Machine Tool Advanced Skills Technology

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ABSTRACT

DOCUMENT RESUME

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Machine Tool Advanced Skills Technology (MAST).Common Ground: Toward a Standards-Based TrainingSystem for the U.S. Machine Tool and Metal RelatedIndustries. Volume 3: Machining, of a 15-Volume Setof Skill Standards and Curriculum Training Materialsfor the Precision Manufacturing Industry.Texas State Technical Coll., Waco.Office of Vocational and Adult Education (ED),Washington, DC.Sep 96V199J40008215p.; For other volumes in this set, see CE 072924-938.World Wide Web: http://machinetool.tstc.eduGuides Classroom Use Teaching Guides (ForTeacher) (052)

MF01/PC09 Plus Postage.Computer Assisted Manufacturing; Course Content;Curriculum Development; *Entry Workers; Hand Tools;*Job Skills; Job Training; Learning Modules;Machinery Industry; Machine Tools; *Machinists;Manufacturing Industry; Metal Working; *NumericalControl; Postsecondary Education; SecondaryEducation; *Standards; Teaching Methods

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 machinist specialty area. (A

machinist is a person who is responsible for the planning, layout,set up, and operation of hand and machine tools to perform machiningoperations necessary to produce a workpiece to referenced engineeringstandards.) This volume is organized in the following sections: (1) aprofile of Texas State Technical College, the development center thatproduced these standards and curriculum; (2) a machinist competencyprofile of job duties and tasks; (3) a machinist duty, task, andsubtask outline; (4) a course curriculum outline, coursedescriptions, and a list of capital equipment needed; (5) a technicalworkplace competencies and course crosswalk; and (6) a Secretary'sCommission on Achieving Necessary Skills (SCANS) proficiencies coursecrosswalk. Individual syllabi for the following courses are provided:Machine Tool Practices .1-IV; Precision Tools and Measurements;Industrial Specifications and Safety; Survey of Welding Processes andApplications; Manufacturing Processes; Introduction to ComputerNumerical Control (CNC); and Advanced CNC. Each course syllabusincludes the following: course hours, course descriptions,prerequisites, required course materials, teaching and evaluationmethods, lecture and laboratory outlines, course objectives fortechnical and SCANS competencies, and suggested references. Twoappendixes contain industry competency profiles and a pilot programnarrative. (KC)

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U.S DEPARTMENT OF EDUCATIONOffice of Ectocafionai Research and improvement

EDUCATIONAL RESOURCES INFORMATIONCENTER (ERIC)

..PS/ch.s document has been reIPOOPCOO as

received from the person Or 0,0111nIzAtIOnor.g.naling .1

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COMMON GROUND:TOWARD A STANDARDS-BASED TRAINING

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

VOLUME 3

MACHINING

ofa 15 volume set of Skills Standards

andCurriculum Training Materials for the

PRECISION MANUFACTURING INDUSTRY

BEST COPY AVAILABLESupported by

the Office of Vocational & Adult EducationU.S. Department of Education

[CENTER COR PP L.60)COMPETITIVE T60.401.00111

AUGUSTA

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,SPRINGFIELD TECHNICAL

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Texas StateTechnical College

Waco

Machine Tool Advanced SkillsTechnology Program

VOLUME 3

-- MACHINING --

Supported byThe Office of Vocational and Adult Education

U.S. Department of Education

September, 1996

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.

ii

4

ACKNOWLEDGMENTS

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

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

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

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

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

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

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

iii

ASSOCIATIONSAmerican Vocational Association (AVA) - Center for Occupational Research and Development (CORD) -CIM in Higher Education (CIMHE) - Heart of Texas Tech-Prep - Midwest (Michigan) ManufacturingTechnology Center (MMTC) - National Coalition For Advanced Manufacturing (NACFAM) - NationalCoalition of Advanced Technology Centers (NCATC) - National Skills Standards Pilot Programs - NationalTooling and Machining Association (NTMA) - New York Manufacturing Extension Partnership (NYMEP)- Precision 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 andorganizations participated in this project. We commend their efforts in our combined attempt toreach some common ground in precision manufacturing skills standards and curriculumdevelopment.

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

iv

6

VOLUME 1

CATALOG OF 15 VOLUMES

EXECUTIVE SUMMARYSTATEMENT OF THE PROBLEMMACHINE TOOL ADVANCED SKILLS TECHNOLOGY

PROJECTPROJECT GOALS AND DELIVERABLESPROJECT METHODOLOGYPROJECT CONCLUSIONS AND RECOMMENDATIONSAPPENDICES

VOLUME 2 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)

VOLUME 9 TOOL AND DIE (TLD)

VOLUME 10 COMPUTER-AIDED DRAFTING AND DESIGN (CAD)

VOLUME 11 COMPUTER-AIDED MANUFACTURING ANDADVANCED CNC (CNC)

VOLUME 12 INSTRUMENTATION (INT)

VOLUME 13 LASER MACHINING (LSR)

VOLUME 14 AUTOMATED EQUIPMENT TECHNOLOGY (CIM)

VOLUME 15 ADMINISTRATIVE INFORMATION

VOLUME 3

MACHINING

Table of Contents

TAB

Foreword 1

Development Center Profile 2

Machinist Competency Profile 3

Machinist Duty/Task/Sub-Task Outline 4

Course Listing/Course Descriptions/Capital Equipment 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

After many interviews with practitioners from industry (see Appendix A), and discussions witheducators, managers, supervisors, and others involved with machine-related occupations andspecifically machining, the MAST Consortium Partners have agreed to present our definition of amachinist as follows:

MACHINIST - responsible for the planning, layout, set up, and operation of hand andmachine tools to perform machining operations necessary to produce a workpiece toreferenced engineering standard&

Other related topics which are included in the MAST Machinist curriculum include:Computer Numerical Control (CNC)Electrical Discharge Machining (EDM)Precision MachiningGrinding

MAST research indicates that a minimum of one year of occupational study and training willprepare students with the entry level skills necessary to enter the machinist trade. These findingsled us to structure our pilot program to a one year schedule.

In this one year program, the students progress through a series of machine tool operationscourses designed to constantly challenge the process skills on manual and Computer NumericalControlled (CNC) machines. Along with comprehensive hands-on training, students also learnabout the various types of materials and processes used by today's manufacturing industries. TheMachining program at Texas State Technical College (TSTC) has been training entry levelmachinists for many years and works closely with advisory committee members to make sure thatthe skills being taught are the skills needed in industry. Students who graduate from this courseof study receive certificates of completion from TSTC. The Machining faculty worked closelywith the MAST staff and made every effort to adopt the recommended MAST materials not onlyfor the pilot program, but also for their non-MAST students. The Machining program at TSTC isrecognized throughout Texas by large and small manufacturing companies as a premier source forquality, entry-level machinists. Upon graduation, students are able to interpret complex drawings,select the correct materials and perform all necessary machining processes. The curriculum hasbeen designed to prepare students to enter the machinist trade. Laboratory work is emphasizedwith actual industrial equipment in order to prepare students for interesting, rewarding work in awide variety of industries. The Machinist program falls under the umbrella of ManufacturingEngineering Technology (MET) at TSTC. The MET Department also offers Associate Degreesin two other exceptional areas of study. These are Computer-Aided Manufacturing and PlasticProcessing.

This volume contains the justification, documentation and course syllabi for the courses which werecommend as minimum training for individuals desiring to become machinists.

PARTNER OCCUPATIONAL SPECIALITY ASSIGNMENTS

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

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

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

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

MAST DEVELOPMENT CENTERTexas State Technical College

Center for Contemporary Technology

3801 Campus DriveWaco, TX 76705

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

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

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

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

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

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

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

ii

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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LE

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 the

MAST 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 the

workplace, as shown in the following pages.

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

The MAST Technical Workplace Competency Outline for this occupational specialty areahas

been included on the following pages.

1?

MACHINISTTECHNICAL WORKPLACE COMPETENCIES

MACHINIST...plan, layout, setup, and operate hand and machine tools to perform machiningoperations necessary to produce a workpiece to referenced engineering standards.

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

a. Assume responsibility for the personal safety of oneself and othersb. Develop a personal attitude towards safetyc. Understand and comply with applicable regulations and industry standardsd. Comply with established company safety practices

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

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

4. Maintain a Clean and Safe Work Environmenta. Keep work areas cleanb. Clean machine/hand tools when work is completedc. Put tools away when work is finishedd. Keep aisles clear of equipment and materialse. Perform preventive maintenance as requiredf. Understand chemical hazards and the use of Material Safety

Data Sheets (MSDS)

B. APPLY MATHEMATICAL CONCEPTS1. Perform Basic Arithmetic Functions

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

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

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

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

5. Calculate Speeds and Feeds for Machininga. Calculate RPM for various metals and various tools

18

b. Calculate feed for various metals, tools, and depths ofcut6. Locate Machining Points from a Datum Point

a. Identify points using the Cartesian coordinate systemb. Identify points using the absolute dimensioning systemc. Identify points using the incremental dimensioning systemd. Identify points using the polar coordinate system

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

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

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

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

pieces

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

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

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

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

4. List the Purpose of Each Type of Drawing 19

a. Identify the purpose of orthographic (3 views) drawingsb. Identify the purpose of isometric drawingc. Identify the purpose of exploded isometric drawingd. Identify the purpose of assembly drawings

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

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

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

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

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

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

10. Understand and Use Quality Systemsa. Understand and apply quality principles, including continuous improvementb. Document paper trails for part revisions

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

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

steels, structural steels, cast irons, aluminum, and other commonly usedmetals

2. Describe the Heat Treating Processa. Discuss the reasons for heat treatingb. Discuss the time/temperature chartc. List the different quenching mediumsd. Estimate metal heat temperature by colore. List reasons for stress relieving workpiecesf. Describe surface hardening processes

3. Test Metal Samples for Hardness

a. Perform spark test to test for metal hardnessb. Perform Rockwell hardness tests

4. Describe Welding Operationsa. Describe the SMAW processb. Describe the Oxy-acetylene cutting and welding processc. Describe the GTAW (Heliarc) processd. Describe the GMAW (MIG) processes

E. PERFORM MEASUREMENT/INSPECTION1. Identify Types of Measurement

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

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

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

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

non-calibrated instrumentsd. Calibrate a micrometer type measuring tool

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

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

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

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

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

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

21

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

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

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

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

and tapping operationse. Drill holes using drill jigs

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

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

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

g. Setup and use special horizontal mill fixtures7. Operate Metal Cutting Lathes

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

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

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

9. Operate Deburring Equipmenta. Debur parts using pneumatic deburring toolsb. Debur parts using electric deburring tools

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

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

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

applications2. Select and Use CNC Tooling Systems

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

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

23

f. Plan and write programs for CNC lathes4. Operate CNC Machining Centers (Mills)

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

run" and final productioni. Edit CNC programs for optimum part productionj. Operate machine in DNC mode if that capability exists

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

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

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

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

24

THE MAST PILOT PROGRAM CURRICULUM, COURSEDESCRIPTIONS AND CAPITAL EQUIPMENT LIST

After completing the Competency Profile and Technical Workplace Competency Outline for each

occupational specialty area, each MAST partner reviewed their existing curricula against theindustry-verified skill standards in order to identify a suitable foundation for new pilot training

programs. 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 goals

mandated in the MAST grant proposal:

0

0

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. Also included in this section is arecommended list of tools, equipment and supplies which should be furnished by the school. This

items on this list will be needed in addition to the tool list found in each of the course syllabi.

MANUFACTURING ENGINEERING TECHNOLOGYMACHINING OPTION

CURRICULUM1995-1996

FIRST QUARTERLEC LAB CR

PSYC 1100* College Success Skills 1 0 1

MET 100 Machine Tool Practices I 3 9 6MET 1103 Precision Tools & Measurements 2 4 3MET 1603 Industrial Specifications and Safety 2 4 3

MTH 115* Occupational Mathematics 2 3 410 20 17

SECOND OUARTER

MET 200 Machine Tool Practices II 3 9 6ENG 107* Oral and Written Communications 3 0 3WLT 105 Survey of Welding Processes and Appl. 3 3 4PSY 112* Human Relations 2 2 3

11 14 16

THIRD QUARTER

MET 300 Machine Tool Practices III 3 12 7MET 301 Manufacturing Processes 3 3 4MET 2303 Introduction to CNC 2 A 3

8 19 14

FOURTH QUARTER

MET 400 Machine Tool Practices IV 3 15 8MET 2406 Advanced CNC 3 _2 6

6 24 14

Program Totals 35 77 61

* Course Syllabi in Volume 2

28


COURSE DESCRIPTIONS 1995-1996

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

MET 200 Machine Tool Practices IT (3-9-6) A course designed to develop additional machineshop skills for those students who were successful in Machine Tool Practices I.

MET 300 Machine Tool Practices III (3-12-7) The students will be required to applyknowledge and skills gained in Machine Tool Practices I & II to make necessarycalculations, select desired machine tools, plan machining operations and sequencesto produce the required work from working drawing and sketches with a minimumof instructor prepared guidelines.

MET 301 Manufacturing Processes (3-3-4) Essential studies into the processes and materialsfor manufacturing, including metal casting, hot and cold forming of steel, powdermetallurgy and plastics. Analysis of newer processes such as electrical dischargemachining, chemical machining and ultra-sonic machining; with an emphasis on theeconomical manufacturing of products.

MET 400 Machine Tool Practices IV ( 3-15-8) This course is designed for the students thathave successfully completed Machine Tool Practices IX, and III. It will cover themachining skills they have mastered in their first three quarters at an advanced level.Additional skills such as production machining, production machine set up andfixturing along with working with assembly drawings will be covered.

MET 1103 Precision Tools and Measurements (2-4-3) Introduction to the function andreason for measurements. Relationship between different types of measuring toolsthat a machinist is required to use. Upon completion, the student will be able toproperly handle, use, care and calibrate instruments.

MET 1603 Industrial Specifications and Safety (2-4-3) This course is designed to give thestudent an opportunity to study the fundamentals of specifications in the form ofblueprints, work orders, and associated engineering directives. Safety as pertains tomachining and shop operations will be covered.

27

MET 2303 Introduction to CNC (2-4-3) Give the student a basic knowledge of numericallycontrolled (NC) and computer numerically controlled (CNC) machine tools. Teachesdifferences between conventional and numerically controlled machines. Emphasis willbe placed on safety of CNC machines. Principles of programming, tooling, setup andmachine operations will be studied.

MET 2406 Advanced CNC (3-9-6) Continuation of MET 2303. Extends basic principles ofnumerical control to actual machine operations. Basic descriptions of computernumerical control and step-by-step procedures for planning and preparing a computer-assisted program are given. CNC lathe and CNC milling machine applications areutilized for machining of complete units or student laboratory projects.

28


SUPPORT COURSES1995-1996

PSYC 1100* College Success Skills This course acquaints the students with the policies of thecollege, services available on and off the campus, and study skills along with otherissues that will help them through their college studies. Students are required totake this course in their first quarter at TSTC.

