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TITLE

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PUB DATECONTRACTNOTE

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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.

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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.

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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).

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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

49

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

50

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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1

1

1

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

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 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

65

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

87

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:

88

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

89

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

90

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

94

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

104

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

113

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

152

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

169

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

It$7

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

190

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

194

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

X98

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

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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

2

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

0 es)r)4k.

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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

230

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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ent

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low

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ope

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for

hand

and

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ork

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man

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c ar

ith-

met

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irm

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ions

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ate

mac

hini

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ints

fro

m a

deni

m p

oint

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er-

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ert

frac

tions

/de

cim

als

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er-

conv

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etri

c./

Eng

lish

mea

sure

men

ts

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form

basi

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igon

omet

ric

func

tions

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eba

r or

sin

e pl

ate

for

mac

hine

oper

atio

ns

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cula

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r di

rect

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rm

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men

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s

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ings

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ach

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ify

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elem

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ntif

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ols

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)

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lyze

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ater

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M)

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stan

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d us

equ

ality

sys

tem

s

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ate

tech

nica

lsk

etch

es

,

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red

prop

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s

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at tr

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form

heat

trea

ting

oper

atio

ns

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-4 T

est m

etal

sam

ples

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hard

ness

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luat

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tern

ativ

em

enuf

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ing

proc

esse

s

.

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met

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stru

men

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nt

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erpr

etlim

its a

ndE

-4 S

elec

tga

ggin

g to

ols

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Use

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r lo

catio

n of

feat

ures

E6

Perf

orm

111f

6S00

met

rolo

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icity

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-m

e of

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ne, a

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ma

mea

sure

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ents

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estig

ate

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nced

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gyto

pics

.to

lera

nces

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Prep

are

and

plan

for

mac

hini

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ions

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pro

per

band

tool

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3 O

pera

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wer

saw

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rate

drill

pre

sses

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vert

ical

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mac

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s

F6 O

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ts!

mill

ing

mac

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s

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tang

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s

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pmen

t

F-10

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ish

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ter

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mac

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s

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and

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ing

cent

ers

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ram

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.)

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ol d

raw

ings

11-2

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ld/

mod

ify/

repa

ir&

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d/m

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pair

mill

fix

ture

s

H-4

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d/m

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yhep

air

dies

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/rep

air

patte

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tem

plat

ea

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Use

com

pute

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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

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gibe

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c pr

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s

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tify

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aulic

flu

ids

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pow

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uble

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Rea

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mac

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it an

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part

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mak

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prot

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uipm

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safe

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for

hand

and

mac

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mac

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/3-3

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frac

tions

/de

cim

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B-4

bie

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ric/

Eng

lish

mea

sure

men

ts

13-5

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form

basi

ctr

igon

omet

ric

func

tions

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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

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feed

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rm

achi

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13-9

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aft a

ngle

dim

ensi

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ink

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rmul

as

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iew

blue

prin

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men

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s

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ntif

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layo

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ntif

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pes

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gs

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t the

purp

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of e

ach

type

of

draw

ing

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ify

draw

ing

elem

ents

C-6

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ntif

ylin

es a

ndem

boli

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1)

C-7

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crib

eth

e re

latio

nshi

pof

eng

inee

ring

draw

ings

topl

anni

ng

C,4

3 L

b.st

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tove

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requ

ire-

mal

ts

C-9

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lyze

bill

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atai

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OM

)

