and DieTechnology Instructors, served as technical advisors for workplace competencies and developedcourse curricula and program materials. They also served as co-instructors and coordinators forthe MAST pilot program in Tool and Die Technology.
12
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.
13
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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.
TOOL AND DIE MAKERTECHNICAL WORKPLACE COMPETENCIES
TOOL AND DIE MAKER...skilled workers who produce tools, dies, and special guiding andholding devices that are used in machines and produce a variety of products.
A. PRACTICE SAFETY1 Follow Safety Manuals and All Safety Regulations/Requirements
a. Comply with established company and OSHA regulationsb. Interpret safety manual directivesc. Wear safety/protective equipment as required
2. Maintain Safe Equipment and Machinerya. Maintain equipment/tooling in safe operating conditionb. Maintain all guards, shields, and barriers in place and in good conditionc. Perform preventive maintenance as requiredd. Practice proper tag-out/lock-out procedures
3. Maintain a Clean and Safe Work Environmenta. Keep work areas clean and free of debrisb. Keep aisles/traffic areas clear of equipment and materialsc. Store materials, tools, and instruments in organized mannerd. Clean machine/hand tools when work is complete
4. Use Safe Operating Procedures For Hand and Machine Toolsa. Use tools for intended purposes onlyb. Acquire proper training/authorization before operating equipmentc. Operate hand and machine tools in safe mannerd. Comply with manufacturer's rated capacity for equipmente. Ensure all rotating or moving parts have stopped before leaving areaf. Inspect for and remove possible hazards before engaging equipment
5. Use Safe Machining Practicesa. Ensure stock/tooling is secure before machiningb. Use chip control methodsc. Use moderate, safe, and calculated speeds and feedsd. Stay alert and prepared to act during machininge. Ensure rotating parts/tooling are completely stopped before handling
6. Use Safe Lifting Practicesa. Use lifting aids when necessaryb. Use OSHA approved chains, straps, and hoistsc. Comply with rated capacity of lifting equipmentd. Comply with company/OSHA regulations regarding lifting procedures
7. Consult and Apply MSDS for Hazards of Various Materialsa. Know format of material safety data sheetsb. Consult and interpret MSDS to determine relevant hazards of materialc. Apply information and take precautionary measures against hazardsd. Notify proper authorities of hazards
B. APPLY MATHEMATICAL CONCEPTS1. Perform Basic Arithmetic Functions
21
a. Add, subtract, multiply, and divide whole numbersb. Add, subtract, multiply, and divide fractionsc. Add, subtract, multiply, and divide decimalsd. Interconvert fractions/decimalse. Interconvert metric/English measurements
2. Perform Basic Algebraic Operationsa. Evaluate equation using standard algebraic hierarchyb. Solve equations with one unknown variablec. Solve ratio/percentage problemsd. Calculate and apply formulas
3. Perform Basic Trigonometric Functionsa. Solve for unknown sides/angles of right triangles using trigonometric
functionsb. Solve for unknown side of right triangle using Pythagorean's Theorem
4. Use Basic Geometric Principlesa. Solve for surface area, perimeter, and volume of cubeb. Solve for surface area, perimeter, and volume of rectangular solidc. Solve for surface area, perimeter, and volume of right triangular solidd. Solve for surface area, perimeter, and volume of cylindere. Find diagonal of a square
5. Use and Apply Cartesian Coordinate Systema. Define the Cartesian coordinate systemb. Calculate coordinates of bolt circle on Cartesian coordinate systemc. Plot machining points using Cartesian coordinate system
C. DEMONSTRATE QUALITY CONTROL AND MANAGEMENTI. Utilize Appropriate Inspection Techniques
a. Discuss factors that affect accurate measurementb. Determine proper procedure to acquire accurate measurementc. Determine proper instrument to use in measurement
2. Perform Appropriate Use and Calibration of Inspection Equipmenta. Explain calibration requirements of various precision instrumentsb. Maintain/care for instruments for optimum performancec. Read and use 0.D., I.D., and depth micrometersd. Read and use vernier, dial, & digital caliperse. Read and use scale and tape measuref. Read and use dial-bore indicatorsg. Use dial indicatorsh. Use precision square and combination seti. Read and use digital read-outj. Use finish/profile gagesk. Use Rockwell hardness testerI. Know operation of coordinate measuring machine (CMM)m. Use surface plates
3. Know Qualitative Parameters of Machinery and Equipment
a. Differentiate between types of machinery by qualitative capabilitiesb. Select appropriate processes to maintain desired tolerancesc. Discuss the effect one process might have on an earlier or later process
4. Maintain Equipment to Produce Quality Partsa. Justify tooling by qualitative requirementsb. Protect/maintain critical surfaces of machinesc. Perform preventive maintenance on equipment
5. Know and Use Quality Systemsa. Know and use ISO 9000 concepts and proceduresb. Know and use Statistical Process Control (SPC) techniques and concepts
6. Write Inspection Proceduresa. Determine/designate proper inspection techniqueb. Determine/designate precautions to take during inspectionc. Determine/design inspection jig or fixture requiredd. List in order and define steps required to ensure accurate measurement
7 Document Inspection Resultsa. Define procedure used during inspectionb. Accurately document measurements taken and compare to standardc. Determine/document if part passes or fails inspectiond. Determine/document rework or scrap recommendations
D. DEMONSTRATE KNOWLEDGE OF MANUFACTURING MATERIALS1. Identify Materials With Desired Properties
a. Determine/identify service requirements (strength, hardness, etc.)b. Determine, interpret, and evaluate availability of materialsc. Describe general characteristics of various metalsd. Know concepts of/calculate statics and stresses
2. Demonstrate Knowledge of Physical Properties of Materialsa. Define hardnessb. Define toughnessc. Define tensile strengthd. Define shear strengthe. Define elasticityf. Define ductility
g. Discuss the Rockwell and Brinell hardness scalesh. Discuss the Charpy/Izod impact tests
3. Identify Manufacturing Properties of Materialsa. Discuss machinability of various materialsb. Discuss cold forming/workability of various materialsc. Define work hardening/edge hardeningd. Identify welding properties of various materialse. Demonstrate knowledge of heat treating procedures and propertiesf. Know stress relieving proceduresg. Know/Find hardness characteristics and chemistry of various materials
4. Discuss Classification System for Metals
23
a. Identify and discuss types of carbon steelb. Determine chemistry of material by classificationc. Distinguish between SAE and AISI classification systemsd. Identify designation of each digit of steel classificatione. Discuss alloy steels
E. DEMONSTRATE KNOWLEDGE OF MANUFACTURING PROCESSES1. Know Operation of Vertical and Horizontal Mills and Tooling
a. Define milling machines, horizontal and verticalb. List, describe, and give function and maintenance of different types of
tooling used on milling machinesc. Set-up and operate horizontal and vertical milling machined. Explain machine components and accessories of milling machinese. Explain milling processesf. Discuss milling machine safetyg. Discuss CNC machining centers and processesh. Calculate speeds and feeds based on materials and toolingi. Set-up and operate CNC machining center
2. Know Operation of Engine and Turret Lathes and Toolinga. Define lathes, engine and turretb. List, describe, and give function and maintenance of various types of
tooling used on lathesc. Set-up and operate engine and turret lathesd. Explain machine components and accessories of lathese. Explain turning processesf. Discuss lathe safetyg. Discuss CNC turning centers and processesh. Calculate speeds and feeds based on materials and toolingi. Set-up and operate CNC turning center
3. Know Operation of Drill Presses and Toolinga. Identify types of drilling machinesb. List, describe, and give function and maintenance of various types of
tooling used on drilling machinesc. Set-up and operate drilling machinesd. Explain machine components and accessories of drilling machinese. Explain processes performed on drilling machinesf. Discuss drilling safetyg. Discuss drilling operations on CNC drilling machinesh. Calculate speeds and feeds based on materials and toolingi. Set-up and operate CNC drilling machine
4. Know Operation of Surface and Cylindrical Grindersa. Define grinders, surface and cylindricalb. Explain types and maintenance of grinding wheelsc. Set-up and operate grinding machinesd. Explain machine components and accessories of grinding machines
e. Explain grinding processesf. Discuss grinding safety
I 5. Know Operation of Heat Treating Equipment and Processesa. Describe types of heat treating equipmentb. Set-up and operate heat treating equipment
I c.
d.Explain machine components and accessories of heat treating equipmentExplain heat treating procedures
e. Discuss heat treating safetyI6. Know Operation of Welding Equipment and Processes
a. Identify various types of welding equipmentb. Identify and discuss the difference in welding processesIc. Inspect welds for cracks and penetrationd. Discuss welding safety
7. Know Sheet Metal OperationsIa. Discuss gas/plasma cutting equipment and processesb. Discuss operation of punch/brake presses and tooling
Ic.
d.
Discuss operation of plate shearsCalculate tonnages required for press/shear operations
e. Calculate blank dimensions of developed parts
I f.
g.
Use yield tables for bending sheet metalDiscuss fabrication of sheet metal parts
h. Demonstrate layout-on-metal
I 8.
i. Apply conservation-of-material conceptsKnow Operation of Jig- Boring Machines and Toolinga. Define jig-boring machine
I b. List, describe, and give function and maintenance of different types oftooling used on jig-boring machines
c. Set-up and operate jig-boring machineId. Explain machine components and accessories of jig-boring machinese. Explain jig-boring processf. Discuss safety on jig-boring machine
Ig. Calculate speeds and feeds based on materials and tooling9. Know Operation of Tool and Cutter Grinders
Ia. Define tool/cutter grinderb. Discuss dressing and maintenance of grinding wheelsc. Explain machine components and accessories of tool/cutter grinder
Id. Discuss tool and cutter grinder safety
10. Know Operation of Metal Sawsa. Define band saw, horizontal and vertical
I b.
c.Set-up and operate band sawDefine abrasive cut-off saw
d. Set-up and operate abrasive cut-off saw
I e. Discuss application of the different tooth forms, pitch sets, and gages ofband saw blades
f. Weld and maintain band saw blade
I25
g. Discuss band saw safetyh. Calculate speeds and feeds based on materials and toolingi. Explain machine components and accessories of band sawsj. Calculate proper length of band saw blade
11. Know Operation of Wire EDMa. Define EDMb. Explain EDM processc. Set-up and operate CNC wire EDMd. Discuss EDM safetye. Calculate E-pac value for wire EDMf. Explain machine components and accessories of wire EDM
12. Estimate Time Required/Cost to Produce a Parta. Determine processes required to produce partb. Calculate actual machining and handling timec. Calculate material quantity and costd. Calculate labor and overhead cost
13. Know Proper Flow of Parts Through Shopa. Discuss proper order of processesb. Discuss ergonomic aspects of plant layout
14. Utilize Concepts and Principles of Fixturinga. Determine need for fixture/jigb. Design appropriate fixture/jigc. Identify components used in fixtures/jigsd. Disassemble and assemble fixture/jige. Discuss relationship between accuracy of fixture and accuracy/repeatability
of parts15. Make Calculations For and Use Sine Bar/Sine Plate
a. Define sine bar/sine plateb. Calculate gage block buildup for sine bar/sine platec. Set-up and use sine bar/sine plate
16. Make Calculations For and Use Rotary Table and Dividing Heada. Set-up and use rotary table/dividing head for machining operationsb. Make calculations for number of rotations requiredc. Determine/select appropriate index plate for dividing head
F. PERFORM CNC PROGRAMMING/CAM TASKS1. Prepare and plan for CNC machining operations
a. Plan sequence of machining eventsb. Determine proper tooling/fixtures required for machiningc. Calculate speeds, feeds, and depth-of-cut for machiningd. Explain the x, y, and z, axis on CNC machines
2. Select and Use Tooling Systems for CNC Machinesa. Understand machinability and chip formationb. Select proper insert materials and geometryc. Select proper tooling system
d. Define and discuss application of HSS, carbide, and borazon cutting tools3. Manually Program CNC Machines
a. Plan and write programs for CNC machinesb. Use MDI panel on machine to program/edit programsc. Set and use tooling offsets at CNC machined. Discuss/use canned or bar cycles in program
4. Use Computer-Aided Manufacturing (CAM) Systema. Create toolpath geometry using CAM systemb. Interconvert CAD and CAM files using acceptable exchange formatc. Transfer files from CAM system to machined. Configure CAM system parameters
G. DEMONSTRATE COMMUNICATION SKILLS1. Use Written Correspondence
a. Read, write, interpret, and apply memorandumsb. Read, write, interpret, and apply business lettersc. Read, write, interpret, and apply written instructions
2. Use Written Technical Informationa. Read, write, interpret, and apply technical reportsb. Read, write, interpret, and apply written proceduresc. Read, write, interpret, and apply technical manuals
3. Communicate Technical Information Verballya. Demonstrate ability to listen to and understand verbal technical
information/instructionsb. Ask appropriate questions to ascertain needed informationc. Demonstrate ability to give verbal technical information/instructions
4. Use Graphics for Visual Aida. Create, read, and apply graphsb. Create, read, and apply chartsc. Create, read, and apply graphical illustrations
H. PERFORM DRAFTING/CAD TASKS1. Demonstrate Traditional Mechanical Drafting Skills
a. Demonstrate use of drafting machine and instrumentsb. Demonstrate drafting technique to create basic geometric elementsc. Demonstrate isometric sketching of objectsd. List and apply the three primary planes of projectione. List and apply the six principle viewsf. Use and apply auxiliary views
g. Create sectional views2. Use Computer-Aided Drafting (CAD) System
a. Create geometry using CAD systemb. Create 3-D solid modelsc. Interconvert CAD and accepted drawing exchange formatsd. Configure CAD system parameters
27
e. Use peripheral devices3. Use and Apply Geometric Dimensioning and Tolerancing (GD&T) Methodology
a. Distinguish between conventional and geometric dimensioning andtolerancing
b. Explain and use geometric positional tolerancingc. Explain and use tolerances of formd. Explain and use the feature control symbole. Explain and use modifiers in geometric dimensioning and tolerancing
I. USE COMPUTERS1. Use Computer Operating Systems
a. Explain the phrase "IBM compatible"b. Use DOS operating system/DOS commandsc. Use Windowsd. Use computer network system
2. Use File Management Systemsa. Discuss file management conceptsb. Create/remove directoriesc. Copy files from floppy disks to hard drive
3. Perform Backup on a Personal Computera. Discuss need to backup hard diskb. Perform complete backup of hard diskc. Perform backup of selected files and directoriesd. Restore backup set to hard diske. Discuss need for/make system disk
4. Install/Use Software Packagesa. Install software package to hard diskb. Configure system parameters for software packagec. Use word processor software (WordPerfect, MS Word)d. Use spreadsheet software (Lotus, MS Excel)
5. Understand and Apply Computer Terminologya. Define Read Only Memory (ROM)b. Define Random Access Memory (RAM)c. Define cache memoryd. Define byte, kilobyte, megabytee. Define Central Processing Unit (CPU)f. Discuss processor speedg. Understand RS-232 protocol
J. INTERPRET/USE BLUEPRINTS AND RELATED DOCUMENTS1. Interpret, Review, and Apply Blueprint Notes, Dimensions, and Tolerances
a. Distinguish between general and specific notesb. Interpret and apply general and specific notesc. Determine and apply dimensions on a drawingd. Identify basic symbols found on a drawing
e. Identify tolerances on a drawingf. Discuss GD&T methodology
2. Interpret and Understand Basic Layout/Types of Drawingsa. Identify types of drawingsb. Identify parts of a drawing and list components of eachc. Identify types of lines on a drawingd. List and describe the different views found on a drawing
3. Understand and Analyze Bill-of-Materialsa. Determine materials requiredb. Determine quantities requiredc. Identify item symbol and/or part number
4. Ascertain Job Requirements From Drawingsa. Interpret part requirementsb. Identify surfaces to be machinedc. Determine critical dimensions
K. PERFORM DIE OPERATIONS1. Utilize Basic Die Theory and Principles of Die Design
a. Discuss shearing action on metal (3 stages)b. Define/calculate cutting clearancec. Define/calculate proper shut-height of die setd. Define/calculate offset displacemente. Define/calculate stripping pressuref. Define/calculate cutting length of piece partg. Define/calculate die progressionh. Design stock strip layouti. Determine die feed directionj. Explain notch, pierce, pilot, form, and cut-off stationsk. Determine stop block length1. Determine press tonnage requirementsm. Define/calculate slug clearancen. Explain operation of die set to make piece parto. Explain spring back in form diesP. Explain bending action in V-form diesq. Explain coining in diesr. Identify components of die sets. Discuss materials of die components
2. Perform Die Repaira. Disassemble and assemble die setb. Visually inspect die components for damagec. Identify component parts to be repaired/sharpenedd. Determine method of repairing/sharpeninge. Determine material for replacement partsf. Manufacture replacement partsg. Demonstrate setting correct punch entry
29
3. Demonstrate Die Making Skillsa. Identify component parts from die blueprintb. Determine material/purchased parts requirementsc. Utilize die making procedures to make component partsd. Utilize die making procedures to mount component partse. Demonstrate mounting of die set in press machinef. Cycle die set in press machine and inspect operationg. Inspect piece part for accuracy
4. Demonstrate Understanding of Different Types of Industrial Diesa.b.c.d.e.
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Describe the operationDescribe the operationDescribe the operationDescribe the operationDescribe the operationDescribe the operationDescribe the operation
and major components of blanking or piercing diesand major components of bending or forming diesand major components of draw diesand major components of compression diesand major components of progressive diesand major components of compound diesand major components of combination dies
THE MAST PILOT PROGRAM CURRICULUMAND COURSE DESCRIPTIONS
After completing the Competency Profile and Technical Workplace Competency Outline for eachoccupational 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.
TOOL & DIE MAKING TECHNOLOGYCURRICULUM
1995 -1996
FIRST SEMESTER LEC LAB CR
MSV 1016 Machine Tool Technology 3 6 6TDT 1114 Introduction to Die Making Procedures 2 4 4DDT 1113 Fundamentals of Drafting 2 2 3
CPT 1113 Introduction to Computers 2 2 3
MAT 1233 Intermediate Algebra 3 0 3
12 14 19
SECOND SEMESTER
TDT 1133 Die Design I 2 2 3
TDT 1146 Die Making I 3 6 6MST 2713 Computer Numerical Control Operations I 2 2 3
DDT 1313 Principles of CAD 2 2 3
ENG 1113 English Composition I 3 0 3
12 12 18
THIRD SEMESTER
TDT 2153 Die Design II 2 2 3
TDT 2166 Die Making II 3 6 6MST 2723 Computer Numerical Control Operations II 2 2 3
MAT 1323 Trigonometry 3 0 3
SPT 1113 Oral Communications 3 0 3
13 10 18
FOURTH SEMESTER
TDT 2174 Die Making III 2 4 4MST 2733 Computer Numerical Control Operations III 2 3 3
TDT 2183 Special Project 1 4 3
Humanities/Fine Arts Elective 3 0 3
Social or Behavioral Science Elective 3 0 3
11 11 16
Program Totals 48 47 71
TOOL AND DIE MAKING TECHNOLOGYCOURSE DESCRIPTIONS
1995-1996
MSV 1016 Machine Tool Technology (3-6-6) This course is composed of fundamentalskills related to machine tool operations. Topics covered in the course includesafety, precision measurement, blueprint reading, hand and bench work,metallurgy, and the operation of a variety of machine tools.
TDT 1114 Introduction to Die Making Procedures (2-4-4) This course is an introductionto tool and die making procedures including an orientation to metallurgy and dierepair. Students are instructed and given practice in the inspection, disassembly,fabrication, and reassembly of die components.
TDT 1133 Die Design I (2-2-3) This course is an introduction to the design of industrialdies and the machining characteristics of die components. This course serves as acontinuation of TDT 1114 and MSV 1016. The student is introduced to additionalmachining skills that will be encountered in typical die shops in the building of dies,jigs, fixtures, and precision machine parts.
TDT 2153 pie Design II (2-2-3) This course is a continuation of TDT 1133 with emphasison actual die design and construction. Instruction is given on the considerationsinvolved in developing die components, such as calculation of clearances, cuttingforce, and press tonnage requirements.
MST 2713 CNC Operations I (2-2-3) This course is an introduction to computer numericalcontrol machines. Included is instruction and practice related to the use of theCartesian coordinate system, programming codes and styles, and operation of basicCNC machines.
MST 2723 CNC Operations II (2-2-3) This course is a continuation of MST 2713 withadditional instruction in writing and editing CNC code manually, utilizing moreadvanced commands and cycles. Additionally, students will be introduced to theuse of a Computer-Aided-Manufacturing (CAM) system for the creation of code.
MST 2733 CNC Operations HI (2-3-3) This course is a continuation of MST 2713 andMST 2723 with additional instruction and practice in the use of the Computer-Aided-Manufacturing (CAM) system for creation of code. Also, the student willbe introduced to the Wire Electrical Discharge Machine (EDM) and theCoordinate Measuring Machine (CMM).
TDT 1146 Die Making I (3-6-6) This course is a continuation of TDT 1114 with instructionand practice in building a complete functional die from a blueprint. Emphasis isplaced on analyzing requirements, managing the project toward completion, andbecoming proficient in shop practices and procedures.
33
TDT 2166 Die Making II (3-6-6) This course is a continuation of TDT 1146 withinstruction and practice in building a progressive die from a blueprint. Emphasis isplaced on the application of the die building procedures learned in TDT 1114 andTDT 1146 toward fabricating more complex dies.
TDT 2174 Die Making III (2-4-4) This course serves as a continuation of TDT 2166 withinstruction and practice in building a compound die from a blueprint. Emphasis isplaced on the application of the die building procedures learned in the TDT 1146and TDT 2166 toward fabricating more complex dies. Instruction and practice isalso given on the use of the Wire Electrical Discharge Machine in the constructionof die components.
TDT 2183 Special Project (1-4-3) This course is designed to provide the student withpractical application of skills and knowledge gained through other courses in theTool and Die program. Students will apply material learned in previous andconcurrent classes to design, produce, and test an industrial quality die. Emphasisis placed on the student making decisions, setting priorities and time lines, andrealizing the overall responsibility of producing a quality product in an allottedtime.
DDT 1113
CPT 1113
MAT 1233
TOOL & DIE MAKING TECHNOLOGYSUPPORT COURSES
1995-1996
Fundamentals of Drafting A course designed to give basic informationrelated to instruments, equipment, principles and techniques used indrafting. Emphasis is placed on drafting conventional practices.
Introduction to Computers Introduction to information processingconcepts and applications including operating systems, word processing,electronic spreadsheets, data management, graphics, and BASICprogramming.
Intermediate Algebra This course is designed for students whose,qualifications are deficient for college algebra or technical math and forstudents whose curriculum requires three hours of mathematics forgraduation. This serves as a pre-requisite for statistics. Materials coveredinclude algebraic factoring, fractions, problem solving, roots and radicals,quadratics, graphs, simultaneous equation and basic geometrical concepts.Prerequisite: One year high school algebra or MAT 1213, CollegeMathematics I.
DDT 1313 Principles of CAD This course will use CAD machines to design anddraw various problems in the architectural, mechanical, and civil draftingareas. Emphasis will be placed on the operations of the CAD system tosolve these problems.
ENG 1113
MAT 1323
SPT 1113
English Composition A study of grammar and composition, withemphasis on the sentence and the paragraph. Reading, frequent themes.
Trigonometry This course is a study of solutions of right and obliquetriangles, identities, trigonometric equations, and polar and parametricequations.
Oral Communication (Principles of Speech) Correct and effectiveEnglish; correct pronunciation; breath control; study and practice in makingspeeches for all occasions, major emphasis on organization of material; andpractice in speaking before the group.
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.
36
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A-1 Follow Safety and All Safety Regulations/Requirements X X X X X X X X X X X 4
A-2 Maintain Safe Equipment and Machinery X X X X X X X X X X X 4
A-3 Maintain a Clean and Safe Work Environment X X X X X X X X X X X 4
A-4 Use Safe Operating Procedures for Hand and Machine Tools X X X X X X X X X X X 4
A-5 Use Safe Machining Practices X X X X X X X X X X X 4
A-6 Use Safe Lifting Practices X X X X X X X X X X X 4
A-7 Consult and Apply MSDS for Hazards of Various Materials X X X X X X X X X X 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 X X 4
6-2 Perform Basic Algebraic Operations X X X X X X X X X X X X X X X 4
6-3 Perform Basic Trigonometric Functions X X X X X X X X X X X X X X X 4
B-4 Use Basic Geometric Principles X X X X 2
B-5 Use and Apply Cartesian Coordinate System X X X X X X X X X X X X X 4
C. DEMONSTRATE QUALITY CONTROL AND MANAGEMENT
C-1 Utilize Appropriate Inspection Techniques X X X X X X X X X X X 4
C-2 Perform Appropriate Use and Calibration of Inspection Equipment X X X X X X X X X X X 4
C-3 Know Qualitative Parameters of Machinery and Equipment X X X X X X X X X X X 4
C-4 Maintain Equipment to Produce Quality Parts X X X X X X X X X X X 4
C-5 Know and Use Quality Systems X X X X X X X X X X X 2
C-6 Write Inspection Procedures X X X X X X X X X X X 4
C-7 Document Inspection Results X X X X X X X X X X X 3
D. DEMONSTRATE KNOWLEDGE OF MANUFACTURING MATERIALS
D-1 Identify Materials With Desired Properties X X X X X X X X 2
D-2 Demonstrate Knowledge of Physical Properties of Materials X X X X X X X X X X X 3
D-3 Identify Manufacturing Properties of Materials X X X X X X X X X X X 3
D-4 Discuss Classification System for Metals X X X X X X X X 3
E. DEMONSTRATE KNOWLEDGE OF MANUFACTURING PROCESSES
E-1 Know Operation of Vertical and Horizontal Mills and Tooling X X X X X X X X X X X 4
E-2 Know Operation of Engine and Turret Lathes and Tooling X X X X X X X X X X X 4
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E-3 Know Operation of Drill Presses and Tooling X XX XX X X XX XXE-4 Know Operation of Surface and Cylindrical Grinders X X X X XX X X 4
E-5 Know Operation of Heat Treating Equipment and Processes X X X X XX XX 4
E-6 Know Operation of Welding Equipment and Processes X XX X XX XX 2
E-7 Know Sheet Metal Operations X X X X XX XX 2
E-8 Know Operation of Jig-Boring Machines and Tooling X X X X XX XX 4
E-9 Know Operation of Tool and Cutter Grinders X X X X XX X X
E-10 Know Operation of Metal Saws X X X X X X X X 4
E-11 Know Operation of Wire EDM X X X X 4
E-12 Estimate Time Required/Cost to Produce a Part X X X X X XX X X X X 3
E-13 Know Proper Flow of Parts Through Shop X XX XX X X X X X X 4
E-14 Utilize Concepts and Principles of Fizturing X XX X X XX X X X X 3
E-15 Make Calculations For and Use Sine Bar/Sine Plate X X X X X X X X 4
E-16 Make Calculations For and Use Rotary Table and Dividing Head X X X XX X
F. PERFORM CNC PROGRAMMING /CAM TASKS
F-1 Prepare and Plan for CNC Machining Operations X X X X
F-2 Select and Use Tooling Systems for CNC Machines X X X X 3
F-3 Manually Program CNC Machines X XX X 4
F-4 Use Computer-Aided Manufacturing (CAM) System X X X 4
G. DEMONSTRATE COMMUNICATION SKILLS
G-1 Use Written Correspondence X X X X X X X X X XX XX1
X XX XX 4
G-2 Use Written Technical Information X X X X X X X X X X X X X X X X X X 3
G-3 Communicate Technical Information Verbally X XX XX X X X X XX XX X X X X 4
G-4 Use Graphics for Visual Aid X X X XX X X XX XX XX X X XX
H. PERFORM DRAFTING/CAD TASKS
H-1 Demonstrate Traditional Mechanical Drafting Skills X X X XX X X XX XX XX
H-2 Use Computer -Aided Drafting (CAD) System X X X X 3
H-3 Understand and Apply Geometric Dimensioning and Tolerancing (GD&T)Methodology X X X X
I. USE COMPUTERS
I-1 Use Computer Operating Systems X XX X X
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1-2 Use File Management Systems X X X X X X 4
1-3 Perform Backup on a Personal Computer X 4
1-4 Install/Use Software Packages X X X X X X 3
1-5 Understand and Apply Computer Terminology X X 4
J. INTERPRET/USE BLUEPRINTS AND RELATED DOCUMENTS
J-1 Interpret, Review, and Apply Blueprint Notes, Dimensions, and Tolerances X X X X X X X X X X X X X 4
J-2 Interpret and Understand Basic LayouVTypes of Drawings X X X X X X X X X X X X X 4
J-3 Understand and Analyze Bill-Of-Materials X X X X X X X X X X X X X 4
J-4 Ascertain Job Requirements from Drawings X X X X X X X X X X X X X 4
K. PERFORM DIE OPERATIONS
K-1 Utilize Basic Die Theory X X X X X X 4
K-2 Perform Die Repair X X X X X X 4
K-3 Demonstrate Die Making Skills X X X X X X X 4
K-4 Demonstrate Understanding of Different Types of Industrial Dies X X X 4
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TLDXWALK.PM5 B.Emlson-021996
TOOL AND DIE MAKERTECHNICAL WORKPLACE COMPETENCIES
EXIT LEVEL PROFICIENCY MATRIX
Tool and Die Maker: skilled workers who produce tools, dies, and special guiding and holdingdevices that are used in machines and produce a variety of products.
The following matrix identifies the five exit levels of technical workplace competencies for theAssociate of Applied Science degree at Itawamba Community College, Tupelo, Mississippi.
EXIT LEVEL OF PROFICIENCY
TechnicalWorkplaceCompetency
1 2 3 4 5
rarely routinelywithsupervision
routinelywith limitedsupervision
routinelywithoutsupervision
initiates/improves/modifies andsupervisesothers
40
1
1
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:Jnterpersonai: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).
41
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"COMPETENCY0,(RS) RESOURCES:
A. Allocates time XX XX XXXX XX XXX XX XXXXX 3
B. Allocates money X XXX X X X X X X X 2
C. Allocates material and facility resources X X X X X X X X X X XXX X
D. Allocates human resources XXXXXXXX X X XXX XX 1
(IN) INTERPERSONAL SKILLS:
A. Participates as a member of a team X X X X X X X X X X XXX XX X X X X X 4
B. Teaches others X X X X X X X X X X X X X X X 1
C. Serves clients/customers XX XX X XXX XX XXX X 2
D. Exercises leadership X X X X X X XXX X XXX X 1
E. Negotiates XXXXXXXXXX XXX XX X X X 2
F. Works with cultural diversity XX X X X X X X XX XXX XX X X X X X 4
(IF) INFORMATION SKILLS:
A. Acquires and evaluates information XX XX XX XX XX XXX XX X X X X X 4
B. Organizes and maintains information X X X X X X X X X X X X X X X XXXX 4
C. Interprets and communicates information X X X X X X X X X X XX XXXXX 4
D. Uses computers to process information X XXX X X 2
(SY) SYSTEMS:
A. Understands systems X X X X X X X X X X X X X XX X X X 4
B. Monitors and corrects performance X X X X X X X X X X X X X XXX 2
C. Improves and designs systems X X X X X X X X XX X 1
(TE) TECHNOLOGY:
A. Selects technology XX XX X XXX XX XXX XX XXXXX 4
B. Applies technology to task X X X X X X X X X X X 4
C. Maintains and troubleshoots technology XX XX X XXX XX XXX XX XXXX X 3
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41A. Reading XXXXXXX XX XXXX XXXXXXXB. Writing XXXX XXX XX XXXX XXXXX XX 41
411C. Arithmetic and mathematics XXXX X X X XX XXXX X XX
D. Listening XXXXXXX XX XX XX XXXXXXX 414E. Speaking X X X X X X X X X X X X X XXXXXXX
I(TS) THINKING SKILLS:
A. Creative thinking XX XXXXX XX XXXX XXXXX XX 313B. Decision making XX XXXXX XX XX XX XXXXXXX
C. Problem solving X XX X XXX XXXXXX XXXXXXX 31
4D. Seeing things in the mind's eye X X X X X X X X X X X X X X X X XXXXE. Knowing how to learn X X X X X X X X X X X X X X X X X X X X 4,
F. Reasoning X X X X XXX XX XX XX X XXXX XX 4
(PQ) PERSONAL QUALITIES:
A. Responsibility XXXX XX X XX XXXX XXXXX XX 4
B. Self-esteem XX XX XX X XX XXXX XX XXXXX 4
C. Social XX XX XXX XX XXXX XX XXXXX 4
D. Self-management X X X X X X X X X X X X X X X X X X X X 4
E. Integrity/honesty X X X X X X X X X X X X X X X X X X X X 4
;.-------- 43
8.En:1:0n-02111
SCANSCOMPETENCIES AND FOUNDATION SKILLS
EXIT LEVEL PROFICIENCY MATRIX
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: 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 of proficiency 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
MASr/03/021996
44
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 the courses which were taughtduring the pilot program.
Machine Tool Advanced SkillsTechnology Program
COURSE SYLLABUS
MACHINE TOOL TECHNOLOGY
46
MAST PROGRAMCOURSE SYLLABUS
MACHINE TOOL TECHNOLOGY
Lecture hours/week: 3
COURSE DESCRIPTION:
Lab hours/week: 6 Credit hours: 6
This course is composed of fundamental skills related to machine tool operations. Topics coveredin the course include safety, precision measurement, blueprint reading, hand and bench work,metallurgy, and the operation of a variety of machine tools.
PREREQUISITES: NONE
REQUIRED COURSE MATERIALS:
Textbook:
Lab Manual:
Technology of Machine Tools, Krar, Oswald, St. Amand, McGraw-Hill.,4th Ed.Student's Shop Reference Handbook, Edward Hoffman, Industrial PressWorkbook for Machine Tools, Krar, Oswald, St. Amand, McGraw-Hill.,4th Ed.
Hand Tools/Quantity Required:Safety Glasses6 inch Ruler
METHOD OF INSTRUCTION:
1 pair1/8, 1/16, 1/32, and 1/64 inch
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 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 Topics Text Reference Page Contact Hrs.
Introduction to Machine Tools 1-7Shop Safety 17-22Blueprint ReadingPrecision Measurement & Inspection 34-99Physics of Metal Cutting 142-153Cutting Tool Materials 532-555The Engine Lathe 216-306Layout 100-116The Bandsaw 154-174Hand Tools and Bench Work 117-141The Milling Machine 323-416Cutting Fluids 556-565Drilling Machines 175-215The Grinding Machine 479-531Metallurgy 566-602Other Manufacturing Processes Handout
Total Lecture Hours 48
LAB OUTLINE:Lab Topics
Shop Orientation and SafetyInspection and MeasurementGrinding a Lathe ToolUse of the Engine LatheProject (Turned Shaft)Thread Cutting on the LatheLayoutUse of the BandsawHand Tools and Bench WorkUse of the Milling MachineProject (T-Bolts)Use of the Drilling MachineProject (Parallel Clamp)Use of the Grinding MachineHeat Treatment of SteelProject (V-Block)Project (Mini-Vise)
Contact Hrs.
Total Lab Hours
COURSE OBJECTIVES: TECHNICAL COMPETENCIES
2223
93
2223
62922
15
3096
After the successful completion of this course the student will be able to:A. PRACTICE SAFETY
1. Follow Safety Manuals and All Safety Regulations/Requirements
4 8
a. Comply with established company and OSHA regulationsb. Interpret safety manual directivesc. Wear safety/protective equipment as required
2. Maintain Safe Equipment and Machinerya. Maintain equipment/tooling in safe operating conditionb. Maintain all guards, shields, and barriers in place and in good conditionc. Perform preventive maintenance as requiredd. Practice proper tag-out/lock-out procedures
3. Maintain a Clean and Safe Work Environmenta. Keep work areas clean and free of debrisb. Keep aisles/traffic areas clear of equipment and materialsc. Store materials, tools, and instruments in organized mannerd. Clean machine/hand tools when work is complete
4. Use Safe Operating Procedures for Hand and Machine Toolsa. Use tools for intended purposes onlyb. Acquire proper training/authorization before operating equipmentc. Operate hand and machine tools in safe mannerd. Comply with manufacturer's rated capacity for equipmente. Ensure all rotating or moving parts have stopped before leaving areaf. Inspect for and remove possible hazards before engaging equipment
5. Use Safe Machining Practicesa. Ensure stock/tooling is secure before machiningb. Use chip control methodsc. Use moderate, safe, and calculated speeds and feedsd. Stay alert and prepared to act during machininge. Ensure rotating parts/tooling are completely stopped before handling
6. Use Safe Lifting Practicesa. Use lifting aids when necessaryb. Use OSHA approved chains, straps, and hoistsc. Comply with rated capacity of lifting equipmentd. Comply with company/OSHA regulations regarding lifting procedures
7. Consult and Apply MSDS for Hazards of Various Materialsa. Know format of material safety data sheetsb. Consult and interpret MSDS to determine relevant hazards of materialc. Apply information and take precautionary measures against hazardsd. Notify proper authorities of hazards
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 decimalsd. Interconvert fractions/decimalse. Interconvert metric/English measurements
2. Perform Basic Algebraic Operationsa. Evaluate equation using standard algebraic hierarchyb. Solve equations with one unknown variablec. Solve ratio/percentage problemsd. Calculate and apply formulas
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3. Perform Basic Trigonometric Functionsa. Solve for unknown sides/angles of right triangles using trigonometric
functionsb. Solve for unknown side of right triangle using Pythagorean's Theorem
4. Use and Apply Cartesian Coordinate Systema. Define the Cartesian coordinate systemb. Plot machining points using Cartesian coordinate system
C. DEMONSTRATE QUALITY CONTROL AND MANAGEMENT1. Utilize Appropriate Inspection Techniques
a. Discuss factors that affect accurate measurementb. Determine proper procedure to acquire accurate measurementc. Determine proper instrument to use in measurement
2. Perform Appropriate Use and Calibration of Inspection Equipmenta. Explain calibration requirements of various precision instrumentsb. Maintain/care for instruments for optimum performancec. Read and use 0.D., I.D., and depth micrometersd. Read and use vernier, dial, & digital caliperse. Read and use scale and tape measuref. Read and use dial-bore indicatorsg. Use dial indicatorsh. Use precision square and combination seti. Read and use digital read-outj. Use finish/profile gaugesk. Use Rockwell hardness tester1. Use surface plates
3. Know Qualitative Parameters of Machinery and Equipmenta. Differentiate between types of machinery by qualitative capabilitiesb. Select appropriate processes to maintain desired tolerancesc. Discuss the effect one process might have on an earlier or later process
4. Maintain Equipment to Produce Quality Partsa. Justify tooling by qualitative requirementsb. Protect/maintain critical surfaces of machinesc. Perform preventive maintenance on equipment
5. Know and Use Quality Systemsa. Know and use ISO 9000 concepts and proceduresb. Know and use Statistical Process Control (SPC) techniques and concepts
6. Write Inspection Proceduresa. Determine/designate proper inspection techniqueb. Determine/designate precautions to take during inspectionc. Determine/design inspection jig or fixture requiredd. List in order and define steps required to ensure accurate measurement
7. Document Inspection Resultsa. Define procedure used during inspectionb. Accurately document measurements taken and compare to standardc. Determine/document if part passes or fails inspectiond. Determine/document rework or scrap recommendations
D. DEMONSTRATE KNOWLEDGE OF MANUFACTURING MATERIALS1. Identify Materials With Desired Properties
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a. Describe general characteristics of various metals2. Demonstrate Knowledge of Physical Properties of Materials
a. Define hardnessb. Define toughnessc.. Define tensile strengthd. Define shear strengthe. Define elasticityf. Define ductilityg. Discuss the Rockwell and Brinell hardness scalesh. Discuss the Charpy/Izod impact tests
3. Identify Manufacturing Properties of Materialsa. Discuss machinability of various materialsb. Discuss cold forming/workability of various materialsc. Define work hardening/edge hardeningd. Identify welding properties of various materialse. Demonstrate knowledge of heat treating procedures and propertiesf Know stress relieving proceduresg. Know/find hardness characteristics and chemistry of various materials
4. Discuss Classification System for Metalsa. Identify and discuss types of carbon steelb. Determine chemistry of material by classificationc. Distinguish between SAE and AISI classification systemsd. Identify designation of each digit of steel classificatione. Discuss alloy steels
E. DEMONSTRATE KNOWLEDGE OF MANUFACTURING PROCESSES1. Know Operation of Vertical and Horizontal Mills and Tooling
a. Define milling machines, horizontal and verticalb. List, describe, and give function and maintenance of different types of
tooling used on milling machinesc. Set-up and operate horizontal and vertical milling machined. Explain machine components and accessories of milling machinese. Explain milling processesf. Discuss milling machine safetyg. Calculate speeds and feeds based on materials and tooling
2. Know Operation of Engine and Turret Lathes and Toolinga. Define lathes, engine and turretb. List, describe, and give function and maintenance of various types of
tooling used on lathesc. Set-up and operate engine and turret lathesd. Explain machine components and accessories of lathese. Explain turning processesf. Discuss lathe safetyg. Calculate speeds and feeds based on materials and tooling
3. Know Operation of Drill Presses and Toolinga. Identify types of drilling machinesb. List, describe, and give function and maintenance of various types of
tooling used on drilling machinesc. Set-up and operate drilling machines
d. Explain machine components and accessories of drilling machinese. Explain processes performed on drilling machinesf. Discuss drilling safetyg. Calculate speeds and feeds based on materials and tooling
4. Know Operation of Surface and Cylindrical Grindersa. Define grinders, surface and cylindricalb. Explain types and maintenance of grinding wheelsc. Set-up and operate grinding machinesd. Explain machine components and accessories of grinding machinese. Explain grinding processesf. Discuss grinding safety
5. Know Operation of Heat Treating Equipment and Processesa. Describe types of heat treating equipmentb. Set-up and operate heat treating equipmentc. Explain machine components and accessories of heat treating equipmentd. Explain heat treating procedurese. Discuss heat treating safety
6. Know Operation of Welding Equipment and Processesa. Identify various types of welding equipmentb. Identify and discuss the difference in welding processesc. Inspect welds for cracks and penetrationd. Discuss welding safety
7. Know Sheet Metal Operationsa. Discuss fabrication of sheet metal partsb. Demonstrate layout-on-metalc. Apply conservation-of-material concepts
8. Know Operation of Jig-Boring Machines and Toolinga. Define jig-boring machineb. List, describe, and give function and maintenance of different types of
tooling used on jig-boring machinesc. Set-up and operate jig-boring machined. Explain machine components and accessories of jig-boring machinese. Explain jig-boring processf. Discuss safety on jig-boring machineg. Calculate speeds and feeds based on materials and tooling
9. Know Operation of Tool and Cutter Grindersa. Define tool/cutter grinderb. Discuss dressing and maintenance of grinding wheelsc. Explain machine components and accessories of tooUcutter grinderd. Discuss tool and cutter grinder safety
10. Know Operation of Metal Sawsa. Define band saw, horizontal and verticalb. Set-up and operate band sawc. Define abrasive cut-off sawd. Set-up and operate abrasive cut-off sawe. Discuss application of the different tooth forms, pitch sets, and gages of
band saw bladesf. Weld and maintain band saw blade 52
g. Discuss band saw safetyh. Calculate speeds and feeds based on materials and toolingi. Explain machine components and accessories of band sawsj. Calculate proper length of band saw blade
11. Estimate Time Required/Cost to Produce a Parta. Determine processes required to produce partb. Calculate actual machining and handling timec. Calculate material quantity and costd. Calculate labor and overhead cost
12. Know Proper Flow of Parts Through Shopa. Discuss proper order of processesb. Discuss ergonomic aspects of plant layout
13. Utilize Concepts and Principles of Fixturinga. Determine need for fixture/jigb. Design appropriate fixture/jigc. Identify components used in fixtures/jigsd. Disassemble and assemble fixture/jige. Discuss relationship between accuracy of fixture and accuracy/repeatability
of parts14. Make Calculations For and Use Sine Bar/Sine Plate
a. Define sine bar/sine plateb. Calculate gage block buildup for sine bar/sine platec. Set-up and use sine bar/sine plate
F. DEMONSTRATE COMMUNICATION SKILLS1. Use Written Correspondence
a. Read, write, interpret, and apply memorandumsb. Read, write, interpret, and apply business lettersc. Read, write, interpret, and apply written instructions
2. Use Written Technical Informationa. Read, write, interpret, and apply technical reportsb. Read, write, interpret, and apply written proceduresc. Read, write, interpret, and apply technical manuals
3. Communicate Technical Information Verballya. Demonstrate ability to listen to and understand verbal technical
information/instructionsb. Ask appropriate questions to ascertain needed informationc. Demonstrate ability to give verbal technical information/instructions
4. Use Graphics for Visual Aida. Create, read, and apply graphsb. Create, read, and apply chartsc. Create, read, and apply graphical illustrations
G. PERFORM DRAFTING/CAD TASKS1. Demonstrate Traditional Mechanical Drafting Skills
a. List and apply the three primary planes of projectionb. List and apply the six principle views.c. Use and apply auxiliary viewsd. Create/use sectional views
H. INTERPRET/USE BLUEPRINTS AND RELATED DOCUMENTS
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1. Interpret, Review, and Apply Blueprint Notes, Dimensions, and Tolerancesa. Distinguish between general and specific notesb. Interpret and apply general and specific notesc. Determine and apply dimensions on a drawingd. Identify basic symbols found on a drawinge. Identify tolerances on a drawingf. Discuss GD&T methodology
2. Interpret and Understand Basic Layout/Types of Drawingsa. Identify types of drawingsb. Identify parts of a drawing and list components of eachc. Identify types of lines on a drawingd. List and describe the different views found on a drawing
3. Understand and Analyze Bill-of-Materialsa. Determine materials requiredb. Determine quantities requiredc. Identify item symbol and/or part number
4. Ascertain Job Requirements From Drawingsa. Interpret part requirementsb. Identify surfaces to be machinedc. Determine critical dimensions
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 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.
The following activities will be performed by each student for successful completion of thiscourse:
I. COMPETENCIESA. Resources: Identifies, organizes, plans, and allocates resources
1. allocates time to complete assigned tasks on schedule2. determines cost associated with meeting objectives3. determines and allocates required materials and resources for meeting
objectives4. evaluates skills, performance, and quality of work and provides feedback
B. Interpersonal: Works with others1. participates as a member of the team, contributing to group effort2. provides individual assistance/direction to peers as requested3. determines and meets internal and external customers' expectations4. exercises leadership qualities to effectively communicate ideas and make
decisions
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5. negotiates resources in order to accomplish objectives6. works well with all members of the classInformation: Acquires and uses information1. acquires and evaluates information2. organizes and maintains information3. interprets and communicates information
D. Systems: Understands complex inter-relationships1. understands and works well with social, organizational, and technological
systems2. monitors and corrects performance of system during operation3. recommend modifications to system to improve performance
E. Technology: Works with a variety of technologies1. chooses relevant procedures, tools and equipment2. applies appropriate procedures and techniques to accomplish tasks3. identifies or solves problems to maintain equipment
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. demonstrates basic reading skills including abilities to perceive main
ideas, draw appropriate conclusions, detect a sequence, locateanswers, find facts, and infer from written texts
b. demonstrates course specific reading skills including abilities toread, interpret, and comprehend information from text andsupplemental materials on a level to facilitate productiveindependent and group study
c. demonstrates ability to read, interpret, and utilize information fromcourse specific instruments (i.e., charts, diagrams, graphs,schematics, blueprints, flow charts, etc.)
d. demonstrates ability to read, interpret, and follow schedules andprocedural instructions in a timely and appropriate manner
e. demonstrates ability to choose and use most appropriate readingmethod (skim, scan, or read for comprehension) for materials
2. Writing: Communicates thoughts, ideas, information, and messages inwriting; and creates documents such as letters, directions, manuals,reports, graphs, and flow chartsa. demonstrates basic writing skills including abilities to produce
written documents which conform with accepted grammatical andcommunication standards required for effective daily functioning
b. demonstrates effective written study skills including note taking,maintaining course specific journals, workbooks, manuals, etc.
c. demonstrates technical writing skills in preparing outlines,summaries, time lines, flow charts, diagrams, etc. appropriate tomaterials covered
d. demonstrates ability to complete all required writings in a timely,complete, and professional manner
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e. demonstrates competence in subject matter through theorganization and presentation of answers to required writtenassessments
3. Arithmetie/MathematicS: Perform basic computations and approachespractical problems by choosing appropriately from a variety ofmathematical techniquesa. demonstrates proficiency in basic arithmetic functions including
ability to add, subtract, multiply, and divide whole numbers,fractions, decimals, and percents
b. demonstrates ability to read, comprehend, and select appropriatemath procedures to work basic math problems
c. demonstrates ability to understand and perform multi-stepcomputations
d. demonstrates ability to read, interpret, and use standard measuringdevices
e. demonstrates ability to comprehend, retain, and utilize coursespecific measuring devices effectively
f. demonstrates ability to understand, retain, and utilize highermathematical formulas and functions required for course specificmath performance
g. demonstrates ability to appropriately transfer mathematicalcalculations and information from paper to machines
4. Listening: Receives, attends to, interprets, and responds to verbalmessages and other cuesa. functions at minimal or above required hearing levels to receive,
attend, interpret, and respond to verbal messages and instructionsand to safely operate machinery
b. demonstrates ability to hear, comprehend, and appropriately followdirections
c. demonstrates auditory ability to hear, comprehend, and utilizeverbal classroom as well as other auditory instruction
d. demonstrates ability to discriminate between essential andnon-essential verbal information and react appropriately
e. demonstrates ability to focus and fine-tune listening skills toreceive, interpret, and respond to various sounds
f. demonstrates ability and maturity to seek and receive additionalindividualized instruction as needed
5. Speaking: Organizes ideas and communicates orallya. demonstrates appropriate listening and speaking skills in personal
conversationsb. demonstrates ability to choose and organize appropriate words to
effectively communicatec. demonstrates ability to speak clearly and distinctly with appropriate
volume, tone, and body language for situationd. demonstrates ability to spontaneously organize and present
appropriate answers and/or short presentations for classroom and/or assessment purposes
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e. demonstrates ability to formulate, organize, and deliver majorpresentations to peers or groups
f. demonstrates ability to speak effectively in one-on-one, smallgroup, or large group presentations
g. demonstrates ability to take responsibility for presentationsB. 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. demonstrates ability to objectively assess personal strengths and
weaknessesb. demonstrates ability to set realistic short-term and long-term goalsc. demonstrates ability to recognize and distinguish between positive
and negative alternativesd. demonstrates ability to identify potential pitfalls and take evasive
actionse. demonstrates ability to objectively and responsibly evaluate
alternatives by testing hypotheses and selecting most appropriateresponse
f. demonstrates ability to profit from negative evaluations or mistakesby reformulating, redirecting, reconstructing, or retestingalternatives
g. demonstrates maturity to take responsibility for decisions2. Problem Solving: Recognizes problems and devises and implements plan
of actiona. demonstrates ability to detect problem through observation, inquiry,
or directiveb. demonstrates ability to grasp appropriate overview and degree of
seriousness of problem and to behave responsibly in situationc. demonstrates ability to generate alternatives or options for problem
solutiond. demonstrates ability to research options, assess and evaluate
options, and determine appropriate and best solutione. demonstrates ability to initiate and effect solutionf. demonstrates ability to take responsibility for outcomesg. demonstrates ability to effectively problem solve in individual, team,
or group situations3. Seeing Things In the Mind's Eye: Organizes, andprocesses symbols,
pictures, graphs, objects, and other informationa. functions at minimum or above required visual levels in order to
see, interpret, attend and respond to visual imagery and meet safetyrequirements for necessary machinery
b. demonstrates ability to read, interpret, and act upon signs, symbols,and other visual cues
c. demonstrates ability to visually discriminate in gross and fineimagery
d. demonstrates ability to visualize abstractlye. demonstrates ability to apply visual imagery to applied tasks
4. Knowing How to Learn: Use efficient learning techniques to acquire andapply new knowledge and skillsa. demonstrates mastery of basic reading, math, and language skills
through applicationb. demonstrates ability to translate abstract theory into practical
applicationc. demonstrates ability to incorporate and generalize new learning into
a sequential learning processd. demonstrates knowledge of good study skills and learning habits
5. Reasoning: Discovers a rule or principle underlying the relationshipbetween two or more objects and applies it when solving a problema. demonstrates use of simple logicb. demonstrates ability to distinguish relationshipsc.- demonstrates ability to determine and isolate factors in relationshipsd. demonstrates and applies knowledge through practicee. recognizes that attitudes, skills, and practice are essential to
productivityf. demonstrates ability to discriminate between positive and negative,
and act accordinglyPersonal Qualities: Displays responsibility, self-esteem, sociability, self-management, and integrity and honesty.1. Responsibility: Exerts a high level of effort and perseveres towards goal
attainmenta. demonstrates ability to formulate realistic and useful short and long
term goals and complete steps necessary to timely achieve goalsb. demonstrates ability to make adjustments, revisions, and changes to
achieve goals in a cooperative and polite mannerc. demonstrates ability to focus on task at hand and work to
completiond. demonstrates good work ethics through regular attendance,
adequate classroom preparations, and appropriate use of classroomtime
e. demonstrates maturity to take responsibility for actionsf. demonstrates ability to cooperatively work in individual, team, and
group situations in timely and effective manner2. Self-Esteem: Believes in own self-worth and maintains a positive view of
selfa. presents a positive attitude toward tasksb. demonstrates ability to separate work and personal behaviorsc. actively participates in learning opportunities by sharing knowledge
and skills with peers and instructorsd. demonstrates ability to accept personal strengths and weaknesses
and builds on positive behaviorse. demonstrates ability to accept and use constructive criticismf. accepts positive reinforcement in an appropriate manner
3. Sociability: Demonstrates understanding, friendliness, adaptability,empathy, and politeness in group settings
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a. demonstrates appropriate and acceptable social behaviors inclassroom interactions
b. demonstrates ability to work cooperatively in individual, team, orgroup situations
c. demonstrates active interest in peers by offering assistance, sharingresources, and sharing knowledge in a professional and acceptablemanner
d. demonstrates professional work ethic by separating work andpersonal social behaviors and acting accordingly
4. Self-Management: Assesses self accurately, sets personal goals,monitors progress, and exhibits self-controla. accepts personal strengths and weaknesses and uses the same for
positive advancementb. demonstrates ability to continuously set, assess, choose, and modify
objectives as the situation demands in an appropriate mannerc. demonstrates ability to formulate and follow personal schedulesd. demonstrates ability to wisely use classroom timee. demonstrates use of good study habits and skillsf demonstrates maturity to take responsibility for own actions
5. Integrity/Honesty: Chooses ethical courses of actiona. knows and demonstrates ability to distinguish between positive and
negative behaviorsb. demonstrates honesty and integrity in working with peers and
supervisorsc. takes full responsibility for personal actionsd. demonstrates understanding of consequences for negative ethical
behaviors and accepts responsibility for same when applicablee. demonstrates positive work and social ethics in undertakings
Appropriate Reference Materials:1. Machinery's Handbook, Industrial Press2. Machine Tool Practices, Kibbe, Neely, and Meyer, Wiley Pub., 4th Ed.3. Basic Blueprint Reading and Sketching, Olivo, Olivo, and Payne, Delmar Publishers
MSVI01603/081496
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Machine Tool Advanced SkillsTechnology Program
COURSE SYLLABUS
INTRODUCTION TO DIE MAKINGPROCEDURES
60
MAST PROGRAMCOURSE SYLLABUS
INTRODUCTION TO DIE MAKING PROCEDURES
Lecture hours/week: 2
COURSE DESCRIPTION:
Lab hours/week: 4 Credit hours: 4
This course is an introduction to tool and die making procedures including an orientation tometallurgy and die repair. Students are instructed and given practice in the inspection,disassembly, fabrication, and reassembly of die components.