ENG 107* Oral & Written Communications The oral and written communications mostneeded by entry level technicians. Emphasis will be on oral communicationsituations between peers, between technician and supervisor or subordinate, andbetween technician and groups.

MTh 115* Occupational Mathematics This course includes English and Metric systems ofmeasurement, geometric principles, solutions of basic algebraic expressions andsolutions of triangular trig problems. Problems from specific occupational areaswill be stressed.

PSY 112*

WLT 105

Human Relations This course presents a study in the interaction of people in thebusiness and industrial complex. Emphasis is placed on the necessity for acooperative environment to satisfy individual needs as well as to increaseproduction efficiency.

Survey of Welding Processes and Applications This course is a survey ofshielded metal arc, gas tungsten arc, gas metal arc, flux cored arc, and submergedarc welding processes. Metals weldability and weld symbols are considered.Process safety, electrode selection, and process parameters are emphasized. Hardsurfacing using shielded metal arc and oxyacetylene processes and techniques arestudied.

* Course syllabi in Volume 2

RECOMMENDED CAPITAL EQUIPMENT, TOOLS, AND SUPPLIESFOR THE MACHINIST PROGRAM

The following tools, capital equipment and supplies will need to be furnished by the school.These items are needed in addition to the Student Tool List which is specified in the coursesyllabus. This list will need to be amended to include items which might be required for differentlaboratory projects selected for use by the instructors.

General Equipment/Supplies:

First Aid KitMachinist Hand and Measuring Tools

dial indicatorsmagnetic baseoutside micrometersinside micrometerstelescope gagescaliperstap handlesdie handleswrencheshacksawssquaresother(s) as required

Metal Lathe(s) w/attachmentsLathe Tool Holders and Cutting ToolsVertical Mill(s) w /attachmentsMill Tool Holders and End MillsHorizontal Mill w /attachmentsDrill Press(s) w /attachmentsSet of Drill Bits (as required)Set of Taps (as required)Set of Dies (as required)Set of Gage BlocksSine BarSurface Plate w/accessoriesClampsAngle PlatesPower Hand DrillHydraulic/Arbor PressPower Cutoff SawVertical Band Saw w/bladesPedestal GrindersWork BenchesBench VisesCutting Oil w/oil cansGrease Gun w/Grease

Brooms & Dust PansBench BrushesTrash CansAbsorbent (for oil spills)Power Belt SanderMetal Storage Rack(s)Fire Extinguisher(s)Storage Cabinets (lockable)Tool Box Storage Racks (lockable)CoolantFasteners (bolts, nuts, washers, rivets, etc.)

Specialized Equipment:

Surface Grinder w/attachmentsCNC Vertical Machining Center

w/attachmentsCNC Turning Center w/attachmentsComputer Programming Station(s)

w/CAM softwareEDM (sinker type) Machine w/attachmentsHardness TesterCoordinate Measurement Machine (CMM)Optical ComparatorSMAW Arc WelderTIG Welder SetupMIG Welder SetupOxy-acetylene Welding/Cutting SetupCoolant Recovery EquipmentForkliftVentilation EquipmentBead BlasterSheet Metal Hand ToolsSheet Metal ShearSheet Metal Finger BrakeIron Worker

30

THE MAST TECHNICAL WORKPLACECOMPETENCY/COURSE CROSSWALK

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

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

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

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A. PRACTICE SAFETY

A-1 Follow Safety Manuals and AD Safety Regulations/RequirementsX X 4

A-2 Use Protective EquipmentX X

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

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

X X 4B. APPLY MATHEMATICAL CONCEPTS

B-1 Perform Basic Arithmetic Functions

48-2 Interconvert Fractions/Decimals

X X 4B-3 Interconvert Metric/Inch measurements

X X 3B-4 Perform Basic Trigonometric Functions

X X X 3B-5 Calculate Speeds and Feeds for Machining

X X X X 3B-6 Locate Machining Points From a Datum Point

X X X 3B-7 Perform Calculations for Sine Bar and Sine Plate

X X 2B-8 Calculate for Direct, Simple, and Angular Indexing

X 2B-9 Perform Calculations Necessary for Turning Tapers

X 2B-10 Calculate Depth of Cut on Round Surfaces

X1

2C. INTERPRET ENGINEERING DRAWINGS AND CONTROL DOCUMENTS

C-1 Review Blueprint Notes and DimensionsX X 3

C-2 Identify Basic Layout of DrawingsX X 3

C-3 Identify Basic Types of DrawingsX X 3

C-4 List the Purpose of Each Type of DrawingX X 3

C-5 Verify Drawing ElementsX 3

C-6 Practice Geometric Dimensioning and Tolerancing (GD&T) Methodology X 2C-7 Describe the Relationship of Engineering Drawings to Planning X X 2C-8 Use Standards to Verify Requirements

X X 2C-9 Analyze Bill of Materials (BOM)

X X 2C -10 Understand and Use Quality Systems

X 21 RECOGNIZE DIFFERENT MANUFACTURING MATERIALS AND PROCESSES

0-1 Identify Materials With Desired Properties. X .X , 2

D-2 Describe Heat Treating ProcessX

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D-4 Describe Welding OperationsX 3

E. PERFORM MEASUREMENT/INSPECTION

E-1 Identify Types of MeasurementX X 4

4E-2 Select Proper Measurement Tools

X X

E-3 Apply Proper Measuring Techniques X X 4

4

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E-4 Perform Measurements With Hand Held Instruments X X

E-5 Perform Measurements on Surface PlateX X

E-6 Perform Inspections Using Stationary EquipmentX

3F. PERFORM CONVENTIONAL MACHINING OPERATIONS

F-1 Prepare and Plan For Machining Operations X 4F-2 Use Proper Hand Tools X 4

F-3 Operate Power Saws X

F-4 Operate Drill Presses X 4

F-5 Operate Vertical Milling Machines . X X 4

F-6 Operate Horizontal Milling Machine X 4

F-7 Operate Metal Cutting Lathes X X 4

F-8 Operate Grinding /Abrasive MachinesX 3

F-9 Operate Deburring Equipment X X X 4

G. PERFORM ADVANCED MACHINING PROCESSES

G-1 Prepare and Plan for CNC Machining OperationsX 3

G-2 Select and Use CNC Tooling SystemsX 3

G-3 Program CNC MachinesX X 3

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

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

G-6 Operate Electrical Discharge MachinesX 1

G-7 Program CNC Machines using a CAM System X 2

+; EST COPY:AVAILABLEel ")CROSWALKLPMS 0 .SAW4fil/WPELTOIVIR_TIA,arruiti 711170S

THE MAST SCANS/COURSE CROSSWALK

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

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

FOUNDATION SKILLS:Basic Skills:

Thinking Skills:

Personal Qualities:

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

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

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

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

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

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

Page 1 , SCANS/Course

CROSSWALK,

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(RS) RESOURCES:

A. Allocates time X X X X X X X X X X X X X X 3

B. Allocates money X X X X X X X X 2

C. Allocates material and facility resources X X X X X X X X X X X 4

D. Allocates human resources X X X X X X X X X X X 1

(IN) INTERPERSONAL SKILLS:

A. Participates as a member of a team X X X X X X X X X X X X X X 4

B. Teaches others X X X X X X X X X X X X X 1

C. Serves clients/customers X X X X X X X X X X X 2

D. Exercises leadership X X X X X X X X X X X X 1

E. Negotiates X X X X X 1

F. Works with cultural diversity X X X X X X X X X X X X X X 4

(IF) INFORMATION SKILLS:

A. Acquires and evaluates information X X X X X X X X X 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 4

C. Interprets and communicates information X X X X X X X X X X X X X X 4

D. Uses computers to process information X X X X X 2

(SY) SYSTEMS:

A. Understands systems X X X X X X X X X X X X X 4

B. Monitors and corrects performance X X X X X X X X X X 2

C. Improves and designs systems .X X X X X X X X X 1

(TE) TECHNOLOGY:

A. Selects technology X X X X X X X X X X X X 4

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

C. Maintains and troubleshoots technology X X X X X X X X X X 3

ScANSwAL.Pm5 In r'eVii' A PI Ii-W/ /AIM Ell Kim r I.SAVI6WW.PELTON/Ft.1iMMONS

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MACHINIST: CERTIFICATE

FOUNDATION SKILLS

(BS) BASIC SKILLS:

A. Reading X X X X X X X X X X X X X X 3

B. Writing X X X X X X X X X X X X X X 3

C. Arithmetic and mathematics X X X X X X X X X X X X 4

D. Listening X X X X X X X X X X X X X X 4

E. Speaking X X X X X X X X X X X X X X 4

(TS) THINKING SKILLS:

A. Creative thinking X X X X X X X X X X X X X X 3

.B. Decision making X X X X X X X X X X X X X X 2

C. Problem solving X X X X X X X X X X X X X X 2

D. Seeing things in the mind's eye X X X X X X X X X X X X X X 4

E. Knowing how to learn X X X X X X X X X X X X X X 4

F. Reasoning X X X X X X X X X X X X X X 4

(PQ) PERSONAL QUALITIES:

A. ResponsibilityX X X X X X X X X X X X X X 4

B. Self-esteem X X X X X X X X X X X X X X 4C. SocialXX X X X X X X X X X X X X 4

D. Self-management 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 4

SCANSWAL.

BEST COPYAVAILABLE 3. . .

SCANSCOMPETENCIES AND FOUNDATION SKILLS

EXIT LEVEL PROFICIENCY MATRIX

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

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

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

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

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

integrity and honesty.

The following matrix identifies the five exit levels 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

MAST/01/012296

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.


COURSE SYLLABUS

MACHINE TOOL PRACTICES I

39

MAST PROGRAMCOURSE SYLLABUS

MACHINE TOOL PRACTICES I

Lecture hours/week: 3

COURSE DESCRIPTION:

Lab hours/week: 9 Credit hours: 6

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

PREREQUISITES: NONE

REQUIRED COURSE MATERIALS:

Textbook:Lab Manual:

Machine Tool Practices, Kibbe, Neely, and Meyer, Wiley Pub., 4th Ed.Machine Tool Practices 1, Raborn, TSTC Pub., 4th Ed.

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

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

10 inch Adjustable Wrench 1

Center Punch 1

Magic marker, Jumbo, black. 1

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

File Handle 1

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

Scribe 1

Center Gage 1

Screw Driver, 8 inch 1

File Card Brush 1

0-6 inch Dial Calipers 1

Shop Apron (blue denim) 1

Shop Towels (1 roll) 1

** A complete list of recommended capital equipment, tools and supplies (to be furnished bythe school) may be found in Tab 5 of this volume.

40

METHODS OF INSTRUCTION:

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

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

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

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

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

LECTURE OUTLINE:Lecture Topics Text Reference Page Contact Hrs.

Introduction to the Course 1

Safety 5-12 1

Tool Grinding 43-45 (lab book) 1

The Machine Shop 1-4 1

The Inch Rule 113-118 1

The Square 163-166 1

The Inch Micrometer 140-145 1

Drawings 28-36 2Layout Tools 249-262 2QUIZ I (over above lectures) 1

Semi-precision Layout 262-266 1

Hand Tools 46-55 1

Hacksaws 55-58 1

Files 58-63 1

Verniers 122-125 1

Vernier Micrometers 151-156 1

The Drill Press 365-374 1

Drilling Tools 375-384 2QUIZ 2 (over above lectures) 1

Drilling Operations 389-402 2Taps 68-74 1

Tapping Procedures 74-79 1

Gage Blocks 178-187 1

Angular Measuring 187-195 1

Precision Layout 267-280 2

QUIZ 3 (over above lectures)Oral Presentations*

1

5

Total Lecture Hours 36

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

LAB OUTLINE:Lab Topics Contact Hrs.

Shop orientation 2Use of the cut-off saw 2Grinding a lathe tool 3Grinding a mill tool 3Using the band saw 3Using the radial drill 3Using the sensitive drill 3

Bench work 27Lathe work 27Mill work 27Leaving the shop in order 3Inspecting the finished work 5

Total Lab Hours 108

COURSE OBJECTIVES: TECHNICAL COMPETENCIES

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

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

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

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

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

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

B. APPLY MATHEMATICAL CONCEPTS1. Calculate Speeds and Feeds for Machining

42

a. Calculate RPM for various metals and various toolsb. Calculate feed for various metals, tools, and depths of cut

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

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

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

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

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

D. PERFORM MEASUREMENT/INSPECTION1. Identify Types of Measurement

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

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




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

gages)d. Measure with direct measuring instruments (e.g.,


4i3

(e.g., calipers, telescope

vernier, dial, and digital

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

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

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

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

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

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

reaming operations5. Operate Vertical Milling Machines

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

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

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

44

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

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

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

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

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

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

standardsE. Technology: Works with a variety of technologies

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

to produce a machined part to acceptable standards

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

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

prose and in documents such as manuals, graphs, and schedulesa. read/studies textbookb. studies student laboratory manual

c. interprets blueprints and technical drawingsd. follow a daily laboratory schedule to maintain appropriate time-line

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

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

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

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

instructions, asking questions for clarification and probing forspecifics

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

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

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

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

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

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

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

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

or preventive action

46

3. Seeing Thine In the Mind's Eye: Organizes, and processes symbols,pictures, graphs, objects, and other informationa. visualize objects in three dimensions from engineering drawingsb. visualize process during instructor lecturec. visualize the relative motions between tool and workpiece to

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

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

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

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

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

sequential process planc. applies knowledge of workpiece machinability, cutter

characteristics and machine tool characteristics to adjust speeds andfeeds

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

attainmenta. displays promptness and preparation for the day's work .

b. plans work to use time efficientlyc. accepts responsibility for mistakes, and takes corrective and

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

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

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

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

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

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

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

resolve or eliminate them

47

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

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

Appropriate Reference Materials:

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

MET10001/072296

48


COURSE SYLLABUS

PRECISION TOOLS & MEASUREMENTS

49


PRECISION TOOLS & MEASUREMENTS


COURSE DESCRIPTION:


Introduction to the function and reason for measurements. Relationship between different typesof measuring tools that a machinist is required to use. Upon completion, the student will be ableto properly handle, use, care for, and calibrate measuring instruments.

This course is designed to familiarize the student with the use, handling and maintenance of avariety of precision tools and instruments which will be encountered in industry. Care andcalibration of instruments and metric conversions will be covered.

Students will use measuring tools such as: rulers, surface gages, verniers, micrometers, dialindicators, dial test indicators, gage blocks and accessories, electronic indicators, opticalcomparators, precision height gages, ring and plug gages, thread gages, snap gages, v-blocks,1-2-3 blocks, angle plates and surface plates to check test specimens for: locations of holes, radiietc., lengths, diameters, surface finish, parallelism, squareness, and concentricity, rectangularcoordinates, angles, thread fits, maximum and minimum material condition to tolerances as closeas +/-.000010". Students will also learn to make comparison measurements and inspections usingthe optical comparator and the coordinate measuring machine (CMM).