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0 U

nder

-st

and

and

use

qual

ity s

yste

ms

C-1

1 C

omte

tech

nica

lsk

etch

es

D-1

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ntif

ym

ater

ials

with

desi

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ertie

s

D-2

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ntif

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at tr

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gpr

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t met

alsa

mpl

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orha

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ss

D-4

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luat

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tern

ativ

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anuf

actu

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proc

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s

0-5

Iden

tify

type

s of

pla

stic

mat

eria

ls

E-1

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of

met

rolo

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8-2

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ctin

stru

men

tsus

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orm

easu

rem

ent

E-3

kita

pret

limits

and

tole

ranc

e

8-4

Sele

ctga

ggin

g to

ols

E-S

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Mfo

r lo

catio

n of

feat

ures

E-6

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form

surf

ace

met

rolo

gy

E-7

Paf

orm

mee

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ent

by c

ompa

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n

E-8

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form

cir

-su

ltrily

,gh

netr

icity

, pro

-fi

le o

flin

e, a

ndne

on m

easu

re-

Am

nia

E-9

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estig

ate

adva

nced

met

rolo

gyto

pics

F-I

Prep

are

and

plan

for

mac

hini

ngop

erat

ions

F-2

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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

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rate

.*bo

ring

mac

hine

s

F-10

Ope

rate

deba

sing

equi

pmen

t

F-11

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ish

mol

d/di

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vitie

s

0-1

Prog

ram

Com

pile

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2 O

pera

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turn

ing

cent

ers

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mac

hine

sN

umer

ical

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(C

NC

)m

achi

nes

H-1

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eto

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raw

ings

H-2

Bui

ld/

mod

ify/

repa

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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

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vari

ous

ccai

nite

rap

plic

atio

ns

1-2

Use

com

pute

rm

quir

y sy

stem

s

BE

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AIL

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ills

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riti

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kills

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n/V

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truc

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hip

Skill

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rgan

indi

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now

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Pol

icie

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oced

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Kno

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ofE

mpl

oyee

/Em

play

er R

espo

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t of

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ompa

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ualit

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ssur

ance

Act

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now

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Reg

ulat

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/Res

pons

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Proj

ect/T

ask

Man

ages

nent

Ski

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mat

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kills

Com

pute

r Sk

ills

Num

eric

aVM

athe

mat

ical

Ski

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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

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hani

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ptitu

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MB

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NIT

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AM

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estm

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Des

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dnin

istr

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mbe

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te C

oed

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R S

AG

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P. R

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ESE

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IVE

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Gen

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Sup

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ffie

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perv

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- T

hol i

t Die

Dep

t.

267

TR

AIT

S A

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AT

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UD

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Stro

ng W

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Eth

icIn

terp

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kills

Punc

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UIP

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ng C

ente

r an

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Too

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Prep

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268

TO

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AN

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AK

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skill

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orke

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ho p

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ce to

ols,

die

s, a

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peci

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ng a

nd h

oldi

ng d

evic

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atar

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mac

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s an

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vari

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Dut

ies

A B

Dem

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Cen

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Dem

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263 I

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Mea

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Skill

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A-6

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saf

elif

ting

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saf

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pro-

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for

hand

sad

ma-

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--,

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sult

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of v

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mat

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atio

ns

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form

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func

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prin

cipl

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cula

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ply

form

ulas

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sic

conc

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tech

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ize

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form

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prop

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s

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Kno

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mat

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Cal

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auge

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Des

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mat

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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

enos

and

cylin

dric

algr

inde

rs

2-S

ICno

w o

p-or

atio

n of

hes

ttr

eatin

g eq

uip-

men

t/pro

cess

es

2-6

Kno

w o

p-m

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

Use

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

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1111

1111

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1111

1111

1111

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1111

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TU

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NT

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DIE

CO

MP

ET

EN

CIE

SP

AG

E 7

rR

AT

ING

SC

ALE

5 K

now

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n of

hea

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atin

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uipm

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11

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'5

,a.

Des

crib

e ty

pes

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eat t

reat

ing

equi

pmen

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-,!-

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b.S

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d op

erat

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at tr

eatin

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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

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-, -,--

Set

-up

and

oper

ate

CN

C w

ire E

DM

i

Dis

cuss

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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

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ia M

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at

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MS

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I M

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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

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14 U

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e co

ncep

ts a

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rinci

ples

of f

ixtu

ring

a.D

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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

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