PREREQUISITES: NONE
REQUIRED COURSE MATERIALS:
Textbook: Basic Diemaking, D. Eugene Ostergaard, McGraw-Hill
Hand Tools/Quantity Required:Safety Glasses6 inch Ruler
METHOD OF INSTRUCTION:
1 pair1/8, 1/16, 1/32, and 1/64 grad.
Lecture: Didactic presentations will include lecture, video and demonstrations.
Laboratory: Laboratory will be a "hands-on" 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 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 Topics
Introduction to DiesSafety in Handling and Transport
Text Reference Page Contact Hrs.1, 191
of DiesDie Terminology and Components 1-5, 192, 193Die Operation and Performance 1-21, 51-62Part Inspection for Identification of
Die Problems 3-6Disassembly and Assembly of Die SetInspection of Die Set and Die
Components HandoutDie Block Construction and Repair 97-108Die Block Mounting Procedures HandoutConstruction, Sharpening, and
Mounting of Punches 63-86Purpose and Construction of Pilots 87-96Purpose and Construction of
Backing Plates HandoutTotal Lecture Hours 32
LAB OUTLINE:Lab Topics
Orientation to Die SetsSafety with Die Sets and in Machine ShopOperation of Die Set in Punch PressProject (Disassembly and Assembly of Die Set)Inspect Die ComponentsProject (Sharpen Die Components)Project (Construction of Die Block)Project (Punch and Pilot)Project (V-Form Die Block)
Total Lab Hours
COURSE OBJECTIVES: TECHNICAL COMPETENCIES
Contact Hrs.22243
9121218
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After the successful completion of this course the student will be able to:A. PRACTICE SAFETY
1. Follow Safety Manuals and All Safety Regulations/Requirementsa. Comply with established company and OSHA regulationsb. Interpret safety manual directivesc. Wear safety/protective equipment as required
2. Maintain Safe Equipment and Machinerya. Maintain equipment/tooling in safe operating conditionb. Maintain all guards, shields, and barriers in place and in good conditionc. Perform preventive maintenance as requiredd. Practice proper tag-out/lock-out procedures
3. Maintain a Clean and Safe Work Environmenta. Keep work areas clean and free of debrisb. Keep aisles/traffic areas clear of equipment and materials
62
c. Store materials, tools, and instruments in organized mannerd. Clean machine/hand tools when work is complete
4. Use Safe Operating Procedures For Hand and Machine Toolsa. Use tools for intended purposes onlyb. Acquire proper training/authorization before operating equipmentc. Operate hand and machine tools in safe mannerd. Comply with manufacturer's rated capacity for equipmente. Ensure all rotating or moving parts have stopped before leaving areaf. Inspect for and remove possible hazards before engaging equipment
5. Use Safe Machining Practicesa. Ensure stock/tooling is secure before machiningb. Use chip control methodsc. Use moderate, safe, and calculated speeds and feedsd. Stay. alert and prepared to act during machininge. Ensure rotating parts/tooling are completely stopped before handling
6. Use Safe Lifting Practicesa. Use lifting aids when necessaryb. Use OSHA approved chains, straps, and hoistsc. Comply with rated capacity of lifting equipmentd. Comply with company/OSHA regulations regarding lifting procedures
7. Consult and Apply MSDS for Hazards of Various Materialsa. Know format of material safety data sheetsb. Consult and interpret MSDS to determine relevant hazards of materialc. Apply information and take precautionary measures against hazardsd. Notify proper authorities of hazards
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 decimalsd. Interconvert fractions/decimalse. Interconvert metric/English measurements
2. Perform Basic Algebraic Operationsa. Evaluate equation using standard algebraic hierarchyb. Solve equations with one unknown variablec. Solve ratio/percentage problemsd. Calculate and apply formulas
3 Perform Basic Trigonometric Functionsa. Solve for unknown sides/angles of right triangles using trigonometric
functionsb. Solve for unknown side of right triangle using Pythagorean's Theorem
4. Use and Apply Cartesian Coordinate Systema. Define the Cartesian coordinate systemb. Plot machining points using Cartesian coordinate system
C. DEMONSTRATE QUALITY CONTROL AND MANAGEMENT1. Utilize Appropriate Inspection Techniques
a. Discuss factors that affect accurate measurementb. Determine proper procedure to acquire accurate measurement
c. Determine proper instrument to use in measurement2. Perform Appropriate Use and Calibration of Inspection Equipment
a. Explain calibration requirements of various precision instrumentsb. Maintain/care for instruments for optimum performancec. Read and use 0.D., I.D., and depth micrometersd. Read and use vernier, dial, & digital caliperse. Read and use scale and tape measuref. Read and use dial-bore indicatorsg. Use dial indicatorsh. Use precision square and combination seti. Read and use digital read-outj. Use finish/profile gagesk. Use Rockwell hardness tester1. Use surface plates
3. Know Qualitative Parameters of Machinery and Equipmenta. Differentiate between types of machinery by qualitative capabilitiesb. Select appropriate processes to maintain desired tolerancesc. Discuss the effect one process might have on an earlier or later process
4. Maintain Equipment to Produce Quality Partsa. Justify tooling by qualitative requirementsb. Protect/maintain critical surfaces of machinesc. Perform preventive maintenance on equipment
5. Know and Use Quality Systemsa. Know and use ISO 9000 concepts and proceduresb. Know and use Statistical Process Control (SPC) techniques and concepts
6. Write Inspection Proceduresa. Determine/designate proper inspection techniqueb. Determine/designate precautions to take during inspectionc. Determine/design inspection jig or fixture requiredd. List in order and define steps required to ensure accurate measurement
7. Document Inspection Resultsa. Define procedure used during inspectionb. Accurately document measurements taken and compare to standardc. Determine/document if part passes or fails inspectiond. Determine/document rework or scrap recommendations
D. DEMONSTRATE KNOWLEDGE OF MANUFACTURING MATERIALS1. Identify Materials With Desired Properties
a. Determine/identify service requirements (strength, hardness, etc.)b. Determine, interpret, and evaluate availability of materialsc. Describe general characteristics of various metalsd. Know concepts of and calculate statics and stresses
2. Demonstrate Knowledge of Physical Properties of Materialsa. Define hardnessb. Define toughnessc. Define tensile strengthd. Define shear strengthe. Define elasticityf. Define ductility
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g. Discuss the Rockwell and Brinell hardness scalesh. Discuss the Charpy/Izod impact tests
3. Identify Manufacturing Properties of Materialsa. Discuss machinability of various materialsb. Discuss cold forming/workability of various materialsc. Define work hardening/edge hardeningd. Identify welding properties of various materialse. Demonstrate knowledge of heat treating procedures and propertiesf. Know stress relieving proceduresg. Know/Find hardness characteristics and chemistry of various materials
4. Discuss Classification System for Metalsa. Identify and discuss types of carbon steelb. Determine chemistry of material by classificationc. Distinguish between SAE and AISI classification systemsd. Identify designation of each digit of steel classificatione. Discuss alloy steels
E. DEMONSTRATE KNOWLEDGE OF MANUFACTURING PROCESSES1. Know Operation of Vertical and Horizontal Mills and Tooling
a. Define milling machines, horizontal and verticalb. List, describe, and give function and maintenance of different types of
tooling used on milling machinesc. Set-up and operate horizontal and vertical milling machined. Explain machine components and accessories of milling machinese. Explain milling processesf. Discuss milling machine safetyg. Calculate speeds and feeds based on materials and tooling
2. Know Operation of Engine and Turret Lathes and Toolinga. Define lathes, engine and turretb. List, describe, and give function and maintenance of various types of
fooling used on lathesc. Set-up and operate engine and turret lathesd. Explain machine components and accessories of lathese. Explain turning processesf. Discuss lathe safetyg. Calculate speeds and feeds based on materials and tooling
3. Know Operation of Drill Presses and Toolinga. Identify types of drilling machinesb. List, describe, and give function and maintenance of various types of
tooling used on drilling machinesc. Set-up and operate drilling machinesd. Explain machine components and accessories of drilling machinese. Explain processes performed on drilling machinesf. Discuss drilling safetyg. Calculate speeds and feeds based on materials and tooling
4. Know Operation of Surface and Cylindrical Grindersa. Define grinders, surface and cylindricalb. Explain types and maintenance of grinding wheelsc. Set-up and operate grinding machines
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d. Explain machine components and accessories of grinding machinese. Explain grinding processesf. Discuss grinding safety
5. Know Operation of Heat Treating Equipment and Processesa. Describe types of heat treating equipmentb. Set-up and operate heat treating equipmentc. Explain machine components and accessories of heat treating equipmentd. Explain heat treating procedurese. Discuss heat treating safety
6. Know Operation of Welding Equipment and Processesa. Identify various types of welding equipmentb. Identify and discuss the difference in welding processesc. Inspect welds for cracks and penetrationd. Discuss welding safety
7. Know Sheet Metal Operationsa. Discuss gas/plasma cutting equipment and processesb. Discuss operation of punch/brake presses and toolingc. Discuss operation of plate shearsd. Discuss fabrication of sheet metal partse. Demonstrate layout-on-metalf. Apply conservation-of-material concepts
8. Know Operation of Jig-Boring Machines and Toolinga. Define jig-boring machineb. List, describe, and give function and maintenance of different types of
tooling used on jig-boring machinesc. Set-up and operate jig-boring machined. Explain machine components and accessories of jig-boring machinese. Explain jig-boring processf. Discuss safety on jig-boring machine
g. Calculate speeds and feeds based on materials and tooling9. Know Operation of Tool and Cutter Grinders
a. Define tool/cutter grinderb. Discuss dressing and maintenance of grinding wheelsc. Explain machine components and accessories of tool/cutter grinderd. Discuss tool and cutter grinder safety
10. Know Operation of Metal Sawsa. Define band saw, horizontal and verticalb. Set-up and operate band sawc. Define abrasive cut-off sawd. Set-up and operate abrasive cut-off sawe. Discuss application of the different tooth forms, pitch sets, and gages of
band saw bladesf. Weld and maintain band saw blade
g. Discuss band saw safetyh. Calculate speeds and feeds based on materials and toolingi. Explain machine components and accessories of band sawsj. Calculate proper length of band saw blade
11. Estimate Time Required/Cost to Produce a Part
66
a. Determine processes required to produce partb. Calculate actual machining and handling timec. Calculate material quantity and costd. Calculate labor and overhead cost
12. Know Proper Flow of Parts Through Shopa. Discuss proper order of processesb. Discuss ergonomic aspects of plant layout
13. Utilize Concepts and Principles of Fixturinga. Determine need for fixture/jigb. Design appropriate fixture/jigc. Identify components used in fixtures/jigsd. Disassemble and assemble fixture/jige. Discuss relationship between accuracy of fixture and accuracy/repeatability
of parts14. Make Calculations For and Use Sine Bar/Sine Plate
a. Define sine bar/sine plateb. Calculate gage block buildup for sine bar/sine platec. Set-up and use sine bar/sine plate
F. DEMONSTRATE COMMUNICATION SKILLS1. Use Written Correspondence
a. Read, write, interpret, and apply memorandumsb. Read, write, interpret, and apply business lettersc. Read, write, interpret, and apply written instructions
2. Use Written Technical Informationa. Read, write, interpret, and apply technical reportsb. Read, write, interpret, and apply written proceduresc. Read, write, interpret, and apply technical manuals
3. Communicate Technical Information Verballya. Demonstrate ability to listen to and understand verbal technical
information/instructionsb. Ask appropriate questions to ascertain needed informationc. Demonstrate ability to give verbal technical information/instructions
4. Use Graphics for Visual Aida. Create, read, and apply graphsb. Create, read, and apply chartsc. Create, read, and apply graphical illustrations
G. PERFORM DRAFTING/CAD TASKS1. Demonstrate Traditional Mechanical Drafting Skills
a. List and apply the three primary planes of projectionb. List and apply the six principle viewsc. Use and apply auxiliary viewsd. Create/use sectional views
H. INTERPRET/USE BLUEPRINTS AND RELATED DOCUMENTS1. Interpret, Review, and Apply Blueprint Notes, Dimensions, and Tolerances
a. Distinguish between general and specific notesb. Interpret and apply general and specific notesc. Determine and apply dimensions on a drawingd. Identify basic symbols found on a drawing
e. Identify tolerances on a drawingf. Discuss GD&T methodology
2. Interpret and Understand Basic Layout/Types of Drawingsa. Identify types of drawingsb. Identify parts of a drawing and list components of eachc. Identify types of lines on a drawingd. List and describe the different views found on a drawing
3. Understand and Analyze Bill-of-Materialsa. Determine materials requiredb. Determine quantities requiredc. Identify item symbol and/or part number
4. Ascertain Job Requirements From Drawingsa. Interpret part requirementsb. Identify surfaces to be machinedc. Determine critical dimensions
I. PERFORM DIE OPERATIONS1. Utilize Basic Die Theory
a. Define/calculate proper shut-height of die setb. Determine die feed directionc. Explain notch, pierce, pilot, form, and cut-off stationsd. Determine stop block lengthe. Define/calculate slug clearancef. Explain operation of die set to make piece partg. Explain bending action in V-form diesh. Identify components of die seti. Discuss materials of die components
2. Perform Die Repaira. Disassemble and assemble die setb. Visually inspect die components for damagec. Identify component parts to be repaired/sharpenedd. Determine method of repairing/sharpeninge. Determine material for replacement partsf. Manufacture replacement partsg. Demonstrate setting correct punch entry
3. Demonstrate Die Making Skillsa. Identify component parts from die blueprintb. Determine material/purchased parts requirementsc. Utilize die making procedures to make component partsd. Utilize die making procedures to mount component partse. Demonstrate mounting of die set in press machinef. Cycle die set in press machine and inspect operationg. Inspect piece part for accuracy
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 should develop a new set of
68
competencies 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.
The following activities will be performed by each student for successful completion of thiscourse:
I. COMPETENCIESA. Resources: Identifies, organizes, plans, and allocates resources
1. allocates time to complete assigned tasks on schedule2. determines cost associated with meeting objectives3. determines and allocates required materials and resources for meeting
objectives4. evaluates skills, performance, and quality of work and provides feedback
B. Interpersonal: Works with others1. participates as a member of the team, contributing to group effort2. provides individual assistance/direction to peers as requested3. determines and meets internal and external customers' expectations4. exercises leadership qualities to effectively communicate ideas and make
decisions5. negotiates resources in order to accomplish objectives6. works well with all members of the classInformation: Acquires and uses information1. acquires and evaluates information2. organizes and maintains information3. interprets and communicates information
D. Systems: Understands complex inter-relationships1. understands and works well with social, organizational, and technological
systems2. monitors and corrects performance of system during operation3. recommend modifications to system to improve performance
E. Technology: Works with a variety of technologies1. chooses relevant procedures, tools and equipment2. applies appropriate procedures and techniques to accomplish tasks3. identifies or solves problems to maintain equipment
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. demonstrates basic reading skills including abilities to perceive main
ideas, draw appropriate conclusions, detect a sequence, locateanswers, find facts, and infer from written texts
b. demonstrates course specific reading skills including abilities toread, interpret, and comprehend information from text and
69
supplemental materials on a level to facilitate productiveindependent and group study
c. demonstrates ability to read, interpret, and utilize information fromcourse specific instruments (i.e., charts, diagrams, graphs,schematics, blueprints, flow charts, etc.)
d. demonstrates ability to read, interpret, and follow schedules andprocedural instructions in a timely and appropriate manner
e. demonstrates ability to choose and use most appropriate readingmethod (skim, scan, or read for comprehension) for materials
2. Writing: Communicates thoughts, ideas, information, and messages inwriting; and creates documents such as letters, directions, manuals,reports, graphs, and flow chartsa. demonstrates basic writing skills including abilities to produce
written documents which conform with accepted grammatical andcommunication standards required for effective daily functioning
b. demonstrates effective written study skills including note taking,maintaining course specific journals, workbooks, manuals, etc.
c. demonstrates technical writing skills in preparing outlines,summaries, time lines, flow charts, diagrams, etc. appropriate tomaterials covered
d. demonstrates ability to complete all required writings in a timely,complete, and professional manner
e. demonstrates competence in subject matter through theorganization and presentation of answers to required writtenassessments.
3. Arithmetic/Mathenzatics: Perform basic computations and approachespractical problems by choosing appropriately from a variety ofmathematical techniquesa. demonstrates proficiency in basic arithmetic functions including
ability to add, subtract, multiply, and divide whole numbers,fractions, decimals, and percentsdemonstrates ability to read, comprehend, and select appropriatemath procedures to work basic math problems
c. demonstrates ability to understand and perform multi-stepcomputations
d. demonstrates ability to read, interpret, and use standard measuringdevices
e. demonstrates ability to comprehend, retain, and utilize coursespecific measuring devices effectively
f. demonstrates ability to understand, retain, and utilize highermathematical formulas and functions required for course specificmath performance
g. demonstrates ability to appropriately transfer mathematicalcalculations and information from paper to machines
4. Listening: Receives, attends to, interprets, and responds to verbalmessages and other cues
70
a. functions at minimal or above required hearing levels to receive,attend, interpret, and respond to verbal messages and instructionsand to safely operate machinery
b. demonstrates ability to hear, comprehend, and appropriately followdirections
c. demonstrates auditory ability to hear, comprehend, and utilizeverbal classroom as well as other auditory instruction
d. demonstrates ability to discriminate between essential andnon-essential verbal information and react appropriately
e. demonstrates ability to focus and fine-tune listening skills toreceive, interpret, and respond to various sounds
f. demonstrates ability and maturity to seek and receive additionalindividualized instruction as needed
5. Speaking: Organizes ideas and communicates orallya. demonstrates appropriate listening and speaking skills in personal
conversationsb. demonstrates ability to choose and organize appropriate words to
effectively communicatec. demonstrates ability to speak clearly and distinctly with appropriate
volume, tone, and body language for situationd. demonstrates ability to spontaneously organize and present
appropriate answers and/or short presentations for classroom and/or assessment purposes
e. demonstrates ability to formulate, organize, and deliver majorpresentations to peers or groups
f. demonstrates ability to speak effectively in one-on-one, smallgroup, or large group presentations
g. demonstrates ability to take responsibility for presentationsB. 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 alternativea. demonstrates ability to objectively assess personal strengths and
weaknessesb. demonstrates ability to set realistic short-term and long-term goalsc. demonstrates ability to recognize and distinguish between positive
and negative alternativesd. demonstrates ability to identify potential pitfalls and take evasive
actionse. demonstrates ability to objectively and responsibly evaluate
alternatives by testing hypotheses and selecting most appropriateresponse
f. demonstrates ability to profit from negative evaluations or mistakesby reformulating, redirecting, reconstructing, or retestingalternatives
g. demonstrates maturity to take responsibility for decisions2. Problem Solving: Recognizes problems and devises and implements plan
of action
a. demonstrates ability to detect problem through observation, inquiry,or directive
b. demonstrates ability to grasp appropriate overview and degree ofseriousness of problem and to behave responsibly in situation
c. demonstrates ability to generate alternatives or options for problemsolution
d. demonstrates ability to research options, assess and evaluateoptions, and.determine appropriate and best solution
e. demonstrates ability to initiate and effect solutionf. demonstrates ability to take responsibility for outcomesg. demonstrates ability to effectively problem solve in individual, team,
or group situations3. Seeing Things In the Mind's Eye: Organizes, and processes symbols,
pictures, graphs, objects, and other informationa. functions at minimum or above required visual levels in order to
see, interpret, attend and respond to visual imagery and meet safetyrequirements for necessary machinery
b. demonstrates ability to read, interpret, and act upon signs, symbols,and other visual cues
c. demonstrates ability to visually discriminate in gross and fineimagery
d. demonstrates ability to visualize abstractlye. demonstrates ability to apply visual imagery to applied tasks
4. Knowing How to Learn: Use efficient learning techniques to acquire andapply new knowledge and skillsa. demonstrates mastery of basic reading, math, and language skills
through applicationb. demonstrates ability to translate abstract theory into practical
applicationc. demonstrates ability to incorporate and generalize new learning into
a sequential learning processd. demonstrates knowledge of good study skills and learning habits
5. Reasoning: Discovers a rule or principle underlying the relationshipbetween two or more objects and applies it when solving a problema. demonstrates use of simple logicb. demonstrates ability to distinguish relationshipsc. demonstrates ability to determine and isolate factors in relationshipsd. demonstrates and applies knowledge through practicee. recognizes that attitudes, skills, and practice are essential to
productivityf. demonstrates ability to discriminate between positive and negative,
and act accordinglyC. 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
attainmenta. demonstrates ability to formulate realistic and useful short and long
term goals and complete steps necessary to timely achieve goals
72
b. demonstrates ability to make adjustments, revisions, and changes toachieve goals in a cooperative and polite manner
c. demonstrates ability to focus on task at hand and work tocompletion
d. demonstrates good work ethics through regular attendance,adequate classroom preparations, and appropriate use of classroomtime
e. demonstrates maturity to take responsibility for actionsf. demonstrates ability to cooperatively work in individual, team, and
group situations in timely and effective manner2. Self-Esteem: Believes in own self-worth and maintains a positive view of
selfa. presents a positive attitude toward tasksb. demonstrates ability to separate work and personal behaviorsc. actively participates in learning opportunities by sharing knowledge
and skills with peers and instructorsd. demonstrates ability to accept personal strengths and weaknesses
and builds on positive behaviorse. demonstrates ability to accept and use constructive criticismf. accepts positive reinforcement in an appropriate manner
3. Sociability: Demonstrates understanding, friendliness, adaptability,empathy, and politeness in group settingsa. demonstrates appropriate and acceptable social behaviors in
classroom interactionsb. demonstrates ability to work cooperatively in individual, team, or
group situationsc. demonstrates active interest in peers by offering assistance, sharing
resources, and sharing knowledge in a professional and acceptablemanner
d. demonstrates professional work ethic by separating work andpersonal social behaviors and acting accordingly
4. Self-Management: Assesses self accurately, sets personal goals,monitors progress, and exhibits self-controla. accepts personal strengths and weaknesses and uses the same for
positive advancementb. demonstrates ability to continuously set, assess, choose, and modify
objectives as the situation demands in an appropriate mannerc. demonstrates ability to formulate and follow personal schedulesd. demonstrates ability to wisely use classroom timee. demonstrates use of good study habits and skillsf. demonstrates maturity to take responsibility for own actions
5. Integrity/Honesty: Chooses ethical courses of actiona. knows and demonstrates ability to distinguish between positiveand
negative behaviorsb. demonstrates honesty and integrity in working with peers and
supervisorsc. takes full responsibility for personal actions
73
d. demonstrates understanding of consequences for negative ethicalbehaviors and accepts responsibility for same when applicable
e. demonstrates positive work and social ethics in undertakings
Appropriate Reference Materials:1. Machinery's Handbook, Industrial Press2. Die Design Fundamentals, J.R. Pacquin and R.E. Crowley, 2nd Ed.
IDT1114031081496
Machine Tool Advanced SkillsTechnology. Program
4 1 A? ,i
COURSE SYLLABUS
FUNDAMENTALS OF DRAFTING
(U
IMAST PROGRAM
COURSE SYLLABUSFUNDAMENTALS OF DRAFTING
Lecture hours/week: 2 Lab hours/week: 2 Credit hours: 3
COURSE DESCRIPTION:
This course is designed to give basic information related to instruments, equipment, principles andtechniques used in drafting. Emphasis is placed on drafting conventional practices.
PREREQUISITES: NONE
REQUIRED COURSE MATERIALS:
Textbook: Technical Drawing, Giesecke, Mitchell, Spencer, Hill, Dygdon, Novack,McMillan., 9th Ed.
Lab Manual: Instructions for Lettering With Practice Sheets
Hand Tools/Quantity Required:Triangular Architect's Scale 1
Triangular Engineer's Scale 1
45° Triangle (8" sides) 1
30° X 60° Triangle (10" long side) 1
Ames Lettering Guide or Lettering Triangle 1
Irregular Curve 1
ProtractorMechanical Pencils and 1-1B, F, and 2H Lead 1
Pencil Eraser 1
Eraser Shield 1
Dusting Brush 1
Drafting Tape 1
Circle Template 1
Compass 1
Dividers 1
1METHOD OF INSTRUCTION:
Lecture: Didactic presentations will include lecture, video and demonstrations.
Laboratory: Laboratory will be a "hands-on" 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 completelaboratory assignments
2. 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 lab rules and safety regulations
LECTURE OUTLINE:Lecture Topics Text Reference Page Contact Hrs.
Introduction to Drafting 1-11Lettering 63-86Drafting Instruments 13-62Geometric Constructions 87-124Engineering Drawing Concepts 125-202Dimensioning 297-356Auxiliary Views 229-252Sectional Views 203-228
Total Lecture Hours 32
LAB OUTLINE:Lab Topics Contact Hrs.
Lab Orientation and Safety 1
Lettering Techniques 2Identification and Nomenclature of Instruments 1
Sketching Exercises 2Drafting Machine Exercises (Geometric Construction) 2Project (Missing View Problems - pp 185-187) 2Project (Safety Key - Fig. 6.53; Pg 188) 2Project (Index Feed - Fig. 6.58; Pg 188) 2Project (Holder Clip - Fig. 6.60; Pg 189) 3Project (Index Arm - Fig. 6.62; Pg 189) 3
Project (Cross-Feed Stop - Fig. 6.74; Pg 191) 3
Project (Tool Holder - Fig. 6.56; Pg 188) 3
Project (Anchor Bracket - Fig. 6.88; Pg 193) 3
Project (Control Bracket - Fig. 8.41; Pg 248) 3
Total Lab Hours 32
COURSE OBJECTIVES: TECHNICAL COMPETENCIES
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 numbers
7 7
b. Add, subtract, multiply, and divide fractionsc. Add, subtract, multiply, and divide decimalsd. Interconvert fractions/decimalse. Interconvert metric/English measurements
2. Perform Basic Algebraic Operationsa. Evaluate equation using standard algebraic hierarchyb. Solve equations with one unknown variablec. Solve ratio/percentage problemsd. Calculate and apply formulas
3. Perform Basic Trigonometric Functionsa. Solve for unknown sides/angles of right triangles using trigonometric
functionsb. Solve for unknown side of right triangle using Pythagorean's Theorem
4. Use Basic Geometric Principlesa. Solve for surface area, perimeter, and volume of cubeb. Solve for surface area, perimeter, and volume of rectangular solidc. Solve for surface area, perimeter, and volume of right triangular solidd. Solve for surface area, perimeter, and volume of cylindere. Find diagonal of a square
B. DEMONSTRATE COMMUNICATION SKILLS1. Use Written Correspondence
a. Read, write, interpret, and apply memorandumsb. Read, write, interpret, and apply business lettersc. Read, write, interpret, and apply written instructions
2. Use Written Technical Informationa. Read, write, interpret, and apply technical reportsb. Read, write, interpret, and apply written proceduresc. Read, write, interpret, and apply technical manuals
3. Communicate Technical Information Verballya. Demonstrate ability to listen to and understand verbal technical
information/instructionsb. Ask appropriate questions to ascertain needed informationc. Demonstrate ability to give verbal technical information/instructions
4. Use Graphics for Visual Aida. Create, read, and apply graphsb. Create, read, and apply chartsc. Create, read, and apply graphical illustrations
C. PERFORM DRAFTING/CAD TASKS1. Demonstrate Traditional Mechanical Drafting Skills
a. Demonstrate use of drafting machine and instrumentsb. Demonstrate drafting technique to create basic geometric elementsc. Demonstrate isometric sketching of objectsd. List and apply the three primary planes of projectione. List and apply the six principle views.f. Use and apply auxiliary viewsg. Create sectional views
2. Use and Apply Geometric Dimensioning and Tolerancing (GD&T) Methodology
a. Distinguish between conventional and geometric dimensioning andtolerancing.
b. Explain and use geometric positional tolerancingc. Explain and use tolerances of formd. Explain and use the feature control symbole. Explain and use modifiers in geometric dimensioning and tolerancing
D. INTERPRET/USE BLUEPRINTS AND RELATED DOCUMENTS1. Interpret, Review, and Apply Blueprint Notes, Dimensions, and Tolerances
a. Distinguish between general and specific notesb. Interpret and apply general and specific notesc. Determine and apply dimensions on a drawingd. Identify basic symbols found on a drawinge. Identify tolerances on a drawingf. Discuss GD&T methodology
2. Interpret and Understand Basic Layout/Types of Drawingsa. Identify types of drawingsb. Identify parts of a drawing and list components of eachc. Identify types of lines on a drawingd. List and describe the different views found on a drawing
3. Understand and Analyze Bill-of-materialsa. Determine materials requiredb. Determine quantities requiredc. Identify item symbol and/or part number
4. Ascertain Job Requirements from Drawingsa. Interpret part requirementsb. Identify surfaces to be machinedc. Determine critical dimensions
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 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.
The following activities will be performed by each student for successful completion of thiscourse:
I. COMPETENCIESA. Resources: Identifies, organizes, plans, and allocates resources
1. allocates time to complete assigned tasks on schedule2. determines and allocates required materials and resources for meeting
objectives3. evaluates skills, performance, and quality of work and provides feedback
79
B. Interpersonal: Works with others1. participates as a member of the team, contributing to group effort2. provides individual assistance/direction to peers as requested3. determines and meets internal and external customers' expectations4. exercises leadership qualities to effectively communicate ideas and make
decisions.5. negotiates resources in order to accomplish objectives6. works well with all members of the classInformation: Acquires and uses information1. acquires and evaluates information2. organizes and maintains information3. interprets and communicates information
D. Systems: Understands complex inter-relationships1. understands and works well with social, organizational, and technological
systems2. monitors and corrects performance of system during operation3. recommend modifications to system to improve performance
E. Technology: Works with a variety of technologies1. chooses relevant procedures, tools and equipment2. applies appropriate procedures and techniques to accomplish tasks3. identifies or solves problems to maintain equipment
II. FOUNDATION SKILLSA. Basic Skills: Reads, writes, performs arithmetic and mathematical operations,
listens and speaks./. Reading: Locates, understands, and interprets written information in
prose and in documents such as manuals, graphs, and schedulesa. demonstrates basic reading skills including abilities to perceive main
ideas, draw appropriate conclusions, detect a sequence, locateanswers, find facts, and infer from written texts
b. demonstrates course specific reading skills including abilities toread, interpret, and comprehend information from text andsupplemental materials on a level to facilitate productiveindependent and group study
c. demonstrates ability to read, interpret, and utilize information fromcourse specific instruments (i.e., charts, diagrams, graphs,schematics, blueprints, flow charts, etc.)
d. demonstrates ability to read, interpret, and follow schedules andprocedural instructions in a timely and appropriate manner
e. demonstrates ability to choose and use most appropriate readingmethod (skim, scan, or read for comprehension) for materials
2. Writing: Communicates thoughts, ideas, information, and messages inwriting; and creates documents such as letters, directions, manuals,reports, graphs, and flow chartsa. demonstrates basic writing skills including abilities to produce
written documents which conform with accepted grammatical andcommunication standards required for effective daily functioning
80
b. demonstrates effective written study skills including note taking,maintaining course specific journals, workbooks, manuals, etc.
c. demonstrates technical writing skills in preparing outlines,summaries, time lines, flow charts, diagrams, etc. appropriate tomaterials covered
d. demonstrates ability to complete all required writings in a timely,complete, and professional manner
e. demonstrates competence in subject matter through theorganization and presentation of answers to required writtenassessments
3. Arithmetic/Mathematics: Perform basic computations and approachespractical problems by choosing appropriately from a variety ofmathematical techniquesa. demonstrates proficiency in basic arithmetic functions including
ability to add, subtract, multiply, and divide whole numbers,fractions, decimals, and percents
b. demonstrates ability to read, comprehend, and select appropriatemath procedures to work basic math problems
c. demonstrates ability to understand and perform multi-stepcomputations
d. demonstrates ability to read, interpret, and use standard measuringdevices
e. demonstrates ability to comprehend, retain, and utilize coursespecific measuring devices effectively
f. demonstrates ability to understand, retain, and utilize highermathematical formulas and functions required for course specificmath performance
g. demonstrates ability to appropriately transfer mathematicalcalculations and information from paper to machines
4. Listening: Receives, attends to, interprets, and responds to verbalmessages and other cuesa. functions at minimal or above required hearing levels to receive,
attend, interpret, and respond to verbal messages and instructionsand to safely operate machinery
b. demonstrates ability to hear, comprehend, and appropriately followdirections
c. demonstrates auditory ability to hear, comprehend, and utilizeverbal classroom as well as other auditory instruction
d. demonstrates ability to discriminate between essential andnon-essential verbal information and react appropriately
e. demonstrates ability to focus and fine-tune listening skills toreceive, interpret, and respond to various sounds
f. demonstrates ability and maturity to seek and receive additionalindividualized instruction as needed
5. Speaking: Organizes ideas and communicates orallya. demonstrates appropriate listening and speaking skills in personal
conversations
81
b. demonstrates ability to choose and organize appropriate words toeffectively communicate
c. demonstrates ability to speak clearly and distinctly with appropriatevolume, tone, and body language for situation
d. demonstrates ability to spontaneously organize and presentappropriate answers and/or short presentations for classroom and/or assessment purposes
e. demonstrates ability to formulate, organize, and deliver majorpresentations to peers or groups
f. demonstrates ability to speak effectively in one-on-one, smallgroup, or large group presentations
g. demonstrates ability to take responsibility for presentationsB. 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. demonstrates ability to objectively assess personal strengths and
weaknessesb. demonstrates ability to set realistic short-term and long-term goalsc. demonstrates ability to recognize and distinguish between positive
and negative alternativesd. demonstrates ability to identify potential pitfalls and take evasive
actionse. demonstrates ability to objectively and responsibly evaluate
alternatives by testing hypotheses and selecting most appropriateresponse
f. demonstrates ability to profit from negative evaluations or mistakesby reformulating, redirecting, reconstructing, or retestingalternatives
g. demonstrates maturity to take responsibility for decisions2. Problem Solving: Recognizes problems and devises and implements plan
of actiona. demonstrates ability to detect problem through observation, inquiry,
or directiveb. demonstrates ability to grasp appropriate overview and degree of
seriousness of problem and to behave responsibly in situationc. demonstrates ability to generate alternatives or options for problem
solutiond. demonstrates ability to research options, assess and evaluate
options, and determine appropriate and best solutione. demonstrates ability to initiate and effect solutiond. demonstrates ability to take responsibility for outcomesg. demonstrates ability to effectively problem solve in individual, team,
or group situations3. Seeing Things In the Mind's Eye: Organizes, and processes symbols,
pictures, graphs, objects, and other information
82
a. functions at minimum or above required visual levels in order tosee, interpret, attend and respond to visual imagery and meet safetyrequirements for necessary machinery
b. demonstrates ability to read, interpret, and act upon signs, symbols,and other visual cues
c. demonstrates ability to visually discriminate in gross and fineimagery
d. demonstrates ability to visualize abstractlye. demonstrates ability to apply visual imagery to applied tasks
4. Knowing How to Learn: Use efficient learning techniques to acquire andapply new knowledge and skillsa. demonstrates mastery of basic reading, math, and language skills
through applicationb. demonstrates ability to translate abstract theory into practical
applicationc. demonstrates ability to incorporate and generalize new learning into
a sequential learning processd. demonstrates knowledge of good study skills and learning habits
5. Reasoning: Discovers a rule or principle underlying the relationshipbetween two or more objects and applies it when solving a problema. demonstrates use of simple logicb. demonstrates ability to distinguish relationshipsc. demonstrates ability to determine and isolate factors in relationshipsd. demonstrates and applies knowledge through practicee. recognizes that attitudes, skills, and practice are essential to
productivityf. demonstrates ability to discriminate between positive and negative,
and act accordinglyPersonal Qualities: Displays responsibility, self-esteem, sociability, self-management, and integrity and honesty.I. Responsibility: Exerts a high level of effort and perseveres towards goal
attainmenta. demonstrates ability to formulate realistic and useful short and long
term goals and complete steps necessary to timely achieve goalsb. demonstrates ability to make adjustments, revisions, and changes to
achieve goals in a cooperative and polite mannerc. demonstrates ability to focus on task at hand and work to
completiond. demonstrates good work ethics through regular attendance,
adequate classroom preparations, and appropriate use of classroomtime
e. demonstrates maturity to take responsibility for actionsf. demonstrates ability to cooperatively work in individual, team, and
group situations in timely and effective manner2. Self-Esteem: Believes in own self-worth and maintains a positive view of
selfa. presents a positive attitude toward tasksb. demonstrates ability to separate work and personal behaviors
83
c. actively participates in learning opportunities by sharing knowledgeand skills with peers and instructors
d. demonstrates ability to accept personal strengths and weaknessesand builds on positive behaviors
e. demonstrates ability to accept and use constructive criticismf. accepts positive reinforcement in an appropriate manner
3. Sociability: Demonstrates understanding, friendliness, adaptability,empathy, and politeness in group settingsa. demonstrates appropriate and acceptable social behaviors in
classroom interactionsb. demonstrates ability to work cooperatively in individual, team, or
group situationsc. demonstrates active interest in peers by offering assistance, sharing
resources, and sharing knowledge in a professional and acceptablemanner
d. demonstrates professional work ethic by separating work andpersonal social behaviors and acting accordingly
4. Self-Management: Assesses self accurately, sets personal goals,monitors progress, and exhibits self-controla. accepts personal strengths and weaknesses and uses the same for
positive advancementb. demonstrates ability to continuously set, assess, choose, and modify
objectives as the situation demands in an appropriate mannerc. demonstrates ability to formulate and follow personal schedulesd. demonstrates ability to wisely use classroom timee. demonstrates use of good study habits and skillsf. demonstrates maturity to take responsibility for own actions
5. Integrity/Honesty: Chooses ethical courses of actiona. knows and demonstrates ability to distinguish between positive and
negative behaviorsb. demonstrates honesty and integrity in working with peers and
supervisorsc. takes full responsibility for personal actionsd. demonstrates understanding of consequences for negative ethical
behaviors and accepts responsibility for same when applicablee. demonstrates positive work and social ethics in undertakings
DDT 111301/081496
Machine Tool Advanced SkillsTechnology Program
COURSE SYLLABUS
INTRODUCTION TO COMPUTERS
MAST PROGRAMCOURSE SYLLABUS
INTRODUCTION TO COMPUTERS
Lecture hours/week: 2
COURSE DESCRIPTION:
Lab hours/week: 2 Credit hours: 3
This course is designed to give the student an introduction to computer terminology andinformation processing concepts including operating systems, word processing, spreadsheets, datamanagement, graphics, and BASIC programming.
PREREQUISITES: NONE
REQUIRED COURSE MATERIALS:
Textbook:Lab Manual:
NoneProvided by Instructor
Hand Tools/Quantity Required:3 '/2" Data Diskette
METHOD OF INSTRUCTION:
Lecture: Didactic presentations will include lecture, video and demonstrations.
Laboratory: Laboratory will be a "hands-on" 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 assignments5. contribute to class discussions6. maintain attendance per current policy7. follow all lab rules and safety regulations
TENTATIVE LECTURE OUTLINE:Lecture Topic
Introduction to ComputersHardware and Software
Text Reference Page Contact Hrs.
86
111
Hardware Components andTerminology
Computer Operating SystemsDirectory Structure and File
ManagementWord Processing SoftwareSpreadsheet SoftwareDatabasesUsing Peripheral DevicesBackup and Restore FunctionsInstallation of SoftwareIntroduction to Use of Networking
TENTATIVE LAB OUTLINE:Lab Topics
Lab Orientation and SafetyDemonstration of HardwareUse Computer Operating SystemsCreate Directories and Save FilesCreate Document using Word Processor SoftwareCreate SpreadsheetCreate DatabasePrinting (in each software program and DOS)Perform Backup and Restore of Selected FilesInstall SoftwareLog in to Network
Total Lecture Hours 32
Contact Hrs.
Total Lab Hours
COURSE OBJECTIVES: TECHNICAL COMPETENCIES
1
2224463
3
3
232
After the successful completion of this course the student will be able to:A. DEMONSTRATE COMMUNICATION SKILLS
1. Use Written Correspondencea. Read, write, interpret, and apply memorandumsb. Read, write, interpret, and apply business lettersc. Read, write, interpret, and apply written instructions
2. Use Written Technical Informationa. Read, write, interpret, and apply technical reportsb. Read, write, interpret, and apply written proceduresc. Read, write, interpret, and apply technical manuals
3. Communicate Technical Information Verballya. Demonstrate ability to listen to and understand verbal technical
information/instructionsb. Ask appropriate questions to ascertain needed informationc. Demonstrate ability to give verbal technical information/instructions
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4. Use Graphics for Visual Aida. Create, read, and apply graphsb. Create, read, and apply chartsc. Create, read, and apply graphical illustrations
B. USE COMPUTERS1. Use Computer Operating Systems
a. Explain the phrase "IBM compatible"b. Use DOS operating system/DOS commandsc. Use Windowsd. Use computer network system
2. Use File Management Systemsa. Discuss file management conceptsb. Create/remove directoriesc. Copy files from floppy disks to hard drive
3. Perform Backup on a Personal Computera. Discuss need to backup hard diskb. Perform complete backup of hard diskc. Perform backup of selected files and directoriesd. Restore backup set to hard diske. Discuss need for/make system disk
4. Install/Use Software Packagesa. Install software package to hard diskb. Configure system parameters for software packagec. Use word processor software (WordPerfect, MS Word)d. Use spreadsheet software (Lotus, MS Excel)
5. Understand and Apply Computer Terminologya. Define Read Only Memory (ROM)b. Define Random Access Memory (RAM)c. Define cache memoryd. Define byte, kilobyte, megabytee. Define Central Processing Unit (CPU)f. Discuss processor speedg. Understand RS-232 protocol
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 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.
The following activities will be performed by each student for successful completion of thiscourse:
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I. COMPETENCIESA. Resources: Identifies, organizes, plans, and allocates resources
1. allocates time to complete assigned tasks on schedule2. determines and allocates required materials and resources for meeting
objectives.3. evaluates skills, performance, and quality of work and provides feedbackInterpersonal: Works with others1. participates as a member of the team, contributing to group effort2. provides individual assistance/direction to peers as requested3. determines and meets internal and external customers' expectations4. exercises leadership qualities to effectively communicate ideas and make
decisions5. negotiates resources in order to accomplish objectives6. works well with all members of the classInformation: Acquires and uses information1. acquires and evaluates information2. organizes and maintains information3. interprets and communicates information
D. Systems: Understands complex inter-relationships1. understands and works well with social, organizational, and technological
systems2. monitors and corrects performance of system during operation3. recommend modifications to system to improve performance
E. Technology: Works with a variety of technologies1. chooses relevant procedures, tools and equipment2. applies appropriate procedures and techniques to accomplish tasks3. identifies or solves problems to maintain equipment
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. demonstrates basic reading skills including abilities to perceive main
ideas, draw appropriate conclusions, detect a sequence, locateanswers, find facts, and infer from written texts
b. demonstrates course specific reading skills including abilities toread, interpret, and comprehend information from text andsupplemental materials on a level to facilitate productiveindependent and group study
c. demonstrates ability to read, interpret, and utilize information fromcourse specific instruments (i.e., charts, diagrams, graphs,schematics, blueprints, flow charts, etc.)
d. demonstrates ability to read, interpret, and follow schedules andprocedural instructions in a timely and appropriate manner
e. demonstrates ability to choose and use most appropriate readingmethod (skim, scan, or read for comprehension) for materials
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2. Writing: Communicates thoughts, ideas, information, and messages inwriting; and creates documents such as letters, directions, manuals,reports, graphs, and flow chartsa. demonstrates basic writing skills including abilities to produce
written documents which conform with accepted grammatical andcommunication standards required for effective daily functioning
b. demonstrates effective written study skills including note taking,maintaining course specific journals, workbooks, manuals, etc.
c. demonstrates technical writing skills in preparing outlines,summaries, time lines, flow charts, diagrams, etc. appropriate tomaterials covered
d. demonstrates ability to complete all required writings in a timely,complete, and professional manner
e. demonstrates competence in subject matter through theorganization and presentation of answers to required writtenassessments
3. Arithmetic/Mathematics: Perform basic computations and approachespractical problems by choosing appropriately from a variety ofmathematical techniquesa. demonstrates proficiency in basic arithmetic functions including
ability to add, subtract, multiply, and divide whole numbers,fractions, decimals, and percents
b. demonstrates ability to read, comprehend, and select appropriatemath procedures to work basic math problems
c. demonstrates ability to understand and perform multi-stepcomputations
d. demonstrates ability to read, interpret, and use standard measuringdevices
e. demonstrates ability to comprehend, retain, and utilize coursespecific measuring devices effectively
f. demonstrates ability to understand, retain, and utilize highermathematical formulas and functions required for course specificmath performance
g. demonstrates ability to appropriately transfer mathematicalcalculations and information from paper to machines
4. Listening: Receives, attends to, interprets, and responds to verbalmessages and other cuesa. functions at minimal or above required hearing levels to receive,
attend, interpret, and respond to verbal messages and instructionsand to safely operate machinery
b. demonstrates ability to hear, comprehend, and appropriately followdirections
c. demonstrates auditory ability to hear, comprehend, and utilizeverbal classroom as well as other auditory instruction
d. demonstrates ability to discriminate between essential andnon-essential verbal information and react appropriately
e. demonstrates ability to focus and fine-tune listening skills toreceive, interpret, and respond to various sounds
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f. demonstrates ability and maturity to seek and receive additionalindividualized instruction as needed
5. Speaking: Organizes ideas and communicates orallya. demonstrates appropriate listening and speaking skills in personal
conversationsb. demonstrates ability to choose and organize appropriate words to
effectively communicatec. demonstrates ability to speak clearly and distinctly with appropriate
volume, tone, and body language for situationd. demonstrates ability to spontaneously organize and present
appropriate answers and/or short presentations for classroom and./or assessment purposes
e. demonstrates ability to formulate, organize, and deliver majorpresentations to peers or groups
f. demonstrates ability to speak effectively in one-on-one, smallgroup, or large group presentations
g. demonstrates ability to take responsibility for presentationsB. 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. demonstrates ability to objectively assess personal strengths and
weaknessesb. demonstrates ability to set realistic short-term and long-term goalsc. demonstrates ability to recognize and distinguish between positive
and negative alternativesd. demonstrates ability to identify potential pitfalls and take evasive
actionse. demonstrates ability to objectively and responsibly evaluate
alternatives by testing hypotheses and selecting most appropriateresponse
f. demonstrates ability to profit from negative evaluations or mistakesby reformulating, redirecting, reconstructing, or retestingalternatives
g. demonstrates maturity to take responsibility for decisions2. Problem Solving: Recognizes problems and devises and implements plan
of actiona. demonstrates ability to detect problem through observation, inquiry,
or directiveb. demonstrates ability to grasp appropriate overview and degree of
seriousness of problem and to behave responsibly in situationc. demonstrates ability to generate alternatives or options for problem
solutiond. demonstrates ability to research options, assess and evaluate
options, and determine appropriate and best solutione. demonstrates ability to initiate and effect solutionf. demonstrates ability to take responsibility for outcomes
g. demonstrates ability to effectively problem solve in individual, team,or group situations
3. Seeing Things In the Mind's Eye: Organizes, and processes symbols,pictures, graphs, objects, and other informationa. functions at minimum or above required visual levels in order to
see, interpret, attend and respond to visual imagery and meet safetyrequirements for necessary machinery
b. demonstrates ability to read, interpret, and act upon signs, symbols,and other visual cues
c. demonstrates ability to visually discriminate in gross and fineimagery
d. demonstrates ability to visualize abstractlye. demonstrates ability to apply visual imagery to applied tasks
4. Knowing How to Learn: Use efficient learning techniques to acquire andapply new knowledge and skillsa. demonstrates mastery of basic reading, math, and language skills
through applicationb. demonstrates ability to translate abstract theory into practical
applicationc. demonstrates ability to incorporate and generalize new learning into
a sequential learning processd. demonstrates knowledge of good study skills and learning habits
5. Reasoning: Discovers a rule or principle underlying the relationshipbetween two or more objects and applies it when solving a problema. demonstrates use of simple logicb. demonstrates ability to distinguish relationshipsc. demonstrates ability to determine and isolate factors in relationshipsd. demonstrates and applies knowledge through practicee. recognizes that attitudes, skills, and practice are essential to
productivityf. demonstrates ability to discriminate between positive and negative,
and act accordinglyPersonal Qualities: Displays responsibility, self-esteem, sociability, self-management, and integrity and honesty.1. Responsibility: Exerts a high level of effort and perseveres towards goal
attainmenta. demonstrates ability to formulate realistic and useful short and long
term goals and complete steps necessary to timely achieve goalsb. demonstrates ability to make adjustments, revisions, and changes to
achieve goals in a cooperative and polite mannerc. demonstrates ability to focus on task at hand and work to
completiond. demonstrates good work ethics through regular attendance,
adequate classroom preparations, and appropriate use of classroomtime
e. demonstrates maturity to take responsibility for actionsf. demonstrates ability to cooperatively work in individual, team, and
group situations in timely and effective manner
2. Self-Esteem: Believes in own self-worth and maintains a positive view ofselfa. presents a positive attitude toward tasksb. demonstrates ability to separate work and personal behaviorsc. actively participates in learning opportunities by sharing knowledge
and skills with peers and instructorsd. demonstrates ability to accept personal strengths and weaknesses
and builds on positive behaviorse. demonstrates ability to accept and use constructive criticismf. accepts positive reinforcement in an appropriate manner
3. Sociability: Demonstrates understanding, friendliness, adaptability,empathy, and politeness in group settingsa. demonstrates appropriate and acceptable social behaviors in
classroom interactionsb. demonstrates ability to work cooperatively in individual, team, or
group situationsc. demonstrates active interest in peers by offering assistance, sharing
resources, and sharing knowledge in a professional and acceptablemanner
d. demonstrates professional work ethic by separating work andpersonal social behaviors and acting accordingly
4. Self-Management: Assesses self accurately, sets personal goals,monitors progress, and exhibits self-controla. accepts personal strengths and weaknesses and uses the same for
positive advancementb. demonstrates ability to continuously set, assess, choose, and modify
objectives as the situation demands in an appropriate mannerc. demonstrates ability to formulate and follow personal schedulesd. demonstrates ability to wisely use classroom timee. demonstrates use of good study habits and skillsf. demonstrates maturity to take responsibility for own actions
5. Integrity/Honesty: Chooses ethical courses of actiona. knows and demonstrates ability to distinguish between positive and
negative behaviorsb. demonstrates honesty and integrity in working with peers and
supervisorsc. takes full responsibility for personal actionsd. demonstrates understanding of consequences for negative ethical
behaviors and accepts responsibility for same when applicablee. demonstrates positive work and social ethics in undertakings
CPT 111301/081496
Machine Tool Advanced SkillsTechnology Program
COURSE SYLLABUS
DIE DESIGN IPrerequisite: INTRODUCTION TO DIE MAKING PROCEDURES
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MAST PROGRAMCOURSE SYLLABUS
DIE DESIGN I
Lecture hours/week: 2
COURSE DESCRIPTION:
Lab hours/week: 2 Credit hours: 3
This course is an introduction to the design of industrial dies and the machining characteristics ofdie components. This course serves as a continuation of Introduction to Die Making Proceduresand Machine Tool Technology. The student is introduced to additional machining.skills that willbe encountered in typical die shops in the building of dies, jigs, fixtures, and precision machineparts.
PREREQUISITES: Machine Tool Technology andIntroduction to Die Making Procedures
REQUIRED COURSE MATERIALS:
Textbook: (1) Technology of Machine Tools, Krar, Oswald, St. Amand, McGraw-Hill.,4th Ed.
(2) Basic Diemaking, D. Eugene Ostergaard, McGraw-Hill.
Hand Tools/Quantity Required:Safety Glasses6 inch Ruler
METHOD OF INSTRUCTION:
1 pair1/8, 1/16, 1/32, and 1/64 grad.
Lecture: Didactic presentations will include lecture, video and demonstrations.
Laboratory: Laboratory will be a "hands-on" 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 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 Topics
Introduction to Die and FixtureDesign
Safety in a Die ShopStampings DesignDie Engineering - Planning and
DesignSpecial Characteristics of Die
ComponentsSpecial Milling OperationsTool and Cutter GrinderIndexing or Dividing HeadSpecial Grinding OperationsSpecial Turning OperationsPunch and Die Shoe ConstructionSine Bar and VisesConstruction of V-DiesHardness Testing of Metal
Text Reference Page Contact Hrs.
HandoutHandout
(2) 1-5, 192, 193, HO
(1) 350-391(1) 520-531(1) 350-362(1) 503-519(1) 244-306(2) 63-86(1) 71-74(2) 23-31(1) 566-602, HO
Total Lecture Hours 32
LAB OUTLINE:Lab Topics
Introduction to the Design of DiesSafety in the Die ShopVisual Survey of StampingsProject (Mill T-Slot and Dovetail in Block)Project (Grind Radius Tool)Project (Mill Convex and Concave Radius in Block)Project (Grind Radius Tool)Project (Dress Grinding Wheel)Project (Grind Radius on Block)Project (Tapered Punch)Project (V-Die Block)
Contact Hrs.