PREREQUISITES: NONE


Textbook: Machine Tool Practices, Kibbe, Neely, and Meyer, Wiley Pub., 4th Ed.Lab Manual: None

Student Tools List

**

**/Qty. Req'd: Same as for Machine Tool Practices I

A complete list of recommended capital equipment, tools and supplies (to be furnished bythe school) may be found in Tab 5 of this volume.



Laboratory: Laboratory will consist of "hands-on" activities.

50


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


Introduction to Precision Tools andMeasurement 89 1

Measuring with Ruled Instruments(English and metric) 108 2

Measuring with Vernier MeasuringTools 122 2

Measuring with Micrometer MeasuringTools 133 2

Using Gage Blocks and Accessories 178 3Measuring Angles 187 2Making Comparison Measurements 157 2Measuring with Fixed and Adjustable

Gages 94 2Using High Amplification Electrical

Comparators 105 2Using Optical Comparators 176 2Using Coordinate Measuring Machines 103 3

Final Examination 1



Using the inch & metric measuring systems 3

Make measurements with inch & metric ruled instruments 1

Measure with inch & metric vernier tools 2Measure with inch & metric dial calipers 1

Read and use inch & metric micrometer tools 2Calculate gage block requirements 2Clean and assemble required gage blocks and accessories 1

Calibrate measuring tools with gage blocks 2Use gage blocks for direct measurement 1

Identify types of angles 1

Measure angles with protractor head and rule 1

Measure angles with the vernier protractor 2Measure angles with sine bar, sine plate, gage blocks, etc. 2Make semi-precision comparison measurements 1

Make precision comparison measurements within +/- .001" 2Make precision comparison measurements within +/- .0001" 2Measure with fixed gages 1

Measure with adjustable gages 2Use dial indicator comparators 1

Use precision height gages 1

Use a Reed-type comparator 1

Measurement by motion using the optical comparator 3Measurement by comparison using the optical comparator 2Angular measurement using the optical comparator 3Measure with the super micrometer 1

Measure with the multi-scale electronic comparator 2Measure/Inspect using the Coordinate Measuring Machine (CMM) 5

Total Lab Hours 48


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

A. APPLY MATHEMATICAL CONCEPTS1. Interconvert Fractions/Decimals

a. Convert fractions to decimal equivalentsb. Convert decimal values to nearest fractional equivalentc. Use Decimal Equivalent Chart for conversions

2. Interconvert Metric/Inch Measurementsa. Convert inch dimensions to metricb. Convert metric dimensions to Inchc. Use metric/inch conversion chart

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

B. PERFORM MEASUREMENT/INSPECTION1. Identify Types of Measurement

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

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

52




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

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


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

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





1. follows a schedule to complete assigned tasks on time2. follows a schedule to maximize metrology lab resources

B. Interpersonal: Works with others1. complete assigned activities within the metrology lab serving as a

member of the team2. provide individual assistance/direction to peers as requested3. works well with classmates, instructors and supervisors

53

Information: Acquires and uses information1. read and interpret tolerances and dimensions from engineering drawings2. organize and apply theories of precision measurement3. perform semi-precision and precision measurements as required


a. organization of personnel and facilities in the metrology labb. systematic approach to the measurement in the machine shopc. dimensioning and measurement systems

2. monitors and corrects performance duringa. the measurement and inspection processesb. adjustments of individual laboratory work schedule

E. Technology: Works with a variety of technologies1. chooses procedure, tools and instruments required to accurately measure a

machined part2. applies appropriate procedures and uses appropriate tools and instruments

to consistently measure a part to the required tolerances



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

and completion of course requirements2. Writing: Communicates thoughts, ideas, information, and messages in

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

3. Arithmetic/Mathematics: Perform basic computations and approachespractical problems by choosing appropriately from a variety ofmathematical techniquesa. interconverts inch to metricb. interconverts fractions to decimal expressionsc. keeps a running computation of individual graded. calculate gage block buildup



5 4



smooth and safe operation of the metrology labB. Thinking Skills: Thinks creatively, makes decisions, solves problems, visualizes,


considers risks, and evaluates and chooses best alternativea. selects appropriate instruments from those available to perform the

measurement task at handb. applies judgement in the use of precision instruments to determine

whether dimensions are within tolerancec. makes initial determination for rework or other disposition of parts

found to be out of tolerance2. Problem Solving: Recognizes problems and devises and implements plan

of actiona. makes daily accommodations to stay on scheduleb. seeks additional instruction/clarification for assignment completionc. plans and executes set-ups for surface plate measurements of

complicated parts3. Seeing Things In the Mind's Eye: Organizes, and processes symbols,

pictures, graphs, objects, and other informationa. visualize process during instructor lectureb. visualizes three-dimensional geometry from technical drawings and

selects appropriate instruments to measure dimensions4. Knowing How to Learn: Use efficient learning techniques to acquire and

apply new knowledge and skillsa. understand that practice will improve skillb. asks questions or seeks help when uncertain about new skills or


between two or more objects and applies it when solving a problema. considers relationships of part features, such as perpendicularity,

cylindricity, angles and radii, and selects appropriate instrumentsand methods to measure those relationships for conformance torequirements


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

preventive actions

5o

d. takes initiative when needed to gain resources or assistance tocomplete assignments

2. Self-Esteem: Believes in own self-worth and maintains a positive view ofselfa. takes pride in work through positive reinforcementb. sees self as a valued member of the group through continued


empathy, and politeness in group settingsa. assist classmates in improving technical skillsb. share laboratory resources (measurement instruments, accessories

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

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

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

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

during examinations and on lab assignmentsd. understand the consequences of unethical behaviors


1. Machinery's Handbook, Industrial Press2. Mathematics for Machine Technology; Robert Smith, Delmar Publishers

hiE71103

01/060596


COURSE SYLLABUS

INDUSTRIAL SPECIFICATIONS ANDSAFETY

57


INDUSTRIAL SPECIFICATIONS AND SAFETY


COURSE DESCRIPTION:


This course is designed to give the student an opportunity to study the fundamentals ofspecifications in the form of blueprints, work orders, and associated engineering directives.Safety as pertains to machining and shop operations will be covered.

Students will identify potential hazards in the machine shop area(s) and will be required todevelop and implement preventive or corrective action(s). The student will be required tointerpret various blueprint dimensions, machining symbols, tolerance zones, GeometricDimensioning & Tolerancing (GD&T) symbols, machining details, sectional views, andperform basic shop sketching.

PREREQUISITES: NONE


Textbook/Lab Manual: B ueprint Reading for Manufacturing, Edward Hoffman and PaulWallach, Delmar Publishers, Latest Edition.

Student Tool List **/Quantity Required: None



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

Laboratory: Laboratory will consist of hands-on activities. Students will complete exercises intheir laboratory workbooks.


laboratory assignments2. apply theory to laboratory assignments

53

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

LECTURE OUTLINE:Lecture Topics

Introduction to the courseSafety in the machine shop

Features of the blueprintInterpreting print dimensionsIdentifying the characteristics

of detail and assemblyprints

Identifying the types and uses ofsectional views

Interpreting machine details onblueprints

Interpreting geometric dimensioningand tolerancing controlsymbols (GD&T)

Interpreting metric blueprintdimensions

Basic shop sketching techniquesReading and interpreting industrial

blueprints, engineeringdirectives and work orders

LAB OUTLINE:

Text Reference Page Contact Hrs.1

Technical Modules MAC-Al 1

"Follow Safety Manuals and AllSafety Regulations/Requirements"Technical Modules MAC-A2 1

"Use Protective Equipment"Technical Modules MAC-A3 1

"Follow Safe Operating Proceduresfor Hand and Machine Tools"Technical Modules MAC-A4 1

"Maintain a Clean and Safe WorkEnvironment"

9 2117 2

153

167

183

233

29539

2

2

3

3

2

1

2Total Lecture Hours 24

Lecture TopicsIdentify features on a blueprint E2-1Interpret print dimensions E8-1, 2, 3Identify characteristics of detail & assembly prints E9-1, 2Identify the types and uses of sectional views E10-1, 2

Exercise Reference

5:9

Contact Hrs.2644

Interpret machine details on blueprints E 1 1-1, 8 4Interpret Geometric Dimensioning and E12-1 4

Tolerancing control symbolsInterpret metric blueprint dimensions E15-1, 2 4Perform basic shop sketching E4-1, 2, 3, 4 6Read and interpret industrial blueprints,

engineering directives and work orders 12

Total Lab Hours 48


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

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

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

4. Maintain a Clean and Safe Work Environmenta. Keep work areas cleanb. Clean machine/hand tools when work is completedc. Put tools away when work is finishedd. Keep aisles clear of equipment and materialse. Understand chemical hazards and the use of Material Safety

Data Sheets (MSDS)B. INTERPRET ENGINEERING DRAWINGS AND CONTROL DOCUMENTS

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

2. Identify Basic Layout of Drawingsa. Identify types of lines within a drawingb. Identify item number symbols

60

c. Identify general note symbolsd. List the essential components found in the title blocke. Locate bill of materials in a drawingf. List the components found in the revision block

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

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

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

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

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

a. Discuss production scheduleb. Discuss shop floor routing documents


9. Analyze Bill of Materials (BOM)a. Discuss components found on BOMb. Determine materials needed to produce the partc. Determine quantities necessary to produce the part



61



1. follows a schedule to complete assigned tasks on time2. recognize hazards and selects and correctly uses protective equipment and

other safeguardsB. Interpersonal: Works with others

1. complete assigned responsibilities within the classroom serving as amember of the team

2. provide individual assistance/direction to peers as requested3. maintains an awareness and concern for the safety of others as well as selfInformation: Acquires and uses information1. read and interpret blueprints2. read and understand safety rules and regulations, Material Safety Data

Sheets, warning signs, labels, and symbols related to job safety and health3. uses standard reference manuals and tables to locate specifications and

other reference informationD. Systems: Understands complex inter-relationships

1. demonstrate knowledge of the following systems:a. recognize major sources of standards and reference materialsb. recognize structure of federal, state and local, and company-level

rules and regulations for safety, health, and the environmentc. recognize and understand the complex documentation required for

communication within the manufacturing process



prose and in documents such as manuals, graphs, and schedulesa. read/studies textbookb. interprets blueprints and technical drawingsc. read and understand reference manuals and tables, safety rules and

regulations, written work instructions and formsd. follow a daily laboratory schedule to maintain appropriate time-line

and completion of course requirements2. Writing: Communicates thoughts, ideas, information, and messages in

writing; and creates documents such as letters, directions, manuals,reports, graphs, and flow chartsa. accurately fill out a sample accident reportb. maintain a lecture notebookc. submit written responses to chapter question assignments

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

62

a. locates and applies formulas from reference manualsb. makes calculations based on values from tables and manuals

4. Listening: Receives, attends to, interprets, and responds to verbalmessages and other cuesa. assimilate classroom instructionb. interpret and assimilate video instructionc. practices active listening by affirming understanding of verbal



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


considers risks, and evaluates and chooses best alternativea. recognizes and evaluates hazards and makes appropriate decisions

on the use of protective equipment and safeguardsb. interprets specifications and makes judgement on how best to meet

the specification with available resources2. Problem Solving: Recognizes problems and devises and implements plan

of actiona. makes daily accommodations to stay on scheduleb. seeks additional instruction/clarification for assignment completionc. recognizes hazards and develops ways to eliminate or protect

against the hazardsd. uses reference manuals to locate information needed for problem

solving3. Seeing Things In the Mind's Eye: Organizes, and processes symbols,

pictures, graphs, objects, and other informationa. visualize objects in three dimensions from engineering drawingsb. visualize process during instructor lecturec. recognizes hazards



between two or more objects and applies it when solving a problema. identifies requirements and specifications, and reasons a way to

conform or measure for conformanceb. recognizes combinations of factors that produce personal hazards

or threats to the processPersonal Qualities: Displays responsibility, self-esteem, sociability, self-management, and integrity and honesty.

S3

1. Responsibility: Exerts a high level of effort and perseveres towards goalattainmenta. displays promptness and preparation for the day's workb. plans work to use time efficientlyc. accepts responsibility for mistakes, and takes corrective and


complete assignmentse. accepts responsibility and demonstrates concern for safety of self

and others2. Self-Esteem: Believes in own self-worth and maintains a positive view of



empathy, and politeness in group settingsa. assist classmates in improving technical skillsb. share laboratory resources

4. Self-Management: Assesses self accurately, sets personal goals,monitors progress, and exhibits self-controla. maintain a record of academic achievement (individual grade book)b. accept responsibility for mistakes and infractions, and take steps to


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

during examination, and on classroom exercisesd. understand the consequences of unethical behaviors



N1E-11603

01/060596


COURSE SYLLABUS

MACHINE TOOL PRACTICES IIPrerequisite: MACHINE TOOL PRACTICES I

S5


MACHINE TOOL PRACTICES II


COURSE DESCRIPTION:


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

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

PREREQUISITES: Machine Tool Practices I


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

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




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


laboratory assignments2. apply theory to laboratory assignments3. perform on written, oral, or practical examinations

86

4. 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



Safety in the Machine Shop 5 1

Gages 88 1

Lathe Parts 414 1

Lathe Accessories 394 1

Cutting Speeds and Feeds 270 1

Aligning Centers 440Machining Between Centers 428 1

Knurling and Grooving 452 1

QUIZ I (over the above units) 1

Tapers 477 2Threads 457 3

Using Chucks 408 1

Drilling and Boring 443 1

Milling Machines 502 1

QUIZ 2 (over the above units) 1

Milling Cutters 507 1

Cutting Speeds 522 1

Milling Operations 526 1

Indexing 592 2Gears 607 1

Gear Cutting 611 1

Assembly of Jig Saw 3

QUIZ 3 (over the above units) 1

Oral Presentations* 6


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


Shop orientation and safety 1

Precision layout 4Precision measuring with gage blocks and sine bar 8Lathe work 27Vertical milling machine work 18Horizontal milling machine 6Bench work 67 27

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

Total Lab Hours 108



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

B. APPLY MATHEMATICAL CONCEPTS1 Perform Basic Trigonometric Functions

a. Solve for unknown anglesb. Calculate bolt hole patterns

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

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

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

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

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

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

piecesC. PERFORM CONVENTIONAL MACHINING OPERATIONS

1. Operate Vertical Milling Machinesa. Demonstrate the use of all controls on the vertical milling machineb. Align the vertical milling machine headc. Select, align and use workholding devicesd. Select milling tool holderse. Select milling cuttersf. Perform all standard vertical milling operationsg. Bore a hole using the offset boring head

88

h. Machine angles using sine bar and gage blocksi. Setup and use special vertical mill fixturesj. Setup and machine dovetailsk. Machine keyways

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

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

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

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





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

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

69

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


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





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


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


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

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

70





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

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


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

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

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

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

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




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

process problems

'71

b. applies knowledge of machining process to develop a logical,sequential process plan

c. applies knowledge of workpiece machinability, cuttercharacteristics and machine tool characteristics to adjust speeds andfeeds









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


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



I. Machinery's H .andbook, Industrial Press2. Technology of Machine Tools, 4th Ed., McGraw Hill Publishers

MET20001/072396


COURSE SYLLABUS

SURVEY OF WELDING PROCESSES ANDAPPLICATIONS

73


SURVEY OF WELDING PROCESSES ANDAPPLICATIONS


COURSE DESCRIPTION:


This course is a survey of shielded metal arc, gas tungsten arc, gas metal arc, flux cored arc, andsubmerged arc welding processes. Metal weldability and weld symbols are considered. Processsafety, electrode selection, and process parameters are emphasized. Hard surfacing, usingshielded metal arc and oxyacetylene processes and techniques are studied.