Total Lab Hours
COURSE OBJECTIVES: TECHNICAL COMPETENCIES
1
1
1
3
3
3
62246
32
After the successful completion of this course the student will be able to:A. PRACTICE SAFETY
1. Follow Safety Manuals and All Safety Regulations/Requirementsa. Comply with established company and OSHA regulationsb. Interpret safety manual directivesc. Wear safety/protective equipment as required
2. Maintain Safe Equipment and Machinerya. Maintain equipment/tooling in safe operating condition
b. Maintain all guards, shields, and barriers in place and in good conditionc. Perform preventive maintenance as requiredd. Practice proper tag-out/lock-out procedures
3. Maintain a Clean and Safe Work Environmenta. Keep work areas clean and free of debrisb. Keep aisles/traffic areas clear of equipment and materialsc. Store materials, tools, and instruments in organized mannerd. Clean machine/hand tools when work is complete
4. Use Safe Operating Procedures for Hand and Machine Toolsa. Use tools for intended purposes onlyb. Acquire proper training/authorization before operating equipmentc. Operate hand and machine tools in safe mannerd. Comply with manufacturer's rated capacity for equipmente. Ensure all rotating or moving parts have stopped before leaving areaf. Inspect for and remove possible hazards before engaging equipment
5. Use Safe Machining Practicesa. Ensure stock/tooling is secure before machiningb. Use chip control methodsc. Use moderate, safe, and calculated speeds and feedsd. Stay alert and prepared to act during machininge. Ensure rotating parts/tooling are completely stopped before handling
6. Use Safe Lifting Practicesa. Use lifting aids when necessaryb. Use OSHA approved chains, straps, and hoistsc. Comply with rated capacity of lifting equipmentd. Comply with company/OSHA regulations regarding lifting procedures
7. Consult and Apply MSDS for Hazards of Various Materialsa. Know format of material safety data sheetsb. Consult and interpret MSDS to determine relevant hazards of materialc. Apply information and take precautionary measures against hazardsd. Notify proper authorities of hazards
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 decimalsd. Interconvert fractions/decimalse. Interconvert metric/English measurements
2. Perform Basic Algebraic Operationsa. Evaluate equation using standard algebraic hierarchyb. Solve equations with one unknown variablec. Solve ratio/percentage problemsd. Calculate and apply formulas
3. Perform Basic Trigonometric Functionsa. Solve for unknown sides/angles of right triangles using trigonometric
functionsb. Solve for unknown side of right triangle using Pythagorean's Theorem
4. Use and Apply Cartesian Coordinate System
a. Define the Cartesian coordinate systemb. Plot machining points using Cartesian coordinate system
C. DEMONSTRATE QUALITY CONTROL AND MANAGEMENT1. Utilize Appropriate Inspection Techniques
a. Discuss factors that affect accurate measurementb. Determine proper procedure to acquire accurate measurementc. Determine proper instrument to use in measurement
2. Perform Appropriate Use and Calibration of Inspection Equipmenta. Explain calibration requirements of various precision instrumentsb. Maintain/care for instruments for optimum performancec. Read and use 0.D., I.D., and depth micrometersd. Read and use vernier, dial, & digital caliperse. Read and use scale and tape measuref. Read and use dial-bore indicatorsg. Use dial indicatorsh. Use precision square and combination seti. Read and use digital read-outj. Use finish/profile gagesk. Use Rockwell hardness tester1. Use surface plates
3. Know Qualitative Parameters of Machinery and Equipmenta. Differentiate between types of machinery by qualitative capabilitiesb. Select appropriate processes to maintain desired tolerancesc. Discuss the effect one process might have on an earlier or later process
4. Maintain Equipment to Produce Quality Partsa. Justify tooling by qualitative requirementsb. Protect/maintain critical surfaces of machinesc. Perform preventive maintenance on equipment
5. Know and Use Quality Systemsa. Know and use ISO 9000 concepts and proceduresb. Know and use Statistical Process Control (SPC) techniques and concepts
6. Write Inspection Proceduresa. Determine/designate proper inspection techniqueb. Determine/designate precautions to take during inspectionc. Determine/design inspection jig or fixture requiredd. List in order and define steps required to ensure accurate measurement
7 Document Inspection Resultsa. Define procedure used during inspectionb. Accurately document measurements taken and compare to standardc. Determine/document if part passes or fails inspectiond. Determine/document rework or scrap recommendations
D. DEMONSTRATE KNOWLEDGE OF MANUFACTURING MATERIALS1. Identify Materials with Desired Properties
a. Determine/identify service requirements (strength, hardness, etc.)b. Determine, interpret, and evaluate availability of materialsc. Describe general characteristics of various metalsd. Know concepts of and calculate statics and stresses
2. Demonstrate Knowledge of Physical Properties of Materials
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a. Define hardnessb. Define toughnessc. Define tensile strengthd. Define shear strengthe. Define elasticityf. Define ductilityg. Discuss the Rockwell and Brinell hardness scalesh. Discuss the Charpy/Izod impact tests
3. Identify Manufacturing Properties of Materialsa. Discuss machinability of various materialsb. Discuss cold forming/workability of various materialsc. Define work hardening/edge hardeningd. Identify welding properties of various materialse. Demonstrate knowledge of heat treating procedures and propertiesf. Know stress relieving proceduresg. Know/Find hardness characteristics and chemistry of various materials
4. Discuss Classification System for Metalsa. Identify and discuss types of carbon steelb. Determine chemistry of material by classificationc. Distinguish between SAE and AISI classification systemsd. Identify designation of each digit of steel classificatione. Discuss alloy steels
E. DEMONSTRATE KNOWLEDGE OF MANUFACTURING PROCESSES1. Know Operation of Vertical and Horizontal Mills and Tooling
a. Define milling machines, horizontal and verticalb. List, describe, and give function and maintenance of different types of
tooling used on milling machinesc. Set-up and operate horizontal and vertical milling machined. Explain machine components and accessories of milling machinese. Explain milling processesf. Discuss milling machine safetyg. Calculate speeds and feeds based on materials and tooling
2. Know Operation of Engine and Turret Lathes and Toolinga. Define lathes, engine and turretb. List, describe, and give function and maintenance of various types of
tooling used on lathesc. Set-up and operate engine and turret lathesd. Explain machine components and accessories of lathese. Explain turning processesf. Discuss lathe safetyg. Calculate speeds and feeds based on materials and tooling
3. Know Operation of Drill Presses and Toolinga. Identify types of drilling machinesb. List, describe, and give function and maintenance of various types of
tooling used on drilling machinesc. Set-up and operate drilling machinesd. Explain machine components and accessories of drilling machinese. Explain processes performed on drilling machines
f. Discuss drilling safetyg. Calculate speeds and feeds based on materials and tooling
4. Know Operation of Surface and Cylindrical Grindersa. Define grinders, surface and cylindricalb. Explain types and maintenance of grinding wheelsc. Set-up and operate grinding machinesd. Explain machine components and accessories of grinding machinese. Explain grinding processesf. Discuss grinding safety
5. Know Operation of Heat Treating Equipment and Processesa. Describe types of heat treating equipmentb. Set-up and operate heat treating equipmentc. Explain machine components and accessories of heat treating equipmentd. Explain heat treating procedurese. Discuss heat treating safety
6. Know Operation of Welding Equipment and Processesa. Identify various types of welding equipmentb. Identify and discuss the difference in welding processesc. Inspect welds for cracks and penetrationd. Discuss welding safety
7. Know Sheet Metal Operationsa. Discuss gas/plasma cutting equipment and processesb. Discuss operation of punch/brake presses and toolingc. Discuss operation of plate shearsd. Calculate tonnages required for press/shear operationse. Calculate blank dimensions of developed partsf. Use yield tables for bending sheet metalg. Discuss fabrication of sheet metal partsh. Demonstrate layout-on-metali. Apply conservation-of-material concepts
8. Know Operation of Jig-boring Machines and Toolinga. Define jig-boring machineb. List, describe, and give function and maintenance of different types of
tooling used on jig-boring machinesc. Set-up and operate jig-boring machined. Explain machine components and accessories of jig-boring machinese. Explain jig-boring processf. Discuss safety on jig-boring machine
g. Calculate speeds and feeds based on materials and tooling9. Know Operation of Tool and Cutter Grinders
a. Define tool/cutter grinderb. Discuss dressing and maintenance of grinding wheelsc. Explain machine components and accessories of tool/cutter grinderd. Discuss tool and cutter grinder safety
10. Know Operation of Metal Sawsa. Define band saw, horizontal and verticalb. Set-up and operate band sawc. Define abrasive cut-off saw
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d. Set-up and operate abrasive cut-off sawe. Discuss application of the different tooth forms, pitch sets, and gages of
band saw bladesf. Weld and maintain band saw bladeg. Discuss band saw safetyh. Calculate speeds and feeds based on materials and toolingi. Explain machine components and accessories of band sawsj. Calculate proper length of band saw blade
11. Estimate Time Required/cost to Produce a Parta. Determine processes required to produce partb. Calculate actual machining and handling timec. Calculate material quantity and costd. Calculate labor and overhead cost
12. Know Proper Flow of Parts Through Shopa. Discuss proper order of processesb. Discuss ergonomic aspects of plant layout
13. Utilize Concepts and Principles of Fixturinga. Determine need for fixture/jigb. Design appropriate fixture/jigc. Identify components used in fixtures/jigsd. Disassemble and assemble fixture/jige. Discuss relationship between accuracy of fixture and accuracy/repeatability
of parts14. Make Calculations for and Use Sine Bar/Sine Plate
a. Define sine bar/sine plateb. Calculate gage block buildup for sine bar/sine platec. Set-up and use sine bar/sine plate
15. Make Calculations for and Use Rotary Table and Dividing Heada. Set-up and use rotary table/dividing head for machining operationsb. Make calculations for number of rotations requiredc. Determine/select appropriate index plate for dividing head
F. DEMONSTRATE COMMUNICATION SKILLS1. Use Written Correspondence
a. Read, write, interpret, and apply memorandumsb. Read, write, interpret, and apply business lettersc. Read, write, interpret, and apply written instructions
2. Use Written Technical Informationa. Read, write, interpret, and apply technical reportsb. Read, write, interpret, and apply written proceduresc. Read, write, interpret, and apply technical manuals
3. Communicate Technical Information Verballya. Demonstrate ability to listen to and understand verbal technical
information/instructionsb. Ask appropriate questions to ascertain needed informationc. Demonstrate ability to give verbal technical information/instructions
4. Use Graphics for Visual Aida. Create, read, and apply graphsb. Create, read, and apply charts
1 01
c. Create, read, and apply graphical illustrationsG. PERFORM DRAFTING /CAD TASKS
1. Demonstrate Traditional Mechanical Drafting Skillsa. List and apply the three primary planes of projectionb. List and apply the six principle views.c. Use and apply auxiliary viewsd. Create/use sectional views
H. INTERPRET/USE BLUEPRINTS AND RELATED DOCUMENTS1. Interpret, Review, and Apply Blueprint Notes, Dimensions, and Tolerances
a. Distinguish between general and specific notesb. Interpret and apply general and specific notesc. Determine and apply dimensions on a drawingd. Identify basic symbols found on a drawinge. Identify tolerances on a drawingf. Discuss GD&T methodology
2. Interpret and Understand Basic Layout/Types of Drawingsa. Identify types of drawingsb. Identify parts of a drawing and list components of eachc.. Identify types of lines on a drawingd. List and describe the different views found on a drawing
3. Understand and Analyze Bill-of-Materialsa. Determine materials requiredb. Determine quantities requiredc. Identify item symbol and/or part number
4. Ascertain Job Requirements from Drawingsa. Interpret part requirementsb. Identify surfaces to be machinedc. Determine critical dimensions
I. PERFORM DIE OPERATIONS1. Demonstrate Die Making Skills
a. Identify component parts from die blueprintb. Determine material/purchased parts requirementsc. Utilize die making procedures to make component partsd. Utilize die making procedures to mount component partse. Inspect piece part for accuracy
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 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.
The following activities will be performed by each student for successful completion of thiscourse:
I. COMPETENCIESA. Resources: Identifies, organizes, plans, and allocates resources
1. allocates time to complete assigned tasks on schedule2. determines cost associated with meeting objectives3. determines and allocates required materials and resources for meeting
objectives4. evaluates skills, performance, and quality of work and provides feedback
B. Interpersonal: Works with others1. participates as a member of the team, contributing to group effort2. provides individual assistance/direction to peers as requested3. determines and meets internal and external customers' expectations4. exercises leadership qualities to effectively communicate ideas and make
decisions5. negotiates resources in order to accomplish objectives6. works well with all members of the classInformation: Acquires and uses information1. acquires and evaluates information2. organizes and maintains information3. interprets and communicates information
D. Systems: Understands complex inter-relationships1. understands and works well with social, organizational, and technological
systems2. monitors and corrects performance of system during operation3. recommend modifications to system to improve performance
E. Technology: Works with a variety of technologies1. chooses relevant procedures, tools and equipment2. applies appropriate procedures and techniques to accomplish tasks3. identifies or solves problems to maintain equipment
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. demonstrates basic reading skills including abilities to perceive main
ideas, draw appropriate conclusions, detect a sequence, locateanswers, find facts, and infer from written texts
b. demonstrates course specific reading skills including abilities toread, interpret, and comprehend information from text andsupplemental materials on a level to facilitate productiveindependent and group study
c. demonstrates ability to read, interpret, and utilize information fromcourse specific instruments (i.e., charts, diagrams, graphs,schematics, blueprints, flow charts, etc.)
d. demonstrates ability to read, interpret, and follow schedules andprocedural instructions in a timely and appropriate manner
e. demonstrates ability to choose and use most appropriate readingmethod (skim, scan, or read for comprehension) for materials
2. Writing: Communicates thoughts, ideas, information, and messages inwriting; and creates documents such as letters, directions, manuals,reports, graphs, and flow chartsa. demonstrates basic writing skills including abilities to produce
written documents which conform with accepted grammatical andcommunication standards required for effective daily functioning
b. demonstrates effective written study skills including note taking,maintaining course specific journals, workbooks, manuals, etc.
c. demonstrates technical writing skills in preparing outlines,summaries, time lines, flow charts, diagrams, etc. appropriate tomaterials covered
d. demonstrates ability to complete all required writings in a timely,complete, and professional manner
e. demonstrates competence in subject matter through theorganization and presentation of answers to required writtenassessments
3. Arithmetic/Mathematics: Perform basic computations and approachespractical problems by choosing appropriately from a variety ofmathematical techniquesa. demonstrates proficiency in basic arithmetic functions including
ability to add, subtract, multiply, and divide whole numbers,fractions, decimals, and percents
b. demonstrates ability to read, comprehend, and select appropriatemath procedures to work basic math problems
c. demonstrates ability to understand and perform multi-stepcomputations
d. demonstrates ability to read, interpret, and use standard measuringdevices
e. demonstrates ability to comprehend, retain, and utilize coursespecific measuring devices effectively
f. demonstrates ability to understand, retain, and utilize highermathematical formulas and functions required for course specificmath performance
g. demonstrates ability to appropriately transfer mathematicalcalculations and information from paper to machines
4. Listening: Receives, attends to, interprets, and responds to verbalmessages and other cuesa. functions at minimal or above required hearing levels to receive,
attend, interpret, and respond to verbal messages and instructionsand to safely operate machinery
b. demonstrates ability to hear, comprehend, and appropriately followdirections
c. demonstrates auditory ability to hear, comprehend, and utilizeverbal classroom as well as other auditory instruction
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d. demonstrates ability to discriminate between essential and non-essential verbal information and react appropriately
e. demonstrates ability to focus and fine-tune listening skills toreceive, interpret, and respond to various sounds
f. demonstrates ability and maturity to seek and receive additionalindividualized instruction as needed
5. Speaking: Organizes ideas and communicates orallya. demonstrates appropriate listening and speaking skills in personal
conversationsb. demonstrates ability to choose and organize appropriate words to
effectively communicatec. demonstrates ability to speak clearly and distinctly with appropriate
volume, tone, and body language for situationd. demonstrates ability to spontaneously organize and present
appropriate answers and/or short presentations for classroomand/or assessment purposes
e. demonstrates ability to formulate, organize, and deliver majorpresentations to peers or groups
f. demonstrates ability to speak effectively in one-on-one, smallgroup, or large group presentations
g. demonstrates ability to take responsibility for presentationsB. 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. demonstrates ability to objectively assess personal strengths and
weaknessesb. demonstrates ability to set realistic short-term and long term goalsc.. demonstrates ability to recognize and distinguish between positive
and negative alternativesd. demonstrates ability to identify potential pitfalls and take evasive
actionse. demonstrates ability to objectively and responsibly evaluate
alternatives by testing hypotheses and selecting most appropriateresponse
f. demonstrates ability to profit from negative evaluations or mistakesby reformulating, redirecting, reconstructing, or retestingalternatives
g. demonstrates maturity to take responsibility for decisions2. Problem Solving: Recognizes problems and devises and implements plan
of actiona. demonstrates ability to detect problem through observation, inquiry,
or directiveb. demonstrates ability to grasp appropriate overview and degree of
seriousness of problem and to behave responsibly in situationc. demonstrates ability to generate alternative or options for problem
solution
105
d. demonstrates ability to research options, assess and evaluateoptions, and determine appropriate and best solution
e. demonstrates ability to initiate and effect solutionf. demonstrates ability to take responsibility for outcomesg. demonstrates ability to effectively problem solve in individual, team,
or group situations3. Seeing Things In the Mind's Eye: Organizes, and processes symbols,
pictures, graphs, objects, and other informationa. functions at minimum or above required visual levels in order to
see, interpret, attend and respond to visual imagery and meet safetyrequirements for necessary machinery
b. demonstrates ability to read, interpret, and at upon signs, symbols,and other visual cues
c. demonstrates ability to visually discriminate in gross and fineimagery
d. demonstrates ability to visualize abstractlye. demonstrates ability to apply visual imagery to applied tasks
4. Knowing How to Learn: Use efficient learning techniques to acquire andapply new knowledge and skillsa. demonstrates mastery of basic reading, math, and language skills
through applicationb. demonstrates ability to translate abstract theory into practical
applicationc. demonstrates ability to incorporate and generalize new learning into
a sequential learning processd. demonstrates knowledge of good study skills and learning habits
5. Reasoning: Discovers a rule or principle underlying the relationshipbetween two or more objects and applies it when solving a problema. demonstrates use of simple logicb. demonstrates ability to distinguish relationshipsc. demonstrates ability to determine and isolate factors in relationshipsd. demonstrates and applies knowledge through practicee. recognizes that attitudes, skills, and practice are essential to
productivityf. demonstrates ability to discriminate between positive and negative,
and act accordinglyPersonal Qualities: Displays responsibility, self-esteem, sociability, self-management, and integrity and honesty.1. Responsibility: Exerts a high level of effort and perseveres towards goal
attainmenta. demonstrates ability to formulate realistic and useful short and long
term goals and complete steps necessary to timely achieve goalsb. demonstrates ability to make adjustments, revisions, and changes to
achieve goals in a cooperative and polite mannerc. demonstrates ability to focus on task at hand and work to
completion
1 0 6
d. demonstrates good work ethics through regular attendance,adequate classroom preparations, and appropriate use of classroomtime
e. demonstrates maturity to take responsibility for actionsf demonstrates ability to cooperatively work in individual, team, and
group situations in timely and effective manner2. Self-Esteem: Believes in own self-worth and maintains a positive view of
selfa. presents a positive attitude toward tasksb. demonstrates ability to separate work and personal behaviorsc. actively participates in learning opportunities by sharing knowledge
and skills with peers and instructorsd. demonstrates ability to accept personal strengths and weaknesses
and builds on positive behaviorse. demonstrates ability to accept and use constructive criticismf. accepts positive reinforcement in an appropriate manner
3. Sociability: Demonstrates understanding, friendliness, adaptability,empathy, and politeness in group settingsa. demonstrates appropriate and acceptable social behaviors in
classroom interactionsb. demonstrates ability to work cooperatively in individual, team, or
group situationsc. demonstrates active interest in peers by offering assistance, sharing
resources, and sharing knowledge in a professional and acceptablemanner
d. demonstrates professional work ethic by separating work andpersonal social behaviors and acting accordingly
4. Self-Management: Assesses self accurately, sets personal goals,'monitors progress, and exhibits self-controla. accepts personal strengths and weaknesses and uses the same for
positive advancementb. demonstrates ability to continuously set, assess, choose, and modify
objectives as the situation demands in an appropriate mannerc. demonstrates ability to formulate and follow personal schedulesd. demonstrates ability to wisely use classroom timee. demonstrates use of good study habits and skillsf. demonstrates maturity to take responsibility for own actions
S. Integrity/Honesty: Chooses ethical courses of actiona. knows and demonstrates ability to distinguish between positive and
negative behaviorsb. demonstrates honesty ad integrity in working with peers and
supervisorsc. takes full responsibility for personal actionsd. demonstrates understanding of consequences for negative ethical
behaviors and accepts responsibility for same when applicablee. demonstrates positive work and social ethics in undertakings
Q'7
Appropriate Reference Materials:
1. Machinery's Handbook, Industrial Press2. Die Design Fundamentals, J.R. Pacquin and R.E. Crowley, 2nd Ed.3. Student's Shop Reference Handbook, Edward G. Hoffman
TDT113303/081496
108
Machine Tool Advanced SkillsTechnology Program
COURSE SYLLABUS
DIE MAKING IPrerequisite: INTRODUCTION TO DIE MAKING PROCEDURES
109
MAST PROGRAMCOURSE SYLLABUS
DIE MAKING I
Lecture hours/week: 3
COURSE DESCRIPTION:
Lab hours/week: 6 Credit hours: 6
This course is a continuation of Introduction to Die Making Procedures with instruction andpractice in building a complete functional die from a blueprint. Emphasis is placed on analyzingrequirements, managing the project toward completion, and becoming proficient in shop practicesand procedures.
PREREQUISITES: Introduction to Die Making Procedures
REQUIRED COURSE MATERIALS:
Textbook: Basic Diemaking, D. Eugene Ostergaard, McGraw-Hill
Hand Tools/Quantity Required:Safety Glasses6 inch Ruler
METHOD OF INSTRUCTION:
1 pair1/8, 1/16, 1/32, and 1/64 grad.
Lecture: Didactic presentations will include lecture, video and demonstrations.
Laboratory: Laboratory will be a "hands-on" 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 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 Topics Text Reference Page Contact Hrs.
Introduction to Die BuildingSafety in the Die ShopThe Die Blueprint HandoutComponent Requirements HandoutMaterial Requirements and
Specifications HandoutPlanning Machining Events 51-57, 97-108, HOImportance of Inspection and
Accuracy HandoutThe Die Shoes, Guide Posts and
Bushings 193, HODie Block Construction 97-108, HOCalculations for V-Form Dies 23-50, HOHeat Treatment of Die Components HandoutMounting Procedures HandoutOverview of the Punch Press
LAB OUTLINE:Lab Topics
Orientation and SafetyMaterial InventoryMaterial Requisitioning for V-Form DieProject (V-Form Die)Tryout of V-Form Die
Total Lecture Hours 48
Total Lab Hours
COURSE OBJECTIVES: TECHNICAL COMPETENCIES
Contact Hrs.222
846
96
After the successful completion of this course the student will be able to:A. PRACTICE SAFETY
1. Follow Safety Manuals and All Safety Regulations/Requirementsa. Comply with established company and OSHA regulationsb. Interpret safety manual directivesc. Wear safety/protective equipment as required
2. Maintain Safe Equipment and Machinerya. Maintain equipment/tooling in safe operating conditionb. Maintain all guards, shields, and barriers in place and in good conditionc. Perform preventive maintenance as requiredd. Practice proper tag-out/lock-out procedures
3. Maintain a Clean and Safe Work Environment
ill
a. Keep work areas clean and free of debrisb. Keep isles/traffic areas clear of equipment and materialsc. Store materials, tools, and instruments in organized mannerd. Clean machine/hand tools when work is complete
4. Use Safe Operating Procedures for Hand and Machine Toolsa. Use tools for intended purposes onlyb. Acquire proper training/authorization before operating equipmentc. Operate hand and machine tools in safe mannerd. Comply with manufacturer's rated capacity for equipmente. Ensure all rotating or moving parts have stopped before leaving areaf. Inspect for and remove possible hazards before engaging equipment
5. Use Safe Machining Practicesa. Ensure stock/tooling is secure before machiningb. Use chip control methodsc. Use moderate, safe, and calculated speeds and feedsd. Stay alert and prepared to act during machininge. Ensure rotating parts/tooling are completely stopped before handling
6. Use Safe Lifting Practicesa. Use lifting aids when necessaryb. Use OSHA approved chains, straps, and hoistsc. Comply with rated capacity of lifting equipmentd. Comply with company/OSHA regulations regarding lifting procedures
7. Consult and Apply MSDS for Hazards of Various Materialsa. Know format of material safety data sheetsb. Consult and interpret MSDS to determine relevant hazards of materialc. Apply information and take precautionary measures against hazardsd. Notify proper authorities of hazards
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 decimalsd. Interconvert fractions/decimalse. Interconvert metric/English measurements
2. Perform Basic Algebraic Operationsa. Evaluate equation using standard algebraic hierarchyb. Solve equations with one unknown variablec. Solve ratio/percentage problemsd. Calculate and apply formulas
3. Perform Basic Trigonometric Functionsa. Solve for unknown sides/angles of right triangles using trigonometric
functionsb. Solve for unknown side of right triangle using Pythagorean's Theorem
4. Use and Apply Cartesian Coordinate Systema. Define the Cartesian coordinate systemb. Plot machining points using Cartesian coordinate system
C. DEMONSTRATE QUALITY CONTROL AND MANAGEMENT1. Utilize Appropriate Inspection Techniques
a. Discuss factors that affect accurate measurementb. Determine proper procedure to acquire accurate measurementc. Determine proper instalment to use in measurement
2. Perform Appropriate Use and Calibration of Inspection Equipmenta. Explain calibration requirements of various precision instrumentsb. Maintain/care for instruments for optimum performancec. Read and use 0.D., I.D., and depth micrometersd. Read and use vernier, dial, & digital caliperse. Read and use scale and tape measuref. Read and use dial-bore indicatorsg. Use dial indicatorsh. Use precision square and combination seti. Read and use digital read-outj. Use finish/profile gagesk. Use Rockwell hardness tester1. Use surface plates
3. Know Qualitative Parameters of Machinery and Equipmenta. Differentiate between types of machinery by qualitative capabilitiesb. Select appropriate processes to maintain desired tolerancesc. Discuss the effect one process might have on an earlier or later process
4. Maintain Equipment to Produce Quality Partsa. Justify tooling by qualitative requirementsb. Protect/maintain critical surfaces of machinesc. Perform preventive maintenance on equipment
5. Know and Use Quality Systemsa. Know and use ISO 9000 concepts and proceduresb. Know and use Statistical Process Control (SPC) techniques and concepts
6. Write Inspection Proceduresa. Determine/designate proper inspection techniqueb. Determine/designate precautions to take during inspectionc. Determine/design inspection jig or fixture requiredd. List in order and define steps required to ensure accurate measurement
7. Document Inspection Resultsa. Define procedure used during inspectionb. Accurately document measurements taken and compare to standardc. Determine/document if part passes or fails inspectiond. Determine/document rework or scrap recommendations
D. DEMONSTRATE KNOWLEDGE OF MANUFACTURING MATERIALS1. Identify Materials with Desired Properties
a. Determine/identify service requirements (strength, hardness, etc.)b. Determine, interpret, and evaluate availability of materialsc. Describe general characteristics of various metalsd. Know concepts of and calculate statics and stresses
2. Demonstrate Knowledge of Physical Properties of Materials
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a. Define hardnessb. Define toughnessc. Define tensile strengthd. Define shear strengthe. Define elasticityf. Define ductilityg. Discuss the Rockwell and Brinell hardness scalesh. Discuss the Charpy/Izod impact tests
3. Identify Manufacturing Properties of Materialsa. Discuss machinability of various materialsb. Discuss cold forming/workability of various materialsc. Define work hardening/edge hardeningd. Identify welding properties of various materialse. Demonstrate knowledge of heat treating procedures and propertiesf. Know stress relieving proceduresg. Know/Find hardness characteristics and chemistry of various materials
4. Discuss Classification System for Metalsa. Identify and discuss types of carbon steelb. Determine chemistry of material by classificationc. Distinguish between SAE and AISI classification systemsd. Identify designation of each digit of steel classificatione. Discuss alloy steels
E. DEMONSTRATE KNOWLEDGE OF MANUFACTURING PROCESSES1. Know Operation of Vertical and Horizontal Mills and Tooling
a. Define milling machines, horizontal and verticalb. List, describe, and give function and maintenance of different types of
tooling used on milling machinesc. Set-up and operate horizontal and vertical milling machined. Explain machine components and accessories of milling machinese. Explain milling processesf. Discuss milling machine safetyg. Calculate speeds and feeds based on materials and tooling
2. Know Operation of Engine and Turret Lathes and Toolinga. Define lathes, engine and turretb. List, describe, and give function and maintenance of various types of
tooling used on lathesc. Set-up and operate engine and turret lathesd. Explain machine components and accessories of lathese. Explain turning processesf. Discuss lathe safetyg. Calculate speeds and feeds based on materials and tooling
3. Know Operation of Drill Presses and Toolinga. Identify types of drilling machinesb. List, describe, and give function and maintenance of various types of
tooling used on drilling machinesc. Set-up and operate drilling machines
d. Explain machine components and accessories of drilling machinese. Explain processes performed on drilling machinesf. Discuss drilling safetyg. Calculate speeds and feeds based on materials and tooling
4. Know Operation of Surface and Cylindrical Grindersa. Define grinders, surface and cylindricalb. Explain types and maintenance of grinding wheelsc. Set-up and operate grinding machinesd. Explain machine components and accessories of grinding machinese. Explain grinding processesf. Discuss grinding safety
5. Know Operation of Heat Treating Equipment and Processesa. Describe types of heat treating equipmentb. Set-up and operate heat treating equipmentc. Explain machine components and accessories of heat treating equipmentd. Explain heat treating procedurese. Discuss heat treating safety
6. Know Operation of Welding Equipment and Processesa. Identify various types of welding equipmentb. Identify and discuss the difference in welding processesc. Inspect welds for cracks and penetrationd. Discuss welding safety
7. Know Sheet Metal Operationsa. Discuss gas/plasma cutting equipment and processesb. Discuss operation of punch/brake presses and toolingc. Discuss operation of plate shearsd. Calculate tonnages required for press/shear operationse. Calculate blank dimensions of developed partsf. Use yield tables for bending sheet metalg. Discuss fabrication of sheet metal partsh. Demonstrate layout-on-metali. Apply conservation-of-material concepts
8. Know Operation of Jig-boring Machines and Toolinga. Define jig-boring machineb. List, describe, and give function and maintenance of different types of
tooling used on jig-boring machinesc. Set-up and operate jig-boring machined. Explain machine components and accessories of jig-boring machinese. Explain jig-boring processf. Discuss safety on jig-boring machineg. Calculate speeds and feeds based on materials and tooling
9. Know Operation of Tool and Cutter Grindersa. Define tool/cutter grinderb. Discuss dressing and maintenance of grinding wheelsc. Explain machine components and accessories of tool/cutter grinderd. Discuss tool and cutter grinder safety
10. Know Operation of Metal Sawsa. Define band saw, horizontal and verticalb. Set-up and operate band sawc. Define abrasive cut-off sawd. Set-up and operate abrasive cut-off sawe. Discuss application of the different tooth forms, pitch sets, and gages
of band saw bladesf. Weld and maintain band saw bladeg. Discuss band saw safetyh. Calculate speeds and feeds based on materials and toolingi. Explain machine components and accessories of band sawsj. Calculate proper length of band saw blade
11. Estimate Time Required/Cost to Produce a Parta. Determine processes required to produce partb. Calculate actual machining and handling timec. Calculate material quantity and costd. Calculate labor and overhead cost
12. Know Proper Flow of Parts Through Shopa. Discuss proper order of processesb. Discuss ergonomic aspects of plant layout
13. Utilize Concepts and Principles of Fixturinga. Determine need for fixture/jigb. Design appropriate fixture/jigc. Identify components used in fixtures/jigsd. Disassemble and assemble fixture/jige. Discuss relationship between accuracy of fixture and accuracy/
repeatability of parts14. Make Calculations for and Use Sine Bar/Sine Plate
a. Define sine bar/sine plateb. Calculate gage block buildup for sine bar/sine platec. Set-up and use sine bar/sine plate
15. Make Calculations for and Use Rotary Table and Dividing Heada. Set-up and use rotary table/dividing head for machining operationsb. Make calculations for number of rotations requiredc. Determine/select appropriate index plate for dividing head
F. DEMONSTRATE COMMUNICATION SKILLS1. Use Written Correspondence
a. Read, write, interpret, and apply memorandumsb. Read, write, interpret, and apply business lettersc. Read, write, interpret, and apply written instructions
2. Use Written Technical Informationa. Read, write, interpret, and apply technical reportsb. Read, write, interpret, and apply written proceduresc. Read, write, interpret, and apply technical manuals
3. Communicate Technical Information Verbally
116
a. Demonstrate ability to listen to and understand verbal technicalinformation/instructions
b. Ask appropriate questions to ascertain needed informationc. Demonstrate ability to give verbal technical information/instructions
4. Use Graphics for Visual Aida. Create, read, and apply graphsb. Create, read, and apply chartsc. Create, read, and apply graphical illustrations
G. PERFORM DRAFTING/CAD TASKS1. Demonstrate Traditional Mechanical Drafting Skills
a. List and apply the three primary planes of projectionb. List and apply the six principle viewsc. Use and apply auxiliary viewsd. Create/use sectional views
H. INTERPRET/USE BLUEPRINTS AND RELATED DOCUMENTS1. Interpret, Review, and Apply Blueprint Notes, Dimensions, and Tolerances
a. Distinguish between general and specific notesb. Interpret and apply general and specific notesc. Determine and apply dimensions on a drawingd. Identify basic symbols found on a drawinge. Identify tolerances on a drawingf. Discuss GD&T methodology
2. Interpret and Understand Basic Layout/Types of Drawingsa. Identify types of drawingsb. Identify parts of a drawing and list components of eachc. Identify types of lines on a drawingd. List and describe the different views found on a drawing
3. Understand and Analyze Bill-of-Materialsa. Determine materials requiredb. Determine quantities requiredc. Identify item symbol and/or part number
4. Ascertain Job Requirements from Drawingsa. Interpret part requirementsb. Identify surfaces to be machinedc. Determine critical dimensions
I. PERFORM DIE OPERATIONS1. Utilize Basic Die Theory
a. Define/calculate cutting clearanceb. Define/calculate proper shut-height of die setc. Determine die feed directiond. Explain notch, pierce, pilot, form, and cut-off stationse. Determine stop block lengthf. Define/calculate slug clearanceg. Explain operation of die set to make piece parth. Identify components of die seti. Discuss materials of die components
2. Perform Die Repaira. Disassemble and assemble die setb. Visually inspect die components for damagec. Identify component parts to be repaired/sharpenedd. Determine method of repairing/sharpeninge. Determine material for replacement partsf. Manufacture replacement partsg. Demonstrate setting correct punch entry
3. Demonstrate Die Making Skillsa. Identify component parts from die blueprintb. Determine material/purchased parts requirementsc. Utilize die making procedures to make component partsd. Utilize die making procedures to mount component partse. Demonstrate mounting of die set in press machinef. Cycle die set in press machine and inspect operationg. Inspect piece part for accuracy
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 high school students must develop anew set of competencies and foundation skills if they are to enjoy a productive, full andsatisfying life. These are in addition to the Technical Workplace Competencies required byindustry. SCANS is made up of five competencies anda three-part foundation of skills andpersonal qualities that are 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. allocates time to complete assigned tasks on schedule2. determines cost associated with meeting objectives3. determines and allocates required materials and resources for meeting
objectives4. evaluates skills, performance, and quality of work and provides feedback
B. Interpersonal: Works with others1. participates as a member of the team, contributing to group effort2. provides individual assistance/direction to peers as requested3. determines and meets internal and external customers' expectations4. exercises leadership qualities to effectively communicate ideas and make
decisions5. negotiates resources in order to accomplish objectives6. works well with all members of the class
C. Information: Acquires and uses information1. acquires and evaluates information2. organizes and maintains information3. interprets and communicates information
D. Systems: Understands complex inter-relationships1. understands and works well with social, organizational, and technological
systems2. monitors and corrects performance of system during operation3. recommend modifications to system to improve performance
E. Technology: Works with a variety of technologies1. chooses relevant procedures, tools and equipment2. applies appropriate procedures and techniques to accomplish tasks3. identifies or solves problems to maintain equipment
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. demonstrates basic reading skills including abilities to perceive main
ideas, draw appropriate conclusions, detect a sequence, locateanswers, find facts, and infer from written texts
b. demonstrates course specific reading skills including abilities toread, interpret, and comprehend information from text andsupplemental materials on a level to facilitate productiveindependent and group study
c. demonstrates ability to read, interpret, and utilize information fromcourse specific instruments (i.e., charts, diagrams, graphs,schematics, blueprints, flow charts, etc.)
d. demonstrates ability to read, interpret, and follow schedules andprocedural instructions in a timely and appropriate manner
e. demonstrates ability to choose and use most appropriate readingmethod (skim, scan, or read for comprehension) for materials
2. Writing: Communicates thoughts, ideas, information, and messages inwriting; and creates documents such as letters, directions, manuals,reports, graphs, and flow chartsa. demonstrates basic writing skills including abilities to produce
written documents which conform with accepted grammatical andcommunication standards required for effective daily functioning
b. demonstrates effective written study skills including note taking,maintaining course specific journals, workbooks, manuals, etc.
c. demonstrates technical writing skills in preparing outlines,summaries, time lines, flow charts, diagrams, etc. appropriate tomaterials covered
d. demonstrates ability to complete all required writings in a timely,complete, and professional manner
e. demonstrates competence in subject matter through theorganization and presentation of answers to required writtenassessments
3. Arithmetic/Mathematics: Perform basic computations and approachespractical problems by choosing appropriately from a variety ofmathematical techniquesa. demonstrates proficiency in basic arithmetic functions including
ability to add, subtract, multiply, and divide whole numbers,fractions, decimals, and percents
b. demonstrates ability to read, comprehend, and select appropriatemath procedures to work basic math problems
c. demonstrates ability to understand and perform multi-stepcomputations
d. demonstrates ability to read, interpret, and use standard measuringdevices
e. demonstrates ability to comprehend, retain, and utilize coursespecific measuring devices effectively
f. demonstrates ability to understand, retain, and utilize highermathematical formulas and functions required for course specificmath performance
g. demonstrates ability to appropriately transfer mathematicalcalculations and information from paper to machines
4. Listening: Receives, attends to, interprets, and responds to verbalmessages and other cuesa. functions at minimal or above required hearing levels to receive,
attend, interpret, and respond to verbal messages and instructionsand to safely operate machinery
b. demonstrates ability to hear, comprehend, and appropriately followdirections
c. demonstrates auditory ability to hear, comprehend, and utilizeverbal classroom as well as other auditory instruction
d. demonstrates ability to discriminate between essential andnon-essential verbal information and react appropriately
e. demonstrates ability to focus and fine-tune listening skills toreceive, interpret, and respond to various sounds
f. demonstrates ability and maturity to seek and receive additionalindividualized instruction as needed
5. Speaking: Organizes ideas and communicates orallya. demonstrates appropriate listening and speaking skills in personal
conversations.b. demonstrates ability to choose and organize appropriate words to
effectively communicatec. demonstrates ability to speak clearly and distinctly with appropriate
volume, tone, and body language for situation
120
d. demonstrates ability to spontaneously organize and presentappropriate answers and/or short presentations for classroom and/or assessment purposes
e. demonstrates ability to formulate, organize, and deliver majorpresentations to peers or groups
f. demonstrates ability to speak effectively in one-on-one, smallgroup, or large group presentations
g. demonstrates ability to take responsibility for presentationsB. 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. demonstrates ability to objectively assess personal strengths and
weaknessesb. demonstrates ability to set realistic short-term and long-term goalsc. demonstrates ability to recognize and distinguish between positive
and negative alternativesd. demonstrates ability to identify potential pitfalls and take evasive
actionse. demonstrates ability to objectively and responsibly evaluate
alternatives by testing hypotheses and selecting most appropriateresponse
f. demonstrates ability to profit from negative evaluations or mistakesby reformulating, redirecting, reconstructing, or retestingalternatives
g. demonstrates maturity to take responsibility for decisions2. Problem Solving: Recognizes problems and devises and implements plan
of actiona. demonstrates ability to detect problem through observation, inquiry,
or directiveb. demonstrates ability to grasp appropriate overview and degree of
seriousness of problem and to behave responsibly in situationc. demonstrates ability to generate alternatives or options for problem
solutiond. demonstrates ability to research options, assess and evaluate
options, and determine appropriate and best solutione. demonstrates ability to initiate and effect solutionf. demonstrates ability to take responsibility for outcomesg. demonstrates ability to effectively problem solve in individual, team,
or group situations3. Seeing Things In the Mind's Eye: Organizes, and processes symbols,
pictures, graphs, objects, and other informationa. functions at minimum or above required visual levels in order to
see, interpret, attend and respond to visual imagery and meet safetyrequirements for necessary machinery
121
b. demonstrates ability to read, interpret, and act upon signs, symbols,and other visual cues
c. demonstrates ability to visually discriminate in gross and fineimagery
d. demonstrates ability to visualize abstractlye. demonstrates ability to apply visual imagery to applied tasks
4. Knowing How to Learn: Use efficient learning techniques to acquire andapply new knowledge and skillsa. demonstrates mastery of basic reading, math, and language skills
through applicationb. demonstrates ability to translate abstract theory into practical
applicationc. demonstrates ability to incorporate and generalize new learning into
a sequential learning processd. demonstrates knowledge of good study skills and learning habits
5. Reasoning: Discovers a rule or principle underlying the relationshipbetween two or more objects and applies it when solving a problema. demonstrates use of simple logicb. demonstrates ability to distinguish relationshipsc. demonstrates ability to determine and isolate factors in relationshipsd. demonstrates and applies knowledge through practicee. recognizes that attitudes, skills, and practice are essential to
productivityf. demonstrates ability to discriminate between positive and negative,
and act accordinglyPersonal Qualities: Displays responsibility, self-esteem, sociability, self-management, and integrity and honesty.1. Responsibility: Exerts a high level of effort and perseveres towards goal
attainmenta. demonstrates ability to formulate realistic and useful short and long
term goals and complete steps necessary to timely achieve goalsb. demonstrates ability to make adjustments, revisions, and changes to
achieve goals in a cooperative and polite mannerc. demonstrates ability to focus on task at hand and work to
completiond. demonstrates good work ethics through regular attendance,
adequate classroom preparations, and appropriate use of classroomtime
e. demonstrates maturity to take responsibility for actionsf. demonstrates ability to cooperatively work in individual, team, and
group situations in timely and effective manner2. Self-Esteem: Believes in own self-worth and maintains a positive view of
selfa. presents a positive attitude toward tasksb. demonstrates ability to separate work and personal behaviors
122
c. actively participates in learning opportunities by sharing knowledgeand skills with peers and instructors
d. demonstrates ability to accept personal strengths and weaknessesand builds on positive behaviors
e. demonstrates ability to accept and use constructive criticismf. accepts positive reinforcement in an appropriate manner
3. Sociability: Demonstrates understanding, friendliness, adaptability,empathy, and politeness in group settingsa. demonstrates appropriate and acceptable social behaviors in
classroom interactionsb. demonstrates ability to work cooperatively in individual, team, or
group situationsc. demonstrates active interest in peers by offering assistance, sharing
resources, and sharing knowledge in a professional and acceptablemanner
d. demonstrates professional work ethic by separating work andpersonal social behaviors and acting accordingly
4. Self-Management: Assesses self accurately, sets personal goals,monitors progress, and exhibits self-controla. accepts personal strengths and weaknesses and uses the same for
positive advancementb. demonstrates ability to continuously set, assess, choose, and modify
objectives as the situation demands in an appropriate mannerc. demonstrates ability to formulate and follow personal schedulesd. demonstrates ability to wisely use classroom timee. demonstrates use of good study habits and skillsf. demonstrates maturity to take responsibility for own actions
5. Integrity/Honesty: Chooses ethical courses of actiona. knows and demonstrates ability to distinguish between positive and
negative behaviorsb. demonstrates honesty and integrity in working with peers and
supervisorsc. takes full responsibility for personal actionsd. demonstrates understanding of consequences for negative ethical
behaviors and accepts responsibility for same when applicablee. demonstrates positive work and social ethics in undertakings
Appropriate Reference Materials:
1. Machinery's Handbook, Industrial Press2. Die Design Fundamentals, J. R. Pacquin and R.E. Crowley, 2nd Ed.
TDT 114601/081496
Machine Tool Advanced SkillsTechnology Program
COURSE SYLLABUS
COMPUTER NUMERICAL CONTROLOPERATIONS I
Prerequisite: MACHINE TOOL TECHNOLOGY
124
MAST PROGRAMCOURSE SYLLABUS
COMPUTER NUMERICAL CONTROL OPERATIONS I
Lecture hours/week: 2
COURSE DESCRIPTION:
Lab hours/week: 2 Credit hours: 3
This course is an introduction to computer numerical control machines. Included is instructionand practice related to the use of the Cartesian coordinate system, programming codes and styles,and operation of basic CNC machines.
PREREQUISITES: Machine Tool Technology
REQUIRED COURSE MATERIALS:
Textbook: An Introduction to CNC Machining and Programming, David Gibbsand Thomas M. Crandell, Industrial Press
Lab Manual: Instructor Provided Materials
Hand Tools/Quantity Required:Safety Glasses6 inch Ruler
METHOD OF INSTRUCTION:
1 pair1/8, 1/16, 1/32, and 1/64 inch
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 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 Topics
Orientation to CNC MachinesText Reference Page Contact Hrs.
1-40
125
Safety with CNC EquipmentCNC versus Conventional Machining 152-161, HOCartesian Coordinate System HandoutIntroduction to CNC Lathe (Training
Lathe) HandoutPlanning Turning Operations 152-308, HOBasic Program Structure HandoutManual Data Input 95,96, HOTool Positioning and Offsets 41-77, HOIntroduction to CNC Mill
(Training Mill) HandoutPlanning CNC Milling Operations 152-308Basic Program Structure HandoutTool Positioning, Offsets, and
Registers 41-77, HOMagnetic and Paper Tape Operation 95-115, HOIntroduction to Direct Numerical
Control (DNC) Handout
LAB OUTLINE:Lab Topics
Introduction to CNC Machines and SafetyDemonstration of CNC EquipmentOperation of CNC Training LatheProject (Turn and Journal Shaft)Project (Turn Part with Radii, Angles, and Grooves)Project (Threaded Shaft)Operation of CNC Training MillProject (Drilled Plate)Project (Milled Plate)Entering Data via Magnetic or Paper TapeProject (Plexi-glass Nameplate)Entering Data via DNCProject (Milled Plate with Pocket and Name)
Total Lecture Hours 32
Total Lab Hours
COURSE OBJECTIVES: TECHNICAL COMPETENCIES
Contact Hrs.2223
3
3
23
3
1
3
1
432
After the successful completion of this course the student will be able to:A. PRACTICE SAFETY
1. Follow Safety Manuals and All Safety Regulations/ Requirementsa. Comply with established company and OSHA regulationsb. Interpret safety manual directivesc. Wear safety/protective equipment as required
2. Maintain Safe Equipment and Machinerya. Maintain equipment/tooling in safe operating condition
126
b. Maintain all guards, shields, and barriers in place and in good conditionc. Perform preventive maintenance as requiredd. Practice proper tag-out/lock-out procedures
3. Maintain a Clean and Safe Work Environmenta. Keep work areas clean and free of debrisb. Keep isles/traffic areas clear of equipment and materialsc. Store materials, tools, and instruments in organized mannerd. Clean machine/hand tools when work is complete
4. Use Safe Operating Procedures for Hand and Machine Toolsa. Use tools for intended purposes onlyb. Acquire proper training/authorization before operating equipmentc. Operate hand and machine tools in safe mannerd. Comply with manufacturer's rated capacity for equipmente. Ensure all rotating or moving parts have stopped before leaving areaf. Inspect for and remove possible hazards before engaging equipment
5. Use Safe Machining Practicesa. Ensure stock/tooling is secure before machiningb. Use chip control methodsc. Use moderate, safe, and calculated speeds and feedsd. Stay alert and prepared to act during machininge. Ensure rotating parts/tooling are completely stopped before handling
6. Use Safe Lifting Practicesa. Use lifting aids when necessaryb. Use OSHA approved chains, straps, and hoistsc. Comply with rated capacity of lifting equipmentd. Comply with company/OSHA regulations regarding lifting procedures
7. Consult and Apply MSDS for Hazards of Various Materialsa. Know format of material safety data sheetsb. Consult and interpret MSDS to determine relevant hazards of materialc. Apply information and take precautionary measures against hazardsd. Notify proper authorities of hazards
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 decimalsd. Interconvert fractions/decimalse. Interconvert metric/English measurements
2. Perform Basic Algebraic Operationsa. Evaluate equation using standard algebraic hierarchyb. Solve equations with one unknown variablec. Solve ratio/percentage problemsd. Calculate and apply formulas
3. Perform Basic Trigonometric Functionsa. Solve for unknown sides/angles of right triangles using trigonometric
functionsb. Solve for unknown side of right triangle using Pythagorean's Theorem
4. Use and Apply Cartesian Coordinate Systema. Define the Cartesian coordinate system
127
b. Calculate coordinates of bolt circle on Cartesian coordinate systemc. Plot machining points using Cartesian coordinate system
C. DEMONSTRATE QUALITY CONTROL AND MANAGEMENT1 Utilize Appropriate Inspection Techniques
a. Discuss factors that affect accurate measurementb. Determine proper procedure to acquire accurate measurementc. Determine proper instrument to use in measurement
2. Perform Appropriate Use and Calibration of Inspection Equipmenta. Explain calibration requirements of various precision instrumentsb. Maintain/care for instruments for optimum performancec. Read and use 0.D., I.D., and depth micrometersd. Read and use vernier, dial, & digital caliperse. Read and use scale and tape measuref. Read and use dial-bore indicatorsg. Use dial indicatorsh. Use precision square and combination seti. Read and use digital read-outj. Use finish/profile gagesk. Use Rockwell hardness tester1. Use surface plates
3. Know Qualitative Parameters of Machinery and Equipmenta. Differentiate between types of machinery by qualitative capabilitiesb. Select appropriate processes to maintain desired tolerancesc. Discuss the effect one process might have on an earlier or later process
4. Maintain Equipment to Produce Quality Partsa. Justify tooling by qualitative requirementsb. Protect/maintain critical surfaces of machinesc. Perform preventive maintenance on equipment
5. Know and Use Quality Systemsa. Know and use ISO 9000 concepts and proceduresb. Know and use Statistical Process Control (SPC) techniques and concepts
6. Write Inspection Proceduresa. Determine/designate proper inspection techniqueb. Determine/designate precautions to take during inspectionc. Determine/design inspection jig or fixture requiredd. List in order and define steps required to ensure accurate measurement
7 Document Inspection Resultsa. Define procedure used during inspectionb. Accurately document measurements taken and compare to standardc. Determine/document if part passes or fails inspectiond. Determine/document rework or scrap recommendations
D. DEMONSTRATE KNOWLEDGE OF MANUFACTURING MATERIALS1. Demonstrate Knowledge of Physical Properties of Materials
a. Define hardnessb. Define toughness
2. Identify Manufacturing Properties of Materialsa. Discuss machinability of various materialsb. Define work hardening/edge hardening
E. DEMONSTRATE KNOWLEDGE OF MANUFACTURING PROCESSES
128
1. Know Operation of Vertical and Horizontal Mills and Toolinga. Define milling machines, horizontal and verticalb. List, describe, and give function and maintenance of different types of
tooling used on milling machinesc. Set-up and operate horizontal and vertical milling machined. Explain machine components and accessories of milling machinese. Explain milling processesf. Discuss milling machine safetyg. Discuss CNC machining centers and processesh. Calculate speeds and feeds based on materials and toolingi. Set-up and operate CNC machining center
2. Know Operation of Engine and Turret Lathes and Toolinga. Define lathes, engine and turretb. List, describe, and give function and maintenance of various types of
tooling used on lathesc. Set-up and operate engine and turret lathesd. Explain machine components and accessories of lathese. Explain turning processesf. Discuss lathe safetyg. Discuss CNC turning centers and processesh. Calculate speeds and feeds based on materials and toolingi. Set-up and operate CNC turning center
3. Know Operation of Drill Presses and Toolinga. Identify types of drilling machinesb. List, describe, and give function and maintenance of various types of
tooling used on drilling machinesc. Set-up and operate drilling machinesd. Explain machine components and accessories of drilling machinese. Explain processes performed on drilling machinesf. Discuss drilling safetyg. Discuss drilling operations on CNC drilling machinesh. Calculate speeds and feeds based on materials and toolingi. Set-up and operate CNC drilling machine
4. Estimate Time Required/Cost to Produce a Parta. Determine processes required to produce partb. Calculate actual machining and handling timec. Calculate material quantity and costd. Calculate labor and overhead cost
5. Know Proper Flow of Parts Through Shopa: Discuss proper order of processesb. Discuss ergonomic aspects of plant layout
6. Utilize Concepts and Principles of Fixturinga. Determine need for fixture/jigb. Design appropriate fixture/jigc. Identify components used in fixtures/jigsd. Disassemble and assemble fixture/jige. Discuss relationship between accuracy of fixture and accuracy/
repeatability of partsF. PERFORM CNC PROGRAMMING/CAM TASKS
1_ 2 9
1. Prepare and Plan for CNC Machining Operationsa. Plan sequence of machining eventsb. Determine proper tooling/fixtures required for machiningc. Calculate speeds, feeds, and depth-of-cut for machiningd. Explain the x, y, and z axis on CNC machines
2. Manually Program CNC Machinesa. Plan and write programs for CNC machinesb. Use MDI panel on machine to program/edit programsc. Set and use tooling offsets at CNC machine
G. DEMONSTRATE COMMUNICATION SKILLS1. Use Written Correspondence
a. Read, write, interpret, and apply memorandumsb. Read, write, interpret, and apply business lettersc. Read, write, interpret, and apply written instructions
2. Use Written Technical Informationa. Read, write, interpret, and apply technical reportsb. Read, write, interpret, and apply written proceduresc. Read, write, interpret, and apply technical manuals
3. Communicate Technical Information Verballya. Demonstrate ability to listen to and understand verbal technical
information/instructionsb. Ask appropriate questions to ascertain needed informationc. Demonstrate ability to give verbal technical information/instructions
4. Use Graphics for Visual Aida. Create, read, and apply graphsb. Create, read, and apply chartsc. Create, read, and apply graphical illustrations
H. PERFORM DRAFTING/CAD TASKS1. Demonstrate Traditional Mechanical Drafting Skills
a. List and apply the three primary planes of projectionb. List and apply the six principle views.c. Use and apply auxiliary viewsd. Create/use sectional views
I. USE COMPUTERS1. Use Computer Operating Systems
a. Use Windowsb. Use computer network system
2. Use File Management Systemsa. Discuss file management conceptsb. Create/remove directoriesc. Copy files from floppy disks to hard drive
J. INTERPRET/USE BLUEPRINTS AND RELATED DOCUMENTS1. Interpret, Review, and Apply Blueprint Notes, Dimensions, and Tolerances
a. Distinguish between general and specific notesb. Interpret and apply general and specific notesc. Determine and apply dimensions on a drawingd. Identify basic symbols found on a drawinge. Identify tolerances on a drawingf. Discuss GD&T methodology
130
2. Interpret and Understand Basic Layout/types of Drawingsa. Identify types of drawingsb. Identify parts of a drawing and list components of eachc. Identify types of lines on a drawingd. List and describe the different views found on a drawing
3. Understand and Analyze Bill-of-Materialsa. Determine materials requiredb. Determine quantities requiredc. Identify item symbol and/or part number
4. Ascertain Job Requirements from Drawingsa. Interpret part requirementsb. Identify surfaces to be machinedc. Determine critical dimensions
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 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.
The following activities will be performed by each student for successful completion of thiscourse:
I. COMPETENCIESA. Resources: Identifies, organizes, plans, and allocates resources
1. allocates time to complete assigned tasks on schedule2. determines cost associated with meeting objectives3. determines and allocates required materials and resources for meeting
objectives4. evaluates skills, performance, and quality of work and provides feedback
B. Interpersonal: Works with others1. participates as a member of the team, contributing to group effort2. provides individual assistance/direction to peers as requested3. determines and meets internal and external customers' expectations4. exercises leadership qualities to effectively communicate ideas and make
decisions5. negotiates resources in order to accomplish objectives6. works well with all members of the classInformation: Acquires and uses information1. acquires and evaluates information2. organizes and maintains information3. interprets and communicates information
D. Systems: Understands complex inter-relationships
13.E
1. understands and works well with social, organizational, and technologicalsystems
2. monitors and corrects performance of system during operation3. recommend modifications to system to improve performance
E. Technology: Works with a variety of technologies1. chooses relevant procedures, tools and equipment2. applies appropriate procedures and techniques to accomplish tasks3. identifies or solves problems to maintain equipment
H. 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. demonstrates basic reading skills including abilities to perceive main
ideas, draw appropriate conclusions, detect a sequence, locateanswers, find facts, and infer from written texts
b. demonstrates course specific reading skills including abilities toread, interpret, and comprehend information from text andsupplemental materials on a level to facilitate productiveindependent and group study
c. demonstrates ability to read, interpret, and utilize information fromcourse specific instruments (i.e., charts, diagrams, graphs,schematics, blueprints, flow charts, etc.)
d. demonstrates ability to read, interpret, and follow schedules andprocedural instructions in a timely and appropriate manner
e. demonstrates ability to choose and use most appropriate readingmethod (skim, scan, or read for comprehension) for materials
2. Writing: Communicates thoughts, ideas, information, and messages inwriting; and creates documents such as letters, directions, manuals,reports, graphs, and flow chartsa. demonstrates basic writing skills including abilities to produce
written documents which conform with accepted grammatical andcommunication standards required for effective daily functioning
b. demonstrates effective written study skills including note taking,maintaining course specific journals, workbooks, manuals, etc.
c. demonstrates technical writing skills in preparing outlines,summaries, time lines, flow charts, diagrams, etc. appropriate tomaterials covered
d. demonstrates ability to complete all required writings in a timely,complete, and professional manner
e. demonstrates competence in subject matter through theorganization and presentation of answers to required writtenassessments
3. Arithmetic/Mathematics: Perform basic computations and approachespractical problems by choosing appropriately from a variety ofmathematical techniques
132
a. demonstrates proficiency in basic arithmetic functions includingability to add, subtract, multiply, and divide whole numbers,fractions, decimals, and percents
b. demonstrates ability to read, comprehend, and select appropriatemath procedures to work basic math problems
c. demonstrates ability to understand and perform multi-stepcomputations
d. demonstrates ability to read, interpret, and use standard measuringdevices
e. demonstrates ability to comprehend, retain, and utilize coursespecific measuring devices effectively
f. demonstrates ability to understand, retain, and utilize highermathematical formulas and functions required for course specificmath performance
g. demonstrates ability to appropriately transfer mathematicalcalculations and information from paper to machines
4. Listening: Receives, attends to, interprets, and responds to verbalmessages and other cuesa. functions at minimal or above required hearing levels to receive,
attend, interpret, and respond to verbal messages and instructionsand to safely operate machinery
b. demonstrates ability to hear, comprehend, and appropriately followdirections
c. demonstrates auditory ability to hear, comprehend, and utilizeverbal classroom as well as other auditory instruction
d. demonstrates ability to discriminate between essential andnon-essential verbal information and react appropriately
e. demonstrates ability to focus and fine-tune listening skills toreceive, interpret, and respond to various sounds
f. demonstrates ability and maturity to seek and receive additionalindividualized instruction as needed
5. Speaking: Organizes ideas and communicates orallya. demonstrates appropriate listening and speaking skills in personal
conversations.b. demonstrates ability to choose and organize appropriate words to
effectively communicatec. demonstrates ability to speak clearly and distinctly with appropriate
volume, tone, and body language for situationd. demonstrates ability to spontaneously organize and present
appropriate answers and/or short presentations for classroom and/or assessment purposes
e. demonstrates ability to formulate, organize, and deliver majorpresentations to peers or groups
f. demonstrates ability to speak effectively in one-on-one, smallgroup, or large group presentations
g. demonstrates ability to take responsibility for presentationsB. Thinking Skills: Thinks creatively, makes decisions, solves problems, visualizes,
knows how to learn and reasons.
33
1. Decision Making: Specifies goals and constraints, generates alternatives,considers risks, and evaluates and chooses best alternativea. demonstrates ability to objectively assess personal strengths and
weaknessesb. demonstrates ability to set realistic short-term and long-term goalsc. demonstrates ability to recognize and distinguish between positive
and negative alternativesd. demonstrates ability to identify potential pitfalls and take evasive
actionse. demonstrates ability to objectively and responsibly evaluate
alternatives by testing hypotheses and selecting most appropriateresponse
f. demonstrates ability to profit from negative evaluations or mistakesby reformulating, redirecting, reconstructing, or retestingalternatives
g. demonstrates maturity to take responsibility for decisions2. Problem Solving: Recognizes problems and devises and implements plan
of actiona. demonstrates ability to detect problem through observation, inquiry,
or directiveb. demonstrates ability to grasp appropriate overview and degree of
seriousness of problem and to behave responsibly in situationc. demonstrates ability to generate alternatives or options for problem
solutiond. demonstrates ability to research options, assess and evaluate
options, and determine appropriate and best solutione. demonstrates ability to initiate and effect solutionf demonstrates ability to take responsibility for outcomesg. demonstrates ability to effectively problem solve in individual, team,
or group situations3 Seeing Things In the Mind's Eye: Organizes, and processes symbols,
pictures, graphs, objects, and other informationa. functions at minimum or above required visual levels in order to
see, interpret, attend and respond to visual imagery and meet safetyrequirements for necessary machinery
b. demonstrates ability to read, interpret, and act upon signs, symbols,and other visual cues
c. demonstrates ability to visually discriminate in gross and fineimagery
d. demonstrates ability to visualize abstractlye. demonstrates ability to apply visual imagery to applied tasks
4. Knowing How to Learn: Use efficient learning techniques to acquire andapply new knowledge and skillsa. demonstrates mastery of basic reading, math, and language skills
through applicationb. demonstrates ability to translate abstract theory into practical
applicationc. demonstrates ability to incorporate and generalize new learning into
a sequential learning process
d. demonstrates knowledge of good study skills and learning habits5. Reasoning: Discovers a rule or principle underlying the relationship
between two or more objects and applies it when solving a problema. demonstrates use of simple logicb. demonstrates ability to distinguish relationshipsc. demonstrates ability to determine and isolate factors in relationshipsd. demonstrates and applies knowledge through practicee. recognizes that attitudes, skills, and practice are essential to
productivityf. demonstrates ability to discriminate between positive and negative,
and act accordinglyPersonal Qualities: Displays responsibility, self-esteem, sociability, self-management, and integrity and honesty.1. Responsibility: Exerts a high level of effort and perseveres towards goal
attainmenta. demonstrates ability to formulate realistic and useful short and long
term goals and complete steps necessary to timely achieve goalsb. demonstrates ability to make adjustments, revisions, and changes to
achieve goals in a cooperative and polite mannerc. demonstrates ability to focus on task at hand and work to
completiond. demonstrates good work ethics through regular attendance,
adequate classroom preparations, and appropriate use of classroomtime
e. demonstrates maturity to take responsibility for actionsf. demonstrates ability to cooperatively work in individual, team, and
group situations in timely and effective manner2. Self-Esteem: Believes in own self-worth and maintains a positive view of
selfa. presents a positive attitude toward tasksb. demonstrates ability to separate work and personal behaviorsc. actively participates in learning opportunities by sharing knowledge
and skills with peers and instructorsd. demonstrates ability to accept personal strengths and weaknesses
and builds on positive behaviorse. demonstrates ability to accept and use constructive criticismf. accepts positive reinforcement in an appropriate manner
3. Sociability: Demonstrates understanding, friendliness, adaptability,empathy, and politeness in group settingsa. demonstrates appropriate and acceptable social behaviors in
classroom interactionsb. demonstrates ability to work cooperatively in individual, team, or
group situationsc. demonstrates active interest in peers by offering assistance, sharing
resources, and sharing knowledge in a professional and acceptablemanner
d. demonstrates professional work ethic by separating work andpersonal social behaviors and acting accordingly
4. Self-Management: Assesses self accurately, sets personal goals,monitors progress, and exhibits self-controla. accepts personal strengths and weaknesses and uses the same for
positive advancementb. demonstrates ability to continuously set, assess, choose, and modify
objectives as the situation demands in an appropriate mannerc. demonstrates ability to formulate and follow personal schedulesd. demonstrates ability to wisely use classroom timee. demonstrates use of good study habits and skillsf. demonstrates maturity to take responsibility for own actions
5. Integrity/Honesty: Chooses ethical courses of actiona. knows and demonstrates ability to distinguish between positive and
negative behaviorsb. demonstrates honesty and integrity in working with peers and
supervisorsc. takes full responsibility for personal actionsd. demonstrates understanding of consequences for negative ethical
behaviors and accepts responsibility for same when applicablee. demonstrates positive work and social ethics in undertakings
Appropriate Reference Materials:
1. Machinist Handbook2. Machinery's Handbook, Industrial Press3. Machine Tool Practices, Kibbe, Neely, and Meyer, Wiley Pub., 4th Ed.4. Technology of Machine Tools, Krar, Oswald, St. Amand, McGraw-Hill., 4th Ed.5. Student's Shop Reference Handbook, Edward Hoffman, Industrial Press
MST 271301/081496
Machine Tool Advanced SkillsTechnology Program
- 4 "
4.4
COURSE SYLLABUS
PRINCIPLES OF CAD
MAST PROGRAMCOURSE SYLLABUSPRINCIPLES OF. CAD
Lecture hours/week: 2
COURSE DESCRIPTION:
Lab hours/week: 2 Credit hours: 3
This course will use CAD machines to design and draw various problems in the architectural,mechanical, and civil drafting areas. Emphasis will be placed on the operations of the CADsystem to solve these problems.
PREREQUISITES: NONE
REQUIRED COURSE MATERIALS:
Textbook:Lab Manual:
NoneSupplied by Instructor
Hand Tools/Quantity Required:3 'A" Floppy Disk3-Ring Binder
METHOD OF INSTRUCTION:
1
1
Lecture: Didactic presentations will include lecture, video and demonstrations.
Laboratory: Laboratory will be a "hands-on" 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 assignments5. contribute to class discussions6. maintain attendance per current policy7. follow all lab rules and safety regulations
LECTURE OUTLINE:Lecture Topic
Computers in Drafting and DesignCAD Hardware and Software
Text Reference Page Contact Hrs.
138
CAD Commands - Getting StartedLines, Circles and ArcsTrimming and EditingSpecial Geometric ShapesMoving, Copying, and RotatingViewpoint and Layer ControlConfiguration SettingsDimensioningSectioningPeripheral Devices
LAB OUTLINE:Lab Topics
Introduction to CAD System and SafetyGetting Started with CAD SystemCreation of Lines, Arc, and CirclesEditing GeometryMoving, Copying, and RotatingViewpoint and Layer ControlProject (Drawing-No Dimensions)Project (Drawing-No Dimensions)DimensioningProjectSectioningProjectPeripheral DevicesProject
Total Lecture Hours 32
Total Lab Hours
COURSE OBJECTIVES: TECHNICAL COMPETENCIES
Contact Hrs,1
222223
3
23
23
23
32
After the successful completion of this course the student will be able to:A. APPLY MATHEMATICAL CONCEPTS
1.
2.
3.
Perform Basic Arithmetic Functionsa. Add, subtract, multiply, and divide whole numbersb. Add, subtract, multiply, and divide fractionsc. Add, subtract, multiply, and divide decimalsd. Interconvert fractions/decimalse. Interconvert metric/English measurementsPerform Basic Algebraic Operationsa. Evaluate equation using standard algebraic hierarchyb. Solve equations with one unknown variablec. Solve ratio / percentage problemsd. Calculate and apply formulasPerform Basic Trigonometric Functions
139
a. Solve for unknown sides / angles of right triangles using trigonometricfunctions
b. Solve for unknown side of right triangle using Pythagorean's Theorem4. Use Basic Geometric Principles
a. Solve for surface area, perimeter, and volume of cubeb. Solve for surface area, perimeter, and volume of rectangular solidc. Solve for surface area, perimeter, and volume of right triangular solidd. Solve for surface area, perimeter, and volume of cylindere. Find diagonal of a square
B. DEMONSTRATE COMMUNICATION SKILLS1. Use Written Correspondence
a. Read, write, interpret, and apply memorandumsb. Read, write, interpret, and apply business lettersc. Read, write, interpret, and apply written instructions
2. Use Written Technical Informationa. Read, write, interpret, and apply technical reportsb. Read, write, interpret, and apply written proceduresc. Read, write, interpret, and apply technical manuals
3. Communicate Technical Information Verballya. Demonstrate ability to listen to and understand verbal technical
information / instructionsb. Ask appropriate questions to ascertain needed informationc. Demonstrate ability to give verbal technical information / instructions
4. Use Graphics for Visual Aida. Create, read, and apply graphsb. Create, read, and apply chartsc. Create, read, and apply graphical illustrations
C. PERFORM DRAFTING/CAD TASKS1. Demonstrate Traditional Mechanical Drafting Skills
a. Demonstrate isometric sketching of objectsb. List and apply the three primary planes of projectionc. List and apply the six principle views.d. Use and apply auxiliary viewse. Create sectional views
2. Use Computer-Aided Drafting (CAD) Systema. Create geometry using CAD systemb. Create 3-D solid modelsc. Interconvert CAD and accepted drawing exchange formatsd. Configure CAD system parameterse. Use peripheral devices
3. Use and Apply Geometric Dimensioning and Tolerancing (GD&T) Methodologya. Distinguish between conventional and geometric dimensioning and
tolerancing.b. Explain and use geometric positional tolerancingc. Explain and use tolerances of formd. Explain and use the feature control symbole. Explain and use modifiers in geometric dimensioning and tolerancing
D. USE COMPUTERS1. Use Computer Operating Systems
a. Use Windowsb. Use computer network system
2. Use File Management Systemsa. Discuss file management conceptsb. Create/remove directoriesc. Copy files from floppy disks to hard drive
E. INTERPRET/USE BLUEPRINTS AND RELATED DOCUMENTS1. Interpret, Review, and Apply Blueprint Notes, Dimensions, and Tolerances
a. Distinguish between general and specific notesb. Interpret and apply general and specific notesc. Determine and apply dimensions on a drawingd. Identify basic symbols found on a drawinge. Identify tolerances on a drawingf. Discuss GD&T methodology
2. Interpret and Understand Basic Layout/Types of Drawingsa. Identify types of drawingsb. Identify parts of a drawing and list components of eachc. Identify types of lines on a drawingd. List and describe the different views found on a drawing
3. Understand and Analyze Bill-of-Materialsa. Determine materials requiredb. Determine quantities requiredc. Identify item symbol and/or part number
4. Ascertain Job Requirements from Drawingsa. Interpret part requirementsb. Identify surfaces to be machinedc. Determine critical dimensions
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 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.
The following activities will be performed by each student for successful completion of thiscourse:
I. COMPETENCIESA. Resources: Identifies, organizes, plans, and allocates resources
1. allocates time to complete assigned tasks on schedule2. determines and allocates required materials and resources for meeting
objectives3. evaluates skills, performance, and quality of work and provides feedback
B. Interpersonal: Works with others 141
1. participates as a member of the team, contributing to group effort2. provides individual assistance/direction to peers as requested3. determines and meets internal and external customers' expectations4. exercises leadership qualities to effectively communicate ideas and make
decisions5. negotiates resources in order to accomplish objectives6. works well with all members of the classInformation: Acquires and uses information1. acquires and evaluates information2. organizes and maintains information3. interprets and communicates information
D. Systems: Understands complex inter-relationships1. understands and works well with social, organizational, and technological
systems2. monitors and corrects performance of system during operation3 recommend modifications to system to improve performance
E. Technology: Works with a variety of technologies,1 chooses relevant procedures, tools and equipment2. applies appropriate procedures and techniques to accomplish tasks3. identifies or solves problems to maintain equipment
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. demonstrates basic reading skills including abilities to perceive main
ideas, draw appropriate conclusions, detect a sequence, locateanswers, find facts, and infer from written texts
b. demonstrates course specific reading skills including abilities toread, interpret, and comprehend information from text andsupplemental materials on a level to facilitate productiveindependent and group study
c. demonstrates ability to read, interpret, and utilize information fromcourse specific instruments (i.e., charts, diagrams, graphs,schematics, blueprints, flow charts, etc.)
d. demonstrates ability to read, interpret, and follow schedules andprocedural instructions in a timely and appropriate manner
e. demonstrates ability to choose and use most appropriate readingmethod (skim, scan, or read for comprehension) for materials
2. Writing: Communicates thoughts, ideas, information, and messages inwriting; and creates documents such as letters, directions, manuals,reports, graphs, and flow chartsa. demonstrates basic writing skills including abilities to produce
written documents which conform with accepted grammatical andcommunication standards required for effective daily functioning
b. demonstrates effective written study skills including note taking,maintaining course specific journals, workbooks, manuals, etc.
142
c. demonstrates technical writing skills in preparing outlines,summaries, time lines, flow charts, diagrams, etc. appropriate tomaterials covered
d. demonstrates ability to complete all required writings in a timely,complete, and professional manner
e. demonstrates competence in subject matter through theorganization and presentation of answers to required writtenassessments
3. Arithmetic/Mathematics: Perform basic computations and approachespractical problems by choosing appropriately from a variety ofmathematical techniquesa. demonstrates proficiency in basic arithmetic functions including
ability to add, subtract, multiply, and divide whole numbers,fractions, decimals, and percents
b. demonstrates ability to read, comprehend, and select appropriatemath procedures to work basic math problems
c. demonstrates ability to understand and perform multi-stepcomputations
d. demonstrates ability to read, interpret, and use standard measuringdevices
e. demonstrates ability to comprehend, retain, and utilize coursespecific measuring devices effectively
f. demonstrates ability to understand, retain, and utilize highermathematical formulas and functions required for course specificmath performance
g. demonstrates ability to appropriately transfer mathematicalcalculations and information from paper to machines
4. Listening: Receives, attends to, interprets, and responds to verbalmessages and other cuesa. functions at minimal or above required hearing levels to receive,
attend, interpret, and respond to verbal messages and instructionsand to safely operate machinery
b. demonstrates ability to hear, comprehend, and appropriately followdirections
c. demonstrates auditory ability to hear, comprehend, and utilizeverbal classroom as well as other auditory instruction
d. demonstrates ability to discriminate between essential andnon-essential verbal information and react appropriately
e. demonstrates ability to focus and fine-tune listening skills toreceive, interpret, and respond to various sounds
f. demonstrates ability and maturity to seek and receive additionalindividualized instruction as needed
5. Speaking: Organizes ideas and communicates orallya. demonstrates appropriate listening and speaking skills in personal
conversationsb. demonstrates ability to choose and organize appropriate words to
effectively communicatec. demonstrates ability to speak clearly and distinctly with appropriate
volume, tone, and body language for situation
143
d. demonstrates ability to spontaneously organize and presentappropriate answers and/or short presentations for classroom andfor assessment purposes
e. demonstrates ability to formulate, organize, and deliver majorpresentations to peers or groups
f. demonstrates ability to speak effectively in one-on-one, smallgroup, or large group presentations
g. demonstrates ability to take responsibility for presentationsB. 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. demonstrates ability to objectively assess personal strengths and
weaknessesb. demonstrates ability to set realistic short-term and long-term goalsc. demonstrates ability to recognize and distinguish between positive
and negative alternativesd. demonstrates ability to identify potential pitfalls and take evasive
actionse. demonstrates ability to objectively and responsibly evaluate
alternatives by testing hypotheses and selecting most appropriateresponse
f. demonstrates ability to profit from negative evaluations or mistakesby reformulating, redirecting, reconstructing, or retestingalternatives
g. demonstrates maturity to take responsibility for decisions2. Problem Solving: Recognizes problems and devises and implements plan
of actiona. demonstrates ability to detect problem through observation, inquiry,
or directiveb. demonstrates ability to grasp appropriate overview and degree of
seriousness of problem and to behave responsibly in situationc. demonstrates ability to generate alternatives or options for problem
solutiond. demonstrates ability to research options, assess and evaluate
options, and determine appropriate and best solutione. demonstrates ability to initiate and effect solutionf. demonstrates ability to take responsibility for outcomesg. demonstrates ability to effectively problem solve in individual, team,
or group situations3. Seeing Things In the Mind's Eye: Organizes, and processes symbols,
pictures, graphs, objects, and other informationa. functions at minimum or above required visual levels in order to
see, interpret, attend and respond to visual imagery and meet safetyrequirements for necessary machinery
b. demonstrates ability to read, interpret, and act upon signs, symbols,and other visual cues
c. demonstrates ability to visually discriminate in gross and fineimagery
144
d. demonstrates ability to visualize abstractlye. demonstrates ability to apply visual imagery to applied tasks
4. Knowing How to Learn: Use efficient learning techniques to acquire andapply new knowledge and skillsa. demonstrates mastery of basic reading, math, and language skills
through applicationb. demonstrates ability to translate abstract theory into practical
applicationc. demonstrates ability to incorporate and generalize new learning into
a sequential learning processd. demonstrates knowledge of good study skills and learning habits
5. Reasoning: Discovers a rule or principle underlying the relationshipbetween two or more objects and applies it when solving a problema. demonstrates use of simple logicb. demonstrates ability to distinguish relationshipsc. demonstrates ability to determine and isolate factors in relationshipsd. demonstrates and applies knowledge through practicee. recognizes that attitudes, skills, and practice are essential to
productivityf. demonstrates ability to discriminate between positive and negative,
and act accordinglyPersonal Qualities: Displays responsibility, self-esteem, sociability, self-management, and integrity and honesty.1. Responsibility: Exerts a high level of effort and perseveres towards goal
attainmenta. demonstrates ability to formulate realistic and useful short and long
term goals and complete steps necessary to timely achieve goalsb. demonstrates ability to make adjustments, revisions, and changes to
achieve goals in a cooperative and polite mannerc. demonstrates ability to focus on task at hand and work to
completiond. demonstrates good work ethics through regular attendance,
adequate classroom preparations, and appropriate use of classroomtime
e. demonstrates maturity to take responsibility for actionsf. demonstrates ability to cooperatively work in individual, team, and
group situations in timely and effective manner2. Self-Esteem: Believes in own self-worth and maintains a positive view of
selfa. presents .a positive attitude toward tasksb. demonstrates ability to separate work and personal behaviorsc. actively participates in learning opportunities by sharing knowledge
and skills with peers and instructorsd. demonstrates ability to accept personal strengths and weaknesses
and builds on positive behaviorse. demonstrates ability to accept and use constructive criticismf. accepts positive reinforcement in an appropriate manner
3. Sociability: Demonstrates understanding, friendliness, adaptability,empathy, and politeness in group settings
X45
a. demonstrates appropriate and acceptable social behaviors inclassroom interactions
b. demonstrates ability to work cooperatively in individual, team, orgroup situations
c. demonstrates active interest in peers by offering assistance, sharingresources, and sharing knowledge in a professional and acceptablemanner
d. demonstrates professional work ethic by separating work andpersonal social behaviors and acting accordingly
4. Self-Management: Assesses self accurately, sets personal goals,monitors progress, and exhibits self-controla. accepts personal strengths and weaknesses and uses the same for
positive advancementb. demonstrates ability to continuously set, assess, choose, and modify
objectives as the situation demands in an appropriate mannerc. demonstrates ability to formulate and follow personal schedulesd. demonstrates ability to wisely use classroom timee. demonstrates use of good study habits and skillsf. demonstrates maturity to take responsibility for own actions
5. Integrity/Honesty: Chooses ethical courses of actiona. knows and demonstrates ability to distinguish between positive and
negative behaviorsb. demonstrates honesty and integrity in working with peers and
supervisorsc. takes full responsibility for personal actionsd. demonstrates understanding of consequences for negative ethical
behaviors and accepts responsibility for same when applicablee. demonstrates positive work and social ethics in undertakings
DDT 131303/081496
Machine Tool Advanced SkillsTechnology Program
COURSE SYLLABUS
DIE DESIGN IIPrerequisite: DIE DESIGN I
1 a 7
MAST PROGRAMCOURSE SYLLABUS
DIE DESIGN II
Lecture hours/week: 2
COURSE DESCRIPTION:
Lab hours/week: 2 Credit hours: 3
This course is a continuation of Die Design I with more emphasis on actual die design andconstruction. Instruction is given on the considerations involved in developing diecomponents,such as calculation of clearances, cutting force, and press tonnage requirements.
PREREQUISITES: Die Design I
REQUIRED COURSE MATERIALS:
Textbook: Basic Diemaking, D. Eugene Ostergaard, McGraw-Hill
Hand Tools/Quantity Required:Safety Glasses6 inch Ruler
METHOD OF INSTRUCTION:
1 pair1/8, 1/16, 1/32, and 1/64 grad.
Lecture: Didactic presentations will include lecture, video and demonstrations.
Laboratory: Laboratory will be a "hands-on" 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 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 Topics
Introduction to Die and FixtureDesign
Text Reference Page Contact Hrs.
148
Safety in a Die Shop HandoutDie Engineering - Planning and
Design 1-5, 192,193, HOShear Action in Metal Cutting 3, HOPrinciples of Blanking/Piercing Dies 1-22, HOPunch Design and Construction 63-86Die Block Construction 97-108Bending of Metals 23-50, HOBending and Forming Die Design
and Construction 27-50, HOStrippers and Stock Guides 11,12, 109-127Shedders and Knockouts 128-136Nest Gages, Pushers, and Die Stops 137-147Compound and Combination Dies HandoutProgressive Dies HandoutStock Material Utilization and Strip
Layouts 172-190Other Types of Industrial Dies Handout
Total Lecture Hours 32
LAB OUTLINE:Lab Topics
Introduction to the Design of DiesSafety in the Die ShopStampings and Their Dies (Visual Survey)Visualization of Die ConstructionProject (Make Drawing of Existing Die)Project (Design Punch, Punch Plate, and Die Block)Project (Design V-Bend Die)Project (Design Combination Die)
Contact Hrs.
Total Lab Hours
COURSE OBJECTIVES: TECHNICAL COMPETENCIES
1
1
1
25
46
32
After the successful completion of this course the student will be able to:A. PRACTICE SAFETY
1. Follow Safety Manuals and All Safety Regulations/ Requirementsa. Comply with established company and OSHA regulationsb. Interpret safety manual directivesc. Wear safety/protective equipment as required
2. Maintain Safe Equipment and Machinerya. Maintain equipment/tooling in safe operating conditionb. Maintain all guards, shields, and barriers in place and in good conditionc. Perform preventive maintenance as requiredd. Practice proper tag-out/lock-out procedures
3. Maintain a Clean and Safe Work Environment
149
a. Keep work areas clean and free of debrisb. Keep isles/traffic areas clear of equipment and materialsc. Store materials, tools, and instruments in organized mannerd. Clean machine/hand tools when work is complete
4. Use Safe Operating Procedures for Hand and Machine Toolsa. Use tools for intended purposes onlyb. Acquire proper training/authorization before operating equipmentc. Operate hand and machine tools in safe mannerd. Comply with manufacturer's rated capacity for equipmente. Ensure all rotating or moving parts have stopped before leaving areaf. Inspect for and remove possible hazards before engaging equipment
5. Use Safe Machining Practicesa. Ensure stock/tooling is secure before machiningb. Use chip control methodsc. Use moderate, safe, and calculated speeds and feedsd. Stay alert and prepared to act during machininge. Ensure rotating parts/tooling are completely stopped before handling
6. Use Safe Lifting Practicesa. Use lifting aids when necessaryb. Use OSHA approved chains, straps, and hoistsc. Comply with rated capacity of lifting equipmentd. Comply with company/OSHA regulations regarding lifting procedures
7. Consult and Apply MSDS for Hazards of Various Materialsa. Know format of material safety data sheetsb. Consult and interpret MSDS to determine relevant hazards of materialc. Apply information and take precautionary measures against hazardsd. Notify proper authorities of haiards
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 decimalsd. Interconvert fractions/decimalse. Interconvert metric/English measurements
2. Perform Basic Algebraic Operationsa. Evaluate equation using standard algebraic hierarchyb. Solve equations with one unknown variablec. Solve ratio/percentage problemsd. Calculate and apply formulas
3. Perform Basic Trigonometric Functionsa. Solve for unknown sides/angles of right triangles using trigonometric
functionsb. Solve for unknown side of right triangle using Pythagorean's Theorem
4. Use and Apply Cartesian Coordinate Systema. Define the Cartesian coordinate systemb. Plot machining points using Cartesian coordinate system
C. DEMONSTRATE QUALITY CONTROL AND MANAGEMENT1. Utilize Appropriate Inspection Techniques
a. Discuss factors that affect accurate measurementb. Determine proper procedure to acquire accurate measurementc. Determine proper instrument to use in measurement
2. Perform Appropriate Use and Calibration of Inspection Equipmenta. Explain calibration requirements of various precision instrumentsb. Maintain/care for instruments for optimum performancec. Read and use 0.D., I.D., and depth micrometersd. Read and use vernier, dial, & digital caliperse. Read and use scale and tape measuref. Read and use dial-bore indicatorsg. Use dial indicatorsh. Use precision square and combination seti. Read and use digital read-outj. Use finish/profile gagesk. Use Rockwell hardness tester1. Use surface plates
3. Know Qualitative Parameters of Machinery and Equipmenta. Differentiate between types of machinery by qualitative capabilitiesb. Select appropriate processes to maintain desired tolerancesc. Discuss the effect one process might have on an earlier or later process
4. Maintain Equipment to Produce Quality Partsa. Justify tooling by qualitative requirementsb. Protect/maintain critical surfaces of machinesc. Perform preventive maintenance on equipment
5. Know and Use Quality Systemsa. Know and use ISO 9000 concepts and proceduresb. Know and use Statistical Process Control (SPC) techniques and concepts
6. Write Inspection Proceduresa. Determine/designate proper inspection techniqueb. Determine/designate precautions to take during inspectionc. Determine/design inspection jig or fixture requiredd. List in order and define steps required to ensure accurate measurement
7. Document Inspection Resultsa. Define procedure used during inspectionb. Accurately document measurements taken and compare to standardc. Determine/document if part passes or fails inspectiond. Determine/document rework or scrap recommendations
D. DEMONSTRATE KNOWLEDGE OF MANUFACTURING MATERIALS1. Identify Materials with Desired Properties
a. Determine/identify service requirements (strength, hardness, etc.)b. Determine, interpret, and evaluate availability of materialsc. Describe general characteristics of various metalsd. Know concepts of and calculate statics and stresses
2. Demonstrate Knowledge of Physical Properties of Materialsa. Define hardnessb. Define toughnessc. Define tensile strengthd. Define shear strength
151
e. Define elasticityf. Define ductilityg. Discuss the Rockwell and Brinell hardness scalesh. Discuss the Charpy/Izod impact tests
3. Identify Manufacturing Properties of Materialsa. Discuss machinability of various materialsb. Discuss cold forming/workability of various materialsc. Define work hardening/edge hardeningd. Identify welding properties of various materialse. Demonstrate knowledge of heat treating procedures and propertiesf. Know stress relieving proceduresg. Know/Find hardness characteristics and chemistry of various materials
4. Discuss Classification System for Metalsa. Identify and discuss types of carbon steelb. Determine chemistry of material by classificationc. Distinguish between SAE and AISI classification systemsd. Identify designation of each digit of steel classificatione. Discuss alloy steels
E. DEMONSTRATE KNOWLEDGE OF MANUFACTURING PROCESSES1. Know Operation of Vertical and Horizontal Mills and Tooling
a. Define milling machines, horizontal and verticalb. List, describe, and give function and maintenance of different types of
tooling used on milling machinesc. Set-up and operate horizontal and vertical milling machined. Explain machine components and accessories of milling machinese. Explain milling processesf. Discuss milling machine safetyg. Calculate speeds and feeds based on materials and tooling
2. Know Operation of Engine and Turret Lathes and Toolinga. Define lathes, engine and turretb. List, describe, and give function and maintenance of various types of
tooling used on lathesc. Set-up and operate engine and turret lathesd. Explain machine components and accessories of lathese. Explain turning processesf. Discuss lathe safetyg. Calculate speeds and feeds based on materials and tooling
3. Know Operation of Drill Presses and Toolinga. Identify types of drilling machinesb. List, describe, and give function and maintenance of various types of
tooling used on drilling machinesc. Set-up and operate drilling machinesd. Explain machine components and accessories of drilling machinese. Explain processes performed on drilling machinesf. Discuss drilling safetyg. Calculate speeds and feeds based on materials and tooling
4. Know Operation of Surface and Cylindrical Grindersa. Define grinders, surface and cylindrical
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b. Explain types and maintenance of grinding wheelsc. Set-up and operate grinding machinesd. Explain machine components and accessories of grinding machinese. Explain grinding processesf. Discuss grinding safety
5. Know Operation of Heat Treating Equipment and Processesa. Describe types of heat treating equipmentb. Set-up and operate heat treating equipmentc. Explain machine components and accessories of heat treating equipmentd. Explain heat treating procedurese. Discuss heat treating safety
6. Know Operation of Welding Equipment and Processesa. Identify various types of welding equipmentb. Identify and discuss the difference in welding processesc. Inspect welds for cracks and penetrationd. Discuss welding safety
7. Know Sheet Metal Operationsa. Discuss gas/plasma cutting equipment and processesb. Discuss operation of punch/brake presses and toolingc. Discuss operation of plate shearsd. Calculate tonnages required for press/shear operationse. Calculate blank dimensions of developed partsf. Use yield tables for bending sheet metalg. Discuss fabrication of sheet metal partsh. Demonstrate layout-on-metali. Apply conservation-of-material concepts
8. Know Operation of Jig-boring Machines and Toolinga. Define jig-boring machineb. List, describe, and give function and maintenance of different types of
tooling used on jig-boring machinesc. Set-up and operate jig-boring machined. Explain machine components and accessories of jig-boring machinese. Explain jig-boring processf. Discuss safety on jig-boring machineg. Calculate speeds and feeds based on materials and tooling
9. Know Operation of Tool and Cutter Grindersa. Define tool/cutter grinderb. Discuss dressing and maintenance of grinding wheelsc. Explain machine components and accessories of tool/cutter grinderd. Discuss tool and cutter grinder safety
10. Know Operation of Metal Sawsa. Define band saw, horizontal and verticalb. Set-up and operate band sawc. Define abrasive cut-off sawd. Set-up and operate abrasive cut-off sawe. Discuss application of the different tooth forms, pitch sets, and gages
of band saw bladesf. Weld and maintain band saw blade i 5 3
g. Discuss band saw safetyh. Calculate speeds and feeds based on materials and toolingi. Explain machine components and accessories of band sawsj. Calculate proper length of band saw blade
11. Estimate Time Required/Cost to Produce a Parta. Determine processes required to produce partb. Calculate actual machining and handling timec. Calculate material quantity and costd. Calculate labor and overhead cost
12. Know Proper Flow of Parts Through Shopa. Discuss proper order of processesb. Discuss ergonomic aspects of plant layout
13. Utilize Concepts and Principles of Fixturinga. Determine need for fixture/jigb. Design appropriate fixture/jigc. Identify components used in fixtures/jigsd. Disassemble and assemble fixture/jige. Discuss relationship between accuracy of fixture and accuracy/
repeatability of parts14. Make Calculations for and Use Sine Bar/Sine Plate
a. Define sine bar/sine plateb. Calculate gage block buildup for sine bar/sine platec. Set-up and use sine bar/sine plate
15. Make Calculations for and Use Rotary Table and Dividing Heada. Set-up and use rotary table/dividing head for machining operationsb. Make calculations for number of rotations requiredc. Determine/select appropriate index plate for dividing head
F. DEMONSTRATE COMMUNICATION SKILLS1. Use Written Correspondence
a. Read, write, interpret, and apply memorandumsb. Read, write, interpret, and apply business lettersc. Read, write, interpret, and apply written instructions
2. Use Written Technical Informationa. Read, write, interpret, and apply technical reportsb. Read, write, interpret, and apply written proceduresc. Read, write, interpret, and apply technical manuals
3. Communicate Technical Information Verballya. Demonstrate ability to listen to and understand verbal technical
information/instructionsb. Ask appropriate questions to ascertain needed informationc. Demonstrate ability to give verbal technical information/instructions
4. Use Graphics for Visual Aida. Create, read, and apply graphsb. Create, read, and apply chartsc. Create, read, and apply graphical illustrations
G. PERFORM DRAFTING/CAD TASKS1. Demonstrate Traditional Mechanical Drafting Skills
a. Demonstrate use of drafting machine and instruments
b. Demonstrate drafting technique to create basic geometric elementsc. Demonstrate isometric sketching of objectsd. List and apply the three primary planes of projectione. List and apply the six principle viewsf. Use and apply auxiliary viewsg. Create/Use sectional views
2. Use Computer-Aided Drafting (Cad) Systema. Create geometry using CAD systemb. Create 3-D solid modelsc. Interconvert CAD and accepted drawing exchange formatsd. Configure CAD system parameterse. Use peripheral devices
3. Use and Apply Geometric Dimensioning and Tolerancing (GD&T) Methodologya. Distinguish between conventional and geometric dimensioning and
tolerancing.b. Explain and use geometric positional tolerancingc. Explain and use tolerances of formd. Explain and use the feature control symbole. Explain and use modifiers in geometric dimensioning and tolerancing
H. INTERPRET/USE BLUEPRINTS AND RELATED DOCUMENTS1. Interpret, Review, and Apply Blueprint Notes, Dimensions, and Tolerances
a. Distinguish between general and specific notesb. Interpret and apply general and specific notesc. Determine and apply dimensions on a drawingd. Identify basic symbols found on a drawinge. Identify tolerances on a drawingf. Discuss GD&T methodology
2. Interpret and Understand Basic Layout/Types of Drawingsa. Identify types of drawingsb. Identify parts of a drawing and list components of eachc. Identify types of lines on a drawingd. List and describe the different views found on a drawing
3. Understand and Analyze Bill-of-Materialsa. Determine materials requiredb. Determine quantities requiredc. Identify item symbol and/or part number
4. Ascertain Job Requirements from Drawingsa. Interpret part requirementsb. Identify surfaces to be machinedc. Determine critical dimensions
I. PERFORM DIE OPERATIONS1. Utilize Basic Die Theory
a. Discuss shearing action on metal (3 stages)b. Define/calculate cutting clearancec. Define/calculate proper shut-height of die setd. Define/calculate offset displacemente. Define/calculate stripping pressuref. Define/calculate cutting length of piece part
155
g. Define/calculate die progressionh. Design stock strip layouti. Determine die feed directionj. Explain notch, pierce, pilot, form, and cut-off stationsk. Determine stop block length1. Determine press tonnage requirementsm. Define/calculate slug clearancen. Explain operation of die set to make piece parto. Explain spring back in form diesP. Explain bending action in V-form diesq. Explain coining in diesr. Identify components of die sets. Discuss materials of die components
2. Perform Die Repaira. Disassemble and assemble die setb. Visually inspect die components for damagec. Identify component parts to be repaired/sharpenedd. Determine method of repairing/sharpeninge. Determine material for replacement partsf. Manufacture replacement partsg. Demonstrate setting correct punch entry
3. Demonstrate Die Making Skillsa. Identify component parts from die blueprintb. Determine material/purchased parts requirementsc. Utilize die making procedures to make component partsd. Utilize die making procedures to mount component partse. Demonstrate mounting of die set in press machinef. Cycle die set in press machine and inspect operationg. Inspect piece part for accuracy
4. Identify Types of Industrial Diesa. Explain blanking or piercing diesb. Explain bending or forming diesc. Explain draw diesd. Explain compression diese. Explain progressive diesf. Explain compound diesg. Explain combination dies
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 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 5 6
The following activities will be performed by each student for successful completion of thiscourse:
I. COMPETENCIESA. Resources: Identifies, organizes, plans, and allocates resources
1. allocates time to complete assigned tasks on schedule2. determines cost associated with meeting objectives3. determines and allocates required materials and resources for meeting
objectives4. evaluates skills, performance, and quality of work and provides feedback
B. Interpersonal: Works with others1. participates as a member of the team, contributing to group effort2. provides individual assistance/direction to peers as requested3. eetermines and meets internal and external customers' expectations4. exercises leadership qualities to effectively communicate ideas and make
decisions5. negotiates resources in order to accomplish objectives6. works well with all members of the classInformation: Acquires and uses information1. acquires and evaluates information2. organizes and maintains information3. interprets and communicates information
D. Systems: Understands complex inter-relationships1. understands and works well with social, organizational, and technological
systems2. monitors and corrects performance of system during operation3. recommend modifications to system to improve performance
E. Technology: Works with a variety of technologies1. chooses relevant procedures, tools and equipment2. applies appropriate procedures and techniques to accomplish tasks3. identifies or solves problems to maintain equipment
IL 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. demonstrates basic reading skills including abilities to perceive main
ideas, draw appropriate conclusions, detect a sequence, locateanswers, find facts, and infer from written texts
b. demonstrates course specific reading skills including abilities toread, interpret, and comprehend information from text andsupplemental materials on a level to facilitate productiveindependent and group study
c. demonstrates ability to read, interpret, and utilize information fromcourse specific instruments (i.e., charts, diagrams, graphs,schematics, blueprints, flow charts, etc.)
15?
demonstrates ability to read, interpret, and follow schedules andprocedural instructions in a timely and appropriate manner
e. demonstrates ability to choose and use most appropriate readingmethod (skim, scan, or read for comprehension) for materials
2. Writing: Communicates thoughts, ideas, information, andmessages in writing; and creates documents such as letters,directions, manuals, reports, graphs, and flow charts
a. demonstrates basic writing skills including abilities to producewritten documents which conform with accepted grammatical andcommunication standards required for effective daily functioning
b. demonstrates effective written study skills including note taking,maintaining course specific journals, workbooks, manuals, etc.
c. demonstrates technical writing skills in preparing outlines,summaries, time lines, flow charts, diagrams, etc. appropriate tomaterials covered
d. demonstrates ability to complete all required writings in a timely,complete, and professional manner
e. demonstrates competence in subject matter through theorganization and presentation of answers to required writtenassessments
3. Arithmetic/Mathematics: Perform basic computations and approachespractical problems by choosing appropriately from a variety ofmathematical techniquesa. demonstrates proficiency in basic arithmetic functions including
ability to add, subtract, multiply, and divide whole numbers,fractions, decimals, and percents
b. demonstrates ability to read, comprehend, and select appropriatemath procedures to work basic math problems
c. demonstrates ability to understand and perform multi-stepcomputations
d. demonstrates ability to read, interpret, and use standard measuringdevices
e. demonstrates ability to comprehend, retain, and utilize coursespecific measuring devices effectively
f. demonstrates ability to understand, retain, and utilize highermathematical formulas and functions required for course specificmath performance
g. demonstrates ability to appropriately transfer mathematicalcalculations and information from paper to machines
4. Listening: Receives, attends to, interprets, and responds to verbalmessages and other cuesa. functions at minimal or above required hearing levels to receive,
attend, interpret, and respond to verbal messages and instructionsand to safely operate machinery
b. demonstrates ability to hear, comprehend, and appropriately followdirections
c. demonstrates auditory ability to hear, comprehend, and utilizeverbal classroom as well as other auditory instruction
158
d. demonstrates ability to discriminate between essential andnon-essential verbal information and react appropriately
e. demonstrates ability to focus and fine-tune listening skills toreceive, interpret, and respond to various sounds
f. demonstrates ability and maturity to seek and receive additionalindividualized instruction as needed
5. Speaking: Organizes ideas and communicates orallya. demonstrates appropriate listening and speaking skills in personal
conversationsb. demonstrates ability to choose and organize appropriate words to
effectively communicatec. demonstrates ability to speak clearly and distinctly with appropriate
volume, tone, and body language for situationd. demonstrates ability to spontaneously organize and present
appropriate answers and/or short presentations for classroom and/or assessment purposes
e. demonstrates ability to formulate, organize, and deliver majorpresentations to peers or groups
f. demonstrates ability to speak effectively in one-on-one, smallgroup, or large group presentations
g. demonstrates ability to take responsibility for presentationsB. 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. demonstrates ability to objectively assess personal strengths and
weaknessesb. demonstrates ability to set realistic short-term and long-term goalsc. demonstrates ability to recognize and distinguish between positive
and negative alternativesd. demonstrates ability to identify potential pitfalls and take evasive
actionse. demonstrates ability to objectively and responsibly evaluate
alternatives by testing hypotheses and selecting most appropriateresponse
f. demonstrates ability to profit from negative evaluations or mistakesby reformulating, redirecting, reconstructing, or retestingalternatives
g. demonstrates maturity to take responsibility for decisions2 Problem Solving: Recognizes problems and devises and implements plan
of actiona. demonstrates ability to detect problem through observation, inquiry,
or directiveb. demonstrates ability to grasp appropriate overview and degree of
seriousness of problem and to behave responsibly in situationc. demonstrates ability to generate alternatives or options for problem
solution
d. demonstrates ability to research options, assess and evaluateoptions, and determine appropriate and best solution
e. demonstrates ability to initiate and effect solutionf. demonstrates ability to take responsibility for outcomesg. demonstrates ability to effectively problem solve in individual, team,
or group situations3. Seeing Things In the Mind's Eye: Organizes, andprocesses symbols,
pictures, graphs, objects, and other informationa. functions at minimum or above required visual levels in order to
see, interpret, attend and respond to visual imagery and meet safetyrequirements for necessary machinery
b. demonstrates ability to read, interpret, and act upon signs, symbols,and other visual cues
c. demonstrates ability to visually discriminate in gross and fineimagery
d. demonstrates ability to visualize abstractlye. demonstrates ability to apply visual imagery to applied tasks
4. Knowing How to Learn: Use efficient learning techniques to acquire andapply new knowledge and skillsa. demonstrates mastery of basic reading, math, and language skills
through applicationb. demonstrates ability to translate abstract theory into practical
applicationc. demonstrates ability to incorporate and generalize new learning into
a sequential learning processd. demonstrates knowledge of good study skills and learning habits
5. Reasoning: Discovers a rule or principle underlying the relationshipbetween two or more objects and applies it when solving a problema. demonstrates use of simple logicb. demonstrates ability to distinguish relationshipsc. demonstrates ability to determine and isolate factors in relationshipsd. demonstrates and applies knowledge through practicee. recognizes that attitudes, skills, and practice are essential to
productivityf. demonstrates ability to discriminate between positive and negative,
and act accordinglyPersonal Qualities: Displays responsibility, self-esteem, sociability, self-management, and integrity and honesty.1. Responsibility: Exerts a high level of effort and perseveres towards goal
attainmenta. demonstrates ability to formulate realistic and useful short and long
term goals and complete steps necessary to timely achieve goalsb. demonstrates ability to make adjustments, revisions, and changes to
achieve goals in a cooperative and polite mannerc. demonstrates ability to focus on task at hand and work to
completion
160
d. demonstrates good work ethics through regular attendance,adequate classroom preparations, and appropriate use of classroomtime
e. demonstrates maturity to take responsibility for actionsf. demonstrates ability to cooperatively work in individual, team, and
group situations in timely and effective manner2. Self-Esteem: Believes in own self-worth and maintains a positive view of
selfa. presents a positive attitude toward tasksb. demonstrates ability to separate work and personal behaviorsc. actively participates in learning opportunities by sharing knowledge
and skills with peers and instructorsd. demonstrates ability to accept personal strengths and weaknesses
and builds on positive behaviorse. demonstrates ability to accept and use constructive criticismf. accepts positive reinforcement in an appropriate manner
3. Sociability: Demonstrates understanding, friendliness, adaptability,empathy, and politeness in group settingsa. demonstrates appropriate and acceptable social behaviors in
classroom interactionsb. demonstrates ability to work cooperatively in individual, team, or
group situationsc. demonstrates active interest in peers by offering assistance, sharing
resources, and sharing knowledge in a professional and acceptablemanner
d. demonstrates professional work ethic by separating work andpersonal social behaviors and acting accordingly
4. Self-Management: Assesses self accurately, sets personal goals,monitors progress, and exhibits self-controla. accepts personal strengths and weaknesses and uses the same for
positive advancementb. demonstrates ability to continuously set, assess, choose, and modify
objectives as the situation demands in an appropriate mannerc. demonstrates ability to formulate and follow personal schedulesd. demonstrates ability to wisely use classroom timee. demonstrates use of good study habits and skillsf. demonstrates maturity to take responsibility for own actions
5. Integrity/Honesty: Chooses ethical courses of actiona. knows and demonstrates ability to distinguish between positive and
negative behaviorsb. demonstrates honesty and integrity in working with peers and
supervisorsc. takes full responsibility for personal actionsd. demonstrates understanding of consequences for negative ethical
behaviors and accepts responsibility for same when applicablee. demonstrates positive work and social ethics in undertakings
161
Appropriate Reference Materials:
1. Machinery's Handbook, Industrial Press2. Pie Design Fundamentals, J. R. Pacquin and R.E. Crowley, 2nd Ed.
TDT 215301/081496
Machine Tool Advanced SkillsTechnology Program
COURSE SYLLABUS
DIE MAKING IIPrerequisite: DIE MAKING I
163
. MAST PROGRAMCOURSE SYLLABUS
DIE MAKING II
Lecture hours/week: 3
COURSE DESCRIPTION:
Lab hours/week: 6 Credit hours: 6
This course is a continuation of Die Making I with instruction and practice in building aprogressive die from a blueprint. Emphasis is placed on the application of the die buildingprocedures learned in Die Making I toward fabricating more complex dies.
PREREQUISITES: Die Making I
REQUIRED COURSE MATERIALS:
Textbook: Basic Diemaking, D. Eugene Ostergaard, McGraw-Hill
Hand Tools/Quantity Required:Safety Glasses6 inch Ruler
METHOD OF INSTRUCTION:
1 pair1/8, 1/16, 1/32, and 1/64 grad.
Lecture: Didactic presentations will include lecture, video and demonstrations.
Laboratory: Laboratory will be a "hands-on" 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 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 Topics
Introduction and SafetyThe Progressive Die
Text Reference Page Contact Hrs.