PREREQUISITES: NONE


Textbook: Oxy-Acetylene Handbook, by Linde, Union Carbide Publisher, LatestEditionNew Lessons in Arc Welding, by Lincoln Electric, Lincoln ElectricPublisher, Latest Edition

Lab Manual: None Required

Student Tool List ** Qty. Req'd.Oxy-acetylene cutting and welding goggles (mono)

with #5 filter lens and one clear plastic lens 1 pairFriction lighter 1

Wire brush 1" wide with long handle 1

Soap stone 2 piecesWelder's cap 1

Welding gloves, long gauntlet 1 pairChipping hammer 1

Safety glasses 1 pairSlip joint pliers 1 pair



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

74

Laboratory: Hands on laboratory activities to enable the students to learn the various aspects ofthe welding process.


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


Introduction to the course 1

Introduction to oxy-acetylene fusion 1 1

Oxy-acetylene welding and cutting 9 2Introduction to mechanical and physicalproperties 77 1

Non-fusion welding 1

Introduction to the oxy-acetylene cuttingprocesses 1

Test #1 1

The shielded metal arc welding process 1-7 1

Running a good quality bead in the flat position 1-21 1

Introduction to shielded metal arc weldingelectrodes 3-3 2Shielded metal arc power sources 2-3 1

Test #2 1

Weld joints, weld types and weld positions 1-54 2Introduction to fillet welds 1-56 1

Test #3 1

Introduction to gas metal arc welding and fluxcore arc welding 7-37 2

Short circuiting metal transfer 1

Test #4 1

Power sources for GMAW and FCAW 1

SMAW and FCAW filler metal transfer modes 1

Test #5 1

Shielding gases used with the GMAW process 7-37 1

Shielding gases used with the FCAW process 1

Test #6 1

Introduction to gas tungsten arc welding 2Power sources for GTAW 1

GTAW electrodes 1

Test #7 1

Introduction to submerged arc welding andtechniques 7-69 1

Submerged arc welding processes 1

Test #8



1 The Oxy-Acetylene Welding and Cutting Process 9Demonstration of setting up and break down of equipmentA. Welding beads on plate

(1) Flat position(2) Without and with filler

B. Square butt joints(1) Flat and vertical position(2) With filler material

C. Brazing beads on plate(1) Flat position(2) With filler material

D. Brazing square butt joint(1) Flat and vertical position(2) With filler

E. Oxy-acetylene cutting(1) Cutting to a straight line

.2 The Shielded Metal Arc Welding Process (SMAW) 9A. Welding beads on plate

(1) E6010, E6011 and/or E7018 dependent on availability(2) Flat, horizontal and vertical

B. Welding tee joint(1) E6010, E6011 and/or E7018 dependent on availability(2) Flat, horizontal and vertical

3 The Gas Metal Arc Welding and Flux Core Welding Processes (GMAW) 6A. Set up 3 machines each processB. Welding beads on plate, both processes

(1) Have hands on with observers at each stationC. Demonstration of GMAW spot welder

4 The Gas Tungsten Arc Welding Process (GTAW) 6A. Set up machines for welding steel and aluminum (2 or 3 each)B. Welding beads on plate steel

(1) Have hands on with observersC. Welding bead on plate aluminum

(2) Have hands on with observers5 The Submerged Arc Welding Process 6

A. Demonstrate beads on plateB. Demonstrate running beads roll position

76

C. Let students have hands on and observationTotal Lab Hours 36



1. Use Protective Equipmenta. Wear protective safety clothing as required when welding

2. Follow Safe Operating Procedures for Welding/Cutting Machinesa. Identify and understand safe welding proceduresb. Demonstrate safe welding procedures

B. PERFORM WELDING OPERATIONS1. Weld With Shielded Metal Arc Welding (SMAW) Process

a. Identify factors for welding electrode selectionb. Adjust welding amperage setting for each applicationc. Demonstrate proper use of safety equipmentd. Weld beads on plate (flat and horizontal)e. Weld tee joints (flat and horizontal)f. Identify weld inspection factors and techniques

2. Weld/Cut With Oxy-acetylenea. Setup and break down the oxy-acetylene welding/cutting stationb. Properly adjust oxy-acetylene regulatorsc. Identify factors that determine torch welding and cutting tip selectiond. Demonstrate routine torch maintenance procedurese. Weld beads on plate (with and without filler) in the flat and horizontal

positionsf. Weld square groove butt joints in the flat and horizontal positionsg. Braze weld beads on plate in the flat positionh. Make square cuts to a straight line with the cutting torchi. Demonstrate proper use of safety equipment

3. Weld With Gas Tungsten Arc Welding (GTAW) (Heliarc)a. Set up GTAW welder for welding steelb. Set up GTAW welder for welding aluminumc. Weld beads on plate (steel) with appropriate filler rod in the flat positiond. Weld beads on plate (aluminum) with appropriate filler rod in the flat

positione. Weld lap joints in the horizontal position on steel platef. Weld lap joints in the horizontal position on aluminum plate

4. Weld With Gas Metal Arc Welding (GMAW)/(MIG)a. Set up machine for gas metal arc weldingb. Set up machine for flux cored arc weldingc. Weld beads on plate with gas metal arc welding system in the flat positiond. Weld beads on plate with flux cored welding system in the flat positione. Weld lap joints on steel plate with the gas metal arc welding system in the

horizontal position

77

f. Weld lap joints on steel plate with the flux cored arc welding system in thehorizontal position





1. follows a schedule to complete assigned tasks on time2. follows a schedule to maximize laboratory resources3. complete a tool crib request form for required materials and supplies

B. Interpersonal: Works with others1. complete assigned responsibilities within the welding lab serving as a

member of the team2. provide individual assistance/direction to peers as requested3. works well with all members of the classInformation: Acquires and uses information1. read and interpret weld symbols2. organize and apply theories of welding and cutting


a. organization of personnel and facilities on the shop floorb. systematic approach to the cutting and welding processesc. welding rod classification and match to various metalsd. systematic organization of training materials

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


1. chooses procedure, tools and equipment required to perform the weldingprocess

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

3. maintains and troubleshoots equipmenta. applies appropriate preventative maintenance

78

b. when using equipmentc. reports all malfunctions of equipment to supervisor/instructor



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


writing; and creates documents such as letters, directions, manuals,reports, graphs, and flow chartsa. outline the steps necessary to set up, properly adjust and weld/cut

using different types of welding equipmentb. maintain a lecture notebook

3. Arithmetic/Mathematics: Perform basic computations and approachespractical problems by choosing appropriately from a variety ofmathematical techniquesa. keeps a running computation of individual grade





smooth and safe operation of the laboratoryB. Thinking Skills: Thinks creatively, makes decisions, solves problems, visualizes,

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

considers risks, and evaluates and chooses best alternativea. analyzes requirements and makes decisions to select appropriate

welding process, equipment, materials, fixturing, and protectiveequipment

b. prioritizes activities for effective use of time

7 9

2. Problem Solving: Recognizes problems and devises and implements planof actiona. makes daily accommodations to stay on scheduleb. seeks additional instruction/clarification for assignment completionc. troubleshoots welding problems and makes process adjustments to

correct3. Seeing Things In the Mind's Eye: Organizes, and processes symbols,

pictures, graphs, objects, and other informationa. visualize process during instructor lectureb. visualize the relative motions between welding rod and workpiece

to generate desired weld patterns and weld strength as required4. Knowing How to Learn: Use efficient learning techniques to acquire and



between two or more objects and applies it when solving a problema. applies knowledge of material characteristics, job requirements, and

welding processes to perform assignmentsb. applies knowledge of material characteristics, job requirements, and

welding processes to troubleshoot and/or imporve the weldingprocess

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






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

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

monitors progress, and exhibits self-controla. perform in-process quality checks on weldmentsb. maintain a record of academic achievement (individual grade book)

so

c. accept responsibility for mistakes and infractions, and take steps toresolve or eliminate them




1. Machinery's Handbook, Industrial Press2. Welding Technology Today. Principles and Practices. Stinchcomb, Craig;: Prentice Hall

Inc., New Jersey 19893. Welder Handbook. W-100 E-1 Corp., Publication #51077, Nov., 19954. Hobart Audio - Visual Training Program5. Miller Audio - Visual Training Program

WLT 10501/060696

81


COURSE SYLLABUS

MACHINE TOOL PRACTICES IIIPrerequisite: MACHINE TOOL PRACTICES II

82


MACHINE TOOL PRACTICES III


COURSE DESCRIPTION:


The students will be required to apply knowledge and skills gained in Machine Tool Practices Iand II to make necessary calculations, select desired machine tools, and plan machining operationsand sequences to produce the required work from working drawings and sketches with aminimum of instructor prepared guidelines.

Special emphasis will be placed on the identification, heat treatment, machinability and otherproperties of various metals which are used in manufacturing. Students will also learn thecorrectsetup and operation of different grinding machines used in the machine shop.

PREREQUISITES: Machine Tool Practices I and II



Student Tool List

Machine Tool Practices, Kibbe, Neely, and Meyer, Wiley Pub., 4th Ed.None Required

**

In addition to the tools required for Machine Tool Practices I and II the students will need thefollowing:

Qty. Req'd.Soft face hammer 1

Drill sharpening gage 1

Edge finder 1

Calculator w/trig functions 1

12" hacksaw & blade 1

Shop towels 1 roll





83




Course Introduction 1

Introduction of Metal Lathe Project Handouts 1

Selection and Identification of FerrousSteels 193 1

Selection and Identification ofNonferrous Steels 199 1

Hardness Testing 218 1

Hardening, Case Hardening andTempering 206 1

Annealing, Normalizing and StressRelieving 218 1

QUIZ I...over the above topics 1

Grinding and Abrasive MachiningProcesses 617 1

Selection and Identification ofGrinding Wheels 630 1

Trueing, Dressing and Balancingof Grinding Wheels 637 1

Sharpening Hand Tools on thePedestal Grinder 79 1

Grinding Fluids 642 1

Horizontal Spindle w/ReciprocatingTable Surface Grinders 646 1

Work Holding on the Surface Grinder 649 1

Using the Surface Grinder 653 1

Grinding Surfaces at Right Angles Handout 1

Problems and Solutions in SurfaceGrinding 660 1

Center-Type Cylindrical Grinders 663 1

Using the Cylindrical Grinder 669 1

Universal Tool and Cutter Grinders 673 1

QUIZ II...over the above topics 1

84

Grinding Internal Surfaces Handout 1

Grinding Radii and Angles Handout 1

Form Grinding Handout 1

Grinding with Superabrasives Handout 1

QUIZ Ill...over the above topicsTotal Lecture Hours 27


Heat Treating Furnace Operation 3Use of the Rockwell Hardness Tester 6Hardening and Tempering Ferrous Metals 6Use of the Surface Grinder 18Machining Components for the Metal Lathe Project 111

Total Lab Hours 144



1. Follow Safe Operating Procedures for Hand and Machine Toolsa. Identify and understand safe heat treatment proceduresb. Demonstrate safe heat treatment proceduresc. Identify and understand safe grinding proceduresd. Demonstrate safe grinding procedures

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



2. Describe the Heat Treating Processa. Discuss the reasons for heat treatingb. Discuss the time/temperature chartc. List the different quenching mediumsd. Estimate metal heat temperature by colore. List reasons for stress relieving workpiecesf. Describe surface hardening processes

3. Test Metal Samples for Hardnessa. Perform spark test to test for metal hardnessb. Perform Rockwell hardness tests

C. PERFORM CONVENTIONAL MACHINING OPERATIONS1. Operate Grinding/Abrasive Machines

a. Discuss the selection and identification of grinding wheels

85

b. Inspect, mount, true, dress, and balance grinding wheelsc. Discuss the selection of grinding fluidsd. Operate horizontal spindle reciprocating table surface grinderse. Discuss common problems and solutions in surface grinding





1. plans work to complete assigned tasks on time2. complete a stock request form for required material

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

member of the team2. provide individual assistance/direction to peers as requestedInformation: Acquires and uses information1. read and interpret blueprints2. organize and apply theories of heat treatment3. organize and apply theories of grinding


a. organization of personnel and facilities on the shop floorb. understand the relationship of carbon content, the time-temperature

chart, and different quenching mediums as they apply to the heattreatment processes

c. codes for designating grinding wheel characteristics2. monitors and corrects performance during

a. the heat treatment processb. the grinding processc. constantly evaluating the quality of work to achieve acceptable




8

H. FOUNDATION SKILLSA. Basic Skills: Reads, writes, performs arithmetic and mathematicaloperations,


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


writing; and creates documents such as letters, directions, manuals,reports, graphs, and flow chartsa. prepare a process plan for parts to be heat-treated and groundb. maintain a lecture notebookc. submit written responses to chapter question assignments

3. Arithmetic/Mathematics: Perform basic computations and approachespractical problems by choosing appropriately from a variety ofmathematical techniquesa. determines optimum machining speeds, feeds, and depth ofcutb. keeps a running computation of individual grade







considers risks, and evaluates and chooses best alternativea. considers heat treating requirements for a part, and selects an

appropriate course of action within the constraints of time andavailable equipment

b. inspects a heat treated part and selects appropriate equipment togrind to finish size

87

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

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

pictures, graphs, objects, and other informationa. visualize process during instructor lectureb. visualize the relative motions between grinding wheel and

workpiece to generate desired surface finish and part dimensions4. Knowing How to Learn: Use efficient learning techniques to acquire and



between two or more objects and applies it when solving a problema. applies knowledge of heat treating, material characteristics, and

part geometry to predict distortion during heat treatmentb. applies knowledge of material characteristics, work requirements,

and grinding wheel characteristics to select the best grinding wheelfor the job









monitors progress, and exhibits self-controla. perform in-process hardness tests on heat-treated parts

b. perform in-process dimensional checks and surface finish checkswhile grinding to print specifications

c. accept responsibility for mistakes and infractions, and take steps toresolve or eliminate them





MET30001/060696


COURSE SYLLABUS

MANUFACTURING PROCESSES

90


MANUFACTURING PROCESSES


COURSE DESCRIPTION:


Essential studies into the processes and materials for manufacturing, including metal casting, hotand cold forming of steel, powder metallurgy and plastics. Analysis of newer processes such aselectrical discharge machining, chemical machining, and ultra-sonic machining; with a emphasis onthe economical manufacturing of products.