Handout
The Die Blueprint HandoutComponent Requirements HandoutMaterial Requirements and
Specifications HandoutCalculations Required 6-22, HOPlanning Events
LAB OUTLINE:Lab Topics
Orientation and SafetyMaterial InventoryMaterial Requisitioning for DieProject (Progressive Blank/Pierce Die)Tryout of Die
Total Lecture Hours 48
Total Lab Hours
COURSE OBJECTIVES: TECHNICAL COMPETENCIES
Contact Hrs.222
846
96
After the successful completion of this course the student will be able to:A. PRACTICE SAFETY
1. Follow Safety Manuals and All Safety Regulations/ Requirementsa. Comply with established company and OSHA regulationsb. Interpret safety manual directivesc. Wear safety/protective equipment as required
2. Maintain Safe Equipment and Machinerya. Maintain equipment/tooling in safe operating conditionb. Maintain all guards, shields, and barriers in place and in good conditionc. Perform preventive maintenance as requiredd. Practice proper tag-out/lock-out procedures
3. Maintain a Clean and Safe Work Environmenta. Keep work areas clean and free of debrisb. Keep aisles/traffic areas clear of equipment and materialsc. Store materials, tools, and instruments in organized mannerd. Clean machine/hand tools when work is complete
4. Use Safe Operating Procedures for Hand and Machine Toolsa. Use tools for intended purposes onlyb. Acquire proper training/authorization before operating equipmentc. Operate hand and machine tools in safe mannerd. Comply with manufacturer's rated capacity for equipmente. Ensure all rotating or moving parts have stopped before leaving areaf. Inspect for and remove possible hazards before engaging equipment
5. Use Safe Machining Practicesa. Ensure stock/tooling is secure before machiningb. Use chip control methodsc. Use moderate, safe, and calculated speeds and feeds
165"
d. Stay alert and prepared to act during machininge. Ensure rotating parts/tooling are completely stopped before handling
6. Use Safe Lifting Practicesa. Use lifting aids when necessaryb. Use OSHA approved chains, straps, and hoistsc. Comply with rated capacity of lifting equipmentd. Comply with company/OSHA regulations regarding lifting procedures
7. Consult and Apply MSDS for Hazards of Various Materialsa. Know format of material safety data sheetsb. Consult and interpret MSDS to determine relevant hazards of materialc. Apply information and take precautionary measures against hazardsd. Notify proper authorities of hazards
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 decimalsd. Interconvert fractions/decimalse. Interconvert metric/English measurements
2. Perform Basic Algebraic Operationsa. Evaluate equation using standard algebraic hierarchyb. Solve equations with one unknown variablec. Solve ratio/percentage problemsd. Calculate and apply formulas
3. Perform Basic Trigonometric Functionsa. Solve for unknown sides/angles of right triangles using trigonometric
functionsb. Solve for unknown side of right triangle using Pythagorean's Theorem
4. Use and Apply Cartesian Coordinate Systema. Define the Cartesian coordinate systemb. Plot machining points using Cartesian coordinate system
C. DEMONSTRATE QUALITY CONTROL AND MANAGEMENT1. Utilize Appropriate Inspection Techniques
a. Discuss factors that affect accurate measurementb. Determine proper procedure to acquire accurate measurementc. Determine proper instrument to use in measurement
2. Perform Appropriate Use and Calibration of Inspection Equipmenta. Explain calibration requirements of various precision instrumentsb. Maintain/care for instruments for optimum performancec. Read and use 0.D., I.D., and depth micrometersd. Read and use vernier, dial, & digital caliperse. Read and use scale and tape measuref. Read and use dial-bore indicatorsg. Use dial indicatorsh. Use precision square and combination seti. Read and use digital read-outj. Use finish/profile gagesk. Use Rockwell hardness tester
1. Use surface plates3. Know Qualitative Parameters of Machinery and Equipment
a. Differentiate between types of machinery by qualitative capabilitiesb. Select appropriate processes to maintain desired tolerancesc. Discuss the effect one process might have on an earlier or later process
4. Maintain Equipment to Produce Quality Partsa. Justify tooling by qualitative requirementsb. Protect/maintain critical surfaces of machinesc. Perform preventive maintenance on equipment
5. Know and Use Quality Systemsa. Know and use ISO 9000 concepts and proceduresb. Know and use Statistical Process Control (SPC) techniques and concepts
6. Write Inspection Proceduresa. Determine/designate proper inspection techniqueb. Determine/designate precautions to take during inspectionc. Determine/design inspection jig or fixture requiredd. List in order and define steps required to ensure accurate measurement
7. Document Inspection Resultsa. Define procedure used during inspectionb. Accurately document measurements taken and compare to standardc. Determine/document if part passes or fails inspectiond. Determine/document rework or scrap recommendations
D. DEMONSTRATE KNOWLEDGE OF MANUFACTURING MATERIALS1. Identify Materials with Desired Properties
a. Determine/identify service requirements (strength, hardness, etc.)b. Determine, interpret, and evaluate availability of materialsc. Describe general characteristics of various metalsd. Know concepts of and calculate statics and stresses
2. Demonstrate Knowledge of Physical Properties of Materialsa. Define hardnessb. Define toughnessc. Define tensile strengthd. Define shear strengthe. Define elasticityf. Define ductilityg. Discuss the Rockwell and Brinell hardness scalesh. Discuss the Charpy/Izod impact tests
3. Identify Manufacturing Properties of Materialsa. Discuss machinability of various materialsb. Discuss cold forming/workability of various materialsc. Define work hardening/edge hardeningd. Identify welding properties of various materialse. Demonstrate knowledge of heat treating procedures and propertiesf. Know stress relieving proceduresg. Know/Find hardness characteristics and chemistry of various materials
4. Discuss Classification System for Metalsa. Identify and discuss types of carbon steelb. Determine chemistry of material by classification
c. Distinguish between SAE and AISI classification systemsd. Identify designation of each digit of steel classificatione. Discuss alloy steels
E. DEMONSTRATE KNOWLEDGE OF MANUFACTURING PROCESSES1. Know Operation of Vertical and Horizontal Mills and Tooling
a. Define milling machines, horizontal and verticalb. List, describe, and give function and maintenance of different types of
tooling used on milling machinesc. Set-up and operate horizontal and vertical milling machined. Explain machine components and accessories of milling machinese. Explain milling processesf. Discuss milling machine safety
g. Calculate speeds and feeds based on materials and tooling2. Know Operation of Engine and Turret Lathes and Tooling
a. Define lathes, engine and turretb. List, describe, and give function and maintenance of various types of
tooling used on lathesc. Set-up and operate engine and turret lathesd. Explain machine components and accessories of lathese. Explain turning processesf. Discuss lathe safetyg. Calculate speeds and feeds based on materials and tooling
3. Know Operation of Drill Presses and Toolinga. Identify types of drilling machinesb. List, describe, and give function and maintenance of various types of
tooling used on drilling machinesc. Set-up and operate drilling machinesd. Explain machine components and accessories of drilling machinese. Explain processes performed on drilling machinesf. Discuss drilling safetyg. Calculate speeds and feeds based on materials and tooling
4. Know Operation of Surface and Cylindrical Grindersa. Define grinders, surface and cylindricalb. Explain types and maintenance of grinding wheelsc. Set-up and operate grinding machinesd. Explain machine components and accessories of grinding machinese. Explain grinding processesf. Discuss grinding safety
5. Know Operation of Heat Treating Equipment and Processesa. Describe types of heat treating equipmentb. Set-up and operate heat treating equipmentc. Explain machine components and accessories of heat treating equipmentd. Explain heat treating procedurese. Discuss heat treating safety
6. Know Operation of Welding Equipment and Processesa. Identify various types of welding equipmentb. Identify and discuss the difference in welding processesc. Inspect welds for cracks and penetration
j s
d. Discuss welding safety7. Know Sheet Metal Operations
a. Discuss gas/plasma cutting equipment and processesb. Discuss operation of punch/brake presses and toolingc. Discuss operation of plate shearsd. Calculate tonnages required for press/shear operationse. Calculate blank dimensions of developed partsf Use yield tables for bending sheet metalg. Discuss fabrication of sheet metal partsh. Demonstrate layout-on-metali. Apply conservation-of-material concepts
8. Know Operation of Jig-boring Machines and Toolinga. Define jig-boring machineb. List, describe, and give function and maintenance of different types of
tooling used on jig-boring machinesc. Set-up and operate jig-boring machined. Explain machine components and accessories of jig-boring machinese. Explain jig-boring processf. Discuss safety on jig-boring machineg. Calculate speeds and feeds based on materials and tooling
9. Know Operation of Tool and Cutter Grindersa. Define tool/cutter grinderb. Discuss dressing and maintenance of grinding wheelsc. Explain machine components and accessories of tool/cutter grinderd. Discuss tool and cutter grinder safety
10. Know Operation of Metal Sawsa. Define band saw, horizontal and verticalb. Set-up and operate band sawc. Define abrasive cut-off sawd. Set-up and operate abrasive cut-off sawe. Discuss application of the different tooth forms, pitch sets, and gages
of band saw bladesf. Weld and maintain band saw bladeg. Discuss band saw safetyh. Calculate speeds and feeds based on materials and toolingi. Explain machine components and accessories of band sawsj. Calculate proper length of band saw blade
11. Know Operation of Wire EDMa. Define EDMb. Explain EDM processc. Set-up and operate CNC wire EDMd. Discuss EDM safetye. Calculate E-pac value for wire EDMf. Explain machine components and accessories of wire EDM
12. Estimate Time Required/Cost to Produce a Parta. Determine processes required to produce partb. Calculate actual machining and handling timec. Calculate material quantity and cost
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d. Calculate labor and overhead cost13. Know Proper Flow of Parts Through Shop
a. Discuss proper order of processesb. Discuss ergonomic aspects of plant layout
14. Utilize Concepts and Principles of Fixturinga. Determine need for fixture/jigb. Design appropriate fixture/jigc. Identify components used in fixtures/jigsd. Disassemble and assemble fixture/jige. Discuss relationship between accuracy of fixture and accuracy/
repeatability of parts15. Make Calculations for and Use Sine Bar/Sine Plate
a. Define sine bar/sine plateb. Calculate gage block buildup for sine bar/sine platec. Set-up and use sine bar/sine plate
16. Make Calculations for and Use Rotary Table and Dividing Heada. Set-up and use rotary table/dividing head for machining operationsb. Make calculations for number of rotations requiredc. Determine/select appropriate index plate for dividing head
F. DEMONSTRATE COMMUNICATION SKILLS1. Use Written Correspondence
a. Read, write, interpret, and apply memorandumsb. Read, write, interpret, and apply business lettersc. Read, write, interpret, and apply written instructions
2. Use Written Technical Informationa. Read, write, interpret, and apply technical reportsb. Read, write, interpret, and apply written proceduresc. Read, write, interpret, and apply technical manuals
3. Communicate Technical Information Verballya. Demonstrate ability to listen to and understand verbal technical
information/instructionsb. Ask appropriate questions to ascertain needed informationc. Demonstrate ability to give verbal technical information/instructions
4. Use Graphics for Visual Aida. Create, read, and apply graphsb. Create, read, and apply chartsc. Create, read, and apply graphical illustrations
G. PERFORM DRAFTING/CAD TASKS1. Demonstrate Traditional Mechanical Drafting Skills
a. List and apply the three primary planes of projectionb. List and apply the six principle viewsc. Use and apply auxiliary viewsd. Create/use sectional views
H. INTERPRET/USE BLUEPRINTS AND RELATED DOCUMENTS1. Interpret, Review, and Apply Blueprint Notes, Dimensions, and Tolerances
a. Distinguish between general and specific notesb. Interpret and apply general and specific notesc. Determine and apply dimensions on a drawing
170
d. Identify basic symbols found on a drawinge. Identify tolerances on a drawingf. Discuss GD&T methodology
2. Interpret and Understand Basic Layout/Types of Drawingsa. Identify types of drawingsb. Identify parts of a drawing and list components of eachc. Identify types of lines on a drawingd. List and describe the different views found on a drawing
3. Understand and Analyze Bill-of-Materialsa. Determine materials requiredb. Determine quantities requiredc. Identify item symbol and/or part number
4. Ascertain Job Requirements from Drawingsa. Interpret part requirementsb. Identify surfaces to be machinedc. Determine critical dimensions
I. PERFORM DIE OPERATIONS1. Utilize Basic Die Theory and Principles of Die Design
a. Discuss shearing action on metal (3 stages)b. Define/calculate cutting clearancec. Define/calculate proper shut-height of die setd. Define/calculate offset displacemente. Define/calculate stripping pressuref. Define/calculate cutting length of piece partg. Define/calculate die progressionh. Design stock strip layouti. Determine die feed directionj. Explain notch, pierce, pilot, form, and cut-off stationsk. Determine stop block length1. Determine press tonnage requirementsm. Define/calculate slug clearancen. Explain operation of die set to make piece parto. Explain spring back in form dies
P. Explain bending action in V-form diesq. Explain coining in diesr. Identify components of die sets. Discuss materials of die components
2. Perform Die Repaira. Disassemble and assemble die setb. Visually inspect die components for damagec. Identify component parts to be repaired/sharpenedd. Determine method of repairing/sharpeninge. Determine material for replacement partsf. Manufacture replacement partsg. Demonstrate setting correct punch entry
3. Demonstrate Die Making Skillsa. Identify component parts from die blueprintb. Determine material/purchased parts requirements
171
c. Utilize die making procedures to make component partsd. Utilize die making procedures to mount component partse. Demonstrate mounting of die set in press machinef. Cycle die set in press machine and inspect operationg. Inspect piece part for accuracy
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 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.
The following activities will be performed by each student for successful completion of thiscourse:
I. COMPETENCIESA. Resources: Identifies, organizes, plans, and allocates resources
1. allocates time to complete assigned tasks on schedule2. determines cost associated with meeting objectives3. determines and allocates required materials and resources for meeting
objectives4. evaluates skills, performance, and quality of work and provides feedback
B. Interpersonal: Works with others1. participates as a member of the team, contributing to group effort2. Provides individual assistance/direction to peers as requested3. determines and meets internal and external customers' expectations4. exercises leadership qualities to effectively communicate ideas and make
decisions5. negotiates resources in order to accomplish objectives6. works well with all members of the classInformation: Acquires and uses it formation1. acquires and evaluates information2. organizes and maintains information3. interprets and communicates information
D. Systems: Understands complex inter-relationships1. understands and works well with social, organizational, and technological
systems2. monitors and corrects performance of system during operation3. recommend modifications to system to improve performance
E. Technology: Works with a variety of technologies1. chooses relevant procedures, tools and equipment2. applies appropriate procedures and techniques to accomplish tasks3. identifies or solves problems to maintain equipment
172
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. demonstrates basic reading skills including abilities to perceive main
ideas, draw appropriate conclusions, detect a sequence, locateanswers, find facts, and infer from written texts
b. demonstrates course specific reading skills including abilities toread, interpret, and comprehend information from text andsupplemental materials on a level to facilitate productiveindependent and group study
c. demonstrates ability to read, interpret, and utilize information fromcourse specific instruments (i.e., charts, diagrams, graphs,schematics, blueprints, flow charts, etc.)
d. demonstrates ability to read, interpret, and follow schedules andprocedural instructions in a timely and appropriate manner
e. demonstrates ability to choose and use most appropriate readingmethod (skim, scan, or read for comprehension) for materials
2. Writing: Communicates thoughts, ideas, information, and messages inwriting; and creates documents such as letters, directions, manuals,reports, graphs, and flow chartsa. demonstrates basic writing skills including abilities to produce
written documents which conform with accepted grammatical andcommunication standards required for effective daily functioningdemonstrates effective written study skills including note taking,maintaining course specific journals, workbooks, manuals, etc.
c. demonstrates technical writing skills in preparing outlines,summaries, time lines, flow charts, diagrams, etc. appropriate tomaterials covered
d. demonstrates ability to complete all required writings in a timely,complete, and professional manner
e. demonstrates competence in subject matter through theorganization and presentation of answers to required writtenassessments
3. Arithmetic/Mathematics: Perform basic computations and approachespractical problems by choosing appropriately from a variety ofmathematical techniquesa. demonstrates proficiency in basic arithmetic functions including
ability to add, subtract, multiply, and divide whole numbers,fractions, decimals, and percents.
b. demonstrates ability to read, comprehend, and select appropriatemath procedures to work basic math problems
c. demonstrates ability to understand and perform multi-stepcomputations
d. demonstrates ability to read, interpret, and use standard measuringdevices
173
e. demonstrates ability to comprehend, retain, and utilize coursespecific measuring devices effectively
f. demonstrates ability to understand, retain, and utilize highermathematical formulas and functions required for course specificmath performance
g. demonstrates ability to appropriately transfer mathematicalcalculations and information from paper to machines
4. Listening: Receives, attends to, interprets, and responds to verbalmessages and other cuesa. functions at minimal or above required hearing levels to receive,
attend, interpret, and respond to verbal messages and instructionsand to safely operate machinery
b. demonstrates ability to hear, comprehend, and appropriately followdirections
c. demonstrates auditory ability to hear, comprehend, and utilizeverbal classroom as well as other auditory instruction
d. demonstrates ability to discriminate between essential andnon-essential verbal information and react appropriately
e. demonstrates ability to focus and fine-tune listening skills toreceive, interpret, and respond to various sounds
f. demonstrates ability and maturity to seek and receive additionalindividualized instruction as needed
5. Speaking: Organizes ideas and communicates orallya. demonstrates appropriate listening and speaking skills in personal
conversationsb. demonstrates ability to choose and organize appropriate words to
effectively communicatec. demonstrates ability to speak clearly and distinctly with appropriate
volume, tone, and body language for situationd. demonstrates ability to spontaneously organize and present
appropriate answers and/or short presentations for classroom and/or assessment purposes
e. demonstrates ability to formulate, organize, and deliver majorpresentations to peers or groups
f. demonstrates ability to speak effectively in one-on-one, smallgroup, or large group presentations
g. demonstrates ability to take responsibility for presentationsB. 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. demonstrates ability to objectively assess personal strengths and
weaknessesb. demonstrates ability to set realistic short-term and long-term goalsc. demonstrates ability to recognize and distinguish between positive
and negative alternativesd. demonstrates ability to identify potential pitfalls and take evasive
actions
e. demonstrates ability to objectively and responsibly evaluatealternatives by testing hypotheses and selecting most appropriateresponse
f. demonstrates ability to profit from negative evaluations or mistakesby reformulating, redirecting, reconstructing, or retestingalternatives
g. demonstrates maturity to take responsibility for decisions2. Problem Solving: Recognizes problems and devises and implements plan
of actiona. demonstrates ability to detect problem through observation, inquiry,
or directiveb. demonstrates ability to grasp appropriate overview and degree of
seriousness of problem and to behave responsibly in situationc. demonstrates ability to generate alternatives or options for problem
solutiond. demonstrates ability to research options, assess and evaluate
options, and determine appropriate and best solutione. demonstrates ability to initiate and effect solutionf. demonstrates ability to take responsibility for outcomesg. demonstrates ability to effectively problem solve in individual, team,
or group situations3. Seeing Things In the Mind's Eye: Organizes, and processes symbols,
pictures, graphs, objects, and other in formationa. functions at minimum or above required visual levels in order to
see, interpret, attend and respond to visual imagery and meet safetyrequirements for necessary machinery
b. demonstrates ability to read, interpret, and act upon signs, symbols,and other visual cues
c. demonstrates ability to visually discriminate in gross and fineimagery
d. demonstrates ability to visualize abstractlye. demonstrates ability to apply visual imagery to applied tasks
4. Knowing How to Learn: Use efficient learning techniques to acquire andapply new knowledge and skillsa. demonstrates mastery of basic reading, math, and language skills
through applicationb. demonstrates ability to translate abstract theory into practical
applicationc. demonstrates ability to incorporate and generalize new learning into
a sequential learning processd. demonstrates knowledge of good study skills and learning habits
5. Reasoning: Discovers a rule or principle underlying the relationshipbetween two or more objects and applies it when solving a problema. demonstrates use of simple logicb. demonstrates ability to distinguish relationshipsc. demonstrates ability to determine and isolate factors in relationshipsd. demonstrates and applies knowledge through practice
e. recognizes that attitudes, skills, and practice are essential toproductivity
f. demonstrates ability to discriminate between positive and negative,and act accordingly
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
attainmenta. demonstrates ability to formulate realistic and useful short and long
term goals and complete steps necessary to timely achieve goalsb. demonstrates ability to make adjustments, revisions, and changes to
achieve goals in a cooperative and polite mannerc. demonstrates ability to focus on task at hand and work to
completiond. demonstrates good work ethics through regular attendance,
adequate classroom preparations, and appropriate use of classroomtime
e. demonstrates maturity to take responsibility for actionsf. demonstrates ability to cooperatively work in individual, team, and
group situations in timely and effective manner2. Self-Esteem: Believes in own self-worth and maintains a positive view of
selfa. presents a positive attitude toward tasksb. demonstrates ability to separate work and personal behaviorsc. actively participates in learning opportunities by sharing knowledge
and skills with peers and instructorsd. demonstrates ability to accept personal strengths and weaknesses
and builds on positive behaviorse.. demonstrates ability to accept and use constructive criticismf. accepts positive reinforcement in an appropriate manner
3. Sociability: Demonstrates understanding, friendliness, adaptability,empathy, and politeness in group settingsa. demonstrates appropriate and acceptable social behaviors in
classroom interactionsb. demonstrates ability to work cooperatively in individual, team, or
group situationsc. demonstrates active interest in peers by offering assistance, sharing
resources, and sharing knowledge in a professional and acceptablemanner
d. demonstrates professional work ethic by separating work andpersonal social behaviors and acting accordingly
4. Self-Management: Assesses self accurately, sets personal goals,monitors progress, and exhibits self-controla. accepts personal strengths and weaknesses and uses the same for
positive advancementb. demonstrates ability to continuously set, assess, choose, and modify
objectives as the situation demands in an appropriate mannerc. demonstrates ability to formulate and follow personal schedules
d. demonstrates ability to wisely use classroom timee. demonstrates use of good study habits and skillsf. demonstrates maturity to take responsibility for own actions
5. Integrity/Honesty: Chooses ethical courses of actiona. knows and demonstrates ability to distinguish between positive and
negative behaviorsb. demonstrates honesty and integrity in working with peers and
supervisorsc. takes full responsibility for personal actionsd. demonstrates understanding of consequences for negative ethical
behaviors and accepts responsibility for same when applicablee. demonstrates positive work and social ethics in undertakings
Appropriate Reference Materials:
1. Machinery's Handbook, Industrial Press2. Die Design Fundamentals, J. R. Pacquin and R.E. Crowley, 2nd Ed.
TDT 216603/081496
Machine Tool Advanced SkillsTechnology Program
COURSE SYLLABUS
COMPUTER NUMERICAL CONTROLOPERATIONS II
Prerequisite: COMPUTER NUMERICAL CONTROL OPERATIONS I
178
MAST PROGRAMCOURSE SYLLABUS
COMPUTER NUMERICAL CONTROL OPERATIONS II
Lecture hours/week: 2
COURSE DESCRIPTION:
Lab hours/week: 2 Credit hours: 3
This course is a continuation of CNC Operations I with additional instruction in writing andediting CNC code manually, utilizing more advanced commands and cycles. Additionally,students will be introduced to the use of a Computer-Aided Manufacturing (CAM) system forcreation of code.
PREREQUISITES: Computer Numerical Control Operations I
REQUIRED COURSE MATERIALS:
Textbook: An Introduction to CNC Machining and Programming, David Gibbsand Thomas M. Crandell, Industrial Press
Lab Manual: Instructor Provided Materials
Hand Tools/Quantity Required:Safety Glasses6 inch Ruler
METHOD OF INSTRUCTION:
1 pair1/8, 1/16, 1/32, and 1/64 inch
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 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 Topics Text Reference Page Contact Hrs.
Safety with CNC EquipmentIntroduction to CNC Lathe
(Industrial Lathe) HandoutTooling Systems for CNC Lathes 41-77, HOAdvanced Programming Cycles
(CANNED) 137-146, HOIntroduction to CNC Mill
(Industrial Mill) HandoutTooling Systems for CNC Mills 41-77, HandoutAdvanced Programming Cycles
(CANNED) 137-146, HOJigs and Fixtures for CNC
Equipment 78-94, HOProgramming for Production
and Efficiency 436-459, HOIntroduction to Computer-Aided
Manufacturing (CAM) 334-435, HOTotal Lecture Hours 32
LAB OUTLINE:Lab Topics
CNC Machines and SafetyOperation of CNC Industrial LatheTooling SystemsProject (Turn and Journal Shaft)Project (Turn Part with Radii, Angles, and Grooves)Project (Threaded Shaft with Tapped End Hole)Operation of CNC Industrial MillTooling SystemsProject (Drilled and Milled Plate)Project (Milled Plate with Pocket and Name)Project (Production Part for Lathe)Project (Production Part for Mill)Field Trip (CNC Machine Shop)
Total Lab Hours
COURSE OBJECTIVES: TECHNICAL COMPETENCIES
Contact Hrs.1
21
23
3.21
23
444
32
After the successful completion of this course the student will be able to:A. PRACTICE SAFETY
1. Follow Safety Manuals and All Safety Regulations/ Requirementsa. Comply with established company and OSHA regulationsb. Interpret safety manual directives
c. Wear safety/protective equipment as required2. Maintain Safe Equipment and Machinery
a. Maintain equipment/tooling in safe operating conditionb. Maintain all guards, shields, and barriers in place and in good conditionc. Perform preventive maintenance as requiredd. Practice proper tag-out/lock-out procedures
3. Maintain a Clean and Safe Work Environmenta. Keep work areas clean and free of debrisb. Keep isles/traffic areas clear of equipment and materialsc. Store materials, tools, and instruments in organized mannerd. Clean machine/hand tools when work is complete
4. Use Safe Operating Procedures for Hand and Machine Toolsa. Use tools for intended purposes onlyb. Acquire proper training/authorization before operating equipmentc. Operate hand and machine tools in safe mannerd. Comply with manufacturer's rated capacity for equipmente. Ensure all rotating or moving parts have stopped before leaving areaf. Inspect for and remove possible hazards before engaging equipment
5. Use Safe Machining Practicesa. Ensure stock/tooling is secure before machiningb. Use chip control methodsc. Use moderate, safe, and calculated speeds and feedsd. Stay alert and prepared to act during machininge. Ensure rotating parts/tooling are completely stopped before handling
6. Use Safe Lifting Practicesa. Use lifting aids when necessaryb. Use OSHA approved chains, straps, and hoistsc. Comply with rated capacity of lifting equipmentd. Comply with company/OSHA regulations regarding lifting procedures
7. Consult and Apply MSDS for Hazards of Various Materialsa. Know format of material safety data sheetsb. Consult and interpret MSDS to determine relevant hazards of materialc. Apply information and take precautionary measures against hazardsd. Notify proper authorities of hazards
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 decimalsd. Interconvert fractions/decimalse. Interconvert metric/English measurements
2. Perform Basic Algebraic Operationsa. Evaluate equation using standard algebraic hierarchyb. Solve equations with one unknown variablec. Solve ratio/percentage problemsd. Calculate and apply formulas
3. Perform Basic Trigonometric Functionsa. Solve for unknown sides/angles of right triangles using trigonometric
functionsb. Solve for unknown side of right triangle using Pythagorean's Theorem
4. Use and Apply Cartesian Coordinate Systema. Define the Cartesian coordinate systemb. Calculate coordinates of bolt circle on Cartesian coordinate systemc. Plot machining points using Cartesian coordinate system
C. DEMONSTRATE QUALITY CONTROL AND MANAGEMENT1. Utilize Appropriate Inspection Techniques
a. Discuss factors that affect accurate measurementb. Determine proper procedure to acquire accurate measurementc. Determine proper instrument to use in measurement
2. Perform Appropriate Use and Calibration of Inspection Equipmenta. Explain calibration requirements of various precision instrumentsb. Maintain/care for instruments for optimum performancec. Read and use 0.D., I.D., and depth micrometersd. Read and use vernier, dial, & digital caliperse. Read and use scale and tape measuref. Read and use dial-bore indicators
g. Use dial indicatorsh. Use precision square and combination seti. Read and use digital read-outj. Use finish/profile gagesk. Use Rockwell hardness tester1. Use surface plates
3. Know Qualitative Parameters of Machinery and Equipmenta. Differentiate between types of machinery by qualitative capabilitiesb. Select appropriate processes to maintain desired tolerancesc. Discuss the effect one process might have on an earlier or later process
4 Maintain Equipment to Produce Quality Partsa. Justify tooling by qualitative requirementsb. Protect/maintain critical surfaces of machinesc. Perform preventive maintenance on equipment
5. Know and Use Quality Systemsa. Know and use ISO 9000 concepts and proceduresb. Know and use Statistical Process Control (SPC) techniques and concepts
6. Write Inspection Proceduresa. Determine/designate proper inspection techniqueb. Determine/designate precautions to take during inspectionc. Determine/design inspection jig or fixture requiredd. List in order and define steps required to ensure accurate measurement
7 Document Inspection Resultsa. Define procedure used during inspectionb. Accurately document measurements taken and compare to standardc. Determine/document if part passes or fails inspectiond. Determine/document rework or scrap recommendations
D. DEMONSTRATE KNOWLEDGE OF MANUFACTURING MATERIALS1. Demonstrate Knowledge of Physical Properties of Materials
a. Define hardness1 8 2
b. Define toughness2. Identify Manufacturing Properties of Materials
a. Discuss machinability of various materialsb. Define work hardening/edge hardening
E. DEMONSTRATE KNOWLEDGE OF MANUFACTURING PROCESSES1. Know Operation of Vertical and Horizontal Mills and Tooling
a. Define milling machines, horizontal and verticalb. List, describe, and give function and maintenance of different types of
tooling used on milling machinesc. Set-up and operate horizontal and vertical milling machined. Explain machine components and accessories of milling machinese. Explain milling processesf. Discuss milling machine safetyg. Discuss CNC machining centers and processesh. Calculate speeds and feeds based on materials and toolingi. Set-up and operate CNC machining center
2. Know Operation of Engine and Turret Lathes and Toolinga. Define lathes, engine and turretb. List, describe, and give function and maintenance of various types of
tooling used on lathesc. Set-up and operate engine and turret lathesd. Explain machine components and accessories of lathese. Explain turning processesf. Discuss lathe safetyg. Discuss CNC turning centers and processesh. Calculate speeds and feeds based on materials and toolingi. Set-up and operate CNC turning center
3. Know Operation of Drill Presses and Toolinga. Identify types of drilling machinesb. List, describe, and give function and maintenance of various types of
tooling used on drilling machinesc. Set-up and operate drilling machinesd. Explain machine components and accessories of drilling machinese. Explain processes performed on drilling machinesf. Discuss drilling safetyg. Discuss drilling operations on CNC drilling machinesh. Calculate speeds and feeds based on materials and toolingi. Set-up and operate CNC drilling machine
4. Estimate Time Required/Cost to Produce a Parta. Determine processes required to produce partb. Calculate actual machining and handling timec. Calculate material quantity and costd. Calculate labor and overhead cost
5. Know Proper Flow of Parts Through Shopa. Discuss proper order of processesb. Discuss ergonomic aspects of plant layout
6. Utilize Concepts and Principles of Fixturinga. Determine need for fixture/jig
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b. Design appropriate fixture/jigc. Identify components used in fixtures/jigsd. Disassemble and assemble fixture/jige. Discuss relationship between accuracy of fixture and accuracy/
repeatability of partsF. PERFORM CNC PROGRAMMING/CAM TASKS
1. Prepare and Plan for CNC Machining Operationsa. Plan sequence of machining eventsb. Determine proper tooling/fixtures required for machiningc. Calculate speeds, feeds, and depth-of-cut for machiningd. Explain the x, y, and z axis on CNC machines
2. Select and Use Tooling Systems for CNC Machinesa. Understand machinability and chip formationb. Select proper insert materials and geometryc. Select proper tooling systemd. Define and discuss applicatiori of HSS, carbide, and borazon cutting tools
3. Manually Program CNC Machinesa. Plan and write programs for CNC machinesb. Use MDI panel on machine to program/edit programsc. Set and use tooling offsets at CNC machined. Discuss/use canned or bar cycles in program
4. Use Computer-Aided Manufacturing (CAM) Systema. Create toolpath geometry using CAM systemb. Transfer files from CAM system to machine
G. DEMONSTRATE COMMUNICATION SKILLS1. Use Written Correspondence
a. Read, write, interpret, and apply memorandumsb. Read, write, interpret, and apply business lettersc. Read, write, interpret, and apply written instructions
2. Use Written Technical Informationa. Read, write, interpret, and apply technical reportsb. Read, write, interpret, and apply written proceduresc. Read, write, interpret, and apply technical manuals
3. Communicate Technical Information Verballya. Demonstrate ability to listen to and understand verbal technical
information/instructionsb. Ask appropriate questions to ascertain needed informationc. Demonstrate ability to give verbal technical information/instructions
4. Use Graphics for Visual Aida. Create, read, and apply graphsb. Create, read, and apply chartsc. Create, read, and apply graphical illustrations
H. PERFORM DRAFTING/CAD TASKS1. Demonstrate Traditional Mechanical Drafting Skills
a. List and apply the three primary planes of projectionb. List and apply the six principle viewsc. Use and apply auxiliary viewsd. Create/use sectional views
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I. USE COMPUTERS1. Use Computer Operating Systems
a. Use Windowsb. Use computer network system
2. Use File Management Systemsa. Discuss file management conceptsb. Create/remove directoriesc. Copy files from floppy disks to hard drive
J. INTERPRET/USE BLUEPRINTS AND RELATED DOCUMENTS1. Interpret, Review, and Apply Blueprint Notes, Dimensions, and Tolerances
a. Distinguish between general and specific notesb. Interpret and apply general and specific notesc. Determine and apply dimensions on a drawingd. Identify basic symbols found on a drawinge. Identify tolerances on a drawingf. Discuss GD&T methodology
2. Interpret and Understand Basic Layout/Types of Drawingsa. Identify types of drawingsb. Identify parts of a drawing and list components of eachc. Identify types of lines on a drawingd. List and describe the different views found on a drawing
3. Understand and Analyze Bill-of-Materialsa. Determine materials requiredb. Determine quantities requiredc. Identify item symbol and/or part number
4. Ascertain Job Requirements from Drawingsa. Interpret part requirementsb. Identify surfaces to be machinedc. Determine critical dimensions
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 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.
The following activities will be performed by each student for successful completion of thiscourse:
I. COMPETENCIESA. Resources: Identifies, organizes, plans, and allocates resources
1. allocates time to complete assigned tasks on schedule2. determines cost associated with meeting objectives
3. determines and allocates required materials and resources for meetingobjectives
4. evaluates skills, performance, and quality of work and provides feedbackB. Interpersonal: Works with others
1. participates as a member of the team, contributing to group effort2. provides individual assistance/direction to peers as requested3. determines and meets internal and external customers' expectations4. exercises leadership qualities to effectively communicate ideas and make
decisions.5. negotiates resources in order to accomplish objectives6. works well with all members of the classInformation: Acquires and uses information1. aquires and evaluates information2. organizes and maintains information3. interprets and communicates information
D. Systems: Understands complex inter-relationships1. understands and works well with social, organizational, and technological
systems2. monitors and corrects performance of system during operation3. recommend modifications to system to improve performance
E. Technology: Works with a variety of technologies1. chooses relevant procedures, tools and equipment2. applies appropriate procedures and techniques to accomplish tasks3. identifies or solves problems to maintain equipment
H. 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. demonstrates basic reading skills including abilities to perceive main
ideas, draw appropriate conclusions, detect a sequence, locateanswers, find facts, and infer from written texts
b. demonstrates course specific reading skills including abilities toread, interpret, and comprehend information from text andsupplemental materials on a level to facilitate productiveindependent and group study
c. demonstrates ability to read, interpret, and utilize information fromcourse specific instruments (i.e., charts, diagrams, graphs,schematics, blueprints, flow charts, etc.)
d. demonstrates ability to read, interpret, and follow schedules andprocedural instructions in a timely and appropriate manner
e. demonstrates ability to choose and use most appropriate readingmethod (skim, scan, or read for comprehension) for materials
2. Writing: Communicates thoughts, ideas, information, and messages inwriting; and creates documents such as letters, directions, manuals,reports, graphs, and flow charts
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a. demonstrates basic writing skills including abilities to producewritten documents which conform with accepted grammatical andcommunication standards required for effective daily functioning
b. demonstrates effective written study skills including note taking,maintaining course specific journals, workbooks, manuals, etc.
c. demonstrates technical writing skills in preparing outlines,summaries, time lines, flow charts, diagrams, etc. appropriate tomaterials covered
d. demonstrates ability to complete all required writings in a timely,complete, and professional manner
e. demonstrates competence in subject matter through theorganization and presentation of answers to required writtenassessments
3. Arithmetic/Mathematics: Perform basic computations and approachespractical problems by choosing appropriately from a variety ofmathematical techniquesa. demonstrates proficiency in basic arithmetic functions including
ability to add, subtract, multiply, and divide whole numbers,fractions, decimals, and percents
b. demonstrates ability to read, comprehend, and select appropriatemath procedures to work basic math problems
c. demonstrates ability to understand and perform multi-stepcomputations
d. demonstrates ability to read, interpret, and use standard measuringdevices
e. demonstrates ability to comprehend, retain, and utilize coursespecific measuring devices effectively
f. demonstrates ability to understand, retain, and utilize highermathematical formulas and functions required for course specificmath performance
g. demonstrates ability to appropriately transfer mathematicalcalculations and information from paper to machines
4. Listening: Receives, attends to, interprets, and responds to verbalmessages and other cuesa. functions at minimal or above required hearing levels to receive,
attend, interpret, and respond to verbal messages and instructionsand to safely operate machinery
b. demonstrates ability to hear, comprehend, and appropriately followdirections
c. demonstrates auditory ability to hear, comprehend, and utilizeverbal classroom as well as other auditory instruction
d. demonstrates ability to discriminate between essential andnon-essential verbal information and react appropriately
e. demonstrates ability to focus and fine-tune listening skills toreceive, interpret, and respond to various sounds
f. demonstrates ability and maturity to seek and receive additionalindividualized instruction as needed
5. Speaking: Organizes ideas and communicates orally
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a. demonstrates appropriate listening and speaking skills in personalconversations
b. demonstrates ability to choose and organize appropriate words toeffectively communicate
c. demonstrates ability to speak clearly and distinctly with appropriatevolume, tone, and body language for situation
d. demonstrates ability to spontaneously organize and presentappropriate answers and/or short presentations for classroom and/or assessment purposes
e. demonstrates ability to formulate, organize, and deliver majorpresentations to peers or groups
f. demonstrates ability to speak effectively in one-on-one, smallgroup, or large group presentations
g. demonstrates ability to take responsibility for presentationsE. 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. demonstrates ability to objectively assess personal strengths and
weaknessesb. demonstrates ability to set realistic short-term and long-term goalsc. demonstrates ability to recognize and distinguish between positive
and negative alternativesd. demonstrates ability to identify potential pitfalls and take evasive
actionse. demonstrates ability to objectively and responsibly evaluate
alternatives by testing hypotheses and selecting most appropriateresponse
f. demonstrates ability to profit from negative evaluations or mistakesby reformulating, redirecting, reconstructing, or retestingalternatives
g. demonstrates maturity to take responsibility for decisions2. Problem Solving: Recognizes problems and devises and implements plan
of actiona. demonstrates ability to detect problem through observation, inquiry,
or directiveb. demonstrates ability to grasp appropriate overview and degree of
seriousness of problem and to behave responsibly in situationc. demonstrates ability to generate alternatives or options for problem
solutiond. demonstrates ability to research options, assess and evaluate
options, and determine appropriate and best solutione. demonstrates ability to initiate and effect solutionf. demonstrates ability to take responsibility for outcomesg. demonstrates ability to effectively problem solve in individual, team,
or group situations3. Seeing Things In the Mind's Eye: Organizes, and processes symbols,
pictures, graphs, objects, and other information
a. functions at minimum or above required visual levels in order tosee, interpret, attend and respond to visual imagery and meet safetyrequirements for necessary machinery
b. demonstrates ability to read, interpret, and act upon signs, symbols,and other visual cues
c. demonstrates ability to visually discriminate in gross and fineimagery
d. demonstrates ability to visualize abstractlye. demonstrates ability to apply visual imagery to applied tasks
4. Knowing How to Learn: Use efficient learning techniques to acquire andapply new knowledge and skillsa. demonstrates mastery of basic reading, math, and language skills
through applicationb. demonstrates ability to translate abstract theory into practical
applicationc. demonstrates ability to incorporate and generalize new learning into
a sequential learning processd. demonstrates knowledge of good study skills and learning habits
5. Reasoning: Discovers a rule or principle underlying the relationshipbetween two or more objects and applies it when solving a problema. demonstrates use of simple logicb. demonstrates ability to distinguish relationshipsc. demonstrates ability to determine and isolate factors in relationshipsd. demonstrates and applies knowledge through practicee. recognizes that attitudes, skills, and practice are essential to
productivityf. demonstrates ability to discriminate between positive and negative,
and act accordinglyPersonal Qualities: Displays responsibility, self-esteem, sociability, self-management, and integrity and honesty.1. Responsibility: Exerts a high level of effort and perseveres towards goal
attainmenta. demonstrates ability to formulate realistic and useful short and long
term goals and complete steps necessary to timely achieve goalsb. demonstrates ability to make adjustments, revisions, and changes to
achieve goals in a cooperative and polite mannerc. demonstrates ability to focus on task at hand and work to
completiond. demonstrates good work ethics through regular attendance,
adequate classroom preparations, and appropriate use of classroomtime
e. demonstrates maturity to take responsibility for actionsf. demonstrates ability to cooperatively work in individual, team, and
group situations in timely and effective manner2. Self-Esteem: Believes in own self-worth and maintains a positive view of
selfa. presents a positive attitude toward tasksb. demonstrates ability to separate work and personal behaviors
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c. actively participates in learning opportunities by sharing knowledgeand skills with peers and instructors
d. demonstrates ability to accept personal strengths and weaknessesand builds on positive behaviors
e. demonstrates ability to accept and use constructive criticismf. accepts positive reinforcement in an appropriate manner
3. Sociability: Demonstrates understanding, friendliness, adaptability,empathy, and politeness in group settingsa. demonstrates appropriate and acceptable social behaviors in
classroom interactionsb. demonstrates ability to work cooperatively in individual, team, or
group situationsc. demonstrates active interest in peers by offering assistance, sharing
resources, and sharing knowledge in a professional and acceptablemanner
d. demonstrates professional work ethic by separating work andpersonal social behaviors and acting accordingly
4. Self-Management: Assesses self accurately, sets personal goals, monitorsprogress, and exhibits self-controla. accepts personal strengths and weaknesses and uses the same for
positive advancementb. demonstrates ability to continuously set, assess, choose, and modify
objectives as the situation demands in an appropriate mannerc. demonstrates ability to formulate and follow personal schedulesd. demonstrates ability to wisely use classroom timee. demonstrates use of good study habits and skillsf. demonstrates maturity to take responsibility for own actions
5. Integrity/Honesty: Chooses ethical courses of actiona. knows and demonstrates ability to distinguish between positive and
negative behaviorsb. demonstrates honesty and integrity in working with peers and
supervisorsc. takes full responsibility for personal actionsd. demonstrates understanding of consequences for negative ethical
behaviors and accepts responsibility for same when applicablee. demonstrates positive work and social ethics in undertakings
Appropriate Reference Materials:1. Machinist Handbook2. Machinery's Handbook, Industrial Press3. Machine Tool Practices, Kibbe, Neely, and Meyer, Wiley Pub., 4th Ed.4. Technology of Machine Tools, Krar, Oswald, St. Amand, McGraw-Hill., 4th Ed.5. Student's Shop Reference Handbook, Edward Hoffman, Industrial Press6. Jig and Fixture Handbook, Carr Lane Manufacturing Co.
MST 272303/081496
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Machine Tool Advanced SkillsTechnology Program
COURSE SYLLABUS
DIE MAKING IIIPrerequisite: DIE MAKING II
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MAST PROGRAMCOURSE SYLLABUS
DIE MAKING III
Lecture hours/week: 2
COURSE DESCRIPTION:
Lab hours/week: 4 Credit hours: 4
This course is a continuation of Die Making II with instruction and practice in building acompound die from a blueprint. Emphasis is placed on the application of the die buildingprocedures learned in Die Making I and Die Making II toward fabricating more complex dies.Instruction and practice is also given on the use of the Wire Electrical Discharge Machine in theconstruction of die components.
PREREQUISITES: Die Making II
REQUIRED COURSE MATERIALS:
Textbook: Basic Diemaking, D. Eugene Ostergaard, McGraw-Hill
Hand Tools/Quantity Required:Safety Glasses6 inch Ruler
METHOD OF INSTRUCTION:
1 pair1/8, 1/16, 1/32, and 1/64 grad.
Lecture: Didactic presentations will include lecture, video and demonstrations.
Laboratory: Laboratory will be a "hands-on" 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 assignments5. contribute to class discussions6. maintain attendance per current policy7. follow all shop rules and safety regulations as stated in the laboratory manual
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LECTURE OUTLINE:Lecture Topics Text Reference Page Contact Hrs.
Introduction and SafetyThe Compound Die HandoutThe Die Blueprint HandoutCapabilities of the Wire EDM in Die
BuildingAssistance Planning Material
Requirements and EventsAssistance with Required Calculations 6-22, HOOperation of the Wire EDM Handout
Total Lecture Hours 32
LAB OUTLINE:Lab Topics
Orientation and SafetyMaterial InventoryMaterial Requisitioning for DieProject (Compound Die)Operation of the Wire EDMTryout of Die
Total Lab Hours
COURSE OBJECTIVES: TECHNICAL COMPETENCIES
Contact Hrs.222
5044
64
After the successful completion of this course the student will be able to:A. PRACTICE SAFETY
1. Follow Safety Manuals and All Safety Regulations/ Requirementsa. Comply with established company and OSHA regulationsb. Interpret safety manual directivesc. Wear safety/protective equipment as required
2. Maintain Safe Equipment and Machinerya. Maintain equipment/tooling in safe operating conditionb. Maintain all guards, shields, and barriers in place and in good conditionc. Perform preventive maintenance as requiredd. Practice proper tag-out/lock-out procedures
3. Maintain a Clean and Safe Work Environmenta. Keep work areas clean and free of debrisb. Keep isles/traffic areas clear of equipment and materialsc. Store materials, tools, and instruments in organized mannerd. Clean machine/hand tools when work is complete
4. Use Safe Operating Procedures for Hand and Machine Toolsa. Use tools for intended purposes onlyb. Acquire proper training/authorization before operating equipment
c. Operate hand and machine tools in safe mannerd. Comply with manufacturer's rated capacity for equipmente. Ensure all rotating or moving parts have stopped before leaving areaf. Inspect for and remove possible hazards before engaging equipment
5. Use Safe Machining Practicesa. Ensure stock/tooling is secure before machiningb. Use chip control methodsc. Use moderate, safe, and calculated speeds and feedsd. Stay alert and prepared to act during machininge. Ensure rotating parts/tooling are completely stopped before handling
6. Use Safe Lifting Practicesa. Use lifting aids when necessaryb. Use OSHA approved chains, straps, and hoistsc. Comply with rated capacity of lifting equipmentd. Comply with company/OSHA regulations regarding lifting procedures
7. Consult and Apply MSDS for Hazards of Various Materialsa. Know format of material safety data sheetsb. Consult and interpret MSDS to determine relevant hazards of materialc. Apply information and take precautionary measures against hazardsd. Notify proper authorities of hazards
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 decimalsd. Interconvert fractions/decimalse. Interconvert metric/English measurements
2. Perform Basic Algebraic Operationsa. Evaluate equation using standard algebraic hierarchyb. Solve equations with one unknown variablec. Solve ratio/percentage problemsd. Calculate and apply formulas
3. Perform Basic Trigonometric Functionsa. Solve for unknown sides/angles of right triangles using trigonometric
functionsb. Solve for unknown side of right triangle using Pythagorean's Theorem
4. Use and Apply Cartesian Coordinate Systema. Define the Cartesian coordinate systemb. Plot machining points using Cartesian coordinate system
C. DEMONSTRATE QUALITY CONTROL AND MANAGEMENT1. Utilize Appropriate Inspection Techniques
a. Discuss factors that affect accurate measurementb. Determine proper procedure to acquire accurate measurementc. Determine proper instrument to use in measurement
2. Perform Appropriate Use and Calibration of Inspection Equipmenta. Explain calibration requirements of various precision instrumentsb. Maintain/care for instruments for optimum performance
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c. Read and use 0.D., I.D., and depth micrometersd. Read and use vernier, dial, & digital caliperse. Read and use scale and tape measuref. Read and use dial-bore indicatorsg. Use dial indicatorsh. Use precision square and combination seti. Read and use digital read-outj. Use finish/profile gagesk. Use Rockwell hardness tester1. Use surface plates
3. Know Qualitative Parameters of Machinery and Equipmenta. Differentiate between types of machinery by qualitative capabilitiesb. Select appropriate processes to maintain desired tolerancesc. Discuss the effect one process might have on an earlier or later process
4. Maintain Equipment to Produce Quality Partsa. Justify tooling by qualitative requirementsb. Protect/maintain critical surfaces of machinesc. Perform preventive maintenance on equipment
5. Know and Use Quality Systemsa. Know and use ISO 9000 concepts and proceduresb. Know and use Statistical Process Control (SPC) techniques and concepts
6. Write Inspection Proceduresa. Determine/designate proper inspection techniqueb. Determine/designate precautions to take during inspectionc. Determine/design inspection jig or fixture requiredd. List in order and define steps required to ensure accurate measurement
7. Document Inspection Resultsa. Define procedure used during inspectionb. Accurately document measurements taken and compare to standardc. Determine/document if part passes or fails inspectiond. Determine/document rework or scrap recommendations
D. DEMONSTRATE KNOWLEDGE OF MANUFACTURING MATERIALS1. Identify Materials with Desired Properties
a. Determine/identify service requirements (strength, hardness, etc.)b. Determine, interpret, and evaluate availability of materialsc. Describe general characteristics of various metalsd. Know concepts of and calculate statics and stresses
2. Demonstrate Knowledge of Physical Properties of Materialsa. Define hardnessb. Define toughnessc. Define tensile strengthd. Define shear strengthe. Define elasticityf. Define ductility
g. Discuss the Rockwell and Brinell hardness scalesh. Discuss the Charpy/Izod impact tests
3. Identify Manufacturing Properties of Materials
a. Discuss machinability of various materialsb. Discuss cold forming/workability of various materialsc. Define work hardening/edge hardeningd. Identify welding properties of various materialse. Demonstrate knowledge of heat treating procedures and propertiesf. Know stress relieving proceduresg. Know/Find hardness characteristics and chemistry of various materials
4. Discuss Classification System for Metalsa. Identify and discuss types of carbon steelb. Determine chemistry of material by classificationc. Distinguish between SAE and AISI classification systemsd. Identify designation of each digit of steel classificatione. Discuss alloy steels
E. DEMONSTRATE KNOWLEDGE OF MANUFACTURING PROCESSES1. Know Operation of Vertical and Horizontal Mills and Tooling
a. Define milling machines, horizontal and verticalb. List, describe, and give function and maintenance of different types of
tooling used on milling machinesc. Set-up and operate horizontal and vertical milling machined. Explain machine components and accessories of milling machinese. Explain milling processesf. Discuss milling machine safetyg. Calculate speeds and feeds based on materials and tooling
2. Know Operation of Engine and Turret Lathes and Toolinga. Define lathes, engine and turretb. List, describe, and give function and maintenance of various types of
tooling used on lathesc. Set-up and operate engine and turret lathesd. Explain machine components and accessories of lathese. Explain turning processesf. Discuss lathe safetyg. Calculate speeds and feeds based on materials and tooling
3. Know Operation of Drill Presses and Toolinga. Identify types of drilling machinesb. List, describe, and give function and maintenance of various types of
tooling used on drilling machinesc. Set-up and operate drilling machinesd. Explain machine components and accessories of drilling machinese. Explain processes performed on drilling machinesf. Discuss drilling safetyg. Calculate speeds and feeds based on materials and tooling
4. Know Operation of Surface and Cylindrical Grindersa. Define grinders, surface and cylindricalb. Explain types and maintenance of grinding wheelsc. Set-up and operate grinding machinesd. Explain machine components and accessories of grinding machinese. Explain grinding processes
f. Discuss grinding safety5. Know Operation of Heat Treating Equipment and Processes
a. Describe types of heat treating equipmentb. Set-up and operate heat treating equipmentc. Explain machine components and accessories of heat treating equipmentd. Explain heat treating procedurese. Discuss heat treating safety.
6. Know Operation of Welding Equipment and Processesa. Identify various types of welding equipmentb. Identify and discuss the difference in welding processesc. Inspect welds for cracks and penetrationd. Discuss welding safety
7 Know Sheet Metal Operationsa. Discuss gas/plasma cutting equipment and processesb. Discuss operation of punch/brake presses and toolingc. Discuss operation of plate shearsd. Calculate tonnages required for press/shear operationse. Calculate blank dimensions of developed partsf. Use yield tables for bending sheet metalg. Discuss fabrication of sheet metal partsh. Demonstrate layout-on-metali. Apply conservation-of-material concepts
8. Know Operation of Jig-boring Machines and Toolinga. Define jig-boring machineb. List, describe, and give function and maintenance of different types of
tooling used on jig-boring machinesc. Set-up and operate jig-boring machined. Explain machine components and accessories of jig-boring machinese. Explain jig-boring processf. Discuss safety on jig-boring machineg. Calculate speeds and feeds based on materials and tooling
9. Know Operation of Tool and Cutter Grindersa. Define tool/cutter grinderb. Discuss dressing and maintenance of grinding wheelsc. Explain machine components and accessories of tool/cutter grinderd. Discuss tool and cutter grinder safety
10. Know Operation of Metal Sawsa. Define band saw, horizontal and verticalb. Set-up and operate band sawc. Define abrasive cut-off sawd. Set-up and operate abrasive cut-off sawe. Discuss application of the different tooth forms, pitch sets, and gages
of band saw bladesf. Weld and maintain band saw blade
g. Discuss band saw safetyh. Calculate speeds and feeds based on materials and toolingi. Explain machine components and accessories of band saws
j. Calculate proper length of band saw blade11. Know Operation of Wire EDM
a. Define EDMb. Explain EDM processc. Set-up and operate CNC wire EDMd. Discuss EDM safetye. Calculate E-pac value for wire EDMf. Explain machine components and accessories of wire EDM
12. Estimate Time Required/Cost to Produce a Parta. Determine processes required to produce partb. Calculate actual machining and handling timec. Calculate material quantity and costd. Calculate labor and overhead cost
13. Know Proper Flow of Parts Through Shopa. Discuss proper order of processesb. Discuss ergonomic aspects of plant layout
14. Utilize Concepts and Principles of Fixturinga. Determine need for fixture/jigb. Design appropriate fixture/jigc. Identify components used in fixtures/jigsd. Disassemble and assemble fixture/jige. Discuss relationship between accuracy of fixture and accuracy/
repeatability of parts15. Make Calculations for and Use Sine Bar/Sine Plate
a. Define sine bar/sine plateb. Calculate gage block buildup for sine bar/sine platec. Set-up and use sine bar/sine plate
16. Make Calculations for and Use Rotary Table and Dividing Heada. Set-up and use rotary table/dividing head for machining operationsb. Make calculations for number of rotations requiredc. Determine/select appropriate index plate for dividing head
F. DEMONSTRATE COMMUNICATION SKILLS1. Use Written Correspondence
a. Read, write, interpret, and apply memorandumsb. Read, write, interpret, and apply business lettersc. Read, write, interpret, and apply written instructions
2. Use Written Technical Informationa. Read, write, interpret, and apply technical reportsb. Read, write, interpret, and apply written proceduresc. Read, write, interpret, and apply technical manuals
3. Communicate Technical Information Verballya. Demonstrate ability to listen to and understand verbal technical
information/instructionsb. Ask appropriate questions to ascertain needed informationc. Demonstrate ability to give verbal technical information/instructions
4. Use Graphics for Visual Aida. Create, read, and apply graphs
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b. Create, read, and apply chartsc. Create, read, and apply graphical illustrations
G. PERFORM DRAFTING/CAD TASKS1. Demonstrate Traditional Mechanical Drafting Skills
a. List and apply the three primary planes of projectionb. List and apply the six principle viewsc. Use and apply auxiliary viewsd. Create/use sectional views
H. INTERPRET/USE BLUEPRINTS AND RELATED DOCUMENTS1. Interpret, Review, and Apply Blueprint Notes, Dimensions, and Tolerances
a. Distinguish between general and specific notesb. Interpret and apply general and specific notesc. Determine and apply dimensions on a drawingd. Identify basic symbols found on a drawinge. Identify tolerances on a drawingf. Discuss GD&T methodology
2. Interpret and Understand Basic Layout/Types of Drawingsa. Identify types of drawingsb. Identify parts of a drawing and list components of eachc. Identify types of lines on a drawingd. List and describe the different views found on a drawing
3. Understand and Analyze Bill-of-materialsa. Determine materials requiredb. Determine quantities requiredc. Identify item symbol and/or part number
4. Ascertain Job Requirements from Drawingsa. Interpret part requirementsb. Identify surfaces to be machinedc. Determine critical dimensions
I. PERFORM DIE OPERATIONS1. Utilize Basic Die Theory and Principles of Die Design
a. Discuss shearing action on metal (3 stages)b. Define/calculate cutting clearancec. Define/calculate proper shut-height of die setd. Define/calculate offset displacemente. Define/calculate stripping pressuref. Define/calculate cutting length of piece partg. Define/calculate die progressionh. Design stock strip layouti. Determine die feed directionj. Explain notch, pierce, pilot, form, and cut-off stationsk. Determine stop block length1. Determine press tonnage requirementsm. Define/calculate slug clearancen. Explain operation of die set to make piece parto. Explain spring back in form diesp. Explain bending action in V-form dies
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q. Explain coining in diesr. Identify components of die sets. Discuss materials of die components
2. Perform Die Repaira. Disassemble and assemble die setb. Visually inspect die components for damagec. Identify component parts to be repaired/sharpenedd. Determine method of repairing/sharpeninge. Determine material for replacement partsf. Manufacture replacement partsg. Demonstrate setting correct punch entry
3. Demonstrate Die Making Skillsa. Identify component parts from die blueprintb. Determine material/purchased parts requirementsc. Utilize die making procedures to make component partsd. Utilize die making procedures to mount component partse. Demonstrate mounting of die set in press machinef. Cycle die set in press machine and inspect operationg. Inspect piece part for accuracy
4. Demonstrate Understanding of Different Types of Industrial Diesa. Describe the operation and major components of blanking or piercing diesb. Describe the operation and major components of bending or forming diesc. Describe the operation and major components of draw diesd. Describe the operation and major components of compression diese. Describe the operation and major components of progressive diesf. Describe the operation and major components of compound diesg. Describe the operation and major components of combination dies
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 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.
The following activities will be performed by each student for successful completion of thiscourse:
I. COMPETENCIESA. Resources: Identifies, organizes, plans, and allocates resources
1. allocates time to complete assigned tasks on schedule2. determines cost associated with meeting objectives
2(11A
3. determines and allocates required materials and resources for meetingobjectives
4. evaluates skills, performance, and quality of work and provides feedbackB. Interpersonal: Works with others
1. participates as a member of the team, contributing to group effort2. provides individual assistance/direction to peers as requested3. determines and meets internal and external customers' expectations4. exercises leadership qualities to effectively communicate ideas and make
decisions5. negotiates resources in order to accomplish objectives6. works well with all members of the classInformation: Acquires and uses information1. acquires and evaluates information2. organizes and maintains information3. interprets and communicates information
D. Systems: Understands complex inter-relationships1. understands and works well with social, organizational, and technological
systems2. monitors and corrects performance of system during operation3. recommend modifications to system to improve performance
E. Technology: Works with a variety of technologies1. chooses relevant procedures, tools and equipment2. applies appropriate procedures and techniques to accomplish tasks3. identifies or solves problems to maintain equipment
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. demonstrates basic reading skills including abilities to perceive main
ideas, draw appropriate conclusions, detect a sequence, locateanswers, find facts, and infer from written texts
b. demonstrates course specific reading skills including abilities toread, interpret, and comprehend information from text andsupplemental materials on a level to facilitate productiveindependent and group study
c. demonstrates ability to read, interpret, and utilize information fromcourse specific instruments (i.e., charts, diagrams, graphs,schematics, blueprints, flow charts, etc.)
d. demonstrates ability to read, interpret, and follow schedules andprocedural instructions in a timely and appropriate manner
e. demonstrates ability to choose and use most appropriate readingmethod (skim, scan, or read for comprehension) for materials
2. Writing: Communicates thoughts, ideas, information, and messages inwriting; and creates documents such as letters, directions, manuals,reports, graphs, and flow charts
201.
a. demonstrates basic writing skills including abilities to producewritten documents which conform with accepted grammatical andcommunication standards required for effective daily functioning
b. demonstrates effective written study skills including note taking,maintaining course specific journals, workbooks, manuals, etc.
c. demonstrates technical writing skills in preparing outlines,summaries, time lines, flow charts, diagrams, etc. appropriate tomaterials covered
d. demonstrates ability to complete all required writings in a timely,complete, and professional manner
e. demonstrates competence in subject matter through theorganization and presentation of answers to required writtenassessments
3. Arithmetic/Mathematics: Perform basic computations and approachespractical problems by choosing appropriately from a variety ofmathematical techniquesa. demonstrates proficiency in basic arithmetic functions including
ability to add, subtract, multiply, and divide whole numbers,fractions, decimals, and percents
b. demonstrates ability to read, comprehend, and select appropriatemath procedures to work basic math problems
c. demonstrates ability to understand and perform multi-stepcomputations
d. demonstrates ability to read, interpret, and use standard measuringdevices
e. demonstrates ability to comprehend, retain, and utilize coursespecific measuring devices effectively
f. demonstrates ability to understand, retain, and utilize highermathematical formulas and functions required for course specificmath performance
g. demonstrates ability to appropriately transfer mathematicalcalculations and information from paper to machines
4. Listening: Receives, attends to, interprets, and responds to verbalmessages and other cuesa. functions at minimal or above required hearing levels to receive,
attend, interpret, and respond to verbal messages and instructionsand to safely operate machinery
b. demonstrates ability to hear, comprehend, and appropriately followdirections
c. demonstrates auditory ability to hear, comprehend, and utilizeverbal classroom as well as other auditory instruction
d. demonstrates ability to discriminate between essential andnon-essential verbal information and react appropriately
e. demonstrates ability to focus and fine-tune listening skills toreceive, interpret, and respond to various sounds
f. demonstrates ability and maturity to seek and receive additionalindividualized instruction as needed
202
5. Speaking: Organizes ideas and communicates orallya. demonstrates appropriate listening and speaking skills in personal
conversationsb. demonstrates ability to choose and organize appropriate words to
effectively communicatec. demonstrates ability to speak clearly and distinctly with appropriate
volume, tone, and body language for situationd. demonstrates ability to spontaneously organize and present
appropriate answers and/or short presentations for classroom and/or assessment purposes
e. demonstrates ability to formulate, organize, and deliver majorpresentations to peers or groups
f. demonstrates ability to speak effectively in one-on-one, smallgroup, or large group presentations
g. demonstrates ability to take responsibility for presentationsB. 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. demonstrates ability to objectively assess personal strengths and
weaknessesb. demonstrates ability to set realistic short-term and long-term goalsc. demonstrates ability to recognize and distinguish between positive
and negative alternativesd. demonstrates ability to identify potential pitfalls and take evasive
actionse. demonstrates ability to objectively and responsibly evaluate
alternatives by testing hypotheses and selecting most appropriateresponse
f. demonstrates ability to profit from negative evaluations or mistakesby reformulating, redirecting, reconstructing, or retestingalternatives
g. demonstrates maturity to take responsibility for decisions2. Problem Solving: Recognizes problems and devises and implements plan
of actiona. demonstrates ability to detect problem through observation, inquiry,
or directiveb. demonstrates ability to grasp appropriate overview and degree of
seriousness of problem and to behave responsibly in situationc. demonstrates ability to generate alternatives or options for problem
solutiond. demonstrates ability to research options, assess and evaluate
options, and determine appropriate and best solutione. demonstrates ability to initiate and effect solutionf. demonstrates ability to take responsibility for outcomesg. demonstrates ability to effectively problem solve in individual, team,
or group situations
203
3. Seeing Things In the Mind's Eye: Organizes, and processes symbols,pictures, graphs, objects, and other informationa. functions at minimum or above required visual levels in order to
see, interpret, attend and respond to visual imagery and meet safetyrequirements for necessary machinery
b. demonstrates ability to read, interpret, and act upon signs, symbols,and other visual cues
c. demonstrates ability to visually discriminate in gross and fineimagery
d. demonstrates ability to visualize abstractlye. demonstrates ability to apply visual imagery to applied tasks
4. Knowing How to Learn: Use efficient learning techniques to acquire andapply new knowledge and skillsa. demonstrates mastery of basic reading, math, and language skills
through applicationb. demonstrates ability to translate abstract theory into practical
applicationc. demonstrates ability to incorporate and generalize new learning into
a sequential learning processd. demonstrates knowledge of good study skills and learning habits
5. Reasoning: Discovers a rule or principle underlying the relationshipbetween two or more objects and applies it when solving a problema. demonstrates use of simple logicb. demonstrates ability to distinguish relationshipsc. demonstrates ability to determine and isolate factors in relationshipsd. demonstrates and applies knowledge through practicee. recognizes that attitudes, skills, and practice are essential to
productivityf. demonstrates ability to discriminate between positive and negative,
and act accordinglyC. 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
attainmenta. demonstrates ability to formulate realistic and useful short and long
term goals and complete steps necessary to timely achieve goalsb. demonstrates ability to make adjustments, revisions, and changes to
achieve goals in a cooperative and polite mannerc. demonstrates ability to focus on task at hand and work to
completiond. demonstrates good work ethics through regular attendance,
adequate classroom preparations, and appropriate use of classroomtime
e. demonstrates maturity to take responsibility for actionsf. demonstrates ability to cooperatively work in individual, team, and
group situations in timely and effective manner
204
2. Self-Esteem: Believes in own self-worth and maintains a positive view ofselfa. presents a positive attitude toward tasksb. demonstrates ability to separate work and personal behaviorsc. actively participates in learning opportunities by sharing knowledge
and skills with peeri and instructorsd. demonstrates ability to accept personal strengths and weaknesses
and builds on positive behaviorse. demonstrates ability to accept and use constructive criticismf. accepts positive reinforcement in an appropriate manner
3. Sociability: Demonstrates understanding, friendliness, adaptability,empathy, and politeness in group settingsa. demonstrates appropriate and acceptable social behaviors in
classroom interactionsb. demonstrates ability to work cooperatively in individual, team, or
group situationsc. demonstrates active interest in peers by offering assistance, sharing
resources, and sharing knowledge in a professional and acceptablemanner
d. demonstrates professional work ethic by separating work andpersonal social behaviors and acting accordingly
4. Self-Management: Assesses self accurately, sets personal goals,monitors progress, and exhibits self-controla. accepts personal strengths and weaknesses and uses the same for
positive advancementb. demonstrates ability to continuously set, assess, choose, and modify
objectives as the situation demands in an appropriate mannerc. demonstrates ability to formulate and follow personal schedulesd. demonstrates ability to wisely use classroom timee. demonstrates use of good study habits and skillsf. demonstrates maturity to take responsibility for own actions
5. Integrity/Honesty: Chooses ethical courses of actiona. knows and demonstrates ability to distinguish between positive and
negative behaviorsb. demonstrates honesty and integrity in working with peers and
supervisorsc. takes full responsibility for personal actionsd. demonstrates understanding of consequences for negative ethical
behaviors and accepts responsibility for same when applicablee. demonstrates positive work and social ethics in undertakings
Appropriate Reference Materials:1. Machinery's Handbook, Industrial Press2. Pie Design Fundamentals, J. R. Pacquin and R.E. Crowley, 2nd Ed.
TDT 2174011081496
205
Machine Tool Advanced SkillsTechnology Program
COURSE SYLLABUS
COMPUTER NUMERICAL CONTROLOPERATIONS III
Prerequisite: COMPUTER NUMERICAL CONTROL OPERATIONS II
206
MAST PROGRAMCOURSE SYLLABUS
COMPUTER NUMERICAL CONTROL OPERATIONS III
Lecture hours/week: 2
COURSE DESCRIPTION:
Lab hours/week: 3 Credit hours: 3
This course is a continuation of CNC Operations I and II with additional instruction and practicein the use of the Computer-Aided Manufacturing (CAM) system for creation of code. Also, thestudent will be introduced to the Wire Electrical Discharge Machine (EDM) and the CoordinateMeasuring Machine (CMM).
PREREQUISITES: Computer Numerical Control Operations II
REQUIRED COURSE MATERIALS:
Textbook: An Introduction to CNC Machining and Programming, David Gibbsand Thomas M. Crandell, Industrial Press
Lab Manual: Instructor Provided Materials
Hand Tools/Quantity Required:Safety Glasses6 inch Ruler
METHOD OF INSTRUCTION:
1 pair1/8, 1/16, 1/32, and 1/64 inch
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 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 Topics Text Reference Page Contact Hrs.
Safety with CNC EquipmentOverview of CAM System 334-435, HOCreating Geometric Elements
and Toolpath 334-351, HOMacros and Automated Roughing
Commands HandoutPostprocessors and Creating Code HandoutImporting CAD Data into CAM
System HandoutIntroduction to Electrical Discharge
Machining HandoutSetup and Operation of the Wire
EDM HandoutProgramming the Wire EDM HandoutOperation of the Coordinate
Measuring Machine (CMM) HandoutQuality Systems and Reverse
Engineering HandoutTotal Lecture Hours 32
LAB OUTLINE:Lab Topics Contact Hrs.
CNC Machines and Safety 1
Installing, Configuring and Modules of CAM System 3Creating Toolpath with CAM System 6Project (Lathe Part) 3
Project (Mill Part) 3
Project (Create and Import CAD File to Create Code) 2Operation of Wire EDM 4Project (Die Block) 4Project (Pinion Gear) 4Project (Die Block with Compound Angles) 6Operation of CMM 6Project (Measure Die Block and Compile Data) 6
Total Lab Hours 32
COURSE OBJECTIVES: TECHNICAL COMPETENCIES
After the successful completion of this course the student will be able to:A. PRACTICE SAFETY
1. Follow Safety Manuals and All Safety Regulations/ Requirementsa. Comply with established company and OSHA regulationsb. Interpret safety manual directives
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c. Wear safety/protective equipment as required2. Maintain Safe Equipment and Machinery
a. Maintain equipment/tooling in safe operating conditionb. Maintain all guards, shields, and barriers in place and in good conditionc. Perform preventive maintenance as requiredd. Practice proper tag-out/lock-out procedures
3. Maintain a Clean and Safe Work Environmenta. Keep work areas clean and free of debrisb. Keep aisles/traffic areas clear of equipment and materialsc. Store materials, tools, and instruments in organized mannerd. Clean machine/hand tools when work is complete
4. Use Safe Operating Procedures for Hand and Machine Toolsa. Use tools for intended purposes onlyb. Acquire proper training/authorization before operating equipmentc. Operate hand and machine tools in safe mannerd. Comply with manufacturer's rated capacity for equipmente. Ensure all rotating or moving parts have stopped before leaving areaf. Inspect for and remove possible hazards before engaging equipment
5. Use Safe Machining Practicesa. Ensure stock/tooling is secure before machiningb. Use chip control methodsc. Use moderate, safe, and calculated speeds and feedsd. Stay alert and prepared to act during machininge. Ensure rotating parts/tooling are completely stopped before handling
6. Use Safe Lifting Practicesa. Use lifting aids when necessaryb. Use OSHA approved chains, straps, and hoistsc. Comply with rated capacity of lifting equipmentd. Comply with company/OSHA regulations regarding lifting procedures
7. Consult and Apply MSDS for Hazards of Various Materialsa. Know format of material safety data sheetsb. Consult and interpret MSDS to determine relevant hazards of materialc. Apply information and take precautionary measures against hazardsd. Notify proper authorities of hazards
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 decimalsd. Interconvert fractions/decimalse. Interconvert metric/English measurements
2. Perform Basic Algebraic Operationsa. Evaluate equation using standard algebraic hierarchyb. Solve equations with one unknown variablec. Solve ratio/percentage problemsd. Calculate and apply formulas
3. Perform Basic Trigonometric Functionsa. Solve for unknown sides/angles of right triangles using trigonometric
20t)
functionsb. Solve for unknown side of right triangle using Pythagorean's Theorem
4. Use and Apply Cartesian Coordinate Systema. Define the Cartesian coordinate systemb. Calculate coordinates of bolt circle on Cartesian coordinate systemc. Plot machining points using Cartesian coordinate system
C. DEMONSTRATE QUALITY CONTROL AND MANAGEMENT1. Utilize Appropriate Inspection Techniques
a. Discuss factors that affect accurate measurementb. Determine proper procedure to acquire accurate measurementc. Determine proper instrument to use in measurement
2. Perform Appropriate Use and Calibration of Inspection Equipmenta. Explain calibration requirements of various precision instrumentsb. Maintain/care for instruments for optimum performancec. Read and use 0.D., I.D., and depth micrometersd. Read and use vernier, dial, & digital caliperse. Read and use scale and tape measuref. Read and use dial-bore indicatorsg. Use dial indicatorsh. Use precision square and combination seti. Read and use digital read-outj. Use finish/profile gagesk. Use Rockwell hardness tester1. Use surface plates
3. Know Qualitative Parameters of Machinery and Equipmenta. Differentiate between types of machinery by qualitative capabilitiesb. Select appropriate processes to maintain desired tolerancesc. Discuss the effect one process might have on an earlier or later process
4. Maintain Equipment to Produce Quality Partsa. Justify tooling by qualitative requirementsb. Protect/maintain critical surfaces of machinesc. Perform preventive maintenance on equipment
5. Know and Use Quality Systemsa. Know and use ISO 9000 concepts and proceduresb. Know and use Statistical Process Control (SPC) techniques and concepts
6. Write Inspection Proceduresa. Determine/designate proper inspection techniqueb. Determine/designate precautions to take during inspectionc. Determine/design inspection jig or fixture requiredd. List in order and define steps required to ensure accurate measurement
7. Document Inspection Resultsa. Define procedure used during inspectionb. Accurately document measurements taken and compare to standardc. Determine/document if part passes or fails inspectiond. Determine/document rework or scrap recommendations
D. DEMONSTRATE KNOWLEDGE OF MANUFACTURING MATERIALS1. Demonstrate Knowledge of Physical Properties of Materials
a. Define hardness
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b. Define toughness2. Identify Manufacturing Properties of Materials
a. Discuss machinability of various materialsb. Define work hardening/edge hardening
E. DEMONSTRATE KNOWLEDGE OF MANUFACTURING PROCESSES1. Know Operation of Vertical and Horizontal Mills and Tooling
a. Define milling machines, horizontal and verticalb. List, describe, and give function and maintenance of different types of
tooling used on milling machinesc. Set-up and operate horizontal and vertical milling machined. Explain machine components and accessories of milling machinese. Explain milling processesf. Discuss milling machine safetyg. Discuss CNC machining centers and processesh. Calculate speeds and feeds based on materials and toolingi. Set-up and operate CNC machining center
2. Know Operation of Engine and Turret Lathes and Toolinga. Define lathes, engine and turretb. List, describe, and give function and maintenance of various types of
tooling used on lathesc. Set-up and operate engine and turret lathesd. Explain machine components and accessories of lathese. Explain turning processesf. Discuss lathe safetyg. Discuss CNC turning centers and processesh. Calculate speeds and feeds based on materials and toolingi. Set-up and operate CNC turning center
3. Know Operation of Drill Presses and Toolinga. Identify types of drilling machinesb. List, describe, and give function and maintenance of various types of
tooling used on drilling machinesc. Set-up and operate drilling machinesd. Explain machine components and accessories of drilling machinese. Explain processes performed on drilling machinesf. Discuss drilling safetyg. Discuss drilling operations on CNC drilling machinesh. Calculate speeds and feeds based on materials and toolingi. Set-up and operate CNC drilling machine
4. Know Operation of Wire EDMa. Define EDMb. Explain EDM processc. Set-up and operate CNC wire EDMd. Discuss EDM safetye. Calculate E-pac value for wire EDMf. Explain machine components and accessories of wire EDM
5. Estimate Time Required/Cost to Produce a Parta. Determine processes required to produce partb. Calculate actual machining and handling time
c. Calculate material quantity and costd. Calculate labor and overhead cost
6. Know Proper Flow of Parts Through Shopa. Discuss proper order of processesb. Discuss ergonomic aspects of plant layout
7. Utilize Concepts and Principles of Fixturinga. Determine need for fixture/jigb. Design appropriate fixture/jigc. Identify components used in fixtures/jigsd. Disassemble and assemble fixture/jige. Discuss relationship between accuracy of fixture and accuracy/
repeatability of partsF. PERFORM CNC PROGRAMMING/CAM TASKS
1. Prepare and Plan for CNC Machining Operationsa. Plan sequence of machining eventsb. Determine proper tooling/fixtures required for machiningc. Calculate speeds, feeds, and depth-of-cut for machiningd. Explain the x, y, and z axis on CNC machines
2. Select and Use Tooling Systems for CNC Machinesa. Understand machinability and chip formationb. Select proper insert materials and geometryc. Select proper tooling systemd. Define and discuss application of HSS, carbide, and borazon cutting tools
3. Manually Program CNC Machinesa. Plan and write programs for CNC machinesb. Use MDI panel on machine to program/edit programsc. Set and use tooling offsets at CNC machined. Discuss/use canned or bar cycles in program
4. Use Computer-Aided Manufacturing (CAM) Systema. Create toolpath geometry using CAM systemb. Interconvert CAD and CAM files using acceptable exchange formatc. Transfer files from CAM system to machined. Configure CAM system parameters
G. DEMONSTRATE COMMUNICATION SKILLS1. Use Written Correspondence
a. Read, write, interpret, and apply memorandumsb. Read, write, interpret, and apply business lettersc. Read, write, interpret, and apply written instructions
2. Use Written Technical Informationa. Read, write, interpret, and apply technical reportsb. Read, write, interpret, and apply written proceduresc. Read, write, interpret, and apply technical manuals
3. Communicate Technical Information Verballya. Demonstrate ability to listen to and understand verbal technical
information/instructionsb. Ask appropriate questions to ascertain needed informationc. Demonstrate ability to give verbal technical information/instructions
4. Use Graphics for Visual Aid
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a. Create, read, and apply graphsb. Create, read, and apply chartsc. Create, read, and apply graphical illustrations
H. PERFORM DRAFTING/CAD TASKS1. Demonstrate Traditional Mechanical Drafting Skills
a. List and apply the three primary planes of projectionb. List and apply the six principle viewsc. Use and apply auxiliary viewsd. Create/use sectional views
2. Use Computer-Aided Drafting (CAD) Systema. Create geometry using CAD systemb. Create 3-D solid modelsc. Interconvert CAD and accepted drawing exchange formatsd. Use peripheral devices
I. USE COMPUTERS1. Use Computer Operating Systems
a. Explain the phrase "IBM compatible"b. Use DOS operating system/DOS commandsc. Use Windowsd. Use computer network system
2. Use File Management Systemsa. Discuss file management conceptsb. Create/remove directoriesc. Copy files from floppy disks to hard drive
3. Install/Use Software Packagesa. Install software package to hard diskb. Configure system parameters for software package
4. Understand and Apply Computer Terminologya. Define Read Only Memory (ROM)b. Define Random Access Memory (RAM)c. Define byte, kilobyte, megabyted. Define Central Processing Unit (CPU)e. Discuss processor speedf. Understand RS-232 protocol
J. INTERPRET/USE BLUEPRINTS AND RELATED DOCUMENTS1. Interpret, Review, and Apply Blueprint Notes, Dimensions, and Tolerances
a. Distinguish between general and specific notesb. Interpret and apply general and specific notesc. Determine and apply dimensions on a drawingd. Identify basic symbols found on a drawinge. Identify tolerances on a drawingf. Discuss GD&T methodology
2. Interpret and Understand Basic Layout/Types of Drawingsa. Identify types of drawingsb. Identify parts of a drawing and list components of eachc. Identify types of lines on a drawingd. List and describe the different views found on a drawing
3. Understand and Analyze Bill-of-Materials
a. Determine materials requiredb. Determine quantities requiredc. Identify item symbol and/or part number
4. Ascertain Job Requirements from Drawingsa. Interpret part requirementsb. Identify surfaces to be machinedc. Determine critical dimensions
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 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.
The following activities will be performed by each student for successful completion of thiscourse:
I. COMPETENCIESA. Resources: Identifies, organizes, plans, and allocates resources
1. allocates time to complete assigned tasks on schedule2. determines cost associated with meeting objectives3. determines and allocates required materials and resources for meeting
objectives4. evaluates skills, performance, and quality of work and provides feedback
B. Interpersonal: Works with others1. participates as a member of the team, contributing to group effort2. provides individual assistance/direction to peers as requested3. determines and meets internal and external customers' expectations4. exercises leadership qualities to effectively communicate ideas and make
decisions5. negotiates resources in order to accomplish objectives6. works well with all members of the classInformation: Acquires and uses information1. acquires and evaluates information2. organizes and maintains information3. interprets and communicates information
D. Systems: Understands complex inter-relationships1. understands and works well with social, organizational, and technological
systems2. monitors and corrects performance of system during operation3. recommend modifications to system to improve performance
E. Technology: Works with a variety of technologies1. chooses relevant procedures, tools and equipment
2. applies appropriate procedures and techniques to accomplish tasks3. identifies or solves problems to maintain equipment
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. demonstrates basic reading skills including abilities to perceive main
ideas, draw appropriate conclusions, detect a sequence, locateanswers, find facts, and infer from written texts
b. demonstrates course specific reading skills including abilities toread, interpret, and comprehend information from text andsupplemental materials on a level to facilitate productiveindependent and group study
c. demonstrates ability to read, interpret, and utilize information fromcourse specific instruments (i.e., charts, diagrams, graphs,schematics, blueprints, flow charts, etc.)
d. demonstrates ability to read, interpret, and follow schedules andprocedural instructions in a timely and appropriate manner
e. demonstrates ability to choose and use most appropriate readingmethod (skim, scan, or read for comprehension) for materials
2. Writing: Communicates thoughts, ideas, information, and messages inwriting; and creates documents such as letters, directions, manuals,reports, graphs, and flow chartsa. demonstrates basic writing skills including abilities to produce
written documents which conform with accepted grammatical andcommunication standards required for effective daily functioning
b. demonstrates effective written study skills including note taking,maintaining course specific journals, workbooks, manuals, etc.
c. demonstrates technical writing skills in preparing outlines,summaries, time lines, flow charts, diagrams, etc. appropriate tomaterials covered
d. demonstrates ability to complete all required writings in a timely,complete, and professional manner
e. demonstrates competence in subject matter through theorganization and presentation of answers to required writtenassessments
3. Arithmetic/Mathematics: Perform basic computations and approachespractical problems by choosing appropriately from a variety ofmathematical techniquesa. demonstrates proficiency in basic arithmetic functions including
ability to add, subtract, multiply, and divide whole numbers,fractions, decimals, and percents
b. demonstrates ability to read, comprehend, and select appropriatemath procedures to work basic math problems
c. demonstrates ability to understand and perform multi-stepcomputations
n A
d. demonstrates ability to read, interpret, and use standard measuringdevices
e. demonstrates ability to comprehend, retain, and utilize coursespecific measuring devices effectively
f. demonstrates ability to understand, retain, and utilize highermathematical formulas and functions required for course specificmath performance
g. demonstrates ability to appropriately transfer mathematicalcalculations and information from paper to machines
4. Listening: Receives, attends to, interprets, and responds to verbalmessages and other cuesa. functions at minimal or above required hearing levels to receive,
attend, interpret, and respond to verbal messages and instructionsand to safely operate machinery
b. demonstrates ability to hear, comprehend, and appropriately followdirections
c. demonstrates auditory ability to hear, comprehend, and utilizeverbal classroom as well as other auditory instruction
d. demonstrates ability to discriminate between essential andnon-essential verbal information and react appropriately
e. demonstrates ability to focus and fine-tune listening skills toreceive, interpret, and respond to various sounds
f. demonstrates ability and maturity to seek and receive additionalindividualized instruction as needed
5. Speaking: Organizes ideas and communicates orallya. demonstrates appropriate listening and speaking skills in personal
conversationsb. demonstrates ability to choose and organize appropriate words to
effectively communicatec. demonstrates ability to speak clearly and distinctly with appropriate
volume, tone, and body language for situationd. demonstrates ability to spontaneously organize and present
appropriate answers and/or short presentations for classroom and/or assessment purposes
e. demonstrates ability to formulate, organize, and deliver majorpresentations to peers or groups
f demonstrates ability to speak effectively in one-on-one, smallgroup, or large group presentations
g. demonstrates ability to take responsibility for presentationsB. 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. demonstrates ability to objectively assess personal strengths and
weaknessesb. demonstrates ability to set realistic short-term and long-term goalsc. demonstrates ability to recognize and distinguish between positive
and negative alternatives
d. demonstrates ability to identify potential pitfalls and take evasiveactions
e. demonstrates ability to objectively and responsibly evaluatealternatives by testing hypotheses and selecting most appropriateresponse
f. demonstrates ability to profit from negative evaluations or mistakesby reformulating, redirecting, reconstructing, or retestingalternatives
g. demonstrates maturity to take responsibility for decisions2. Problem Solving: Recognizes problems and devises andimplements plan
of actiona. demonstrates ability to detect problem through observation, inquiry,
or directiveb. demonstrates ability to grasp appropriate overview and degree of
seriousness of problem and to behave responsibly in situationc. demonstrates ability to generate alternatives or options for problem
solutiond. demonstrates ability to research options, assess and evaluate
options, and determine appropriate and best solutione. demonstrates ability to initiate and effect solutionf. demonstrates ability to take responsibility for outcomesg. demonstrates ability to effectively problem solve in individual, team,
or group situations3. Seeing Things In the Mind's Eye: Organizes, and processes symbols,
pictures, graphs, objects, and other informationa. functions at minimum or above required visual levels in order to .
see, interpret, attend and respond to visual imagery and meet safetyrequirements for necessary machinery
b. demonstrates ability to read, interpret, and act upon signs, symbols,and other visual cues
c. demonstrates ability to visually discriminate in gross and fineimagery
d. demonstrates ability to visualize abstractlye. demonstrates ability to apply visual imagery to applied tasks
4. Knowing How to Learn: Use efficient learning techniques to acquire andapply new knowledge and skillsa. demonstrates mastery of basic reading, math, and language skills
through applicationb. demonstrates ability to translate abstract theory into practical
applicationc. demonstrates ability to incorporate and generalize new learning into
a sequential learning processd. demonstrates knowledge of good study skills and learning habits
5. Reasoning: Discovers a rule or principle underlying the relationshipbetween two or more objects and applies it when solving a problema. demonstrates use of simple logicb. demonstrates ability to distinguish relationshipsc. demonstrates ability to determine and isolate factors in relationships
217
d. demonstrates and applies knowledge through practicee. recognizes that attitudes, skills, and practice are essential to
productivityf. demonstrates ability to discriminate between positive and negative,
and act accordinglyPersonal Qualities: Displays responsibility, self-esteem, sociability, self-management, and integrity and honesty./. Responsibility: Exerts a high level of effort and perseveres towards goal
attainmenta. demonstrates ability to formulate realistic and useful short and long
term goals and complete steps necessary to timely achieve goalsb. demonstrates ability to make adjustments, revisions, and changes to
achieve goals in a cooperative and polite mannerc. demonstrates ability to focus on task at hand and work to
completiond. demonstrates good work ethics through regular attendake,
adequate classroom preparations, and appropriate use of classroomtime
e. demonstrates maturity to take responsibility for actionsf. demonstrates ability to cooperatively work in individual, team, and
group situations in timely and effective manner2. Self-Esteem: Believes in own self-worth and maintains a positive view of
selfa. presents a positive attitude toward tasksb. demonstrates ability to separate work and personal behaviorsc. actively participates in learning opportunities by sharing knowledge
and skills with peers and instructorsd. demonstrates ability to accept personal strengths and weaknesses
and builds on positive behaviorse. demonstrates ability to accept and use constructive criticismf. accepts positive reinforcement in an appropriate manner
3. Sociability: Demonstrates understanding, friendliness, adaptability,empathy, and politeness in group settingsa. demonstrates appropriate and acceptable social behaviors in
classroom interactionsb. demonstrates ability to work cooperatively in individual, team, or
group situationsc. demonstrates active interest in peers by offering assistance, sharing
resources, and sharing knowledge in a professional and acceptablemanner
d. demonstrates professional work ethic by separating work andpersonal social behaviors and acting accordingly
4. Self-Management: Assesses self accurately, sets personal goals,monitors progress, and exhibits self-controla. accepts personal strengths and weaknesses and uses the same for
positive advancementb. demonstrates ability to continuously set, assess, choose, and modify
objectives as the situation demands in an appropriate manner
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c. demonstrates ability to formulate and follow personal schedulesd. demonstrates ability to wisely use classroom timee. demonstrates use of good study habits and skillsf. demonstrates maturity to take responsibility for own actions
5. Integrity/Honesty: Chooses ethical courses of actiona. knows and demonstrates ability to distinguish between positive and
negative behaviorsb. demonstrates honesty and integrity in working with peers and
supervisorsc. takes full responsibility for personal actionsd. demonstrates understanding of consequences for negative ethical
behaviors and accepts responsibility for same when applicablee. demonstrates positive work and social ethics in undertakings
Appropriate Reference Materials:1. Machinery's Handbook, Industrial Press2. Machine Tool Practices, Kibbe, Neely, and Meyer, Wiley Pub., 4th Ed.3. Technology of Machine Tools, Krar, Oswald, St. Amand, McGraw-Hill., 4th Ed.4. Student's Shop Reference Handbook, Edward Hoffman, Industrial Press
MST 273303/011496
Machine Tool Advanced SkillsTechnology Program
COURSE SYLLABUS
SPECIAL PROJECTPrerequisite: DIE MAKING II
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MAST PROGRAMCOURSE SYLLABUSSPECIAL PROJECT
Lecture hours/week: 1
COURSE DESCRIPTION:
Lab hours/week: 4 Credit hours: 3
This course is designed to provide the student with practical application of skills and knowledgegained through other courses in the Tool and Die Technology Program. Students will applymaterial learned in previous and concurrent classes to design, produce, and test an industrialquality die. Emphasis is placed on the student making decisions, setting priorities and time lines,and realizing the overall responsibility of producing a quality product in a given amount of time.
PREREQUISITES: Die Making II
REQUIRED COURSE MATERIALS:
Textbook: Basic Diemaking, D. Eugene Ostergaard, McGraw-Hill
Hand Tools/Quantity Required:Safety Glasses6 inch Ruler
METHOD OF. INSTRUCTION:
1 pair1/8, 1/16, 1/32, and 1/64 grad.
Lecture: Didactic presentations will include lecture, video and demonstrations.
Laboratory: Laboratory will be a "hands-on" 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 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 Topics Text Reference Page Contact Hrs.
Introduction and SafetyAssignment of ProjectInstructor Assistance as Needed
LAB OUTLINE:
Handout
Total Lecture Hours 16
Lab TopicsOrientation and SafetyProject (Design of Progressive Die)Project (Fabrication of Die)Tryout of Die
Total Lab Hours
COURSE OBJECTIVES: TECHNICAL COMPETENCIES
Contact Hrs.1
950
464
After the successful completion of this course the student will be able to:A. PRACTICE SAFETY
1. Follow Safety Manuals and All Safety Regulations/Requirementsa. Comply with established company and OSHA regulationsb. Interpret safety manual directivesc. Wear safety/protective equipment as required
2. Maintain Safe Equipment and Machinerya. Maintain equipment/tooling in safe operating conditionb. Maintain all guards, shields, and barriers in place and in good conditionc. Perform preventive maintenance as requiredd. Practice proper tag-out/lock-out procedures
3. Maintain a Clean and Safe Work Environmenta. Keep work areas clean and free of debrisb. Keep isles/traffic areas clear of equipment and materialsc. Store materials, tools, and instruments in organized mannerd. Clean machine/hand tools when work is complete
4. Use Safe Operating Procedures for Hand and Machine Toolsa. Use tools for intended purposes onlyb. Acquire proper training/authorization before operating equipmentc. Operate hand and machine tools in safe mannerd. Comply with manufacturer's rated capacity for equipmente. Ensure all rotating or moving parts have stopped before leaving areaf. Inspect for and remove possible hazards before engaging equipment
5. Use Safe Machining Practicesa. Ensure stock/tooling is secure before machiningb. Use chip control methodsc. Use moderate, safe, and calculated speeds and feeds
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d. Stay alert and prepared to act during machininge. Ensure rotating parts/tooling are completely stopped before handling
6. Use Safe Lifting Practicesa. Use lifting aids when necessaryb. Use OSHA approved chains, straps, and hoistsc. Comply with rated capacity of lifting equipmentd. Comply with company/OSHA regulations regarding lifting procedures
7 Consult and Apply MSDS for Hazards of Various Materialsa. Know format of material safety data sheetsb. Consult and interpret MSDS to determine relevant hazards of materialc. Apply information and take precautionary measures against hazardsd. Notify proper authorities of hazards
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 decimalsd. Interconvert fractions/decimalse. Interconvert metric/English measurements
2. Perform Basic Algebraic Operationsa. Evaluate equation using standard algebraic hierarchyb. Solve equations with one unknown variablec. Solve ratio/percentage problemsd. Calculate and apply formulas
3. Perform Basic Trigonometric Functionsa. Solve for unknown sides/angles of right triangles using trigonometric
functionsb. Solve for unknown side of right triangle using Pythagorean's Theorem
4. Use and Apply Cartesian Coordinate Systema. Define the Cartesian coordinate systemb. Calculate coordinates of bolt circle on Cartesian coordinate systemc. Plot machining points using Cartesian coordinate system
C. DEMONSTRATE QUALITY CONTROL AND MANAGEMENT1. Utilize Appropriate Inspection Techniques
a. Discuss factors that affect accurate measurementb. Determine proper procedure to acquire accurate measurementc. Determine proper instrument to use in measurement
2. Perform Appropriate Use and Calibration of Inspection Equipmenta. Explain calibration requirements of various precision instrumentsb. Maintain/care for instruments for optimum performancec. Read and use 0.D., I.D., and depth micrometersd. Read and use vernier, dial, & digital caliperse. Read and use scale and tape measuref. Read and use dial-bore indicatorsg. Use dial indicatorsh. Use precision square and combination seti. Read and use digital read-out
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j. Use finish/profile gagesk. Use Rockwell hardness tester1. Know operation of coordinate measuring machine (CMM)m. Use surface plates
3. Know Qualitative Parameters of Machinery and Equipmenta. Differentiate between types of machinery by qualitative capabilitiesb. Select appropriate processes to maintain desired tolerancesc. Discuss the effect one process might have on an earlier or later process
4. Maintain Equipment to Produce Quality Partsa. Justify tooling by qualitative requirementsb. Protect/maintain critical surfaces of machinesc. Perform preventive maintenance on equipment
5. Know and Use Quality Systemsa. Know and use ISO 9000 concepts and proceduresb. Know and use Statistical Process Control (SPC) techniques and concepts
6. Write Inspection Proceduresa. Determine/designate proper inspection techniqueb. Determine/designate precautions to take during inspectionc. Determine/design inspection jig or fixture requiredd. List in order and define steps required to ensure accurate measurement
7. Document Inspection Resultsa. Define procedure used during inspectionb. Accurately document measurements taken and compare to standardc. Determine/document if part passes or fails inspectiond. Determine/document rework or scrap recommendations
D. DEMONSTRATE KNOWLEDGE OF MANUFACTURING MATERIALS1. Identify Materials with Desired Properties
a. Determine/identify service requirements (strength, hardness, etc.)b. Determine, interpret, and evaluate availability of materialsc. Describe general characteristics of various metalsd. Know concepts of/calculate statics and stresses
2. Demonstrate Knowledge of Physical Properties of Materialsa. Define hardnessb. Define toughnessc. Define tensile strengthd. Define shear strengthe. Define elasticityf. Define ductility
g. Discuss the Rockwell and Brinell hardness scalesh. Discuss the Charpy/Izod impact tests
3. Identify Manufacturing Properties of Materialsa. Discuss machinability of various materialsb. Discuss cold forming/workability of various materialsc. Define work hardening/edge hardeningd. Identify welding properties of various materialse. Demonstrate knowledge of heat treating procedures and propertiesf. Know stress relieving procedures
g. Know/Find hardness characteristics and chemistry of various materials4. Discuss Classification System for Metals
a. Identify and discuss types of carbon steelb. Determine chemistry of material by classificationc. Distinguish between SAE and AISI classification systemsd. Identify designation of each digit of steel classificatione. Discuss alloy steels
E. DEMONSTRATE KNOWLEDGE OF MANUFACTURING PROCESSES1. Know Operation of Vertical and Horizontal Mills and Tooling
a. Define milling machines, horizontal and verticalb. List, describe, and give function and maintenance of different types of
tooling used on milling machinesc. Set-up and operate horizontal and vertical milling machined. Explain machine components and accessories of milling machinese. Explain milling processesf. Discuss milling machine safetyg. Discuss CNC machining centers and processesh. Calculate speeds and feeds based on materials and toolingi. Set-up and operate CNC machining center
2. Know Operation of Engine and Turret Lathes and Toolinga. Define lathes, engine and turretb. List, describe, and give function and maintenance of various types of
tooling used on lathesc. Set-up and operate engine and turret lathesd. Explain machine components and accessories of lathese. Explain turning processesf. Discuss lathe safetyg. Discuss CNC turning centers and processesh. Calculate speeds and feeds based on materials and toolingi. Set-up and operate CNC turning center
3. Know Operation of Drill Presses and Toolinga. Identify types of drilling machinesb. List, describe, and give function and maintenance of various types of
tooling used on drilling machinesc. Set-up and operate drilling machinesd. Explain machine components and accessories of drilling machinese. Explain processes performed on drilling machinesf. Discuss drilling safetyg. Discuss drilling operations on CNC drilling machinesh. Calculate speeds and feeds based on materials and toolingi. Set-up and operate CNC drilling machine
4. Know Operation of Surface and Cylindrical Grindersa. Define grinders, surface and cylindricalb. Explain types and maintenance of grinding wheelsc. Set-up and operate grinding machinesd. Explain machine components and accessories of grinding machinese. Explain grinding processes
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f Discuss grinding safety5. Know Operation of Heat Treating Equipment and Processes
a. Describe types of heat treating equipmentb. Set-up and operate heat treating equipmentc. Explain machine components and accessories of heat treating equipmentd. Explain heat treating procedurese. Discuss heat treating safety
6. Know Operation of Welding Equipment and Processesa. Identify various types of welding equipmentb. Identify and discuss the difference in welding processesc. Inspect welds for cracks and penetrationd. Discuss welding safety
7. Know Sheet Metal Operationsa. Discuss gas/plasma cutting equipment and processesb. Discuss operation of punch/brake presses and toolingc. Discuss operation of plate shearsd. Calculate tonnages required for press/shear operationse. Calculate blank dimensions of developed partsf. Use yield tables for bending sheet metalg. Discuss fabrication of sheet metal partsh. Demonstrate layout-on-metali. Apply conservation-of-material concepts
8. Know Operation of Jig-boring Machines and Toolinga. Define jig-boring machineb. List, describe, and give function and maintenance of different types of
tooling used on jig-boring machinesc. Set-up and operate jig-boring machined. Explain machine components and accessories of jig-boring machinese. Explain jig-boring processf. Discuss safety on jig-boring machineg. Calculate speeds and feeds based on materials and tooling
9. Know Operation of Tool and Cutter Grindersa. Define tool/cutter grinderb. Discuss dressing and maintenance of grinding wheelsc. Explain machine components and accessories of tool/cutter grinderd. Discuss tool and cutter grinder safety
10. Know Operation of Metal Sawsa. Define band saw, horizontal and verticalb. Set-up and operate band sawc. Define abrasive cut-off sawd. Set-up and operate abrasive cut-off sawe. Discuss application of the different tooth forms, pitch sets, and gages of
band saw bladesf. Weld and maintain band saw blade
g. Discuss band saw safetyh. Calculate speeds and feeds based on materials and toolingi. Explain machine components and accessories of band saws
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j. Calculate proper length of band saw blade11. Know Operation of Wire EDM
a. Define EDMb. Explain EDM processc. Set-up and operate CNC wire EDMd. Discuss EDM safetye. Calculate E-pac value for wire EDMf. Explain machine components and accessories of wire EDM
12. Estimate Time Required/Cost to Produce a Parta. Determine processes required to produce partb. Calculate actual machining and handling timec. Calculate material quantity and costd. Calculate labor and overhead cost
13. Know Proper Flow of Parts Through Shopa. Discuss proper order of processesb. Discuss ergonomic aspects of plant layout
14. Utilize Concepts and Principles of Fixturinga. Determine need for fixture/jigb. Design appropriate fixture/jigc. Identify components used in fixtures/jigsd. Disassemble and assemble fixture/jige. Discuss relationship between accuracy of fixture and accuracy/repeatability
of parts15. Make Calculations for and Use Sine Bar/Sine Plate
a. Define sine bar/sine plateb. Calculate gage block buildup for sine bar/sine platec. Set-up and use sine bar/sine plate
16. Make Calculations for and Use Rotary Table and Dividing Heada. Set-up and use rotary table/dividing head for machining operationsb. Make calculations for number of rotations requiredc. Determine/select appropriate index plate for dividing head
F. PERFORM CNC PROGRAMMING/CAM TASKS1. Prepare and Plan for CNC Machining Operations
a. Plan sequence of machining eventsb. Determine proper tooling/fixtures required for machiningc. Calculate speeds, feeds, and depth-of-cut for machiningd. Explain the x, y, and z axis on CNC machines
2. Select and Use Tooling Systems for CNC Machinesa. Understand machinability and chip formationb. Select proper insert materials and geometryc. Select proper tooling systemd. Define and discuss application of HSS, carbide, and borazon cutting tools
3. Manually Program CNC Machinesa. Plan and write programs for CNC machinesb. Use MDI panel on machine to program/edit programsc. Set and use tooling offsets at CNC machined. Discuss/use canned or bar cycles in program
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4. Use Computer-Aided Manufacturing (CAM) Systema. Create toolpath geometry using CAM systemb. Interconvert CAD and CAM files using acceptable exchange formatc. Transfer files from CAM system to machined. Configure CAM system parameters
G. DEMONSTRATE COMMUNICATION SKILLS1. Use Written Correspondence
a. Read, write, interpret, and apply memorandumsb. Read, write, interpret, and apply business lettersc. Read, write, interpret, and apply written instructions
2. Use Written Technical Informationa. Read, write, interpret, and apply technical reportsb. Read, write, interpret, and apply written proceduresc. Read, write, interpret, and apply technical manuals
3. Communicate Technical Information Verballya. Demonstrate ability to listen to and understand verbal technical
information/instructionsb. Ask appropriate questions to ascertain needed informationc. Demonstrate ability to give verbal technical information/instructions
4. Use Graphics for Visual Aida. Create, read, and apply graphsb. Create, read, and apply chartsc. Create, read, and apply graphical illustrations
H. PERFORM DRAFTING/CAD TASKS1. Demonstrate Traditional Mechanical Drafting Skills
a. Demonstrate use of drafting machine and instrumentsb. Demonstrate drafting technique to create basic geometric elementsc. Demonstrate isometric sketching of objectsd. List and apply the three primary planes of projectione. List and apply the six principle viewsf. Use and apply auxiliary views
g. Create sectional views2. Use Computer-Aided Drafting (CAD) System
a. Create geometry using CAD systemb. Create 3-D solid models.c. Interconvert CAD and accepted drawing exchange formatsd. Use peripheral devices
3. Use and Apply Geometric Dimensioning and Tolerancing (GD&T) Methodologya. Distinguish between conventional and geometric dimensioning and
tolerancing.b. Explain and use geometric positional tolerancingc. Explain and use tolerances of formd. Explain and use the feature control symbole. Explain and use modifiers in geometric dimensioning and tolerancing
I. USE COMPUTERS1. Use Computer Operating Systems
a. Use Windows
b. Use computer network system2. Use File Management Systems
a. Discuss file management conceptsb. Create/remove directoriesc. Copy files from floppy disks to hard drive
J. INTERPRET/USE BLUEPRINTS AND RELATED DOCUMENTS1. Interpret, Review, and Apply Blueprint Notes, Dimensions, and Tolerances
a. Distinguish between general and specific notesb. Interpret and apply general and specific notesc. Determine and apply dimensions on a drawingd. Identify basic symbols found on a drawinge. Identify tolerances on a drawingf. Discuss GD&T methodology
2. Interpret and Understand Basic Layout/Types of Drawingsa. Identify types of drawingsb. Identify parts of a drawing and list components of eachc. Identify types of lines on a drawingd. List and describe the different views found on a drawing
3. Understand and Analyze Bill-of-Materialsa. Determine materials requiredb. Determine quantities requiredc. Identify item symbol and/or part number
4. Ascertain Job Requirements from Drawingsa. Interpret part requirementsb. Identify surfaces to be machinedc. Determine critical dimensions
K. PERFORM DIE OPERATIONS1. Utilize Basic Die Theory and Principles of Die Design
a. Discuss shearing action on metal (3 stages)b. Define/calculate cutting clearancec. Define/calculate proper shut-height of die setd. Define/calculate offset displacemente. Define/calculate stripping pressuref. Define/calculate cutting length of piece partg. Define/calculate die progressionh. Design stock strip layouti. Determine die feed directionj. Explain notch, pierce, pilot, form, and cut-off stationsk. Determine stop block length1. Determine press tonnage requirementsm. Define/calculate slug clearancen. Explain operation of die set to make piece parto. Explain spring back in form diesP. Explain bending action in V-form diesq. Explain coining in diesr. Identify components of die sets. Discuss materials of die components
2. Perform Die Repaira. Disassemble and assemble die setb. Visually inspect die components for damagec. Identify component parts to be repaired/sharpenedd. Determine method of repairing/sharpeninge. Determine material for replacement partsf. Manufacture replacement partsg. Demonstrate setting correct punch entry
3. Demonstrate Die Making Skillsa. Identify component parts from die blueprintb. Determine material/purchased parts requirementsc. Utilize die making procedures to make component partsd. Utilize die making procedures to mount component partse. Demonstrate mounting of die set in press machinef. Cycle die set in press machine and inspect operation
g. Inspect piece part for accuracy4. Demonstrate Understanding of Different Types of Industrial Dies
a. Describe the operation and major components of blanking or piercing diesb. Describe the operation and major components of bending or forming diesc. Describe the operation and major components of draw diesd. Describe the operation and major components of compression diese. Describe the operation and major components of progressive diesf. Describe the operation and major components of compound dies
g. Describe the operation and major components of combination dies
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 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.