PREREQUISITES: NONE


Textbook:

Lab Manual:

Modern Materials and Manufacturing Processes, John E. Neeley &Richard R. Kibbe, Prentice Hall Career & Technology, Englewood Cliffs,N.J., 1987None Required

Student Tool List **: Safety glasses




Laboratory: Laboratory will consist of "hands-on" activities. Students will operate variousconventional metalworking machines to manufacture a product.


laboratory assignments2. apply theory to laboratory assignments3. perform on written, oral, or practical examinations4. perform on outside assignments including writing assignments5. contribute to class discussions6. maintain attendance per current policy

91

7. follow all shop rules and safety regulations as stated in the laboratory manual



The Manufacturing Industry 21 3

Material Resource Planning (MRP) 25 2Processing of Metals: Casting 7 3

Processing of Metals: Hot Working 8 3Processing of Metals: Cold Working 9 3QUIZ I 1

Powder Metallurgy 10 2Non-traditional Machining Processes 13 3

Plastics & Composite Processes 15 4QUIZ II 1

Joining Processes 14 3Corrosion & Protection for Materials 16 1

Design, Tooling & Production Lines 18 5QUIZ III


Lab Orientation and Safety 2Lab Sheet #1 - Stock preparation; measure (semi-precision), shear and debur 3Lab Sheet #2 - Layout, drill, ream and debur holes 3Lab Sheet #3 - Metal forming (bending) and countersinking holes 3Lab Sheet #4 - Metal joining (welding), stress relieving and sawing 3

Mid-term project evaluation and rework 2Lab Sheet #5 - Surface preparation (sand blast) and surface finish (paint) 3CNC stock preparation 2CNC Machining Demonstration and CIM Lab Demonstration 3Lab Sheet #6 - Component sub-assembly and precision machining activity 3Lab Sheet #7 - Sub-assembly manufacture (handle) 3

Lab Sheet #8 - Final assembly and test (final project evaluation) 3Lab clean-up 3

Total Lab Hours 36




1. Follow Safe Operating Procedures for Hand and Machine Toolsa. Identify and understand safe machine operating procedures

92

b. Demonstrate safe machine operationB. INTERPRET ENGINEERING DRAWINGS AND CONTROL DOCUMENTS

1. Describe the Relationship of Engineering Drawings to Planninga. Discuss production scheduleb. Discuss Material Resource Planning (MRP)c. Discuss inventory control recordsd. Discuss shop floor routing documents


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

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




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 requiredby industry. SCANS ismade up of five competencies and a three-part foundation of skills and personalqualities thatare needed for solid job performance.



1. follows a schedule to complete assigned tasks on time2. follows a schedule to maximize laboratory resources3. determine the initial cost of materials and "value added" as result of

processingB. Interpersonal: Works with others

1. complete assigned responsibilities within the manufacturing lab serving as amember of the team

2. provide individual assistance/direction to peers as requested

93

Information: Acquires and uses information1. read and interpret blueprints2. organize and apply theories of manufacturing processes3. perform basic semi-precision and precision layout as necessary


a. organization of personnel and facilities in the manufacturing labb. systematic approach to the production piocessc. dimensioning and measurement systems

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


1. chooses procedure, tools and equipment required to fabricate a product2. applies appropriate procedures and uses appropriate tools and equipment

to fabricate a part to referenced engineering standards



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

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

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

3. Arithmetic/Mathematics: Perform basic computations and approachespractical problems by choosing appropriately from a variety ofmathematical techniquesa. calculate bend allowances for sheet metal and metal plateb. keeps a running computation of individual grade

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

94

e. practices active listening by affirming understanding of verbalinstructions, asking questions for clarification and probing forspecifics





considers risks, and evaluates and chooses best alternativea. applies knowledge of process and materials to select appropriate

material and process for safe and economical service in a given .

applicationb. prioritizes activities for effective use of time

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

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

pictures, graphs, objects, and other informationa. visualize objects in three dimensions from engineering drawingsb. visualize process during instructor lecturec. visualize the capabilities of various manufacturing processes and

machine tools to generate desired features in raw stock in order tomanufacture a simple product



between two or more objects and applies it when solving a problema. apply general understanding of process and material characteristics

to determine the process by which a part or piece of stock has beenmade

b. applies knowledge of manufacturing materials and processes todevelop a logical, sequential process plan

c. apply broad understanding of processes, materials, productrequirements, and manufacturing economics to consider and applynew or alternative techniques to reduce costs, save time andimprove quality

95









monitors progress, and exhibits self-controla. perform in-process quality checks on manufactured component

partsb. maintain a record of academic achievement (individual grade book)c. accept responsibility for mistakes and infractions, and take steps to





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

MET30101/060796

96


COURSE SYLLABUS

INTRODUCTION TO CNC

97


INTRODUCTION TO CNC


COURSE DESCRIPTION:


Gives the student a basic knowledge of numerically controlled (NC) and computer numericallycontrolled (CNC) machine tools. Teaches differences between conventional and numericallycontrolled machines. Emphasis will be placed on safety of CNC machines. Principles ofprogramming, tooling, setup will be studied.

Included in the course will be a study of manual CNC programming techniques. Related topicsto be discussed include: Cartesian coordinates, absolute/incremental, word address, G & Mcodes, fixed cycles and CNC systems.

PREREQUISITES: Machine Tool Practices I and II and Occupational Math



Student Tool List

Machine Tool Practices, Kibbe, Neely, and Meyer, Wiley Pub., 4th Ed.Supplied by the instructor.

**. Required tools will be found on the basic Machine Tool Practices ITool List.



Lecture: Didactic presentations will include lecture, video and demonstrations

Laboratory: Laboratory will be a "hands-on" activities relating to CNC programming


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

9R

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

LECTURE OUTLINE:

NOTE: THE PILOT CURRICULUM WAS DEVELOPED AND TESTED IN ALABORATORY THAT WAS EQUIPPED WITH A FADAL VMC-20 VERTICALMACHINING CENTER, AN OKUMA LB-15 TURNING CENTER AND ACOMPUTER LAB LOADED WITH THE "SMARTCAM" SOFTWAREPACKAGE. NO TEXTBOOK WAS FOUND TO INCLUDE ALL THREE OFTHESE IMPORTANT LAB COMPONENTS; THEREFORE, THE FACTORYSUPPLIED MANUALS WERE USED IN THE DEVELOPMENT ANDPRESENTATION OF THE TOPICS COVERED IN THIS COURSE.

Lecture Topics Contact Hrs.CNC Overview 3

Description of CNCJob opportunities in the CNC fieldEmployability skills in CNCWorking Safely with CNC machines

The Structure of a CNC System 3

CNC vs. conventional machining terminology5 Questions to answer before programming startsCartesian Coordinate system

Process Planning (Mill) 3

Interpreting a part printCreating a job sheet from a part printIntroduction to SMARTCAM'S Job Plan moduleEntering tool information into the Job Plan

Programming Format (Mill) 6Basic CNC code structure (FADAL)Starting a CNC ProgramMachining examplesEnding a CNC programIntroduction to SMARTCAM'S Edit Plus moduleand Tape-to-Shape capabilitiesUsing SMARTCAM to simulate machine tool movements

Programming CNC Machining Operations (Mill) 3

Straight millingDrillingCircular milling

Process Planning (Lathe) 3

CNC lathe coordinate systemsCarbide tooling inserts for CNC lathesProcess planning (lathes)

99

Entering tool information into the Job PlanProgramming the CNC Lathe 3

Basic program structureTurning, Facing, Boring and Drilling



CNC Lab Organization and Safety 3Identification of Major CNC Components 3

CNC (Mill) Tooling Systems 3

Introduction to SMARTCAM Programming Software 6Job Plan, Applications and Edit Plus Modules

Programming CNC Machining Center 18Basic Program StructureLinear Milling, Drilling, Circular Milling, and Canned Cycles

CNC (Lathe) Tooling Systems 3Programming CNC Lathes 6

Basic Program StructureTurning, Facing, Boring, Drilling, and Threading

Final Project 6Total Lab Hours 48


After the successful completion of this course the student will be able to:A. APPLY MATHEMATICAL CONCEPTS

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

2. Calculate Speeds and Feeds for Machininga. Calculate RPM for various metals and various toolsb. Write CNC code for programming RPMc. Calculate feed for various metals, tools, and depths of cutd. Write CNC code for programming feed and depth of cut

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

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

a. Read and interpret blueprintsb. Plan CNC machining operations

100

c. Calculate speeds, feeds, and depth of cut for various CNC machineapplications

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

applications2. Program CNC Machines

a. Identify CNC applicationsb. List various types of CNC machinesc. Discuss CNC machine control systemsd. Describe absolute and incremental coordinate systemse. Plan and write programs for CNC millsf. Plan and write programs for CNC lathesg. Verify CNC programs using computer softwareh. Edit CNC programs





1. follows a schedule to complete assigned tasks on time2. follows a schedule to maximize laboratory resources

B. Interpersonal: Works with others1. complete assigned responsibilities within the CNC lab serving as a

member of the team2. provide individual assistance/direction to peers as requestedInformation: Acquires and uses information1. read and interpret blueprints2. read and interpret CNC machine programming manuals3. read and write CNC machine code


a. organization of personnel and facilities in the CNC labb. systematic approach to the metal removal process using CNCc. dimensioning and measurement systems

101

d. relationships among the machine tool, its control system, and theprogram

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


1. chooses procedure required to program a part using CNC2. applies appropriate procedures to program a part using CNC


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

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


writing; and creates documents such as letters, directions, manuals,reports, graphs, and flow chartsa. outline the steps necessary to program and produce a machine part

using CNCb. maintain a lecture notebookc. write CNC programs for CNC mills and CNC lathes

3. Arithmetic/Mathematics: Perform basic computations and approachespractical problems by choosing appropriately from a variety ofmathematical techniquesa. determines optimum machining speeds, feeds, and depth of cutb. interconverts fractions to decimal expressionsc. keeps a running computation of individual graded. identify machining points using the Cartesian coordinate system




skill

102

d. communicate with peers, instructors and supervisors to ensure thesmooth and safe operation of the CNC lab

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

considers risks, and evaluates and chooses best alternativea. identifies requirements and uses knowledge and judgement to select

a best CNC machining approach from among available alternativesb. applies knowledge of processes and requirements to confirm that

the process is functioning properly, or to improve the process2. Problem Solving: Recognizes problems and devises and implements plan

of actiona. makes daily accommodations to stay on scheduleb. seeks additional instruction/clarification for assignment completionc. troubleshoots and debugs CNC programs

3. Seeing Things In the Mind's Eye: Organizes, and processes symbols,pictures, graphs, objects, and other informationa. visualize objects in three dimensions from engineering drawingsb. visualize process during instructor lecturec. visualize the relative motions between tool and workpiece to


d. visualize cutter path and position of clamps and workholdingdevices while preparing CNC programs



between two or more objects and applies it when solving a problema. applies knowledge of machining processes, tooling, and materials to

optimize CNC programmingb. applies knowledge of programming system to develop CNC

programs in a logical, efficient mannerc. applies knowledge of workpiece machinability, cutter

characteristics and machine tool characteristics to programoptimum speeds and feeds

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


preventive actions

103

d. takes initiative when needed to gain resources or assistance tocomplete assignments

2. Self-Esteem: Believes in own self-worth and maintains a positive view ofselfa. takes pride in work through positive reinforcementb. sees self as a valued member of the group through continued


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

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

monitors progress, and exhibits self-controla. maintain a record of academic achievement (individual grade book)b. accept responsibility for mistakes and infractions, and take steps to





1. Machinery's Handbook_ Industrial Press2. Technology of Machine Tools, 4th Ed. McGraw Hill Publishers3. Computer Numerical Control by Warren S. Seams, Delmar Publishers

MET230301/060796

104


COURSE SYLLABUS

MACHINE TOOL PRACTICES IVPrerequisite: MACHINE TOOL PRACTICES III

1O3


MACHINE TOOL PRACTICES IV


COURSE DESCRIPTION:


This course is designed for students who have successfully completed Machine Tool Practices I,II and III. This course will cover the machining skills they have mastered in their first threequarters at an advanced level. Additional skills such as production machining, productionmachine set up and fixturing along with working with working with assembly drawings will becovered.

Students will be challenged to further refine and hone their machining skills which werepresented in earlier machining courses. Students will be encouraged to strive for mastery oftheir machining skills and to increase their knowledge about metal working procedures.

Emphasis will be placed on developing the skills and attitudes which are sought by employers inthe machine trade industries. Topics which will be discussed are: quality in manufacturing, thehigh cost of scrap, the value added to a product by the machinist, and the machinist's role in theoverall manufacturing process.

Students will be introduced to more complex machining operations through the production ofseveral parts that are required for the assembly of their final project. Students will not only beexpected to perform all machining operations but also plan, layout, and set up any machinesnecessary to produce the part.

Lab activities will be performed in more of a "real life" machine shop atmosphere with theinstructor serving in the role of the supervisor. Students will be challenged to become problemsolvers and team players while in the machine shop. A large portion of this class is dedicated tomolding the students into the type of employees which are sought by industry...machinists withgood basic machining skills coupled with a positive attitude and a willingness to learn.

PREREQUISITES: Machine Tool Practices I, H and III



Machine Tool Practices, Kibbe, Neely, and Meyer, Wiley Pub., 4th Ed.Instructor Prepared Lessons/Modules


Student Tool List **. Tools are the same as those used in Machine Tool Practices I, IIand III.