The following activities will be performed by each student for successful completion of thiscourse:
I. COMPETENCIESA. Resources: Identifies, organizes, plans, and allocates resources
1. allocates time to complete assigned tasks on schedule2. determines cost associated with meeting objectives3.. determines and allocates required materials and resources for meeting
objectives4. evaluates skills, performance, and quality of work and provides feedback
B. Interpersonal: Works with others
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1. participates as a member of the team, contributing to group effort2. provides individual assistance/direction to peers as requested3. determines and meets internal and external customers' expectations4. exercises leadership qualities to effectively communicate ideas and make
decisions5. negotiates resources in order to accomplish objectives6. works well with all members of the class
C Information: Acquires and uses information1. acquires and evaluates information2. organizes and maintains information3. interprets and communicates information
D. Systems: Understands complex inter-relationships1. understands and works well with social, organizational, and technological
systems2. monitors and corrects performance of system during operation3. recommend modifications to system to improve performance
E. Technology: Works with a variety of technologies1. chooses relevant procedures, tools and equipment2. applies appropriate procedures and techniques to accomplish tasks3. identifies or solves problems to maintain equipment
II. FOUNDATION SKILLSA. Basic Skills: Reads, writes, performs arithmetic and mathematicaloperations,
listens and speaks.1. Reading: Locates, understands, and interprets written information in
prose and in documents such as manuals, graphs, and schedulesa. demonstrates basic reading skills including abilities to perceive main
ideas, draw appropriate conclusions, detect a sequence, locateanswers, find facts, and infer from written texts
b. demonstrates course specific reading skills including abilities toread, interpret, and comprehend information from text andsupplemental materials on a level to facilitate productiveindependent and group study
c. demonstrates ability to read, interpret, and utilize information fromcourse specific instruments (i.e., charts, diagrams, graphs,schematics, blueprints, flow charts, etc.)
d. demonstrates ability to read, interpret, and follow schedules andprocedural instructions in a timely and appropriate manner
e. demonstrates ability to choose and use most appropriate readingmethod (skim, scan, or read for comprehension) for materials
2. Writing: Communicates thoughts, ideas, information, and messages inwriting; and creates documents such as letters, directions, manuals,reports, graphs, and flow chartsa. demonstrates basic writing skills including abilities to produce
written documents which conform with accepted grammatical andcommunication standards required for effective daily functioning
1
Y.
b. demonstrates effective written study skills including note taking,maintaining course specific journals, workbooks, manuals, etc.
c. demonstrates technical writing skills in preparing outlines,summaries, time lines, flow charts, diagrams, etc. appropriate tomaterials covered
d. demonstrates ability to complete all required writings in a timely,complete, and professional manner
e. demonstrates competence in subject matter through theorganization and presentation of answers to required writtenassessments
3. Arithmetic/Mathematics: Perform basic computations and approachespractical problems by choosing appropriately from a variety ofmathematical techniquesa. demonstrates proficiency in basic arithmetic functions including
ability to add, subtract, multiply, and divide whole numbers,fractions, decimals, and percents
b. demonstrates ability to read, comprehend, and select appropriatemath procedures to work basic math problems
c. demonstrates ability to understand and perform multi-stepcomputations
d. demonstrates ability to read, interpret, and use standard measuringdevices
e. demonstrates ability to comprehend, retain, and utilize coursespecific measuring devices effectively
f. demonstrates ability to understand, retain, and utilize highermathematical formulas and functions required for course specificmath performance
g. demonstrates ability to appropriately transfer mathematicalcalculations and information from paper to machines
4. Listening: Receives, attends to, interprets, and responds to verbalmessages and other cuesa. functions at minimal or above required hearing levels to receive,
attend, interpret, and respond to verbal messages and instructionsand to safely operate machinery
b. demonstrates ability to hear, comprehend, and appropriately followdirections
c. demonstrates auditory ability to hear, comprehend, and utilizeverbal classroom as well as other auditory instruction
d. demonstrates ability to discriminate between essential andnon-essential verbal information and react appropriately
e. demonstrates ability to focus and fine-tune listening skills toreceive, interpret, and respond to various sounds
f. demonstrates ability and maturity to seek and receive additionalindividualized instruction as needed
5. Speaking: Organizes ideas and communicates orallya. demonstrates appropriate listening and speaking skills in personal
conversations
2 (.12
b. demonstrates ability to choose and organize appropriate words toeffectively communicate
c. demonstrates ability to speak clearly and distinctly with appropriatevolume, tone, and body language for situation
d. demonstrates ability to spontaneously organize and presentappropriate answers and/or short presentations for classroom andfor assessment purposes
e. demonstrates ability to formulate, organize, and deliver majorpresentations to peers or groups
f. demonstrates ability to speak effectively in one-on-one, smallgroup, or large group presentations
g. demonstrates ability to take responsibility for presentationsB. 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. demonstrates ability to objectively assess personal strengths and
weaknessesb. demonstrates ability to set realistic short-term and long-term goalsc. demonstrates ability to recognize and distinguish between positive
and negative alternativesd. demonstrates ability to identify potential pitfalls and take evasive
actionse. demonstrates ability to objectively and responsibly evaluate
alternatives by testing hypotheses and selecting most appropriateresponse
f. demonstrates ability to profit from negative evaluations or mistakesby reformulating, redirecting, reconstructing, or retestingalternatives
g. demonstrates maturity to take responsibility for decisions2. Problem Solving: Recognizes problems and devises and implements plan
of actiona. demonstrates ability to detect problem through observation, inquiry,
or directiveb. demonstrates ability to grasp appropriate overview and degree of
seriousness of problem and to behave responsibly in situationc. demonstrates ability to generate alternatives or options for problem
solutiond. demonstrates ability to research options, assess and evaluate
options, and determine appropriate and best solutione. demonstrates ability to initiate and effect solutionf. demonstrates ability to take responsibility for outcomesg. demonstrates ability to effectively problem solve in individual, team,
or group situations3. Seeing Things In the Mind's Eye: Organizes, and processes symbols,
pictures, graphs, objects, and other information
a. functions at minimum or above required visual levels in order tosee, interpret, attend and respond to visual imagery and meet safetyrequirements for necessary machinery
b. demonstrates ability to read, interpret, and act upon signs, symbols,and other visual cues
c. demonstrates ability to visually discriminate in gross and fineimagery
d. demonstrates ability to visualize abstractlye. demonstrates ability to apply visual imagery to applied tasks
4. Knowing How to Learn: Use efficient learning techniques to acquire andapply new knowledge and skillsa. demonstrates mastery of basic reading, math, and language skills
through applicationb. demonstrates ability to translate abstract theory into practical
applicationc. demonstrates ability to incorporate and generalize new learning into
a sequential learning processd. demonstrates knowledge of good study skills and learning habits
5. Reasoning: Discovers a rule or principle underlying the relationshipbetween two or more objects and applies it when solving a problema. demonstrates use of simple logicb. demonstrates ability to distinguish relationshipsc. demonstrates ability to determine and isolate factors in relationshipsd. demonstrates and applies knowledge through practicee. recognizes that attitudes, skills, and practice are essential to
productivityf. demonstrates ability to discriminate between positive and negative,
and act accordinglyPersonal Qualities: Displays responsibility, self-esteem, sociability, self-management, and integrity and honesty.1. Responsibility: Exerts a high level of effort and perseveres towards goal
attainmenta. demonstrates ability to formulate realistic and useful short and long
term goals and complete steps necessary to timely achieve goalsb. demonstrates ability to make adjustments, revisions, and changes to
achieve goals in a cooperative and polite mannerc. demonstrates ability to focus on task at hand and work to
completiond. demonstrates good work ethics through regular attendance,
adequate classroom preparations, and appropriate use of classroomtime
e. demonstrates maturity to take responsibility for actionsf. demonstrates ability to cooperatively work in individual, team, and
group situations in timely and effective manner2. Self-Esteem: Believes in own self-worth and maintains a positive view of
selfa. presents a positive attitude toward tasks
b. demonstrates ability to separate work and personal behaviorsc. actively participates in learning opportunities by sharing knowledge
and skills with peers and instructorsd. demonstrates ability to accept personal strengths and weaknesses
and builds on positive behaviorse. demonstrates ability to accept and use constructive criticismf. accepts positive reinforcement in an appropriate manner
3. Sociability: Demonstrates understanding, friendliness, adaptability,empathy, and politeness in group settingsa. demonstrates appropriate and acceptable social behaviors in
classroom interactionsb. demonstrates ability to work cooperatively in individual, team, or
group situationsc. demonstrates active interest in peers by offering assistance, sharing
resources, and sharing knowledge in a professional and acceptablemanner
d. demonstrates professional work ethic by separating work andpersonal social behaviors and acting accordingly
4. Self-Management: Assesses self accurately, sets personal goals,monitors progress, and exhibits self-controla. accepts personal strengths and weaknesses and uses the same for
positive advancementb. demonstrates ability to continuously set, assess, choose, and modify
objectives as the situation demands in an appropriate mannerc. demonstrates ability to formulate and follow personal schedulesd. demonstrates ability to wisely use classroom timee. demonstrates use of good study habits and skillsf. demonstrates maturity to take responsibility for own actions
5. Integrity/Honesty: Chooses ethical courses of actiona. knows and demonstrates ability to distinguish between positive and
negative behaviorsb. demonstrates honesty and integrity in working with peers and
supervisorsc. takes full responsibility for personal actionsd. demonstrates understanding of consequences for negative ethical
behaviors and accepts responsibility for same when applicablee. demonstrates positive work and social ethics in undertakings
Appropriate Reference Materials:
1. Machinery's Handbook, Industrial Press2. Die Design Fundamentals, J. R. Pacquin and R.E. Crowley, 2nd Ed.
TDT 218303/081496
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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Chr
estm
anD
tan/
Dir
eeto
r
Don
Bat
j sm
inA
ssoe
lets
Dam
oSita
Ark
eini
nnto
r
Bar
ry E
lliso
nsi
te C
oord
inat
or
AIR
CA
P/M
TD
RE
PRE
SEN
TA
TIV
ES
Cha
rles
Ald
ridg
eT
ool &
Dig
Mis
er
Ron
Bat
eman
Too
l & D
ie M
unge
r
Nat
han
Hug
hes
lbol
& D
ie S
uper
viso
r
Ber
ry L
edbe
tter
Too
l & D
ie M
aker
Tod
d Sh
ield
s/W
I &
Dk
Mak
er
237
TR
AIT
S A
ND
AT
TIT
UD
ES
Stro
ng W
ork
Eth
icIn
terp
erso
nal S
kills
Punc
tual
ityD
epen
dabi
lity
Hon
esty
Nea
tnes
sSa
fety
Con
scie
ntio
usM
otiv
atio
nR
espo
nsib
lePh
ysic
al A
bilit
yPr
ofes
sion
alT
rust
wor
thy
Pers
onal
Eth
ics
Inno
vativ
e
TO
OL
S A
ND
EQ
UIP
ME
NT
Mac
hini
sts
Too
ls (
e.g.
, cal
iper
s, d
ial
indi
cato
rsm
agne
tic to
ol h
olde
rs, e
tc.)
Mea
suri
ng T
ools
Met
al L
ayou
t Too
lsPo
wer
Too
lsM
etal
Lat
he w
ith A
ttach
men
tsD
rill
Pres
ses
Ver
tical
Mill
with
Atta
chm
ents
Ban
d Sa
ws
Pow
er D
rills
Hyd
raul
ic/A
rbor
Pre
ssH
eat T
reat
men
t Equ
ipm
ent
Har
dnes
s T
astin
g E
quip
men
tG
rind
ing
Mac
hine
s w
ith A
ttach
men
tsW
eldi
ng E
quip
men
tC
NC
Mac
hini
ng C
ente
r an
d T
unin
gC
ente
rlig
Bor
ing
Mac
hine
sA
lignm
ent/C
alib
ratio
n T
ools
0:41
Paer
Vm
tilat
ion
Equ
ipm
ent
Fork
lift
Pers
onal
Saf
ety
Equ
ipm
ent
Oxy
acet
ylen
e E
quip
men
tT
ool S
tang
e E
quip
men
tW
orkb
ench
esV
ises
Pede
stal
Gri
nder
sC
oord
inat
e M
eann
emen
t Mac
hine
FUT
UR
E T
RE
ND
S A
ND
CO
NC
ER
NS
Com
posi
tes
In-P
roce
ss G
augi
ngR
apid
Too
l Cha
ngin
gE
xpan
ded
Com
mun
icat
ion
with
Sho
p Fl
oor
Mul
ti-A
xis
Equ
ipm
ent
Com
pute
r-In
tegr
ated
Man
ufac
turi
ngA
dapt
ive
Con
trol
sC
onve
rsat
iona
l Pro
gnur
anin
gA
rtif
icia
l Int
ellig
ence
CO
MP
ET
EN
CY
PR
OF
ILE
Too
l & D
ie M
aker
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
.199
J400
08)
AIR
CA
P/M
TD
BE
ST
CO
PY
AV
AIL
AB
LE
238
I
'I
'
111
SS
a11
.14
o.ar
or..
I/I
.1
II
11or
ooo
1II
III,
I .1
11
ImIo
nE
lm I=
NE
NE
EN
No
um N
E E
N I=
am
I= N
o E
N
Dut
ies
J
Inte
rpre
t/Use
jeB
luep
rint
s an
dR
elat
ed vets
Mpr
ojeh
iczi
rim
elm
:>m
ig
Port
on&
Die
°wid
ows
WID
TD
.ItT
M1
11A
9VO
U11
1005
4T
asks
1-1
Use
com
pute
rop
erat
ing
syst
ems
1-2
Use
file
man
agem
ent
syst
ems
J-3
Und
erst
and
RS-
232
prot
ocol
J-4
Inst
alV
use
soft
war
e pa
ck-
ages
3-5
Use
com
pute
rne
twor
k sy
stem
1-6
Use
file
tran
sfer
syst
ems
K-I
Des
ign
port
s fo
r in
anu.
fact
urab
ility
K-2
Pla
n an
dde
sign
for
"mat
ing
ofpa
rts"
K-3
Be
cost
cons
ciou
s w
ithde
sign
of
part
s
K-4
Det
erm
ine,
inte
rpre
t, an
dev
alua
tecu
stom
ersp
ecif
icat
ions
1_-_
____
_"l
inte
rPre
k___
.
IWW
W,_
and
appl
y °'
u5Pl
uil
note
s, d
imen
-*i
ons,
and
tole
ranc
es
L-2
Int
erpr
etan
dan
d un
ders
tand
basi
c la
yout
/ty
pe, o
fdr
awin
gs
L-3
Und
erst
and
and
anal
yze
bill
of m
ater
ials
L-4
Asc
erta
injo
b re
quir
e-m
eets
fro
mdr
awin
gs
L-5
Int
erpr
etan
d ap
ply,
geom
etri
cdi
men
sion
ing
and
tole
ranc
e%
M-1
Com
pre-
hand
ent
ire
scop
e of
Peer
et
M-2
Con
duct
mul
tiple
pro
ject
man
agem
ent
M-3
Set
and
mai
ntai
ntin
elin
es
14-4
Pri
oriti
zeta
sks/
dutie
s/pr
ojec
ts
M-5
Pre
plan
proj
ect
activ
ities
1.46
Dem
onst
rate
time/
reso
urce
man
agem
ent
N-I
Win
sba
sic
die
theo
ry
N-2
Vis
ually
insp
ect d
ieco
mpo
nent
s fo
rda
mag
e
N-3
Dis
asse
mbl
ean
d as
sem
ble
die
set
N-4
Det
erm
ine
prop
er c
uttin
g,cl
eara
nce,
and
slug
rel
ief
N-5
Cal
cula
tepr
oper
shu
t-he
ight
of
die
set
N-6
Des
ign
stoc
k st
rip
layo
ut
N-7
Det
erm
ine
pres
s to
nnag
ere
quir
emen
ts
N-8
Cal
cula
test
ripp
ing
pres
sure
s
242
ME
M O
INIM
INM
IIIIII
1111
=11
1111
1111
PM
1111
1.11
1111
1M11
1111
1111
11
SKIL
LS
AN
D K
NO
WL
ED
GE
Com
mun
icat
ion
Skill
sU
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
Won
plac
eO
rgan
izat
iona
l Ski
llsK
now
ledg
e of
Com
pany
Pol
icie
s/Pr
oced
ures
Mec
hani
cal A
ptitu
deA
bilit
y to
Com
preh
end
Wri
tten/
Ver
bal I
nstr
uctio
nsK
now
ledg
e of
Cut
ting
Flui
ds/L
ubri
cant
sB
asic
Kno
wle
dge
of F
aste
ners
Abi
lity
to W
ork
as P
art o
f a
Tea
mC
onve
rse
in th
e T
echn
ical
Lan
guag
e of
the
Tra
deK
now
ledg
e of
Occ
upat
iona
l Opp
ortim
ities
Kno
wle
dge
of E
mpl
oyee
/Em
ploy
er R
espo
nsib
ilitie
sK
now
ledg
e of
Com
pany
Qua
lity
Ass
uran
ce A
ctiv
ities
Prac
tice
Qua
lity-
Con
scio
usne
ss in
Per
form
ance
of
the
Job
SPR
ING
FIE
LD
TE
CH
NIC
AL
CO
MM
UN
ITY
CO
LL
EG
EM
AST
PR
OG
RA
M R
EPR
ESE
NT
AT
IVE
S
DR
. TH
OM
AS
E. H
OL
LA
ND
Dis
cus
Cat
e fa
r B
ois=
& T
edro
key
GA
RY
J. M
ASC
IAD
RE
LL
IN
orm
s C
hin=
Mec
turi
cal E
ngin
eer*
Tec
tosl
ogy
NIC
K h
t MA
SSA
DIn
xtar
of
Ted
salo
p D
svel
opm
at
RO
SE M
AR
Y T
IMM
ON
SSe
nor
Seas
tryS
tnis
ticia
(M
t)
Furn
ishe
d B
y:
AM
ER
ICA
N S
AW
& M
FG. C
O.
Mik
e L
ytle
'T
ed H
eade
rG
eorg
e Z
ades
Pete
r L
askl
ewle
sSc
ott B
ruld
osR
on B
ootie
Al W
elde
r
NPR
114
4; V
IRL
Dw
i II:
AL
CO
MM
UN
ITY
CO
LL
EG
E 243
TR
AIT
S A
ND
AT
TIT
UD
ES
Stro
ng W
ork
Eth
icIn
terp
erso
nal S
kills
Punc
tual
ityD
epen
dabi
lity
Hon
esty
Nea
tnes
sSa
fety
Con
scie
ntio
usM
otiv
atio
n
Res
pons
ible
Phys
ical
Abi
lity
Prof
essi
onal
Tru
stw
orth
yC
usto
mer
Rel
atio
nsPe
rson
al E
thic
s
TO
OL
S A
ND
EQ
UIP
ME
NT
Mac
hini
st's
Too
ls (
e.g.
, cal
iper
s, d
ial i
ndic
ator
s,m
agne
tic to
ol h
olde
n, e
tc.)
Mea
suri
ng T
ools
Pow
er T
ools
Met
al L
athe
with
Atta
chm
ents
Dri
ll Pr
esse
sV
ertic
al M
ill w
ith A
ttach
men
tsPo
wer
Saw
sPo
wer
Dri
llsH
ydra
ulic
/Arb
or P
ress
Hea
t Tre
atm
ent E
quip
men
tH
ardn
ess
Tes
ting
Equ
ipm
ent
Gri
ndin
g M
achi
nes
with
Atta
chm
ent"
Wel
ding
Equ
ipm
ent (
SMA
W, °
MA
W, F
CA
W)
CN
C M
achi
ning
Cen
ter
sod
'Dim
ing
Cen
ter
Gea
r Pr
oduc
ing
Mac
hine
s w
ith A
ttach
men
tsA
ligm
nent
/Cal
ibra
tice
Too
lsC
oola
nt R
ecov
ery
Equ
ipm
ent
Com
pute
rV
entil
atio
n E
quip
men
tFo
rklif
tPe
rson
al S
afet
y E
quip
men
tO
xyac
etyl
ene
Equ
ipm
ead
Too
l Sto
rage
Equ
ipm
ent
Wor
kben
ches
Vis
esPe
dest
al G
rind
ers
Wel
d T
est E
quip
men
t
Opt
ical
Com
para
tor
Coo
rdin
ate
Mea
sure
men
t Mac
hine
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
atio
nsR
obot
ics
Env
iron
men
tal C
once
rns
Fibe
r O
ptic
Con
trol
sA
utom
ated
Mat
eria
l Han
dlin
g E
quip
men
tC
ompu
ter
Inte
grat
ed M
anuf
actu
ring B
ES
T C
OP
Y A
VA
ILA
BLE
CO
MPE
TE
NC
Y P
RO
FIL
E
Too
l & D
ie M
aker
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
.199
J400
08)
SPR
ING
FIE
LD
TE
CH
NIC
AL
CO
WL
-NM
CO
LL
EG
E
244
TO
OL
& D
IE M
AK
ER
.... a
naly
ze v
arie
ty o
f sp
ecif
icat
ions
, lay
out
met
al s
tock
, set
up a
nd o
pera
te m
achi
ne to
ols,
and
fit
and
asse
mbl
e pa
rts
to m
ake
and
repa
ir d
ies,
cut
ting
tool
s, ji
gs, f
ixtu
res,
gag
es, a
nd m
achi
nist
's h
and
tool
s.
Tas
ks4
Dut
ies
B
Sele
ctM
azur
faet
uria
gSt
ater
ale
and
Proc
esse
s
pith
.hs
.ot
E...
d
Perf
orm
c.d.
!FM
ackl
ulas
edo
ns
1Per
feem
Adv
ance
dG
Mac
hhila
gPr
oces
ses
HT
ooL
>s
I
245 J
SAU
TO
OL
110
IlE
AST
/01/
0
A-1
Fol
low
safe
ty m
anua
lsan
d al
l saf
ety
regu
latio
ra/
requ
irem
ents
A-2
Use
prot
ectiv
eeq
uipm
ent
A-3
Fol
low
safe
ope
ratin
gpr
oced
ures
for
hand
and
mac
hine
tool
s
A-4
Mai
ntai
n a
clea
n an
d sa
few
ork
envi
ron-
man
B-1
Per
form
basi
c ar
ith-
met
ic f
irm
-L
ions
13-2
Loc
ate
mac
hini
ngpo
ints
fro
m a
deni
m p
oint
B-3
Int
er-
conv
ert
frac
tions
/de
cim
als
B-4
Int
er-
conv
ert M
etri
c./
Eng
lish
mea
sure
men
ts
B-5
Per
form
basi
ctr
igon
omet
ric
func
tions
B-6
Use
sin
eba
r or
sin
e pl
ate
for
mac
hine
oper
atio
ns
13-7
Cal
cula
tefo
r di
rect
,si
mpl
e, a
ndan
gula
rM
imin
g
B-8
Cal
cula
tesp
eeds
and
feed
s fo
rm
achi
ning
C-1
Rev
iew
blue
prin
t not
esan
d di
men
sion
s
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
Ide
ntif
ylin
es a
nd_b
ols
(W M
)
C-7
Ana
lyze
Bill
°M
ater
ials
(BO
M)
C-8
Und
er-
stan
d an
d us
equ
ality
sys
tem
s
C-9
Cre
ate
tech
nica
lsk
etch
es
,
D-1
Ide
ntif
ym
ater
ials
with
desi
red
prop
ertie
s
D-2
Ide
ntif
yhe
at tr
eatin
gpr
oces
ses
D-3
Per
form
heat
trea
ting
oper
atio
ns
,D
-4 T
est m
etal
sam
ples
for
hard
ness
D-5
Eva
luat
eal
tern
ativ
em
enuf
acha
ing
proc
esse
s
.
E-1
Stu
dyba
sics
of
met
rolo
gy
B2
Sele
ctin
stru
men
tsus
ed f
orm
easu
rcne
nt
E-3
Int
erpr
etlim
its a
ndE
-4 S
elec
tga
ggin
g to
ols
E-5
Use
CM
Mfo
r lo
catio
n of
feat
ures
E6
Perf
orm
111f
6S00
met
rolo
gy
P.7
Perf
orm
mea
sure
men
tby
com
pari
son
E-8
Per
il:m
ica-
cula
rity
.cy
linch
icity
, pro
-m
e of
a li
ne, a
ndro
ma
mea
sure
-m
ents
E-9
Inv
estig
ate
adva
nced
met
rolo
gyto
pics
.to
lera
nces
F-1
Prep
are
and
plan
for
mac
hini
ngop
erat
ions
F-2
Use
pro
per
band
tool
sF-
3 O
pera
tepo
wer
saw
sF4
Ope
rate
drill
pre
sses
F-5
Ope
rate
vert
ical
nul
ling
mac
hine
s
F6 O
pera
teha
irne
ts!
mill
ing
mac
hine
s
F-7
Ope
rate
met
al =
tang
lath
es
F-8
Ope
rate
Find
ing/
abra
sive
mac
hine
s
F-9
Ope
rate
deba
ting
equi
pmen
t
F-10
Pol
ish
mol
d/di
eca
vitie
s
0-1
Prog
amC
ompu
ter
Num
eric
alC
ontr
ol (
CN
C)
mac
hine
s
0-2
Ope
rate
CN
C m
achi
narg
cent
ers
and
turn
ing
cent
ers
0-3
Prog
ram
CN
C m
achi
new
ith a
CA
Msy
stem
.)
H-1
Int
erpr
etto
ol d
raw
ings
11-2
Bui
ld/
mod
ify/
repa
ir&
Mks
11-3
Bud
d/m
odif
y/re
pair
mill
fix
ture
s
H-4
Bu2
d/m
odif
yhep
air
dies
H-5
13t
uld/
mod
ify
/rep
air
patte
rn,/
tem
plat
ea
I-1
Use
com
pute
rV
endi
ngsy
stem
s
1-2
Use
com
pute
rin
quir
y sy
stem
s
1-3
Use
Com
pute
r-A
ided
Dra
ftin
g (C
AD
)so
ftw
are
2 4
n1-
1 U
se te
steq
uipm
ent
1-2
De
gibe
basi
c pr
inci
ples
othy
drau
licsy
stem
s
1-3
Iden
tify
hydr
aulic
flu
ids
14 R
ewar
med
pow
er d
iatr
ibe-
lion
and
seal
ing
devi
ces
1-5
Rec
ogni
zepu
mps
,ac
tuat
ors,
and
hydr
aulic
cont
rol d
evic
es
1-6
Tro
uble
-sh
oot h
ydra
u-lic
/pne
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g E
quip
men
tC
ompu
ter
Inte
grat
ed M
anuf
actu
ring
CO
MPE
TE
NC
Y P
RO
FIL
ET
ool &
Die
Mak
er
BE
ST C
OPY
AV
AIL
AB
LE
Con
duct
ed B
yM
.A.S
.T.
Mac
hine
Too
l Adv
ance
d Sk
ills
Tec
hnol
ogy
Prog
ram
and
Con
sort
ia P
artn
ers
(V.1
99J4
0008
)
Tec
Tgr
aiSV Lal
ege
Wac
o
TO
OL
CO
MP
AN
YA
111
U11
101A
AT
OF
CA
MC
O
260
I
41
I-I
II
III
III
II
I
l
p 1i
iiiI
eel
MI N
MI M
I Ili
MI
MB
MI N
M M
N M
I UM
MIM
I MS
MO
MI M
I MI O
M
SKIL
LS
AN
D K
NO
WL
ED
GE
Com
mun
icat
ion
Skill
sU
se M
easu
rem
ent T
ools
Use
Ins
pect
ion
Dev
ices
Mat
hem
atic
al S
kills
Rea
ding
/Wri
th8
Skill
s'K
now
ledg
e of
Saf
ety
Reg
ulat
ions
Prac
tice
Safe
ty in
the
Wor
kpla
ceO
rgan
izat
iona
l Ski
llsK
now
ledg
e of
Com
pany
Pol
icie
a/Pr
oced
ures
Mec
hani
cal A
ptitu
deA
bilit
y to
Com
preh
end
Wri
tten/
Ver
bal I
nstr
uctio
nsK
now
ledg
e of
Cut
ting
Flui
ds/L
ubri
cant
sB
asic
Kno
wle
dge
of F
aste
ners
Abi
lity
to W
ork
as P
art o
f a
Tea
mC
onve
ne in
the
Tec
hnic
al L
angu
age
of th
e T
rade
Kno
wle
dge
of O
ccup
atio
nal O
ppor
tuni
ties
Kno
wle
dge
ofE
nipl
oyee
/Em
ploy
er R
espo
nsib
ilitie
sK
now
ledg
e of
Com
pany
Qua
lity
Ass
uran
ce A
ctiv
ities
Prac
tice
Qua
lity-
Con
scio
usne
ss in
Per
form
ance
of
the
Job
SPR
ING
FIE
LD
TE
CH
NIC
AL
CO
MM
UN
ITY
CO
LL
EG
EM
AST
PR
OG
RA
M R
EPR
ESE
NT
AT
IVE
S
DR
. TH
OM
AS
E. H
OL
LA
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Dir
ecto
r. C
ala
fore
man
= &
ildn
olea
y
OA
RY
J. M
ASC
IAD
RE
LL
ID
erm
as C
lara
=M
ahri
cal E
rsia
terk
g T
edus
kay
MC
I( M
MA
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Dir
ecto
r at
rect
eoke
yDev
elap
rout
RO
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AR
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IMM
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SSe
nors
ecre
twA
niat
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y)
Furn
ishe
d B
y:
SMIT
H &
WE
SSO
N
RIC
HA
RD
MA
RL
OW
Stra
leta
stla
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Serv
ices
BO
B P
ION
terc
et%
Mat
ra R
isaw
arsD
evel
opm
eat
RO
NA
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P. B
OR
GIO
Mat
er T
QW
190
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it
SPR
INC
VIE
LO
7m
OIN
ICA
LC
OM
MU
NC
IY C
OL
LE
GZ
263
TR
AIT
S A
ND
AT
TIT
UD
ES
Stro
ng W
ork
Eth
icIn
terp
erso
nal S
kills
Punc
tual
ityD
epen
dabi
lity
Hon
esty
Nea
tnes
sSa
fety
Con
scie
ntio
usM
otiv
atio
nR
espo
nsib
lePh
ysic
al A
bilit
yPr
ofes
sion
al
Tru
stw
orth
yC
usto
mer
Rel
atio
nsPe
rson
al E
thic
s
TO
OL
S A
ND
EQ
UIP
ME
NT
Mac
hini
st's
Too
ls (
e.g.
, cal
iper
s, d
ial i
ndic
ator
s,m
agne
tic to
ol h
olde
rs, e
tc.)
Mea
suri
ng T
ools
Pow
er T
ools
Met
al L
athe
with
Atta
chm
ents
Dri
ll Pr
esse
sV
ertic
al M
ill w
ith A
ttach
men
tsPo
wer
Saw
sPo
wer
Dri
llsH
ydra
ulic
/Arb
or P
ress
Hea
t Tre
atm
ent E
quip
men
t
Har
dnes
s T
estin
g E
quip
men
tO
rind
ing
Mac
hine
s w
ith A
ttach
men
tsW
eldi
ng E
quip
men
t (SM
AW
, OM
AW
, FC
AW
)C
NC
Mac
hini
ng C
ente
r an
d Il
anin
g C
ente
rO
eer
Prod
ucin
g M
achi
nes
with
Atta
chm
ents
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nmen
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ibra
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Too
lsC
oola
nt R
ecov
ery
Equ
ipm
ent
Com
pute
rV
entil
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n E
quip
men
tFo
rklif
t
Pers
onal
Saf
ety
Equ
ipm
ent
Oxy
acet
ylen
e E
quip
men
tT
ool S
tora
ge E
quip
men
tW
orkb
ench
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ises
Pede
stal
(hi
nder
sW
ald
Tes
t Equ
ipm
ent
Opt
ical
Com
para
tor
Coo
rdin
ate
Mea
sure
men
t Mac
hine
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
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hini
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dvan
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Com
pute
r A
pplic
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obot
ics
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iron
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tal C
once
rns
Fibe
r O
ptic
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trol
sA
utom
ated
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eria
l Han
dlin
g E
quip
men
tC
ompu
ter
Inte
grat
ed M
anuf
actu
ring
CO
MPE
TE
NC
Y P
RO
FIL
E
Too
l & D
ie M
aker
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
.199
J400
08)
SPR
ING
FIE
LD
TE
CH
NIC
AL
CO
MM
IZO
TY
CO
LL
EG
E 264
TO
OL
& D
IE M
AK
ER
.... a
naly
ze v
arie
ty o
f sp
ecif
icat
ions
, lay
out
met
al s
tock
, set
up
and
oper
ate
mac
hine
tool
s, a
nd f
it an
d as
sem
ble
part
s to
mak
e an
d re
pair
die
s, c
uttin
gto
ols,
jigs
, fix
ture
s, g
ages
, and
mac
hini
st's
han
d to
ols.
Dut
ies
B
Sele
ctM
aauf
aita
rIng
I)M
odal
s's
sad
Proc
esse
s
Perf
orm
Mea
sisr
ease
at
Ese
c/
Port
en.
Cam
milo
sel
Fhu
m.*
Mie
s
Perf
orm
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amed
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ackh
dag
Proc
esse
s
HR
epai
r T
ools
I
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IlAS
T/0
1/01
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Tas
ksA
-1 F
ollo
wsa
fety
man
uals
and
all s
afet
yre
gula
tions
/re
quir
emen
ts
A-2
Use
prot
ectiv
eeq
uipm
ent
A-3
Fol
low
safe
ope
ratin
gpr
oced
ures
for
hand
and
mac
hine
tool
s
A-4
Mai
ntai
n a
clea
n en
d sa
few
ork
envi
ron-
men
t
B-1
Per
form
basi
c w
ith-
mod
s fu
ns-
Lio
ns
B-2
Loc
ate
mac
hini
ngpo
ints
fro
m a
datu
m p
oint
/3-3
Int
er-
conv
ert
frac
tions
/de
cim
als
B-4
bie
r-co
nver
t Met
ric/
Eng
lish
mea
sure
men
ts
13-5
Per
form
basi
ctr
igon
omet
ric
func
tions
B-6
Use
sin
eba
r or
site
pla
tefo
r m
achi
neop
erat
ions
DT
Cal
cula
tefo
r di
rect
,si
mpl
e, a
ndan
gula
rin
dexi
ng
B-8
Cal
cula
tesp
eeds
and
feed
s fo
rm
achi
ning
13-9
Cal
cula
tedr
aft a
ngle
dim
ensi
ons
B-1
0 A
pply
"shr
ink
rate
"fo
rmul
as
C-1
Rev
iew
blue
prin
t not
esan
d di
men
sion
s
C-2
Ide
ntif
yba
sic
layo
ut o
fdr
awin
gs
C-3
Ide
ntif
yba
it ty
pes
ofdr
awin
gs
C-4
Lis
t the
purp
ose
of e
ach
type
of
draw
ing
C-3
Ver
ify
draw
ing
elem
ents
C-6
Ide
ntif
ylin
es a
ndem
boli
(MR
1)
C-7
Des
crib
eth
e re
latio
nshi
pof
eng
inee
ring
draw
ings
topl
anni
ng
C,4
3 L
b.st
anda
rds
tove
rify
requ
ire-
mal
ts
C-9
Ana
lyze
bill
ofm
atai
ah(B
OM
)
C-1
0 U
nder
-st
and
and
use
qual
ity s
yste
ms
C-1
1 C
omte
tech
nica
lsk
etch
es
D-1
Ide
ntif
ym
ater
ials
with
desi
red
Prop
ertie
s
D-2
Ide
ntif
yhe
at tr
eatin
gpr
oces
ses
D-3
Tes
t met
alsa
mpl
es f
orha
rdne
ss
D-4
Eva
luat
eal
tern
ativ
em
anuf
actu
ring
proc
esse
s
0-5
Iden
tify
type
s of
pla
stic
mat
eria
ls
E-1
Stu
dyba
sics
of
met
rolo
gy
8-2
Sele
ctin
stru
men
tsus
ed f
orm
easu
rem
ent
E-3
kita
pret
limits
and
tole
ranc
e
8-4
Sele
ctga
ggin
g to
ols
E-S
Use
CM
Mfo
r lo
catio
n of
feat
ures
E-6
Per
form
surf
ace
met
rolo
gy
E-7
Paf
orm
mee
nrem
ent
by c
ompa
riso
n
E-8
Per
form
cir
-su
ltrily
,gh
netr
icity
, pro
-fi
le o
flin
e, a
ndne
on m
easu
re-
Am
nia
E-9
Inv
estig
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 °p
aste
pow
er s
aws
F-4
Ope
rate
drill
pre
sses
F-5
Ope
rate
vert
ical
mil
ling
mac
hine
s
F-6
Ope
rate
honz
onta
lsl
idin
gm
achi
nes
F-7
Ope
rate
met
al c
uttin
gla
thes
F-8
Ope
rate
grin
ding
/ab
rasi
vem
achi
nes
F-9
Ope
rate
.*bo
ring
mac
hine
s
F-10
Ope
rate
deba
sing
equi
pmen
t
F-11
Pol
ish
mol
d/di
eca
vitie
s
0-1
Prog
ram
Com
pile
r0-
2 O
pera
teC
NC
=di
king
cent
ers
and
turn
ing
cent
ers
0-3
Ope
rate
elec
tric
aldi
scha
rge
mac
hine
sN
umer
ical
Cce
nrol
(C
NC
)m
achi
nes
H-1
War
eto
ol d
raw
ings
H-2
Bui
ld/
mod
ify/
repa
irdr
ill ji
gs
11-3
Bui
ld/
mod
ify/
repa
irm
ill &
tires
H-4
Bui
ld/
mod
ify/
repa
irdi
es
H-5
Bui
ld/
mod
ifyf
repa
irm
olds
11-6
Bui
ld/
mol
ly/ r
epai
rpa
ttenu
i/te
mpl
ates
I-1
Use
vari
ous
ccai
nite
rap
plic
atio
ns
1-2
Use
com
pute
rm
quir
y sy
stem
s
BE
ST
CO
PY
AV
AIL
AB
LE
En
Es
No!
gmN
ggm
Ns
gm g
m01
1.M
N IN
SIM
OIM
O11
.
NM
NIB
MN
MI
SIM
MI G
NI
MID
NIS
MN
NM
IR
IOO
il
SKIL
LS
AN
D K
NO
WL
ED
GE
Com
mai
katio
n Sk
ills
Tec
hnic
al R
eadi
ng/W
riti
ng S
kills
Abi
lity
to C
ompr
ehen
d W
ritte
n/V
erba
l Ins
truc
tions
Lea
ders
hip
Skill
sO
rgan
indi
onal
Sia
sIC
now
lecl
geof
Com
pany
Pol
icie
s/Pr
oced
ures
Kno
wle
dge
ofE
mpl
oyee
/Em
play
er R
espo
nsib
ilitie
sA
bilit
y to
Wor
k as
Per
t of
a T
eam
Kno
wle
dge
of C
ompa
ny Q
ualit
y A
ssur
ance
Act
iviti
esK
now
ledg
e of
Saf
ety
Reg
ulat
ions
/Res
pons
ibili
ties
Proj
ect/T
ask
Man
ages
nent
Ski
llsL
ogic
al/S
yste
mat
ic P
robl
em S
olvi
ng S
kills
Com
pute
r Sk
ills
Num
eric
aVM
athe
mat
ical
Ski
llsU
se M
easu
rem
ent T
ools
Use
Ins
pect
ion
Dev
ices
Dra
ftin
g Sk
ills
Kno
wle
dge
of I
ndus
tria
l Mat
eria
lsK
now
ledg
e of
Man
ufac
turi
ng P
roce
sses
Mec
hani
cal A
ptitu
de
ITA
WA
MB
A C
OM
MU
NIT
Y C
OL
LE
GE
MA
ST P
RO
GR
AM
RE
PRE
SEN
TA
TIV
ES
Dr.
Cha
rles
Chr
estm
anD
anei
rset
or
Don
Ben
jam
inA
ssoc
ies
Des
alSi
ts A
dnin
istr
itor
Bar
ry E
mbe
rsSi
te C
oed
sew
SUPE
R S
AG
LE
SS C
OR
P. R
EPR
ESE
NT
AT
IVE
S
Hoy
t Hub
bard
Gen
eral
Sup
ervi
sor
-'The
is D
ept
Rod
She
ffie
ldSu
perv
isor
- T
hol i
t Die
Dep
t.
267
TR
AIT
S A
ND
AT
TIT
UD
ES
Stro
ng W
ork
Eth
icIn
terp
erso
nal S
kills
Punc
tual
ityD
epen
dabi
lity
Hon
esty
Nea
tnes
sSa
fety
Con
scie
ntio
usM
otiv
atio
nR
espo
nsib
lePh
ysic
al A
bilit
yPr
ofes
sion
alT
rust
wor
thy
Pers
onal
Eth
ics
Inno
vativ
e
TO
OL
S A
ND
EQ
UIP
ME
NT
Mac
hini
st's
Too
ls (
e.g,
cal
iper
s, d
ial
indi
cato
rsm
agne
tic to
ol h
olde
rs, e
tc.)
Mea
suri
ng T
ools
Met
al L
ayou
t Too
lsPo
wer
Too
lsM
etal
Lat
he w
ith A
ttach
men
tsD
rillP
rass
esV
ertic
al M
ill w
ith A
ttach
men
tsB
and
Saw
sPo
wer
Dri
llsH
ydra
ulic
/Arb
or P
ress
Hea
t Tre
atm
ent E
quip
men
tB
adne
ss T
astin
g E
quip
men
tG
rind
ing
Mac
hine
s w
ith A
ttach
men
tsW
eldi
ng E
quip
men
tC
NC
Mac
hini
ng C
ente
r an
d T
umin
gC
ente
rlig
Boe
ing
Mac
hine
sA
lignr
nent
/Cab
linst
ion
Too
lsC
ompu
ter
Ven
tilat
ion
Equ
ipm
ent
Paid
&Pa
ssio
nal S
afet
y E
quip
men
tO
xyac
etyl
ene
Equ
ipm
ent
Too
l Sto
rage
Equ
ipm
ent
Wor
kben
ches
Vis
esPe
dest
al G
rind
.=C
oord
inat
e M
easu
rem
ent M
achi
ne
FUT
UR
E T
RE
ND
S A
ND
CO
NC
ER
NS
mop
esIn
-Pro
cess
Gau
ging
Rap
id T
ool C
hang
ing
Exp
ande
d C
omm
mic
atim
with
Sho
p Fl
oor
Mul
ti-A
xis
Equ
ipm
ent
Com
pute
r-In
tegr
ated
Man
ufac
turi
ngA
dapt
ive
Con
trol
sC
onve
rsat
iona
l Pro
gram
min
gA
rtif
icia
l Int
ellig
ence
CO
MPE
TE
NC
Y P
RO
FIL
E
BE
ST
CO
PY
AV
AIL
AB
LE
Too
l & D
ie M
aker
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
.199
J400
08)
268
TO
OL
AN
D D
IE M
AK
ER
....
skill
ed w
orke
rs w
ho p
rodu
ce to
ols,
die
s, a
nd s
peci
al g
uidi
ng a
nd h
oldi
ng d
evic
es th
atar
e us
ed in
mac
hine
s an
d pr
oduc
e a
vari
ety
of p
rodu
cts
Dut
ies
A B
Dem
onst
rate
CQ
ualty
Cen
tral
iised
nu:R
aim
ent
Dem
onst
rate
EIC
stow
kdge
of
Msa
afee
tarl
egPr
oces
ses
F
263 I
SSC
TD
IUM
S
lithX
DO
1/11
10:1
1
Perf
orm
Mea
sure
men
t/In
spec
tion
Dem
onst
rate
Com
mun
icat
ion
Skill
s
Tas
ksA
-1 F
ollo
wsa
fety
man
uals
and
all s
afet
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gula
tions
/re
quir
emen
ts
A-2
Mai
ntai
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quip
men
tan
d m
achi
nery
A-3
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clea
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d sa
few
ork
envi
ron-
man
A-4
Ens
ure
safe
ope
ratio
nof
mac
hine
s
A-5
Use
saf
em
achi
ning
prac
tices
A-6
Use
saf
elif
ting
prac
tices
A-7
Use
saf
eop
erat
ing
pro-
cedu
res
for
hand
sad
ma-
chin
e to
ols
--,
A4
Con
sult
and
appl
yM
SDS
for
haza
rds
of v
an-
iota
mat
eria
ls
A-9
Pra
ctic
epr
oper
tag-
out/
lock
-out
proc
edur
es
A -
10 P
ract
ice
elec
tric
al s
afet
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B-1
Per
form
basi
car
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func
tions
B-2
Int
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conv
ert
frac
tions
/de
cim
als
B-3
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er-
conv
ert M
etri
c/E
nglis
hm
easu
rem
ents
B-4
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form
basi
c al
gebr
aic
oper
atio
ns
B-S
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form
basi
ctr
igon
omet
ric
func
tions
B-6
Use
bas
icge
omet
ric
prin
cipl
es
B-7
Cal
cula
tean
d ap
ply
form
ulas
B-8
Use
end
appl
y ba
sic
conc
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of
tech
nica
lph
ysic
s,..
C-1
Util
ize
appr
opri
ate
msp
ectio
nte
chni
ques
C-2
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form
appr
opri
ate
use
and
calib
ratio
nof
inal
tect
ion
**M
ont
C-3
Kno
wqu
alita
tive
para
met
ers
ofm
achi
nery
and
equi
pmen
t
C-4
Kno
wop
erat
ion
ofco
ordi
nate
mea
suri
ngm
achi
ne
C-5
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ntai
n=
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oqu
ality
part
s
C-6
Kno
w a
ndus
e SP
C te
ch-
niqu
es a
nd c
on-
mitt
C-7
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tein
spec
tion
proc
edur
es
C.8
Doo
rman
insp
ectio
nre
sults
D-I
Ide
ntif
ym
ater
ials
with
desi
red
prop
ertie
s
D-2
Kno
wm
achi
nabi
lity/
wor
kabi
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ofva
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sm
ater
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D-3
App
lyco
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ts o
f an
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lcul
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stat
ics
and
stre
sses
D-4
Kno
w/F
ind
hard
ness
cha
r-ac
teri
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cs/
chem
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veno
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ater
ial
13-5
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on-
stud
s', m
uwi,
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atSs
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now
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r
0.7
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mat
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8-1
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8-2
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and
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and
tool
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E-3
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esan
d to
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8-4
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ders
8-5
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11.6
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8-7
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of g
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/ bra
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. 8-9
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8-10
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ofjig
-bo
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mac
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E-1
1 K
now
oper
atio
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and
cut
ter
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ders
8-12
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urn
saw
s
8-13
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cost
to p
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part
8-14
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roug
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r arT
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r
8-16
Cal
cula
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quir
ed f
orpr
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atio
ns
8-17
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llow
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e yi
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etal
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atic
s
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8 A
pply
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eter
ial
conc
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8-19
Cal
cula
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eeds
and
feed
s ba
sed
onm
ater
ish
and
tool
ing
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eco
ncep
ts a
nd8-
21 M
ake
calc
ulat
ions
for
sine
bar
/pla
te
8-22
&tin
geca
paci
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feq
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rm
arm
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8-23
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ulat
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for
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8-24
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ite E
OM
8-25
Kno
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conc
epts
of in
dust
rial
Pain
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plat
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8-26
Sch
edul
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mai
nten
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for
tool
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end/
orst
schi
se
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f
F-1
Prep
are
end
plan
for
CN
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erat
ions
F-2
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ct, m
e,en
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quir
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stem
s fo
rC
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mac
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s
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ually
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ram
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F-4
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Com
pute
r-A
ided
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r-&
duri
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AM
) sy
stem
.F-6
Tra
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fron
t CA
Msy
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tom
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ne
F-7
Inte
ract
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AD
and
CA
M f
iles
us,-
ing
MR
or
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IES
form
ats
F43
Inst
all a
ndm
aint
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file
tran
sfer
syst
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figu
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sys
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para
met
ers
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of
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., an
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s
0-2
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p-'ra
tion
of v
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tier,
dia
l, &
digi
tal c
alip
ers
0-3
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d an
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e sc
ale
and
tape
mea
sure
0-4
Kno
w o
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otio
n of
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re in
dica
tors
0-5
Kno
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p-na
tion
of d
ial
indi
cato
rs
0-6
Use
pre
ci-
sion
squ
are,
cent
er f
used
,an
d pr
otra
ctor
0-7
Use
dig
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read
out
0-8
Use
fin
ish/
prof
ile g
auge
s0-
9 K
now
oper
atio
n of
Ral
reel
lha
rdne
ss te
ster
H-1
Rea
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-te
rpre
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d ri
p-pl
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dorm
, let
ters
,an
d w
ritte
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-st
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H-2
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ter-
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, and
app
lyte
chni
cal r
e-po
rts,
pro
ce-
dare
s an
dm
enia
ls
H-3
Cor
rem
mi-
cats
tech
nica
lin
form
atio
nver
-be
lly
H-4
Rea
d, in
ter-
act,
and
appl
yFr
afila
, cha
rts,
and
calla
vis
ual
aids
H-5
Wri
tete
chni
cal
repo
rts,
proc
edur
es,
and
guid
elin
es
H-6
Wri
tem
anor
andt
me,
lette
rs, o
rin
stru
ctio
ns
1-1
Dem
onst
rate
trad
ition
alm
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nica
ldr
aftin
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ills
1-2
Use
Com
pute
r-A
ided
Dra
ftin
g(C
AD
) sy
stem
1-3
Cre
ate
3-D
solid
mod
els
1-4
Use
and
ap-
ply
OD
&T
met
hodo
logy
1-5
Gen
erat
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d/or
app
lyin
dust
ry o
rco
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1-6
Wat
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CA
D a
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or K
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ats
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um g
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MS
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In
MIS
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1111
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MPr
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ie(*
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1111
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ks
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Use
com
pute
sop
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syst
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1-2
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file
man
agem
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syst
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rmba
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on
ape
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ter
1-4
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-ag
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1-5
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com
pute
rne
twor
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stem
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Use
file
tran
sfer
syst
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1-7
Und
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appl
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ter
tam
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rdw
Ere
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Und
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232
prot
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K-3
Des
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part
s fo
rm
arke
tabi
lity
K-4
Pla
n an
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sign
for
"mat
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cost
cons
ciou
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ithde
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pats
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Inc
orpo
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safe
ty in
topr
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ign
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Int
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L-7
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hydr
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Con
duct
mul
tiple
pro
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activ
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N-2
Vis
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N-3
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sem
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die
set
N-4
Det
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slug
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N-5
Cal
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Det
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stri
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5r
271
BE
ST
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PY
AV
AIL
AB
LE
MO
1111
MIN
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R N
M 1
111
NIS
OM
MI M
O O
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I MN
IND
MIM
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ill
SKIL
LS
AN
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Com
mim
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Skill
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/Wri
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bilit
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Com
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ills
Org
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Com
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Kno
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bilit
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kills
Log
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/Sys
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Num
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athe
mat
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kills
Use
Mea
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men
t Too
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Way
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nM
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enan
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273
TR
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S A
ND
AT
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Stro
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Eth
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terp
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kills
Punc
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tnes
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Con
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espo
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bilit
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easu
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Con
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BE
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aker
Prep
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By
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TE
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TS
274
TO
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AN
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AK
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.... s
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Dut
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s(V
.199
J400
08)
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. TH
OM
AS
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IGH
TIN
G
213.
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TO
OL
AN
D D
IE M
AK
ER
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safe
wor
k en
v ir
on-
min
t
A-4
Ens
ure
safe
ope
ratio
nof
mac
hine
s
A-5
Use
saf
em
achi
ning
prac
tices
A-6
Use
saf
elif
ting
prac
tices
A-7
Use
saf
eop
erat
ing
pro-
cedu
res
for
hand
and
ma-
chin
e to
ols
A-8
Con
sult
and
appl
yM
SDS
for
haza
rds
of v
ar-
ions
mat
eria
ls
A-9
Pra
ctic
eFw
a ta
g-ou
t/lo
ck-o
utpr
oced
ures
A-1
0 Pr
actic
eel
ectr
ical
saf
ety
proc
edur
es
B-1
Per
form
basi
car
ithm
etic
func
tions
B-2
Int
er-
conv
ert
frac
tions
/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
B-5
Per
form
basi
ctr
igon
omet
ric
func
tions
B-6
Use
bas
icge
omet
ric
prin
cipl
es
13-7
Cal
cula
tean
d ap
ply
form
ulas
B-8
Use
and
appl
y ba
sic
conc
epts
of
tech
nica
lph
ysic
s
B-9
Use
and
appl
y ca
rtes
ian
coor
dina
tesy
stem
C-1
Wiz
. aap
prop
riat
ein
spec
tion
tech
niqu
es
C-2
Per
form
appr
opri
ate
use
and
calf
twet
ion
of in
spec
tion
equi
pmen
t
C-3
Kno
wqu
alita
tive
para
met
ers
ofm
achi
nery
and
equi
pmen
t
C-4
Kno
wop
erat
ion
ofco
ordi
nate
mea
suri
ngm
achi
ne
C-5
Mai
ntai
neq
uipm
ent t
opr
oduc
e qu
ality
part
s
C-6
Kno
w a
ndU
S. S
PC te
ch-
tinoc
e an
d co
n-ce
pts
C-7
Kno
w a
ndus
e R
IO 9
000
conc
epts
and
proc
edur
es
C-8
Doc
umen
tin
spec
tion
resu
lts
C-9
Wri
tein
spec
tion
proc
edur
es
D-1
Ide
ntif
ym
ater
ials
with
desi
red
prop
ertie
s
D-2
Kno
wm
achi
nabi
lity/
wor
kabi
lity
ofva
riou
sm
ater
ials
D-3
App
lyco
ncep
ts o
f an
dca
lcul
ate
stat
ics
and
stre
sses
D-4
1C
now
/Fix
lha
rdne
ss c
har-
nota
rial
&ch
emis
try
ofva
riou
s m
ater
ial
13-5
Dem
on-
know
'-It
ilte.
_ "E
w',.
. :e°
86..
..."
"es'
ursa
wa8
,___
_ and
"le
uss
Prop
ertie
s
D-6
Dem
on-
stat
e kn
owl-
edge
of
carb
onin
dex
D-7
Kno
wdr
ess
relie
ving
proc
edur
es
8-8
Det
erm
ine,
inte
rpre
t, an
dev
alua
teav
aila
bilit
y of
mat
eria
ls
B-1
Kno
w(w
akes
of
vert
ical
end
1101
i213
11M
I nu
llsan
d to
olin
g
2-2
Kno
wop
erat
ion
ofen
gine
and
turr
et la
thes
and
tool
ing
2-3
Kno
wop
erat
ion
ofdr
ill p
ress
esan
d to
olin
g
13-4
Kno
wop
erat
ion
ofst
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and
cylin
dric
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rs
2-S
ICno
w o
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atio
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hes
ttr
eatin
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uip-
men
t/pro
cess
es
2-6
Kno
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otio
n of
wel
d-in
g eq
uipm
ent
2-7
Kno
wop
erat
ion
of g
ascu
tting
equi
pmen
t
13-8
Kno
wop
erat
ion
ofpu
nch
/ bak
epr
esse
s an
dto
olin
g
E-9
Kno
wof
p et
a sh
ears
2-10
Kno
wop
erat
ion
ofjig
-bo
ring
rosc
hmee
end
tool
ing
2-11
Kno
wop
erat
ion
ofto
ol a
nd c
utte
rgr
inde
rs
E-1
2 K
now
op-
emtio
n of
ben
dan
d ra
dial
um
saw
s
2-13
Kno
wop
erat
ion
ofim
e 2D
M
2-14
Kno
wpr
oper
flo
w o
fpa
rts
thro
ugh
shop
2-15
Hav
ekn
owle
dge
ofC
NC
l arr
uare
ung.
2-16
Cal
cula
teto
nnag
esre
quir
ed f
orpr
ess
oper
atio
ns
E-1
7 C
alcu
late
bend
allo
wan
ces
/ use
yie
ld ta
bles
for
shee
t met
alop
erat
ions
2-18
App
lyco
nser
vatio
nof
mat
eria
lco
ncep
ts
2-19
Cal
cula
tesp
eeds
and
feed
s ba
sed
onm
star
ials
and
tool
ing
2-20
Ulli
nsco
ncep
ts a
ndpr
inci
ples
of
2-21
Mak
eca
lcul
atio
ns f
orsi
ne b
ar/p
lata
2-22
Est
inah
stin
e re
quir
edsi
xVor
cos
t to
prod
uce
past
2-23
Mak
eca
lcul
atio
ns f
orro
tary
tabl
e an
d..1
g he
ed
2-24
Sch
edul
epr
even
tive
mai
nten
ance
for
tool
ing
mis
el/e
rm
achi
ne
2-25
Kno
wba
sic
conc
epts
of in
dust
rial
pain
ting/
plat
ing
F-1
Prep
are
and
plan
for
CN
C m
arin
es-
Mg
oper
atio
ns
F-2
Sele
ct, u
se,
and
acqu
ire
tool
ing
syst
ems
for
CN
C m
achi
nes
F-3
Man
ually
prog
ram
CN
Cm
achi
nes
F-4
Set a
nd u
seto
olin
g of
fset
sat
CN
C m
achi
ne
F-5
Use
Com
pute
r-A
ided
- M
enu
-le
ctur
ing
(CA
M)
syst
em
17-4
5 T
rans
fer
file
s fr
om C
AM
syst
em to
mac
hke
F-7
Inte
rnal
-ve
nt C
AD
and
CA
M f
iles
us-
ing
DX
17 o
r10
ES
form
ats
1741
Ins
tall
and
mai
ntai
n fi
letr
ansf
ersy
stem
s
F-9
Cm
fieu
eC
AM
sys
tem
para
met
ers
0-1
Kno
w o
p-=
rim
of
0.D
.,ID
., w
id d
epth
mic
rom
eter
s
0-2
Kno
w o
p-er
asio
n of
ver
-ni
ts-,
dia
l, &
digi
tal c
alip
ers
0-3
Rea
d an
dus
e sc
ale
end
tape
mea
sure
0-4
Kno
w o
p-*r
atio
n of
dia
l-bo
re in
dica
tors
0-5
Kno
w o
p-or
atio
n of
dia
lin
dica
tors
0-6
Use
pre
oi-
sion
squ
are,
cent
er h
eld,
and
prot
ract
or
0-7
Use
dig
ital
read
-out
0-8
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fin
ish/
prof
ile g
auge
s0-
9 K
now
oper
atio
n of
Roc
kwel
lha
rdne
ss te
ster
(3-1
0 K
now
oper
atio
n of
osci
llosc
ope
0-11
Kno
wop
erat
ion
ofm
ultin
eter
0-12
Kno
wop
erat
ion
ofm
es-o
lin m
eter
(mw
ner)
WI
Ree
d, in
-te
rpre
t, an
d ap
-pl
y m
ane:
ran-
duns
, let
ters
,an
d w
ritte
n in
-st
ruct
ions
11-2
Rea
d, in
ter-
pret
, and
app
lyts
chnk
alre
-po
rts,
pro
ne-
rite
s an
dm
anua
ls
11-3
Cum
uli-
care
tech
nica
lin
form
atio
n ve
r-be
lly
H-4
Rea
d, in
ter-
Pret
, and
app
lygi
Bla
h% c
hart
.6n
4 O
ther
vis
ual
aids
31-5
Wri
tete
chni
cal
repo
rts,
proc
edur
es,
and
guid
elin
es
1-1-
6 W
rite
mem
oran
dum
s,le
tters
, or
inst
ruct
ions
1-1
Dem
onst
rate
trad
ition
alm
eclu
mic
aldr
aftin
g sk
ills
1-2
Use
Com
pute
r-A
ided
Dra
ftin
g(C
AD
) sy
stem
1-3
Cre
ate
IDso
lid m
odel
s1-
4 U
se a
nd a
p-*0
MT
met
hodo
logy
1-5
Gen
erat
ean
d/or
app
lyin
dust
ry o
rco
mpa
nyst
anda
rds
1-6
Inte
rcon
-ve
tt C
AD
and
DX
F or
IC
ES
form
ats
1-7
conn
ive
CA
D s
yste
mpa
ram
eter
s
BE
ST C
OPY
AV
AIL
AB
LE
an a
m s
o lie
MI
Nil
MI
INE
itM
tM
I M
O O
N -
-N
ipis
mgi
s
1111
11M
INM
ID M
I M
ISI1
111
1111
1M
I M
I M
IS a
l NM
I M
N I
MO
- M
I N
MI
ON
Dut
ies In
ergi
nefU
seH
hisp
rIed
e an
dR
aide
d eats
MPt
elea
ske
Pesf
erse
Die
Ope
ratio
ns
TH
OIL
UV
IIIP
MS
KO
SOO
U11
1093
Tas
ksJ-
I U
seco
mpu
ter
Wor
ding
syst
ems
1-2
Use
file
man
agem
ent
syst
ems
J-3
Perf
orm
back
up o
n a
pers
onal
com
pute
r
J-4
buta
llAue
soft
war
e pa
ck-
ages
1-5
Use
com
pute
rne
twor
k sy
stem
16 U
se f
iletr
ansf
ersy
stem
s
3-7
Und
erst
and
and
appl
yco
mpu
ter
term
inol
ogy
1-8
Hav
ew
orki
ngkn
owle
dge
ofhi
rdw
anco
mpo
nent
s
1-9
Und
erst
and
RS-
232
prot
ocol
K-I
Des
ign
pans
for
men
u-fa
cto
abili
ty
K-2
Des
ign
pens
for
func
tiona
lity
K-3
Des
ign
part
s fo
rm
arke
tabi
lity
K-4
Pla
n an
dde
sign
for
"mat
ing
ofpa
rts"
K-5
Be
coat
cons
ciou
s w
ithde
sign
of
part
s
K-6
Inc
orpo
rate
safe
ty in
topr
oduc
t des
ign
K-7
Det
erm
ine,
inte
rpre
t, an
dev
alua
tecu
stom
ersp
ecif
icat
ions
K-8
Des
ign,
docu
men
t, an
dva
lidat
e te
stin
gm
etho
ds
K-9
Coo
rdin
ate
Prod
uctio
n of
prot
otyp
e
I-'_
_1Inta
lrek
_,rr
virw
wig
.
aPPl
y bl
unPr
in,
note
s, d
imen
-si
tes,
and
tole
ranc
es)
L2
Inte
rpre
tan
d un
ders
tand
basi
c la
yout
/ty
pes
of
L-3
Und
erst
and
and
anal
yze
bill
ofm
ater
nbi
L-4
Asc
erta
injo
b re
quir
e-m
anta
fro
mdr
awin
gs
L-5
Int
erpr
etan
d ap
ply
geom
etri
cdi
rmen
sion
in,g
and
tole
ranc
mg
L-6
Int
erpr
etan
d ap
ply
elec
tric
alsc
hem
atic
diag
ram
s
L-7
Int
erpr
etan
d ap
ply
hydr
aulic
or
pneu
mat
icdi
agra
ms
1..-
13 I
nter
pret
and
appl
y pl
ant
layo
ut d
raw
ings
L-9
Int
erpr
etan
d ap
ply
digi
tal l
ogic
diag
ram
s
M-1
Com
pile
and
colla
tein
form
atio
n
M-2
Con
duct
mul
tiple
pro
ject
man
agem
ent
M-3
Set
and
mai
ntai
ntim
elin
es
.-
M-4
Pri
oriti
zeag
dutie
proj
ects
M-5
Pre
plan
proj
ect
activ
ities
M.6
Dem
onst
rate
timeh
esou
roe
man
agem
ent
M-7
Per
form
rese
arch
M8
Car
greh
end
entir
e sc
ope
ofpr
ojec
t
M-9
Ass
ess
and
eval
uate
/R
evis
e or
mod
ifY
Proi
ocl
met
hodo
logy
N-I
Ubl
ize
basi
c di
eth
eory
N-2
Vis
ually
insp
ect d
ieco
mpo
nent
s fo
rda
mag
e
N-3
Dis
asse
mbl
ean
d as
sem
ble
die
set
N-4
Det
erm
ine
prop
er c
uttin
g,eJ
eara
noe,
and
slug
rel
ief
N-5
Cal
cula
tepr
oper
shu
t-he
ight
of
die
set
N-6
Des
ign
stoc
k st
rip
layo
ut
N-7
Det
erm
ire
prar
a to
nnag
ere
quir
emen
ts
N-8
Cal
cula
test
ripp
ing
pres
sure
s
0S
283
BE
ST C
OPY
AV
AIL
AB
LE
APPENDIX B - PILOT PROGRAM NARRATIVE
What follows is a narrative of the pilot program which was conducted for this particularoccupational specialty.
285
MAST STUDENT PILOT PROGRAMDESCRIPTION / NARRATIVE
Located in the industrialized northeast section of Mississippi, Itawamba Community College'sTupelo campus is a primary training facility for traditional and non-traditional students desiringemployment in the industrial sector by making quality training accessible and affordable to thegeneral population. Having worked closely with local manufacturing and industrial partners, thecollege has maintained an open training policy with the flexibility to meet local manpower needs.Many graduates transfer and successfully complete higher degrees at four year institutions whileothers enter successful careers in manufacturing and industry.
During the fall semester, 1995, and spring semester, 1996, Itawamba Community Collegeparticipated in the MAST Pilot Program for Tool and Die Making Technology. Instructorstrained students to the technical workplace competencies defined by MAST and industrialpartners in the project using curriculum currently endorsed by the Mississippi State Department ofEducation.
Members of the pilot group included all freshmen entering the Tool and Die Making Technologyprogram on the Tupelo campus. The normal student population for the college is mirrored in thepilot group with the majority being traditional, full time students. Special populations representedinclude veterans, single parents, socioeconomically depressed, and non-traditional occupationalfields.
As most students attending Itawamba Community College on a full time basis do secure someform of outside financial assistance, all pilot program participants have followed standard entranceprocedures of the college which included the opportunity for making application to variousavailable funding sources for aid. Nearly 85% of the participants financed their training through acombination of grants, scholarships, loans, and part time work: two grants were awarded; fiveloans have been secured; eight scholarships were given; and one position through the Work-StudyProgram was filled. One participant received the 1995-1996 Luther Garrett-Joe Lewis MemorialScholarship, a statewide honor given annually to one outstanding high school student to beenrolled at the community college level. Instructors have worked closely with financiallydepressed students in helping them secure part time work in the private sector. Of pilot projectparticipants, 38% are currently employed in out-of-school, field-related positions.
To determine the program's effectiveness, the students were assessed at the beginning of the Fallsemester using criteria contained in the Student Examination. A copy of this form is provided anda brief description given below. As indicated, the students will be evaluated again near the end ofthe Spring semester to assess theprogress made in the first year of the program. As Tool and DieTechnology is a two-year Associate Degree program, participants will not have received fullbenefits of instruction by the end of this period. The students, however, will be evaluated uponcompletion of training to insure mastery of all competencies as defined by MAST and industrialpartners. Intentions are to track these individuals into the workforce and determine their actualreadiness and performance against the employers' expectations.
286
MAST Pilot Program Student AssessmentAnalysis of Results
1. MAST Consortia Partner College:Itawamba Community College at Tupelo, Mississippi
2. Number and category of those enrolled in the program:
Started Finished
13 13 100 % Completion Rate
12 12 Male1 Female
12 12 White1 1 Black0 0 Hispanic0 0 Asian0 0 Native American0 0 Foreign
* Please note that in the following section that some students fall into more than onecategory.
0 0 Single Head of Household2 2 Single Parent0 0 Disability (Physical or Mental)2 2 Social / Economic Status (gross family income of
$22,800 or less)1 1 Non-traditional Occupational Fields (females in all
high technology areas, and all minorities in all hightechnology fields except welding and conventionalmachining)
12 12 Traditional Students
3. Entrance and exit examination description:
All students were evaluated on their individual abilities to meet the minimum standards fortechnical workplace competencies of a Tool and Die Maker. These evaluations wereconducted by the Tool and Die Technology instructors at the college after given sufficienttime to observe the students during the first weeks of their first semester. The student'sgrade reflects a subjective evaluation of his/her ability to perform the required duties andtasks of a Tool and Die Maker. Emphasis was placed on the students' classroom
287
participation, shop demeanor, test performance, and overall ability to comprehend thematerial presented. This evaluation will be conducted again near the end of the secondsemester and will be compared to the first to determine the effectiveness of the program.At the time this was written, the exit examination had not been conducted since theprogram is only partially completed. A copy of the evaluation form, showing eachcompetency and the rating scale, is provided.
4. Pilot Test Results:
entry Category
7 48 Single Parent22 63 Social / Economic Status (gross family income of
$22,800 or less)5 44 Non-traditional Occupational Fields (females in all
high technology areas, and all minorities in all hightechnology fields except welding and conventionalmachining)
19 60 Traditional Students
* Values shown are the average score for each category and reflect ratio between currentproficiency level and expected exit proficiency level (after 2 years in program)
258
WM
All
OM
' Eli
IRIS
NM
IM
INI
ON
OIl
iaIW
O O
M o
rs M
INM
IMI
Ill/
1111
111
SIM
.
TE
CH
NIC
AL
WO
RK
PLA
CE
CO
MP
ET
EN
CIE
S F
OR
TO
OL
& D
IEM
AK
ER
ST
UD
EN
T E
XA
MIN
AT
ION
Nam
e:D
ate:
Inst
ruct
or:
Dire
ctio
ns: S
elec
t the
app
ropr
iate
rat
ing
for
this
stu
dent
on e
ach
com
pete
ncy
liste
d be
low
.R
atin
g S
cale
:1
No
or v
ery
little
kno
wle
dge
inar
ea; r
equi
res
cons
tant
sup
ervi
sion
2 Li
mite
d kn
owle
dge
in a
rea;
req
uire
s cl
ose
supe
rvis
ion
3 A
vera
ge k
now
ledg
e in
are
a; r
equi
res
regu
lar s
uper
visi
on4
Abo
ve a
vera
ge k
now
ledg
e in
are
a; r
equi
res
min
imum
supe
rvis
ion
5 M
aste
ry o
f kno
wle
dge
in a
rea;
abl
e to
com
preh
end
and
appl
y w
ithou
t sup
ervi
sion
A.
PR
AC
TIC
E S
AF
ET
Y:
1 F
ollo
w s
afet
y m
anua
ls a
nd a
ll sa
fety
regu
latio
ns/r
equi
rem
ents
:a.
Com
ply
with
est
ablis
hed
com
pany
and
OS
HA
reg
ulat
ions
b.In
terp
ret s
afet
y m
anua
l dire
ctiv
esc.
Wea
r sa
fety
/ pr
otec
tive
equi
pmen
tas
req
uire
d2
Mai
ntai
n sa
fe e
quip
men
t and
mac
hine
ry:
a.M
aint
ain
equi
pmen
t/too
ling
in s
afe
oper
atio
n co
nditi
onb.
Mai
ntai
n al
l gua
rds,
shi
elds
, and
bar
riers
in p
lace
and
in g
ood
cond
ition
c.P
erfo
rm p
reve
ntiv
e m
aint
enan
ce a
s re
quire
dd.
Pra
ctic
e pr
oper
tag-
out/l
ock-
out p
roce
dure
s3
Mai
ntai
n a
clea
n an
d sa
fe w
ork
envi
ronm
ent:
RA
TIN
G S
CA
LE1
12
34
a.K
eep
wor
k ar
eas
clea
n an
d fr
ee o
f deb
risb.
Kee
p is
les
/ tra
ffic
area
s cl
ear
of e
quip
men
t and
mat
eria
lsc.
Sto
re m
ater
ials
, too
ls, a
nd in
stru
men
ts in
org
aniz
edm
anne
rd.
Cle
an m
achi
ne /
hand
tool
s w
hen
wor
k is
com
plet
e4
Use
saf
e op
erat
ing
proc
edur
es fo
r ha
nd a
nd m
achi
neto
ols
a.U
se to
ols
for
inte
nded
pur
pose
s on
lyb.
Acq
uire
pro
per
trai
ning
/ au
thor
izat
ion
befo
re o
pera
ting
equi
pmen
tc.
Ope
rate
han
d an
d m
achi
ne to
ols
in s
afe
man
ner
i
_4d.
Com
ply
with
man
ufac
ture
r's r
ated
cap
acity
for
equi
pmen
t!
re.
Ens
ure
all r
otat
ing
or m
ovin
g pa
rts
have
sto
pped
bef
ore
leav
ing
area
i
289
f.In
spec
t for
and
rem
ove
poss
ible
haz
ards
bef
ore
enga
ging
equi
pmen
t
291
NA
ME
:IN
ST
RU
CT
OR
:S
TU
DE
NT
EX
AM
INA
TIO
N: T
OO
L A
ND
DIE
CO
MP
ET
EN
CIE
SP
AG
E 2
RA
TIN
G S
CA
LEi
2131
4151
5 U
se s
afe
mac
hini
ng p
ract
ices
a.E
nsur
e st
ock
/ too
ling
is s
ecur
e be
fore
mac
hini
ngb.
Use
chi
p co
ntro
l met
hods
c.U
se m
oder
ate,
saf
e, a
nd c
alcu
late
d sp
eeds
and
feed
sd.
Sta
y al
ert a
nd p
repa
red
to a
ct d
urin
g m
achi
ning
e.E
nsur
e ro
tatin
g pa
rts
/ too
ling
are
com
plet
ely
stop
ped
befo
reha
ndlin
g6
Use
saf
e lif
ting
prac
tices
a.U
se li
fting
aid
s w
hen
nece
ssa
b.U
se O
SH
A a
ppro
ved
chai
ns, s
trap
s, a
nd h
oist
sc.
Com
ply
with
rat
ed c
apac
ity o
f lift
ing
equi
pmen
td.
Com
ply
with
com
pany
/ O
SH
A r
egul
atio
ns r
egar
ding
lifti
ngpr
oced
ures
7 C
onsu
lt an
d ap
ply
MS
DS
for
haza
rds
of v
ario
usm
ater
ials
a.K
now
form
at o
f mat
eria
l saf
ety
data
she
ets
b.C
onsu
lt an
d in
terp
ret M
SD
S to
det
erm
ine
rele
vant
haz
ards
of m
ater
ial
c.A
pply
info
rmat
ion
and
take
pre
caut
iona
rym
easu
res
agai
nst h
azar
dsd.
Not
ify p
rope
r au
thor
ities
of h
azar
ds
ry
B.
AP
PLY
MA
TH
EM
AT
ICA
L C
ON
CE
PT
S1
Per
form
bas
ic a
rithm
etic
func
tions
a.A
dd, s
ubtr
act,
mul
tiply
, and
div
ide
who
le n
umbe
rsb.
Add
, sub
trac
t, m
ultip
ly, a
nd d
ivid
e fr
actio
nsc.
Add
, sub
trac
t, m
ultip
ly, a
nd d
ivid
e de
cim
als
d.In
terc
onve
rt fr
actio
ns /
deci
mal
se.
Inte
rcon
vert
Met
ric /
Eng
lish
mea
sure
men
ts2
Per
form
bas
ic a
lgeb
raic
ope
ratio
nsa.
Eva
luat
e eq
uatio
n us
ing
stan
dard
alg
ebra
ic h
iera
rchy
Ir
b.S
olve
equ
atio
ns w
ith o
ne u
nkno
wn
varia
ble
c.S
olve
rat
io /
perc
enta
ge p
robl
ems
d.C
alcu
late
and
app
ly fo
rmul
as1
3 P
erfo
rm b
asic
trig
onom
etric
func
tions
a.S
olve
for
unkn
own
side
s/an
gles
of r
ight
tria
ngle
s us
in tr
igon
omet
ricfu
nctio
ns f
b.S
olve
for
unkn
own
side
of r
ight
tria
ngle
usi
ng P
ytha
gore
an's
The
orem
1
} 1
rr
1
r
Ole
MIN
=IC
IN
K M
N I
NS
1111
11 -
IM
PIN
S SO
ME
MI
iOM
MI
NI
NM
inO
N
1111
1111
1111
1i N
M M
IMI
kill'
All
lilt
Oil
apt
NIB
1111
:111
111
1111
11.1
1111
1,11
1111
1111
0
NA
ME
:IN
ST
RU
CT
OR
:S
TU
DE
NT
EX
AM
INA
TIO
N: T
OO
L A
ND
DIE
CO
MP
ET
EN
CIE
SP
AG
E 3
RA
TIN
G S
CA
LE4
Use
bas
ic g
eom
etric
prin
cipl
esa.
Sol
ve fo
r su
rfac
ear
ea, p
erim
eter
, and
vol
ume
of c
ube
b.S
olve
for
surf
ace
area
, per
imet
er, a
nd v
olum
e of
rect
angu
lar
solid
c.S
olve
for
surf
ace
area
, per
imet
er, a
nd v
olum
e of
rig
ht tr
iang
ular
sol
idd.
Sol
ve fo
r su
rfac
e ar
ea, p
erim
eter
, and
vol
ume
ofcy
linde
re.
Fin
d di
agon
al o
f a s
quar
e5
Use
and
app
ly C
arte
sian
coo
rdin
ate
syst
ema.
Def
ine
the
Car
tesi
an c
oord
inat
esy
stem
b.C
alcu
late
coo
rdin
ates
of b
olt c
ircle
on C
arte
sian
coo
rdin
ate
syst
emc.
Plo
t mac
hini
ng p
oint
s us
ing
Car
tesi
an c
oord
inat
esy
stem
2
T
I
1C
.D
EM
ON
ST
RA
TE
QU
ALI
TY
CO
NT
RO
L A
ND
MA
NA
GE
ME
NT
1 U
tiliz
e ap
prop
riate
insp
ectio
nte
chni
ques
a. b. c.
Dis
cuss
fact
ors
that
affe
ct a
ccur
ate
mea
sure
men
tD
eter
min
epr
oper
pro
cedu
re to
acq
uire
acc
urat
e m
easu
rem
ent
Det
erm
ine
prop
er in
stru
men
t to
use
in m
easu
rem
ent
2 P
erfo
rm a
ppro
pria
teus
e an
d ca
libra
tion
of in
spec
tion
equi
pmen
ta.
Exp
lain
cal
ibra
tion
requ
irem
ents
of v
ario
us p
reci
sion
inst
rum
ents
b.M
aint
ain
/ car
e fo
r in
stru
men
ts fo
r opt
imum
per
form
ance
c.R
ead
and
use
0.D
., I.D
., an
d de
pth
mic
rom
eter
sd.
Rea
d an
d us
e ve
rnie
r, d
ial,
&di
gita
l cal
iper
se.
Rea
d an
d us
e sc
ale
and
tape
mea
sure
f.R
ead
and
use
dial
-bor
e in
dica
tors
g.U
se d
ial i
ndic
ator
sh.
Use
pre
cisi
onsq
uare
and
com
bina
tion
set
i.R
ead
and
use
digi
tal r
ead-
out
j.U
se fi
nish
/ pr
ofile
gaug
esk.
Use
Roc
kwel
l har
dnes
s te
ster
I.K
now
ope
ratio
n of
coo
rdin
ate
mea
surin
g m
achi
ne (
CM
ML
m.
Use
sur
face
pla
tes
293
-L
--
---
1--
- -
T
NA
ME
:IN
ST
RU
CT
OR
:S
TU
DE
NT
EX
AM
INA
TIO
N: T
OO
L A
ND
DIE
CO
MP
ET
EN
CIE
SP
AG
E 4
RA
TIN
G S
CA
LE1
3 K
now
qua
litat
ive
para
met
ers
ofm
achi
nery
and
equ
ipm
ent
112!
3 L
4151
a.D
iffer
entia
te b
etw
een
type
s of
mac
hine
ry b
y qu
alita
tive
capa
bilit
ies
F--
T tj
b.S
elec
t app
ropr
iate
pro
cess
es to
mai
ntai
n de
sire
dto
lera
nces
c.D
iscu
ss th
e ef
fect
one
pro
cess
mig
ht h
ave
on a
n ea
rlier
or
late
r pr
oces
s4
Mai
ntai
n eq
uipm
ent t
o pr
oduc
e qu
ality
part
sa.
Just
ify to
olin
g by
qua
litat
ive
requ
irem
ents
b.P
rote
ct /
mai
ntai
n cr
itica
l sur
face
s of
mac
hine
sc.
Per
form
pre
vent
ive
mai
nten
ance
on e
quip
men
t5
Kno
w a
nd u
se q
ualit
y sy
stem
sa.
Kno
w a
nd u
se IS
O 9
000
conc
epts
and
proc
edur
esb.
Kno
w a
nd u
se S
tatis
tical
Pro
cess
Con
trol
(SP
C)
tech
niqu
es a
nd c
once
pts
6 W
rite
insp
ectio
n pr
oced
ures
a.D
eter
min
e / d
esig
nate
pro
per
insp
ectio
n te
chni
que
b.D
eter
min
e / d
esig
nate
pre
caut
ions
to ta
kedu
ring
insp
ectio
nc.
Det
erm
ine
/ des
ign
insp
ectio
n jig
or fi
xtur
e re
quire
dI
--r
--I
1----1
--1
d.Li
st in
ord
er a
nd d
efin
e st
eps
requ
ired
toen
sure
acc
urat
e m
easu
rem
ent
4--
7 D
ocum
ent i
nspe
ctio
n re
sults
a.D
efin
e pr
oced
ure
used
dur
ing
insp
ectio
n1
1
b.A
ccur
atel
y do
cum
ent m
easu
rem
ents
take
n an
dco
mpa
re to
sta
ndar
d1
rc.
Det
erm
ine
/ doc
umen
t if p
art
pass
es o
r fa
ils in
spec
tion
!
d.D
eter
min
e / d
ocum
ent r
ewor
kor
scr
ap r
ecom
men
datio
ns
DD
EM
ON
ST
RA
TE
KN
OW
LED
GE
OF
MA
NU
FA
CT
UR
ING
MA
TE
RIA
LS1
Iden
tify
mat
eria
ls w
ith d
esire
d pr
oper
ties
295
a.D
eter
min
e/id
entif
y se
rvic
e re
quire
men
ts (
stre
ngth
,ha
rdne
ss, e
tc.)
Jb.
Det
erm
ine,
inte
rpre
t, an
d ev
alua
te a
vaila
bilit
y of
mat
eria
lsL
I, !
c.D
escr
ibe
gene
ral c
hara
cter
istic
s of
var
ious
met
als
d.K
now
con
cept
s of
/ ca
lcul
ate
stat
ics
and
stre
sses
I--
"T-r
-
2 D
emon
stra
te k
now
ledg
e of
phy
sica
lpr
oper
ties
of m
ater
ials
a.D
efin
es h
ardn
ess
b.D
efin
es to
ughn
ess
gig
um,
,iniA
Nag
ale
gm a
ss a
tel
k ra
ta /h
i11
1111
1M
B-
MI
AM
MIN
II Ili
MIN
1111
1111
111
1111
111
1111
111
0 M
N M
IN 0
11 la
AM
R M
N Il
i MN
NA
ME
:S
TU
DE
NT
INS
TR
UC
TO
R:
EX
AM
INA
TIO
N: T
OO
L A
ND
DIE
CO
MP
ET
EN
CIE
S
2 D
emon
stra
te k
now
ledg
e of
phys
ical
pro
pert
ies
of m
ater
ials
con
t.L
1c. d. e. f. g. h.
Def
ine
tens
ile s
tren
gth
Def
ine
shea
r st
reng
thD
efin
e el
astic
ityD
efin
e du
ctili
tyD
iscu
ss th
e R
ockw
ell a
nd B
rinel
l har
dnes
ssc
ales
Dis
cuss
the
Cha
rpy
/ lzo
d im
pact
test
s.
3 Id
entif
y m
anuf
actu
ring
prop
ertie
s of
mat
eria
lsa.
Dis
cuss
mac
hina
bilit
y of
var
ious
mat
eria
ls1
rL
b.D
iscu
ss c
old
form
ing
/ wor
kabi
lity
of v
ario
us m
ater
ials
, ,T
-tc.
Def
ine
wor
k ha
rden
ing
/ edg
eha
rden
ing
1
1
d.Id
entif
y w
eldi
ng p
rope
rtie
s of
var
ious
mat
eria
lsr
T-
I
1---
----
-4-
----
- -1
.---
--1
- -
- -
---
e.D
emon
stra
te k
now
ledg
e of
hea
t tre
atin
g pr
oced
ures
and
_pro
pert
ies
f.K
now
Kno
w s
tres
s re
lievi
ngpr
oced
ures
g.K
now
/ F
ind
hard
ness
cha
ract
eris
tics
and
chem
istr
y of
var
ious
mat
eria
lsI
-44
Dis
cuss
cla
ssifi
catio
nsy
stem
for
met
als
PA
GE
5R
AT
ING
SC
ALE
2 i
3
1_
a.Id
entif
y an
d di
scus
s ty
pes
of c
arbo
n st
eel
b.D
eter
min
e ch
emis
try
of m
ater
ial b
y cl
assi
ficat
ion
c.D
istin
guis
h be
twee
n S
AE
and
AIS
I cla
ssifi
catio
nsy
stem
sd.
Iden
tify
desi
gnat
ion
of e
ach
digi
t of s
teel
cla
ssifi
catio
ne.
Dis
cuss
allo
y st
eels
E.
DE
MO
NS
TR
AT
E K
NO
WLE
DG
E O
F M
AN
UF
AC
TU
RIN
GP
RO
CE
SS
ES
1 K
now
ope
ratio
n of
ver
tical
and
horiz
onta
l mill
s an
dto
olin
ga.
Def
ine
mill
ing
mac
hine
s, h
oriz
onta
l and
vert
ical
b.Li
st, d
escr
ibe,
and
giv
e fu
nctio
n an
d m
aint
enan
ceof
diff
eren
t typ
esof
tool
ing
used
on
mill
ing
mac
hine
sc.
Set
-up
and
oper
ate
horiz
onta
l and
ver
tical
mill
ing
mac
hine
d.E
xpla
in m
achi
ne c
ompo
nent
s an
d ac
cess
orie
s of
mill
ing
mac
hine
se.
Exp
lain
mill
ing
proc
esse
sf.
Dis
cuss
mill
ing
mac
hine
saf
ety
g.D
iscu
ss C
NC
mac
hini
ng c
ente
rs a
ndpr
oces
ses
h.C
alcu
late
spe
eds
and
feed
s ba
sed
on m
ater
ials
and
tool
ing
i.S
et-u
p an
d op
erat
e C
NC
mac
hini
ng c
ente
r
297
-+
-_
BE
STC
OPY
AV
AIL
AB
LE
as
293
NA
ME
:IN
ST
RU
CT
OR
:S
TU
DE
NT
EX
AM
INA
TIO
N: T
OO
L A
ND
DIE
CO
MP
ET
EN
CIE
S
2 K
now
ope
ratio
n of
eng
ine
and
turr
et la
thes
and
tool
ing
a.D
efin
e la
thes
, eng
ine
and
turr
etb.
List
, des
crib
e, a
nd g
ive
func
tion
and
mai
nten
ance
of v
ario
us ty
pes
of to
olin
g us
ed o
n la
thes
c.S
et-u
p an
d op
erat
e en
gine
and
turr
et la
thes
d.E
xpla
in m
achi
ne c
ompo
nent
s an
d ac
cess
orie
s of
lath
ese.
Exp
lain
turn
ing
proc
esse
sf.
Dis
cuss
lath
e sa
fety
g.D
iscu
ss C
NC
turn
ing
cent
ers
and
proc
esse
sh.
Cal
cula
te s
peed
s an
d fe
eds
base
don
mat
eria
ls a
nd to
olin
gi.
Set
-up
and
oper
ate
CN
C tu
rnin
g ce
nter
3 K
now
ope
ratio
n of
dril
l pre
sses
and
tool
ing
a.Id
entif
y ty
pes
of d
rillin
g m
achi
nes
b.Li
st, d
escr
ibe,
and
giv
e fu
nctio
n an
d m
aint
enan
ceof
var
ious
type
s of
tool
ing
used
on
drill
ing
mac
hine
sc.
Set
-up
and
oper
ate
drill
ing
mac
hine
sd.
Exp
lain
mac
hine
com
pone
nts
and
acce
ssor
ies
of d
rillin
g m
achi
nes
e.E
xpla
in p
roce
sses
per
form
ed o
n dr
illin
g m
achi
nes
f.D
iscu
ss d
rillin
g sa
fety
g.D
iscu
ss d
rillin
g op
erat
ions
on
CN
C d
rillin
g m
achi
nes
h.C
alcu
late
spe
eds
and
feed
s ba
sed
on m
ater
ials
and
tool
ing
i.S
et-u
p an
d op
erat
e C
NC
dril
ling
mac
hine
4 K
now
ope
ratio
n of
sur
face
and
cyl
indr
ical
grin
ders
a.D
efin
e gr
inde
rs, s
urfa
ce a
nd c
ylin
dric
alb.
Exp
lain
type
s an
d m
aint
enan
ce o
f grin
ding
whe
els
c.S
et-u
p an
d op
erat
e gr
indi
ng m
achi
nes
d.E
xpla
in m
achi
ne c
ompo
nent
s an
d ac
cess
orie
s of
grin
ding
mac
hine
se.
Exp
lain
grin
ding
pro
cess
esf.
Dis
cuss
grin
ding
saf
ety
PA
GE
6R
AT
ING
SC
ALE
23
441
NM
I11
111
SM
. NO
ION
II*
1111
1M
C M
I all
1111
1111
01N
MI U
N M
I 1 IN
S M
N a
il
oak
ern
me
1111
1111
1111
1M
IN il
l UM
111
0IN
KN
MI
INN
1111
OM
MIN
MI *
In
NA
ME
:IN
ST
RU
CT
OR
:S
TU
DE
NT
EX
AM
INA
TIO
N: T
OO
L A
ND
DIE
CO
MP
ET
EN
CIE
SP
AG
E 7
rR
AT
ING
SC
ALE
5 K
now
ope
ratio
n of
hea
t tre
atin
g eq
uipm
ent a
nd p
roce
sses
11
2 !
3L 4
'5
,a.
Des
crib
e ty
pes
of h
eat t
reat
ing
equi
pmen
t1
-,!-
---
-.:-
b.S
et-u
p an
d op
erat
e he
at tr
eatin
g eq
uipm
ent
.
1
c.E
xpla
in m
achi
ne c
ompo
nent
s an
d ac
cess
orie
s of
at tr
eatin
g eq
uipm
ent
-i---
-r
I--
I1
-Id.
Exp
lain
hea
t tre
atin
g pr
oced
ures
e.D
iscu
ss h
eat t
reat
ing
safe
tyF
I6
Kno
w o
pera
tion
of w
eldi
ng e
quip
men
t and
proc
esse
sa.
Iden
tify
vario
us ty
pes
of w
eldi
ng e
quip
men
tb.
Iden
tify
and
disc
uss
the
diffe
renc
e in
wel
ding
proc
esse
sc.
Insp
ect w
elds
for
crac
ks a
nd p
enet
ratio
nd.
Dis
cuss
wel
ding
saf
ety
7 K
now
she
et m
etal
ope
ratio
nsa. b. C
. d. e. f. g. h.
8 K
now
ope
ratio
n of
jog-
borin
g m
achi
nes
and
tool
ing
a.D
efin
e jig
-bor
ing
mac
hine
b.Li
st, d
escr
ibe,
and
giv
e fu
nctio
n an
d m
aint
enan
ce o
f diff
eren
t typ
of to
olin
g us
ed o
n jig
-bor
ing
mac
hine
sc.
Set
-up
and
oper
ate
jig-b
orin
g m
achi
ned.
Exp
lain
mac
hine
com
pone
nts
and
acce
ssor
ies
of ji
g:po
ring
mac
hine
se.
Exp
lain
jig-
borin
g pr
oces
sf.
Dis
cuss
saf
ety
on ji
g-bo
ring
mac
hine
Dis
cuss
gas
/ pl
asm
a cu
tting
equ
ipm
ent a
ndpr
oces
ses
--I
Dis
cuss
ope
ratio
n of
pun
ch /
brak
e pr
esse
s an
d to
olin
gD
iscu
ss o
pera
tion
of p
late
she
ars
----
IC
alcu
late
tonn
ages
req
uire
d fo
r pr
ess
/ she
ar o
pera
tions
iH
Cal
cula
te b
lank
dim
ensi
ons
of d
evel
oped
par
tsU
se y
ield
tabl
es fo
r be
ndin
g sh
eet m
etal
II
Dis
cuss
fabr
icat
ion
of s
heet
met
al p
arts
Dem
onst
rate
layo
ut-o
n-m
etal
._
__
_1.
4_
Cal
cula
te s
peed
s an
d fe
eds
base
d on
mat
eria
ls a
nd to
olin
g1
301
302
393
NA
ME
:S
TU
DE
NT
EX
AM
INA
TIO
N: T
OO
L A
ND
DIE
CO
MP
ET
EN
CIE
SIN
ST
RU
CT
OR
:
9 K
now
ope
ratio
n of
tool
and
cut
ter
grin
ders
a.D
efin
e to
ol /
cutte
r gr
inde
rb.
Dis
cuss
dre
ssin
g an
d m
aint
enan
ce o
f grin
ding
whe
els
c.E
xpla
in m
achi
ne c
ompo
nent
s an
d ac
cess
orie
sof
tool
/ cu
tter
grin
der
d.D
iscu
ss to
ol a
nd c
utte
r gr
inde
r sa
fety
10 K
now
ope
ratio
n of
met
alsa
ws
a.D
efin
e ba
nd s
aw, h
oriz
onta
l and
ver
tical
b.S
et-u
p an
d op
erat
e ba
ndsa
wc.
Def
ine
abra
sive
cut
-off
saw
d.S
et-u
p an
d op
erat
e ab
rasi
ve c
ut-o
ffsa
we.
Dis
cuss
app
licat
ion
of th
e di
ffere
nt to
oth
form
s,pi
tch
sets
, and
gage
s of
ban
d sa
w b
lade
sf.
Wel
d an
d m
aint
ain
band
saw
bla
deg.
Dis
cuss
ban
d sa
w s
afet
yh.
Cal
cula
te s
peed
s an
d fe
eds
base
don
mat
eria
ls a
nd to
olin
gi.
Exp
lain
mac
hine
com
pone
nts
and
acce
ssor
ies
of b
and
saw
s
r
PA
GE
SR
AT
ING
SC
ALE
11!
2!3
45
j.C
alcu
late
pro
per
leng
th o
f ban
dsa
w b
lade
11 K
now
ope
ratio
n of
wire
ED
Ma. b. c. d. e. f.
12 E
stim
ate
time
requ
ired/
cost
to p
rodu
cea
part
a.D
eter
min
e pr
oces
ses
requ
ired
to p
rodu
ce p
art
b.C
alcu
late
act
ual m
achi
ning
and
han
dlin
g tim
ec.
Cal
cula
te m
ater
ial q
uant
ity a
nd c
ost
T T
Def
ine
ED
MI
Exp
lain
ED
M p
roce
ss4-
-, -,--
Set
-up
and
oper
ate
CN
C w
ire E
DM
i
Dis
cuss
ED
M s
afet
yC
alcu
late
E-p
ac v
alue
for
wire
ED
ME
xpla
in m
achi
ne c
ompo
nent
s an
d ac
cess
orie
sof
wire
ED
M1
1
d.C
alcu
late
labo
r an
d ov
erhe
ad c
ost
INN
"IS
A-1
111
"IN
* O
il M
N M
O Il
ia M
a IO
N la
iIM
O M
it1.
10O
N 'M
at
SIR
IN
Ali
MI
INN
1111
1111
111
IIIP
MI*
MX
, AM
MO
MS
SIM
I M
I11
11
NA
ME
:IN
ST
RU
CT
OR
:
T-1
ST
UD
EN
T E
XA
MIN
AT
ION
: TO
OL
AN
D D
IE C
OM
PE
TE
NC
IES
13 K
now
pro
per
flow
of p
arts
thro
ugh
shop
i
a.D
iscu
ss p
rope
r or
der
of p
roce
sses
b.D
iscu
ss e
rgon
omic
asp
ects
of p
lant
layo
utL
14 U
tiliz
e co
ncep
ts a
nd p
rinci
ples
of f
ixtu
ring
a.D
eter
min
e ne
ed fo
r fix
ture
/ jig
b.D
esig
n ap
prop
riate
fixt
ure
/ jig
c.Id
entif
y co
mpo
nent
s us
ed in
fixt
ures
/ jig
sd.
Dis
asse
mbl
e an
d as
sem
ble
fixtu
re /
jige.
Dis
cuss
rel
atio
nshi
p be
twee
n ac
cura
cy o
f fix
ture
& o
f rep
eata
bilit
y of
part
s15
Mak
e ca
lcul
atio
ns fo
r an
d us
e si
ne b
ar/s
ine
plat
ea.
Def
ine
sine
bar
/ si
ne p
late
b.C
alcu
late
gag
e bl
ock
build
up fo
r si
ne b
ar /
sine
pla
tec.
Set
-up
and
use
sine
bar
/ si
ne p
late
16 M
ake
calc
ulat
ions
for
and
use
rota
ry ta
ble
and
divi
ding
hea
da.
Set
-up
and
use
rota
ry ta
ble
/ div
idin
g he
ad fo
r m
achi
ning
oper
atio
ns4-
b.M
ake
calc
ulat
ions
for
num
ber
of r
otat
ions
req
uire
df-
-
c.D
eter
min
e / s
elec
t app
ropr
iate
inde
x pl
ate
for
divi
ding
hea
d
FP
ER
FO
RM
CN
C P
RO
GR
AM
MIN
G/C
AM
TA
SK
S1
Pre
pare
and
pla
n fo
r C
NC
mac
hini
ng o
pera
tions
a.P
lan
sequ
ence
of m
achi
ning
eve
nts
r
b.D
eter
min
e pr
oper
tool
ing
/ fix
ture
s re
quire
d fo
r m
achi
ning
-Lc.
Cal
cula
te s
peed
s, fe
eds,
and
dep
th-o
f-cu
t for
mac
hini
ngd.
Exp
lain
the
x, y
, and
z, a
xis
on C
NC
mac
hine
s2
Sel
ect a
nd u
se to
olin
g sy
stem
s fo
r C
NC
mac
hine
sa.
Und
erst
and
mac
hina
bilit
y an
d ch
ip fo
rmat
ion
b.S
elec
t pro
per
inse
rt m
ater
ials
and
geo
met
iy_
c.S
elec
t pro
per
tool
ing
syst
emd.
Def
ine
and
disc
uss
appl
icat
ion
of H
SS
, car
bide
, and
bor
azon
cut
ting
tool
s3_
Man
ually
pro
gram
CN
C m
achi
nes
a.P
lan
and
writ
e pr
ogra
ms
for
CN
C m
achi
nes
b.U
se M
DI p
anel
on
mac
hine
to p
rogr
am /
edit
prog
ram
s30
5
PA
GE
9R
AT
ING
SC
ALE
213
4!51
-.
--
-
ao6
307
NA
ME
:IN
ST
RU
CT
OR
:S
TU
DE
NT
EX
AM
INA
TIO
N: T
OO
L A
ND
DIE
CO
MP
ET
EN
CIE
SP
AG
E 1
0R
AT
ING
SC
ALE
3 M
anua
lly p
rogr
am C
NC
mac
hine
s co
nt.
___
__1
2 I
3c.
Set
and
use
tool
ing
offs
ets
at C
NC
mac
hine
I
d.D
iscu
ss /
use
cann
ed o
r ba
r cy
cles
inpr
ogra
mj
I 7i
t;
i4
Use
Com
pute
r-A
ided
-Man
ufac
turin
g (C
AM
)sy
stem
a.C
reat
e to
olpa
th g
eom
etry
usi
ng C
AM
sys
tem
-7i
I1
i-'r
Ib.
Inte
rcon
vert
CA
D a
nd C
AM
file
s us
ing
acce
ptab
leex
chan
ge fo
rmat
!1
.
Hi--
-
i
c.T
rans
fer
files
from
CA
M s
yste
m to
mac
hine
t-7 1
d.C
onfig
ure
CA
M s
yste
m p
aram
eter
sI-
----
-r-
11
t1
I!
!
G.
DE
MO
NS
TR
AT
E C
OM
MU
NIC
AT
ION
SK
ILLS
1 U
se w
ritte
n co
rres
pond
ence
a.R
ead,
writ
e, in
terp
ret,
and
appl
y m
emor
andu
ms
b.R
ead,
writ
e, in
terp
ret,
and
appl
y bu
sine
ss le
tters
c.R
ead,
writ
e, in
terp
ret,
and
appl
y w
ritte
n in
stru
ctio
ns2
Use
writ
ten
tech
nica
l inf
orm
atio
na.
Rea
d, w
rite,
inte
rpre
t, an
d ap
ply
tech
nica
l rep
orts
b.R
ead,
writ
e, in
terp
ret,
and
appl
y w
ritte
npr
oced
ures
c.R
ead,
writ
e, in
terp
ret,
and
appl
y te
chni
cal
man
uals
3 C
omm
unic
ate
tech
nica
l inf
orm
atio
n ve
rbal
lya. b. c.
Dem
onst
rate
abi
lity
to g
ive
verb
al te
chni
cal i
nfor
mat
ion
/ ins
truc
tions
4 U
se g
raph
ics
for
visu
al a
ida.
Cre
ate,
rea
d, a
nd a
pply
gra
phs
b.C
reat
e, r
ead,
and
app
ly c
hart
sc.
Cre
ate,
rea
d, a
nd a
pply
gra
phic
al il
lust
ratio
ns
r
Dem
onst
rate
abi
lity
to li
sten
to a
nd u
nder
stan
d ve
rbal
info
rmat
ion
/ ins
truc
tion
S'
Ask
app
ropr
iate
que
stio
ns to
asc
erta
in n
eede
din
form
atio
n-1
-
__--
_-i
1F
r
H.
PE
RF
OR
M D
RA
FT
ING
/CA
D T
AS
KS
1 D
emon
stra
te tr
aditi
onal
mec
hani
cal d
rafti
ng s
kills
a.D
emon
stra
te u
se o
f dra
fting
mac
hine
and
inst
rum
ents
b.D
emon
stra
te d
rafti
ng te
chni
que
to c
reat
e ba
sic
geom
etric
ele
men
tsi
Ile,1
1111
1 -
,111
111
MIN
I 1=
1/N
il,M
il11
1111
'N
MI
1111
1-11
1111
11M
ISIN
N
am N
u N
O u
m o
r m
ot la
w a
* m
ai O
m m
g41
11.1
ems
Om
:al
l
NA
ME
:S
TU
DE
NT
EX
AM
INA
TIO
N: T
OO
L A
ND
DIE
CO
MP
ET
EN
CIE
S
1 D
emon
stra
te tr
aditi
onal
mec
hani
cal d
rafti
ng s
kills
con
t.
INS
TR
UC
TO
R:
PA
GE
11
1R
AT
ING
SC
ALE
2j3
4I5
I
c.D
emon
stra
te is
omet
ric s
ketc
hing
of o
bjec
tsd.
List
and
app
ly th
e th
ree
prim
ary
plan
es o
f pro
ject
ion
e.Li
st a
nd a
pply
the
six
prin
cipl
e vi
ews.
f.U
se a
nd a
pply
aux
iliar
y vi
ews
g.C
reat
e se
ctio
nal v
iew
s2
Use
Com
pute
r-A
ided
-Dra
fting
(C
AD
) sy
stem
.C
reat
e ge
omet
ry u
sing
CA
D s
yste
mb.
Cre
ate
3-D
sol
id m
odel
sc.
Inte
rcon
vert
CA
D a
nd a
ccep
ted
draw
ing
exch
ange
form
ats
d.C
onfig
ure
CA
D s
yste
m p
aram
eter
se.
Use
per
iphe
ral d
evic
es3
Use
and
app
ly g
eom
etric
dim
ensi
onin
g an
d to
lera
ncin
g (G
D&
T)
met
hodo
logy
a. b. c. d. e.
Dis
tingu
ish
betw
een
conv
entio
nal a
nd g
eom
etric
dim
ensi
onin
g an
d to
lera
ncin
g.E
xpla
in a
nd u
se g
eom
etric
pos
ition
al to
lera
ncin
gi
Exp
lain
and
use
tole
ranc
es o
f for
m.
Exp
lain
and
use
the
feat
ure
cont
rol s
ymbo
l1
Exp
lain
and
use
mod
ifier
s in
geo
met
ric d
imen
sion
ing
and
tole
ranc
ing
1
I.U
SE
CO
MP
UT
ER
S1
Use
com
pute
r op
erat
ing
syst
ems
a.E
xpla
in th
e ph
rase
"IB
M c
ompa
tible
"b.
Use
DO
S o
pera
ting
syst
em /
DO
S c
omm
ands
c.U
se W
indo
ws
d.U
se c
ompu
ter
netw
ork
syst
em2
Use
file
man
agem
ent s
yste
ms
a.D
iscu
ss fi
le m
anag
emen
t con
cept
sb.
Cre
ate
/ rem
ove
dire
ctor
ies
c..
Cop
y fil
es fr
om fl
oppy
dis
ks to
har
d dr
ive
309
31O
NA
ME
:IN
ST
RU
CT
OR
:S
TU
DE
NT
EX
AM
INA
TIO
N: T
OO
L A
ND
DIE
CO
MP
ET
EN
CIE
SP
AG
E 1
2R
AT
ING
SC
ALE
23
111
4T 5
13
Per
form
bac
kup
on a
per
sona
l com
pute
r,I
-7
a.D
iscu
ss n
eed
to b
acku
p ha
rd d
isk
b.P
erfo
rm c
ompl
ete
back
up o
f har
d di
sk1
-4.-
----
f-i
II
c.P
erfo
rm b
acku
p of
sel
ecte
d fil
es a
nd d
irect
orie
s,
,
.
d.R
esto
re b
acku
p se
t to
hard
dis
k,
,
e.D
iscu
ss n
eed
for
/ mak
e sy
stem
dis
kt
t1
a. b.
4 In
stal
l/use
sof
twar
e pa
ckag
esIn
stal
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twar
e pa
ckag
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har
d di
skC
onfig
ure
syst
em p
aram
eter
s fo
r so
ftwar
epa
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wor
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oces
sor
softw
are
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fect
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spr
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heet
sof
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otus
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Exc
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5 U
nder
stan
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d ap
ply
com
pute
r te
rmin
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Def
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Rea
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nly
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ory
(RO
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b.D
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ando
m A
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emor
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Def
ine
cach
e m
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Def
ine
byte
, kilo
byte
, meg
abyt
ee.
Def
ine
Cen
tral
Pro
cess
ing
Uni
t (C
PU
)f.
Dis
cuss
pro
cess
or s
peed
Und
erst
and
RS
-232
pro
toco
l
J.IN
TE
RP
RE
T/U
SE
BLU
EP
RIN
TS
AN
D R
ELA
TE
DD
OC
UM
EN
TS
1 In
terp
ret,
revi
ew, a
nd a
pply
blu
eprin
t not
es, d
imen
sion
s, a
nd to
lera
nces
a.D
istin
guis
h be
twee
n ge
nera
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spe
cific
not
es1
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b.In
terp
ret a
nd a
pply
gen
eral
and
spe
cific
not
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-
ic.
Det
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ine
and
appl
y di
men
sion
son
a d
raw
ing
I!
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tify
basi
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mbo
ls fo
und
on a
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g;
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2 In
terp
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nd u
nder
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sic
layo
ut/ty
pes
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gsa.
Iden
tify
type
s of
dra
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gsb.
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tify
part
s of
a d
raw
ing
and
list c
ompo
nent
s of
each
312
arm
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ret a
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nder
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layo
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12
34
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Iden
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type
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line
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raw
ing
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escr
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ws
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nder
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eria
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Det
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eter
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e qu
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ies
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c.Id
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m s
ymbo
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/or
part
num
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scer
tain
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irem
ents
from
dra
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Inte
rpre
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t req
uire
men
ts1
b.Id
entif
y su
rfac
es to
be
mac
hine
d1
c.D
eter
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e cr
itica
l dim
ensi
ons
K.
PE
RF
OR
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IE O
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RA
TIO
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1 U
tiliz
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sic
die
theo
ry a
nd p
rinci
ples
of d
ie d
esig
na.
Dis
cuss
she
arin
g ac
tion
on m
etal
(3
stag
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iI
rb.
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ine
/ cal
cula
te c
uttin
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eara
nce
i ]-.
c.D
efin
e / c
alcu
late
pro
per
shut
-hei
ght o
f die
set
d.D
efin
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alcu
late
offs
et d
ispl
acem
ent
e.D
efin
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str
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ure
f.D
efin
e / c
alcu
late
cut
ting
leng
th o
f pie
ce p
art
g.D
efin
e / c
alcu
late
die
pro
gres
sion
h.D
esig
n st
ock
strip
layo
uti.
Det
erm
ine
die
feed
dire
ctio
nj. k.
Det
erm
ine
stop
blo
ck le
ngth
I.D
eter
min
e pr
ess
tonn
age
requ
irem
ents
m.
Def
ine
/ cal
cula
te s
lug
clea
ranc
en.
Exp
lain
ope
ratio
n of
die
set
to m
ake
piec
e pa
rto.
Exp
lain
spr
ing
back
in fo
rm d
ies
p.E
xpla
in b
endi
ng a
ctio
n in
V-f
orm
die
sg,
Exp
lain
coi
ning
in d
ies
-r-
4-
Exp
lain
not
ch, p
ierc
e, p
ilot,
form
, and
cut
-off
stat
ions
4
313
314
315
NA
ME
:S
TU
DE
NT
EX
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N: T
OO
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ND
DIE
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1 U
tiliz
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sic
die
theo
ry a
nd p
rinci
ples
of d
ie d
esig
n co
nt.
r.Id
entif
y co
mpo
nent
s of
die
set
s.D
iscu
ss m
ater
ials
of d
ie c
ompo
nent
s2
Per
form
die
rep
air
a.D
isas
sem
ble
and
asse
mbl
e di
e se
tb.
Vis
ually
insp
ect d
ie c
ompo
nent
s fo
r da
mag
ec.
Iden
tify
com
pone
nt p
arts
to b
e re
paire
d / s
harp
ened
d.D
eter
min
e m
etho
d of
rep
airin
g / s
harp
enin
ge.
Det
erm
ine
mat
eria
l for
rep
lace
men
t par
tsf.
Man
ufac
ture
rep
lace
men
t par
tsD
emon
stra
te s
ettin
g co
rrec
t pun
ch e
ntry
3 D
emon
stra
te D
ie M
akin
g S
kills
Iden
tify
com
pone
nt p
arts
from
die
blu
eprin
tD
eter
min
e m
ater
ial /
pur
chas
ed p
arts
req
uire
men
tsU
tiliz
e di
e m
akin
g pr
oced
ures
to m
ake
com
pone
nt p
arts
Util
ize
die
mak
ing
proc
edur
es to
mou
nt c
ompo
nent
par
tsD
emon
stra
te m
ount
ing
of d
ie s
et in
pre
ss m
achi
neC
ycle
die
set
in p
ress
mac
hine
and
insp
ect o
pera
tion
Insp
ect p
iece
par
t for
acc
urac
y
a. b. C. d. e. f. g.
4a. b. C
. d. e. f.
23
4
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-7
1
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---i-
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;
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---i
Dem
onst
rate
und
erst
andi
ng o
f diff
eren
t typ
es o
f ind
ustr
ial d
ies
Des
crib
e th
e op
erat
ion
and
Des
crib
e th
e op
erat
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and
Des
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e th
e op
erat
ion
and
Des
crib
e th
e op
erat
ion
and
Des
crib
e th
e op
erat
ion
and
Des
crib
e th
e op
erat
ion
and
maj
or c
ompo
nent
sm
ajor
com
pone
nts
maj
or c
ompo
nent
sm
ajor
com
pone
nts
maj
or c
ompo
nent
sm
ajor
com
pone
nts
of b
lank
ing
or p
ierc
ing
dies
of b
endi
nor
form
in_g
_ di
esof
dra
w d
ies
of p
rogr
essi
ve d
ies
of c
ompr
essi
on d
ies
of c
ompo
und
dies
1--
-;
ITg.
Des
crib
e th
e op
erat
ion
and
maj
or c
ompo
nent
s of
com
bina
tion
dies
jI
T T
RE
MA
RK
S:
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Mlle
UM
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MO
111
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is
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