106








Course Introduction 1

Continuation of the Metal Lathe Project Handout 3

Quality in Manufacturing...Importance Module MET -L1 1

Implementing Concepts of Quality in theWorkplace Module MET-L2 1

Principles and Tools of ContinuousImprovement Module MET-L3 5

What is "ISO 9000"? Handout 1

QUIZ I...over the above topics 1

How Companies Make Their Money... Handout 1

Direct vs. Indirect Costs Handout 1

Company Expectations of Their Handout 1

EmployeesEmployee Expectations of the Company Handout 1

QUIZ II...over the above topics 1

Introduction to Electrical DischargeMachining Module MET-G6 1

EDM Electrodes...Roughing and Finishing Handout 3

Set up and Operation of the Sinker EDM Demonstration 6Introduction to 3R Tooling Handout 1

Set up and Operation of the Wire EDM Demonstration 6QUIZ HI...over the above topics 1


107


Set Up and Operation of Sinker EDM 10Set Up and Operation of Wire EDM 10Machining of Most Advanced Metal Lathe Components 120Inspect Components for the Metal Lathe Project 10Assembly/Test the Metal Lathe Project 30

Total Lab Hours 180



1. Follow Safe Operating Procedures for Hand and Machine Toolsa. Identify and understand safe heat treatment proceduresb. Demonstrate safe heat treatment proceduresc. Identify and understand safe grinding proceduresd. Demonstrate safe grinding procedures

B. PERFORM ADVANCED MACHINING PROCESSES1. Operate Electrical Discharge Machines

a. Discuss the EDM processb. List advantages and disadvantages of the EDM processc. Identify electrode materialsd. Machine EDM electrodese. Setup and operate sinker EDM machinef. Calculate overburng. Identify generator setting of machineh. Choose proper techniques for flushingi. Setup and operate wire EDM machine





1. plans lab work to complete assigned tasks on time

108

2. complete a stock request form for required material3. determine the initial cost of materials and "value added" as result of

machiningB. Interpersonal: Works with others

1. complete assigned responsibilities within the shop floor serving as amember of the team

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


a. organization of personnel and facilities on the shop floorb. systematic approach to the metal removal process through the

EDM processc. dimensioning and measurement systems





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


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


writing; and creates documents such as letters, directions, manuals,reports, graphs, and flow chartsa. maintain a lecture notebook

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

4. Listening: Receives, attends to, interprets, and responds to verbalmessages and other cues

109

a. assimilate classroom instructionb. interpret and assimilate video instructionc. observe and assimilate laboratory demonstrationsd. seek and receive individualized instruction in the laboratorye. practices active listening by affirming understanding of verbal






considers risks, and evaluates and chooses best alternativea. considers and applies quality improvements to machining processesb. considers and applies actions to reduce costs of machining

processes2. Problem Solving: Recognizes problems and devises and implements plan

of actiona. makes daily accommodations to stay on scheduleb. seeks additional instruction/clarification for assignment completionc. troubleshoots machining processes and equipmentd. recognize problems in machining and selects appropriate corrective

or preventive actione. identifies quality problems and takes appropriate actions to correct

and prevent the problems3. Seeing Things In the Mind's Eye: Organizes, and processes symbols,





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

problems or to improve the processb. applies knowledge of EDM process to develop a logical, sequential

process plan

I 0

c. applies knowledge of systems involving people, planning, materials,processing, routing and handling, and quality principles to identifythe root cause of a quality problem















MET40001/060796

111


COURSE SYLLABUS

ADVANCED CNCPrerequisite: INTRODUCTION TO CNC

12


ADVANCED CNC


COURSE DESCRIPTION:


Continuation of Introduction to CNC. Extends basic principles of numerical control to actualmachine operations. Basic descriptions of Computer Numerical Control and step-by-stepprocedures for planning and preparing a computer-assisted program are given. CNC lathe andCNC milling machine applications are utilized for machining of complete units or studentlaboratory projects.

Student activities are planned to focus on the safe setup and operation of the CNC mill centerand the CNC lathe. Students will learn the basics of IGF programming using the Okuma CNClathe. Students will also be introduced to the SMARTCAM programming system with specialemphaSis on job planning and 3-axis milling applications.

PREREQUISITES: INTRODUCTION TO CNC


Textbook: NoneLab Manual: None

Student Tool List **: Tools will be the same as required for Introduction to CNC



Lecture: Didactic presentations will include lecture, video and demonstrations

Laboratory: Laboratory activities will be strictly hands on with approximately 1/3 time spent onthe CNC lathe, 1/3 time on the CNC mill and 1/3 time using the SMARTCAMcomputer lab.


laboratory assignments

11_3

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

LECTURE OUTLINE:

NOTE: THE PILOT CURRICULUM WAS DEVELOPED AND TESTED IN ALABORATORY THAT WAS EQUIPPED WITH A FADAL VMC-20 VERTICALMACHINING CENTER, AN OKUMA LB-15 TURNING CENTER AND ACOMPUTER LAB LOADED WITH THE SMARTCAM" SOFTWAREPACKAGE. NO TEXTBOOK WAS FOUND TO INCLUDE ALL THREE OFTHESE IMPORTANT LAB COMPONENTS; THEREFORE, THE FACTORYSUPPLIED MANUALS WERE USED IN THE DEVELOPMENT ANDPRESENTATION OF THE TOPICS COVERED IN THIS COURSE.

Lecture Topics Contact Hrs.Advanced Programming Techniques (Lathe) 3

Threading cycles and grooving cyclesRoughing for turning and facing operations

Set-up and Operation of the CNC Mill 6Tooling for CNC millsCNC mill set-upCNC mill operation

Set-up and Operation of the CNC Lathe 12Tooling for CNC lathesCNC lathe set-upCNC lathe operationBoring soft jaws for the CNC lathe

SMARTCAM CNC Programming System 14The Structure of a CAM SystemProcess Planning (Mill)Working with a CNC Process Model (Mill)Generating CNC Code with a CAM SystemAdditional Modeling Practices (Mill)



Introduction to FADAL CNC Mill Controls and MDI Functions 3FADAL Setup and Operations 33Uploading/Downloading via CIMNET Networking System 2Introduction to OKUMA Controls and MDI Functions 3

114

Introduction to IGF Programming 6OKUMA Setup and Operations 27SMARTCAM CNC Programming 36

Total Lab Hours 108



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

B. APPLY MATHEMATICAL CONCEPTS1. Calculate Speeds and Feeds for Machining

a. Calculate RPM for various metals and various toolsb. Calculate feed for various metals, tools, and depths of cut

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

C. PERFORM ADVANCED MACHINING PROCESSES1. Select and Use CNC Tooling Systems

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

2. Program CNC Machinesa. Identify CNC applicationsb. List various types of CNC machinesc. Discuss CNC machine control systemsd. Describe absolute and incremental coordinate systemse. Plan and write programs for CNC millsf. Plan and write programs for CNC lathesg. Edit CNC programs

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

run" and final production

115

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

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

productioni. Edit CNC programs for optimum part production

5. Generate CNC Programs Using a CAM systema. Create a Job Planb. Describe the partc. Edit the partd. Verify tool pathe. Generate the CNC codef. Verify/edit the codeg. Download the code into the machine via network





1. follows a schedule to complete assigned tasks on time2. follows a schedule to maximize laboratory resources

B. Interpersonal: Works with others1. complete assigned responsibilities within the CNC lab serving as a

member of the team2. provide individual assistance/direction to peers as requestedInformation: Acquires and uses information1. read and interpret blueprints2. read and interpret CNC machine tool manuals

116

3. read and write CNC machine codeD. Systems: Understands complex inter-relationships

1. demonstrate knowledge of the following systems:a. organization of personnel and facilities in the CNC labb. systematic approach to the metal removal process using CNCc. dimensioning and measurement systemsd. relationships among the machine tool, its control system, and the

program2. monitors and corrects performance during

a. the CNC machining processb. adjustments of individual laboratory work schedulec. constantly evaluating the quality of work to achieve acceptable


1. chooses procedure, tools and equipment required to program and producea part using CNC

2. applies appropriate procedures and uses appropriate tools and equipmentto program and produce a machined part using CNC to acceptablestandards



prose and in documents such as manuals, graphs, and schedulesa. read/studies CNC machine operating and programming manualsb. interprets blueprints and technical drawingsc. follow a daily laboratory schedule to maintain appropriate time-line


writing; and creates documents such as letters, directions, manuals,reports, graphs, and flow chartsa. outline the steps necessary to program and produce a machine part

using CNCb. maintain a lecture notebookc. write CNC programs for CNC mills and CNC lathes

3. Arithmetic/Mathematics: Perform basic computations and approachespractical problems by choosing appropriately from a variety ofmathematical techniquesa. determines optimum machining speeds, feeds, and depth of cutb. interconverts fractions to decimal expressionsc. keeps a running computation of individual graded. identify machining points using the Cartesian coordinate system

4. Listening: Receives, attends to, interprets, and responds to verbalmessages and other cuesa. assimilate classroom instructionb. interpret and assimilate video instruction

117

c. observe and assimilate laboratory demonstrationsd. seek and receive individualized instruction in the laboratorye. practices active listening by affirming understanding of verbal




smooth and safe operation of the CNC labB. Thinking Skills: Thinks creatively, makes decisions, solves problems, visualizes,


considers risks, and evaluates and chooses best alternativea. identifies requirements and uses knowledge and judgement to select

a best CNC machining approach from among available alternativesb. applies knowledge of processes and requirements to confirm that

the process is functioning properly, or to improve the process2. Problem Solving: Recognizes problems and devises and implements plan

of actiona. makes daily accommodations to stay on scheduleb. seeks additional instruction/clarification for assignment completionc. troubleshoots and debugs CNC programsd. troubleshoots CNC machining systems and takes appropriate

actions3. Seeing Things In the Mind's Eye: Organizes, and processes symbols,



d. visualize cutter path and position of clamps and workholdingdevices while preparing CNC programs



between two or more objects and applies it when solving a problema. applies knowledge of machining processes, tooling, and materials to

optimize CNC machiningb. applies knowledge of programming system to develop CNC

programs in a logical, efficient manner

118

c. applies knowledge of workpiece machinability, cuttercharacteristics and machine tool characteristics to adjust speeds andfeeds







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

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






1. Machinery's Handbook, Industrial Press2. Technology of Machine Tools, 4th Ed. McGraw Hill Publishers3. Computer Numerical Control by Warren S. Seams, Delmar Publishers

ME7240601/060796

119

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.

I 2 0

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easu

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ing

(OD

&T

)m

ettr

i ho d

-

olog

y

C-7

Des

crib

e th

ere

latio

nshi

p of

engi

neer

ing

draw

ings

topl

umin

g

C-8

Ulm

stan

dard

s to

vet*

req

uire

-m

ente

C-9

Ana

lyze

tell

of m

ater

ials

(130

M)

D-1

Iden

tity

mat

erie

ls w

ithde

sire

d

prop

ertie

s

11-2

Des

crib

eth

e he

at tr

eatin

gjE

CC

OPI

I

D-3

Per

form

heat

test

ing

oper

atio

ns

D-4

Tes

t met

alsa

mpl

es fo

rha

rdne

ss

DJ

Ides

*ty

pes

of p

last

icm

ater

ials

and

proc

esse

s

E-I

Iden

tity

type

, of m

easu

re-

mea

ts

E-2

Sel

ect

prop

erm

easu

rem

ent

tool

s

E-3

App

ly p

rope

rre

assu

ring

tech

niqu

es

E-4

Use

Met

rican

d E

nglis

hst

anda

rds

ofm

easu

rem

ent

E-5

Per

form

mea

sure

men

tsw

ith h

and

held

nutr

imen

ts

E-6

Per

form

mea

sure

men

t on

surf

ace

plat

e

E-7

Per

form

insp

ectio

ns to

ngst

atio

nery

equi

pmen

t

F-I

Pre

pare

and

plan

for

mac

hini

ngop

erat

ions

F-2

Use

pro

per

hod

tool

sP

-3

Ope

rate

pow

erO

WN

F4

Ope

rate

dul

lpr

esse

sF

-5 O

pera

teve

rtic

al tr

illin

gm

achi

nes

,F

4 O

pera

teho

rizon

tal

mill

ing

mac

hine

s

F-7

Ope

rate

met

al c

uttin

gla

thes

F-8

Ope

rate

gind

ing/

abnu

ive

mac

hine

s

F-9

Ope

rate

tool

and

cutte

r

grim

ier.

F-1

0 O

pera

tede

barr

ing

equi

pmen

t

F -

11 P

arm

apr

even

tativ

em

aint

enan

ce

0-I P

repa

re a

ndpl

an fo

r C

NC

mac

hini

ngop

erat

ion.

0-2

Sel

ect a

ndm

e C

NC

tool

ing

syst

ems

0-3

Pro

gram

CN

C m

achi

nes

0-4

Ope

rate

CN

C m

achi

ning

cent

ers

(mill

i)

0-5

Ope

rate

CN

C tu

rnin

goa

ten

(lith

o)

0-6

prev

enta

tive

mai

nten

ance

...H

-I U

seco

mpu

ter

oper

atin

gsw

arm

s

H-2

Use

com

pute

rin

csdr

y sy

stem

s

H-3

Use

uni

ons

com

pute

rap

plic

atio

ns

H-4

Bee

be:

codi

ngH

-3 U

se C

AD

/C

AM

ert

en

14 D

efin

equ

ality

inin

sauf

acts

ing

and

expl

ain

impo

rtan

ce

1-2

Per

form

Sta

tistic

alP

roce

ss C

ontr

ol(S

PC

) fli

nctio

ns

1-3

Ana

lyze

mac

hini

ngpr

oble

ms

and

reco

mm

end

solu

tions

41

SKIL

LS

AN

D K

NO

WL

ED

GE

Con

miu

nica

tion

dolls

Use

Mea

sure

men

t Too

lsU

se I

nspe

ctio

n D

evic

esM

athe

mat

ical

SU

LR

eadi

ngA

Vri

ting

Skill

sK

now

ledg

e of

Saf

ety

Reg

ulat

ions

Prac

tice

Safe

ty in

the

Wor

kpla

ceO

rgan

izat

iona

l Ski

llsK

now

ledg

e of

Com

pany

Pol

icie

s/Pr

ooed

ures

Mec

hani

cal A

ptitu

deA

bilit

y to

Com

preh

end

Wri

tten/

Ver

bal I

nstr

uctio

nsK

now

ledg

e of

Cut

ting

Flui

ds/L

ubri

cant

sB

asic

Kno

wle

dge

ofFa

sten

ers

Abi

lity

to W

ork

as P

art o

f a

Tea

mC

onve

rse

in th

e T

echn

ical

Lan

guag

e of

the

Tra

deK

now

ledg

e of

Occ

upat

iona

l Opp

ortu

nitie

sK

now

ledg

e of

Em

ploy

ee/E

mpl

oyer

Res

pons

ibili

ties

Kno

wle

dge

of C

ompa

ny Q

ualit

y A

ssur

ance

Act

iviti

esPr

actic

e Q

ualit

y-C

onsc

ioum

en in

Per

form

ance

of

the

Job

TE

XA

S ST

AT

E T

EC

HN

ICA

L C

OL

LE

GE

WA

CO

MA

ST P

RO

GR

AM

RE

PRE

SEN

TA

TIV

ES

DR

. HU

3HR

OC

IER

SD

irec

tor

DR

. JO

N B

GIS

FOR

DM

IMI=

Dir

ecto

r

JOH

PEN

ICK

.Pr

ojec

t Coo

rdin

ator

TE

RR

Y S

AW

MA

Res

eirc

ti C

oord

inat

or

WA

UA

CE

PEL

TO

NSi

te C

ooni

nsto

r

RO

SEM

AR

YII

MM

ON

SSe

nior

Sec

tels

o/St

atis

ticia

t

Fur

nish

ed B

y:

LA

RR

Y W

RIG

HT

, mem

ber

RO

BE

RT

LIN

DSA

Y,s

tscs

Ann

JOH

N H

AM

MO

ND

, kin

tilab

t

4an

nege

141

TR

AIT

S A

ND

AT

TIT

UD

ES

Stro

ng W

ork

Eth

icIn

terp

emon

al S

kills

Puri

caud

ityD

epen

dabi

lity

Hon

esty

Nea

tnes

sSa

fety

Com

oien

tious

Mot

ivat

ion

Rem

onsb

lePh

ysic

al A

bilit

yPr

ofes

sion

alT

rust

wor

thy

Cus

tom

er R

elat

ions

Pers

onal

Eth

ics

TO

OL

S A

ND

EQ

UIP

ME

NT

Mac

hini

st's

Too

ls (

e.g,

cal

iper

s, d

ial i

ndic

ator

s,m

agne

tic to

ol h

olde

rs, e

tc.)

Mea

suri

ng T

ools

Pow

er T

ools

Met

al L

athe

with

Atta

chm

ents

Dri

ll Pr

esse

sV

ertic

al M

ill w

ith A

ttach

men

tsPo

wer

Saw

sPo

wer

Dri

llsH

ydra

ulic

/Arb

or P

ress

Hea

t Tre

atm

ent E

quip

men

tH

ardn

ess

Tes

ting

Equ

ipm

ent

Gri

ndin

g M

achi

nes

with

Atta

chm

ents

Wel

ding

Equ

ipm

ent (

SHA

W, °

MA

W, F

CA

W)

CN

C M

achi

ning

Cen

ter

and

Tun

ing

Cen

ter

Gea

r Pr

oduc

ing

Mac

hine

s w

ith A

ttach

men

tsA

lignm

ent/C

alkr

atio

n T

ools

Coo

lant

Rec

over

y E

quip

men

tC

ompu

ter

Ven

tihrt

ion

Equ

ipm

ent

Fork

lift

Pers

onal

Saf

ety

Equ

ipm

ent

Oxy

acet

ylen

e E

quip

ped

Too

l Sto

rage

Equ

ipm

ent

Wor

kben

ches

Vis

esPe

dest

al G

rind

ers

Wel

d T

est E

quip

men

tO

ptic

al C

ompa

rato

rC

oord

inat

e M

easu

rem

ent M

achi

ne

FUT

UR

E T

RE

ND

S A

ND

CO

NC

ER

NS

Com

posi

tes

Las

er M

achi

ning

Adv

ance

d C

ompu

ter

App

licat

ions

Rob

otic

Con

trol

of

Mac

hoE

nvir

onm

enta

l Con

sent

sFi

ber

Opt

ic C

ontr

ols

Aut

omat

ed M

ater

ial H

andl

ing

Equ

ipm

ent

Com

pute

r In

tegr

ated

Man

ufac

turi

ngM

ore

Var

iety

of

Mac

hine

s(V

ertic

al a

nd H

oriz

onta

l Mill

s)

CO

MPE

TE

NC

Y P

RO

FIL

E

Mac

hini

st

Prep

ared

By

M.A

.S.T

.M

achi

ne T

ool A

dvan

ced

Skill

sT

echn

olog

y Pr

ogra

man

dC

onso

rtia

Par

tner

s(V

.199

J400

08)

lbct

=ln

ege

DID

AR

RC

O.

CA

T

BE

ST C

OPY

AV

AIL

AB

LE

142

MA

CH

INIS

T...

. pla

n, la

yout

, set

up, a

nd o

pera

te h

and

and

mac

hine

tool

s to

per

form

mac

hini

ng o

pera

tions

nec

essa

ry to

pro

duce

a w

orkp

iece

to r

efer

ence

den

gine

erin

g st

anda

rds.

Tas

ksD

utie

s

Inte

rpre

tE

ngln

eeri

ngD

raw

-M

gt a

nd C

ontr

olD

ocus

ents

Perf

orm

Mea

sure

men

t/E

Insp

edie

m

Perf

orm

Con

vend

owd

FM

acbt

nlag

dons

Perf

orm

Wel

ding

GO

pera

tions

143

DA

LMA

CE

LPIO

MA

ST

/01/

0105

91

A-I

Fol

low

safe

ty m

anua

lsan

d al

l saf

ety

regu

latio

ns/

requ

irem

ents

A-2

Use

pro

tec-

two

equi

pmen

tA

-3 F

ollo

w

safi

atm

......

..fo

rra

rs7r

and

mac

hine

tool

s

A-4

Mai

ntai

n a

clea

n an

d sa

few

ork

envi

ron-

mad

B-I

Pak

ern

basi

car

ithm

etic

fim

ctio

ns

8-2

Inte

r-co

nver

tfr

actio

ns/

deci

mal

s

B-3

Int

er-

conv

ert M

etri

c/E

nglis

hm

easu

rem

ents

B-4

Per

form

basi

ctr

igon

omet

ric

ftm

ctio

ns

13-5

Cal

cula

tesp

eeds

and

feed

s fo

rm

achi

ning

B-6

Loc

ate

mac

hini

ngpo

ints

fro

m a

datu

m p

oint

B-7

Per

form

calc

ulat

ions

nece

ssar

y fo

rtu

rnin

g ta

pers

C-1

Rev

iew

blue

prin

t not

esan

d di

men

sion

s

C-2

Ide

ntif

yba

sic

layo

ut o

fdr

awin

gs

C-3

Ide

ntif

yba

sic

type

s of

draw

ings

C-4

Lis

t the

purp

ose

of e

ach

type

of

draw

ing

C-5

Ver

ify

draw

ing

elem

ents

C-6

Des

crib

eth

e re

latio

nshi

pof

eng

inee

ring

draw

ings

topl

anni

ng

C-7

Use

stan

dard

s to

veri

fy r

equi

re-

man

ta

C-8

Ana

lyze

bill

ofm

ater

ials

(130

M)

D-1

Ide

ntif

ym

ater

ials

with

desi

red

prop

ertie

s

D-2

Dam

aoth

e he

attr

eatin

g pr

oces

s

D-3

Tes

t met

alsa

mpl

es f

orha

rdne

ss

D-4

Ide

ntif

yca

st ir

on/c

ast

stee

l for

ging

s

D-5

Des

ign

and

fabr

icat

eha

nd to

olin

g

E-1

Ide

ntif

yty

pes

ofm

easu

rem

ents

8-2

Sele

ctpr

oper

mem

arer

nent

tool

s

E-3

App

lypr

oper

mea

sur-

mg

tech

niqu

es

E-4

Use

Met

ric

and

Eng

lish

stan

dard

s of

mea

sure

men

t

134

Perf

orm

mea

sure

men

tsw

ith b

and

held

inst

rum

ents

F-I

Prep

ayan

d pl

an f

orm

achi

ning

opm

atio

ns

F-2

Use

pro

per

band

tool

sF-

3 O

pera

tepo

wer

saw

sF-

4 O

pera

tedr

ill p

ress

esF-

5 O

pera

tem

etal

cut

ting

lath

es

F6 O

pera

tegr

indi

ng/

abra

sive

mac

hine

s

F-7

Ope

rate

jig

bori

ngm

achi

nes

F-8

Ope

rate

&bu

rrin

g'

equi

pmen

t

F-9

Ope

rate

vert

ical

tinn

ing

mac

hine

(Bul

lard

)

F -1

0 O

pera

teho

rizo

ntal

bori

ng m

ill

F-11

Ope

rate

hydr

aulic

pres

ses

0-1

Wel

d w

ithSh

ield

ed M

etal

Arc

Wel

ding

(SM

AW

)pr

oces

s

0-2

Wel

d/cu

tw

ith o

xyac

ety-

lens

0-3

Had

surf

ace

met

alw

ith s

pray

tran

sfer

(met

aliz

ing

144

BE

ST C

OPY

AV

AIL

AB

LE

SKIL

LS

AN

D K

NO

WL

ED

GE

Con

tam

inat

ion

Skill

sU

se M

easu

rem

ent T

ools

Use

Ins

pect

ion

Dev

ices

Mat

hem

atic

al S

kills

Rea

ding

/Wri

ting

Skill

sK

now

ledg

e of

Saf

ety

Reg

ulat

ions

Prac

tice

Safe

ty in

the

Wor

kpla

ceO

rgan

isat

iona

l Ski

llsM

echa

nica

l Apt

itude

Abi

lity

to C

ompr

ehen

d W

ritte

n/V

erba

l Ins

truc

tions

Bas

ic K

now

ledg

e of

Fas

tene

rsA

bilit

y to

Wor

k as

Par

t of

a T

eem

Con

vene

in th

e T

echn

ical

Lan

guag

e of

the

Tra

deK

now

ledg

e of

Occ

upat

iona

l Opp

ortu

nitie

sK

now

ledg

e of

Em

ploy

ee/E

mpl

oyer

Res

pons

ibili

ties

Kno

wle

dge

of C

ompa

ny Q

ualit

y Im

prov

emen

t Act

iviti

esPr

actic

e Q

ualit

y-C

onsc

ious

ness

in P

erfo

rman

ce o

f th

e Jo

b

CE

NT

RA

L F

LO

RID

A C

OM

MU

NIT

Y C

OL

LE

GE

PRO

GR

AM

RE

PRE

SEN

TA

TIV

ES

DR

HU

GH

RO

GE

RS

Den

neT

edin

cti E

duca

tion

MIK

EFO

XD

irec

tor/

Indu

stry

Ser

vice

s

LA

RR

Y M

YFO

RD

Coo

rdin

ator

/Man

ufac

turi

ng T

echn

olog

y

KE

ND

EW

HU

RST

Inst

ruct

or/I

ndus

tria

l Mac

hine

ry M

aint

enan

ce &

Rep

air

EM

ER

GE

NC

Y O

NE

, IN

C.

MA

NA

GE

ME

NT

TE

AM

AN

DE

XPE

RT

WO

RK

ER

S

DA

N W

OM

BO

LD

, Vic

e Pr

esid

ent H

uman

Res

ourc

esJI

M W

HIT

E, V

ice

Pres

iden

t/Mar

tufa

ctur

ing

C. S

HIM

EA

LL

, Pla

nt M

anag

er, C

hass

isB

ILL

RH

OD

ES,

Pro

duct

ion

Man

ager

/Bod

y Pl

ant

RO

N S

TE

PHE

NS,

Hum

an R

esou

rces

Man

ager

EL

AIN

E S

WIG

AR

T, H

uman

Res

ourc

es S

uper

viso

rD

ON

NA

TA

CK

ET

T, H

ealth

& S

afet

y Su

perv

isor

JEFF

()S

TE

EN

, Sup

ervi

sor 14

5

TR

AIT

S A

ND

AT

TIT

UD

ES

Stro

ng W

ork

Eth

icIn

terp

erso

nal S

kills

Punc

tual

ityD

epen

dabi

lity

Hon

esty

Nea

tnes

sSa

fety

Aw

aren

ess

Mot

ivat

ion

Res

pons

ible

Phys

ical

Abi

lity

Prof

essi

onal

Tru

stw

orth

yC

usto

mer

Rel

atio

nsPe

rson

al E

thic

s

TO

OL

S A

ND

EQ

UIP

ME

NT

Scre

wdr

iver

s, W

renc

hes,

etc

.E

lect

ric

Dri

lls a

nd S

ews

Mea

suri

ng T

ools

C.a

ulki

ngC

bms

Bas

ic D

raft

ing

Too

lsE

lect

rica

l Lig

htin

g E

quip

men

tG

ener

al T

ools

(H

acks

aws,

She

et M

etal

Sni

ps,

Dia

gona

l Cut

ting

Plie

rs, E

tc.)

Cut

-olf

Saw

sH

and

Ori

nden

Han

d T

appi

ng H

oles

Han

d R

eam

ers

File

sM

achi

nes

Too

ls (

man

ual a

nd C

NC

): la

thes

, mill

ing

mac

hine

s,dr

ill p

ress

, pun

ch p

ress

, she

ars,

bra

keIm

pact

end

Tor

que

Wre

nche

sA

rbor

/Sho

p Pr

esse

s

FUT

UR

E T

RE

ND

S A

ND

CO

NC

ER

NS

Rea

mer

sSo

cket

Dri

ves

Pop

Riv

ets

CO

MPE

TE

NC

Y P

RO

FIL

E

Fabr

icat

ion

Ope

rato

r

Prep

ared

by

Cen

tral

Flo

rida

Com

mun

ity C

olle

ge

and

Em

erge

ncy

One

, Inc

.

Dec

embe

r 19

95

Dut

ies

woo

er n

oM

AS

T/0

1/04

0M

14

Dem

onst

rate

Com

mon

leat

hie

Skill

s

Mat

hem

atic

alSk

ills

Inte

rpre

tE

ngin

eeri

ng D

raw

ings

and

Con

trol

Doe

omen

ts

FAB

RIC

AT

ION

OPE

RA

TO

R...

uses

mec

hani

cal s

kills

to m

anuf

actu

re a

ssem

blie

s an

d su

b-as

sem

blie

s of

the

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Tas

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fsa

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stan

dard

s fo

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lf a

nd o

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A-3

Sup

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all p

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and

use

of p

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n un

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prop

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uwdo

usm

ater

ial h

urdl

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A-5

Kno

w f

irst

aid

and

CPR

A-6

Fol

low

safe

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anua

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regu

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ns/

requ

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ents

A-7

Use

pro

les-

five

equ

ipm

ent

A-8

Fol

low

safe

ope

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gpr

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ures

for

hand

and

mac

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tool

s

A-9

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ntai

n a

clam

and

saf

ew

ork

envi

ronm

ent

B-I

App

lypr

inci

ples

and

tool

s of

con

tain

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s qu

ality

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ovem

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erst

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rtan

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qua

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ctur

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proc

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B-3

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plem

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conc

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qual

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B-4

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and

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met

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mai

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ptan

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job

in a

owed

ance

with

wor

ksc

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le

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Wne

hone

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ork

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cs e

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spon

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Dem

on-

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play

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at a

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kpla

ce

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Pra

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ance

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mit-

ted

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sent

ago

od c

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ude

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port

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ctic

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ude

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Mut

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ted

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ills

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Sum

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Und

ers

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rs

E-2

Res

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peer

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text

-sh

ips

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Sha

rere

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ces

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plis

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ork

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E41

Be

wili

ngto

lead

in a

reas

of k

now

ledg

ean

d ex

pert

ise

E-1

2 D

emon

-st

ate

will

ing-

new

to le

ant

new

met

hods

and

skill

s

E-1

3 D

emon

-st

rata

goo

dpe

rson

elR

elat

ions

dai

s

F-I

Perf

orm

basi

c ar

ithm

etic

iiinc

tions

F4 I

nter

-co

met

frac

tions

/de

cim

als

F-3

Inte

r;co

nvec

t Met

ric/

Eng

lish

mea

n:te

men

te

F-4

Perf

orm

basi

c M

eow

-m

etri

c tr

actio

ns

F-5

Cal

cula

tesp

eeds

and

fee

dsfo

r m

achi

ning

F4 L

ocat

e m

a-di

ning

poi

nts

from

dat

umpo

int

F-7

Perf

orm

cal

-re

latio

ns f

or s

ine

bar

end

sine

pla

te

F4 C

alcu

late

for

dire

ct, s

impl

een

d im

ply

Min

ting

F-9

Perf

orm

calc

ulat

ions

nece

ssity

for

turn

ing

tilpe

n

F-10

Sol

ve f

orlit

tle "

H"

cakm

-to

ting

for

dept

hof

cut

0-I

Rev

iew

blue

prin

t not

esen

d di

men

sion

s

0-2

!den

t*ba

sic

layo

ut o

fdr

awin

gs

0-3

Iden

tify

basi

c ty

pes

ofdr

awin

gs

0-4

Lis

t the

purp

ose

of e

ach

type

of

draw

ing

0-5

Ver

ilydr

awin

gel

emen

ts, c

heck

for

revi

sion

, &ou

t-of

-dat

ebl

uepr

ints

0-6

Prac

tice

geom

etri

c di

men

-&

nil%

end

tole

rano

ing

(OD

&T

)m

etho

dolo

av

0-7

Ana

lyze

eat o

f M

ater

ials

(BO

M)

0-8

Rea

dfni

ter-

pret

pri

nts

from

diff

eren

t tra

des/

occu

patio

ns

H-I

Ide

ntif

yty

pes

ofm

easu

rem

ent

H-2

Sel

ect

prop

er m

easu

re-

moo

t too

ls

H-3

App

lypr

oper

mea

nt-

ing

tech

niqu

es

H-4

Use

Met

ric

and

Eng

lish

stan

dard

s of

mea

sure

men

t

H-5

Per

form

mea

sure

men

tsw

ith h

and

held

inst

rum

ents

/1-6

Per

form

mea

sure

men

tson

sur

face

pla

te

H-7

Alig

nw

orkp

iece

sus

ing

heig

htga

ge a

nd d

ial

indi

cato

rs

I-I

Prep

are

and

plan

for

mac

hin-

tang

ope

ratio

ns

1-2

Use

pro

per

hand

tool

s1-

3 O

pera

tepo

wer

111

1111

1

1-4

Ope

rate

del

lpr

esse

sI-

5 O

pera

teve

rtic

alrr

ollin

gm

achi

ne,

16 O

pera

teho

rizo

ntal

milt

ing

mac

hine

s

1-7

Ope

rate

met

al c

uttin

gla

thes

1-8

Ope

rate

spiz

' lin

g/ _

abra

sive

mac

hine

s

1-9

Ope

rate

debt

arin

geq

uipm

ent

1-1

Prep

are

and

plan

for

CN

Cm

achi

ning

oper

atio

ns

1-2

Sele

ct a

ndar

se C

NC

tool

ing

syst

ems

1-3

Ope

rate

CN

C M

achi

ning

cent

er. (

mill

s)

153

BE

ST C

OPY

AV

AIL

AB

LE

154

Dut

ies

ION

DIA

Cno

s

11A

STA

7A10

314

MA

CH

INIS

T...

cont

inue

d

Tas

ksM

-I D

ispl

ay a

gene

tsl u

nder

-st

andi

ng o

fem

erge

ncy

vehi

cle

term

inol

ogy

M-2

Und

enta

ndth

e fu

nctio

ns o

feq

uipm

ent b

eing

usem

bled

M-3

Und

er-

Wan

d ho

wco

mpo

nent

rela

te a

s a

tota

lsy

stem

.

N-1

Dem

on-

stra

ta a

bilit

y to

lift 5

0 po

unds

N-2

Dem

on-

dent

e ab

ility

toto

lera

te h

eigh

tsop

to 1

00 f

eet

N-3

Abi

lity

tow

ork

from

Vili

OU

S Po

sitio

nsw

hile

sta

ndin

g on

conc

rete

for

exte

nded

per

iods

N-4

Dis

play

abili

ty to

wor

kin

hot

/col

den

viro

nmen

tfo

r 8.

10 h

ome

N-5

Pre

sent

ahi

lari

ty o

fdo

cum

ente

dre

gula

r ea

st.

once

at w

ork

N-6

App

lyw

elln

ess

info

rmat

ion

tolif

esty

le to

mai

ntai

n he

alth

155

BE

ST C

OPY

AV

AIL

AB

LE

SKIL

LS

AN

D K

NO

WL

ED

GE

Dir

ect v

s. I

ndir

ect C

oat U

nder

stan

ding

Con

emm

icat

ion

Sk E

lsU

se M

easi

nsm

ent T

ools

Use

Ins

pect

ion

Dev

ices

Mat

hem

atic

al S

kills

Rea

ding

/Wri

ting

Skill

sK

now

ledg

e of

Saf

ety

Reg

ulat

ions

Prac

tice

Safe

ty in

the

Wor

kpla

ceO

rgan

isat

iona

l SE

MK

now

ledg

e of

Com

pany

Pol

icie

s/Pr

ooed

ures

Mec

hani

cal A

ptitu

deA

bilit

y to

Com

preh

end

Wri

tten/

Ver

bal I

nstr

uctio

nsK

now

ledg

e of

Cut

ting

Flui

ds/L

ubri

cant

sB

asic

Kno

wle

dge

of F

aste

ners

Abi

lity

to W

ork

as P

art o

f a

Tea

mC

onve

ne in

the

Tec

hnic

al L

angu

age

of th

e T

rade

Kno

wle

dge

of O

ccup

atio

nal O

ppor

tuni

ties

Kno

wle

dge

ofE

rnpl

oyee

lEm

ploy

er R

espo

nsib

ilitie

sK

now

ledg

e of

Com

pany

Qua

lity

Ass

uran

ce A

ctiv

ities

Prac

tice

Qua

lity-

Con

scie

ntio

usne

ss in

Per

form

ance

of th

e lo

b

TE

XA

S ST

AT

E T

EC

HN

ICA

L C

OL

LE

GE

WA

CO

MA

ST P

RO

GR

AM

RE

PRE

SEN

TA

TIV

ES

DR

. HU

GH

RO

GE

RS

Dim

mer

DR

. IO

N B

OT

SFO

RD

Aid

e= d

rake

JOE

PE

NIC

KPr

ojee

tOoa

nim

er

TE

RR

Y S

AW

MA

Roa

r* C

oard

inno

r

WA

LL

AC

E M

ILT

ON

Site

Cca

dira

tor

RO

SE M

AR

Y T

IMM

ON

SSa

rler

Seae

nryS

rari

seci

on

Furn

ishe

d B

y:R

ICK

Y F

LA

KW

e Pr

odde

d- O

pera

tion

NIC

K N

ICH

OL

Shi

sect

lidar

keM

anag

er -

Dim

med

Red

acts

BO

BB

Y I

RW

INtd

amhB

t

"1*-

c

Tec

irig

fte 15

7

TR

AIT

S A

ND

AT

TIT

UD

ES

Cos

t Con

scie

ntio

usne

ssE

mpo

wer

men

t of

Em

ploy

ees

Stro

ng W

ork

Eth

icIn

terp

erso

nal S

kills

Punc

tual

ityD

epen

dabi

lity

Hon

esty

Nea

tnes

sSa

fety

Con

scie

ntio

usM

otiv

atio

nR

espo

suhl

ePh

ysic

al A

bilit

yPr

ofes

sio

nal

Tru

stw

orth

yC

usto

mer

Rel

atio

nsPe

rson

al E

thic

s

TO

OL

S A

ND

EQ

UIP

ME

NT

Mac

hini

st's

Too

ls (

e.g.

cal

iper

s. d

ial i

ndic

ator

s,m

agne

tic to

ol h

olde

rs, e

tc.)

Mea

suri

ng T

ools

Pow

er T

ools

Met

al L

athe

with

Atta

chm

ents

Dri

ll Pr

esse

sV

ertic

al M

ill w

ith A

ttach

men

t.Po

wer

Saw

sPo

wer

Dri

llsH

ydra

ulic

/Arb

or P

ress

Hea

t Tre

atm

ent E

quip

men

tH

ardn

ess

Tes

ting

Equ

ipm

ent

Gri

ndin

g M

achi

nes

with

Atta

chm

ents

Wel

ding

Equ

ipm

ent (

SMA

W, G

MA

W. F

CA

W)

CN

C M

achi

ning

Cen

ter

and

Tur

ning

Cen

ter

Gea

r Pr

oduc

ing

Mac

hine

s w

ith A

ttach

men

OA

ligm

nent

/Cal

ibra

tion

Too

lsC

oola

nt R

ecov

ery

Equ

ipm

ent

Com

pute

rV

entil

ittio

n E

quip

men

tFo

rklif

t

Pers

onal

Saf

ety

Equ

ipm

ent

Oxy

acet

ylen

e E

quip

men

tT

ool S

tora

ge E

quip

men

tW

orkb

ench

esV

ises

Pede

stal

Gri

nder

sW

eld

Tes

t Equ

ipm

ent

Opt

ical

Com

para

tor

Coo

rdin

ate

Mea

sure

men

t Mac

hine

FUT

UR

E T

RE

ND

S A

ND

CO

NC

ER

NS

Stsa

istic

al P

roce

ss C

ontr

ol

Com

posi

tes

Las

er M

achi

ning

Adv

ance

d C

ompu

ter

App

licat

ions

Rob

otic

sE

nvir

onm

enta

l Con

cern

sFl

ew O

ptic

Con

trol

sA

utom

ated

Mat

eria

l Han

dlin

g E

quip

men

tC

ompu

ter

Inte

grat

ed M

anuf

actu

ring

CO

MPE

TE

NC

Y P

RO

FIL

E

Mac

hini

st

Prep

ared

By

M.A

.S.T

.M

achi

ne T

ool A

dvan

ced

Skill

sT

echn

olog

y Pr

ogra

man

dC

onso

rtia

Par

tner

s(V

.199

J400

08)

A'a

:215

e

Miii

GE

OD

IAM

OD

BE

ST C

OPY

158

MA

CH

INIS

T...

. pla

n, la

yout

, set

up,

and

ope

rate

han

d an

d m

achi

ne to

ols t

o pe

rfor

m m

achi

ning

ope

ratio

ns n

eces

sary

to p

rodu

ce a

wor

kple

ce to

ref

eren

ced

engi

neer

ing

stan

dard

s.

Tas

ksD

utie

s

Inte

rpre

tE

mis

sari

es D

raw

-in

g an

d C

ontr

olD

ocum

ents

Perf

ora

Mea

sure

men

t/In

spec

tion

Perf

orm

Cog

natio

n=M

achi

ning

Ope

ratio

ns

Perf

orm

Adv

ance

dG

Mad

ialm

Proc

esse

s

GIO

KA

CE

IY10

WA

STP1

1411

1403

Perf

orm

Wel

ding

Ope

ratio

ns

A-1

Fol

low

safe

ty m

arm

alan

d al

l saf

ety

regi

atio

nel

requ

irem

ents

A-2

Use

pin

ta-

tint e

quip

men

tA

-3 F

ollo

w e

ats

oper

atin

gpr

oced

ares

for

head

and

mac

hine

toot

A-4

Mai

ntai

n a

clea

n an

d sa

few

ork

=vi

ten-

mea

t

B-I

Per

form

basi

c ar

ithm

etic

func

tions

(3-2

Int

erco

:ave

rtft

ectio

nel

deci

mal

s

B-3

Per

form

basi

ctr

igon

omet

ric

&na

tions

13-4

Cal

cula

tesp

eeds

and

fee

dsfo

r m

achi

ning

13-5

Loc

ate

=di

ning

poi

nts

from

datu

mpo

int

B-6

Per

form

adco

latio

us f

orri

ne b

ar a

nd e

rne

plat

e

B-7

Cal

cula

tefo

r di

rect

sim

ple.

and

angu

lar

inde

xing

13-8

Per

form

calm

/aim

sne

cess

ary

for

tatti

ng ta

per.

B-9

Sol

ve f

orka

le I

t"

C-1

Rev

iew

blue

prin

t not

esan

d di

men

sion

s

C-2

!de

in&

basi

c la

yout

of

draw

ings

C-3

Ide

ntif

yba

sic

type

. of

draw

ings

C-4

Lis

t the

porp

oire

of

each

type

of

draw

ing

C-5

Wri

tdr

awin

gel

emen

ts

C-6

Pra

ctic

eSe

atie

llic

anis

-si

onm

g an

dto

laen

cing

(GM

T)

wed

-ob

ey

C-7

Dam

ao th

ere

letio

nehi

p of

=Sn

eeri

ngdr

awin

g. to

.___

...Pm

...

C-8

Use

stan

dard

s to

veri

fy r

equi

re.

men

ts

C-9

Ana

lyze

bill

of m

ater

ials

(B01

14)

D-I

Ide

ntif

ym

ater

ials

with

desi

red

ProP

ertir

e

13-2

Des

crib

eth

e he

at tr

eatin

gpr

oces

s

D-3

Per

form

hest

trea

ting

oper

atio

ns

0-4

Tar

t met

alar

mie

s fo

rha

rdne

ss

E-I

hie

n*ty

pes

of m

easu

re-

sent

s

8-2

Sele

ctpr

ops

mea

sure

men

tto

ols

8-3

App

ly m

opes

Imm

urin

gte

chni

que.

8-4

Use

Eng

lish

stan

dard

s of

mea

sure

men

t

8-3

Perf

orm

mes

eare

men

tew

ith h

and

held

inst

rum

ents

8-6

Perf

orm

mem

urem

ents

on

surf

ace

plat

e

E-7

Per

form

inep

ectio

us r

ang

stat

ione

ryeq

uipm

ent

F-1

Prop

ose

and

plea

for

mac

hini

ng;

oper

atio

ns

F-2

Use

pro

per

hand

tool

sF-

3 O

pera

tepo

wer

saw

sF-

4 O

pera

te d

alpr

esse

sF-

5 O

pera

teve

rtic

al =

Din

gm

achi

nes

F4 U

se r

otar

yta

bles

and

divi

ding

hea

ds

F-7

Ope

rate

met

al c

uttin

gla

thes

F-8

Ope

rate

grin

ding

ebnu

ive

mac

hine

s

F-9

Ope

rate

debu

ting

equi

pmen

t

0-1

Prep

are

and

plan

for

CN

Cm

achi

ning

oper

atic

=

0-2

Sele

ct a

ndus

e C

NC

tool

ing

syst

ems

0-3

Prog

ram

CN

C m

achi

ne.

0-4

Ope

rate

CN

C m

achi

ning

cent

ers

(mill

s)

0-5

Ope

rate

CN

C ta

min

gce

nter

s (l

athe

s)

0-6

Ope

rate

elec

tric

aldi

scha

rge

mac

hine

.

H-1

Wel

d w

ithSh

ield

ed M

etal

Arc

Wel

ding

(SM

AW

) pr

oms

H-2

Wel

d/cu

tw

ith =

peat

y-la

ne

H-3

Wel

d w

ithG

ee M

etal

Arc

Wel

ding

K1M

Aw

Y(M

i8)

& F

lux

Cor

e A

rcW

eldi

ng (

FCA

W)

159

BE

ST C

OPY

AV

AIL

AB

LE

160

SKIL

LS

AN

D K

NO

WL

ED

GE

Com

mtm

icat

ion

slot

hU

se M

easu

rem

ent T

ools

Use

Ins

pect

ion

Dev

ices

Mat

hem

atic

al S

kills

Rea

ding

/Wri

ting

Skill

sK

now

ledg

e of

Saf

ety

Reg

ulat

ions

Prac

tice

Safe

ty in

the

Wor

kpla

ceO

rgan

izat

iona

l Ski

llsK

now

ledg

e of

Com

pany

Pol

icie

s/Pr

oced

ures

Mec

hani

cal A

ptitu

deA

bilit

y to

Com

preh

end

Wri

tten/

Vab

al I

nstr

uctio

nsK

now

ledg

e of

Cut

ting

Flui

da/L

ubri

cant

sB

asic

Kno

wle

dge

of F

aste

ners

Abi

lity

to W

ok a

s Pe

rt o

f a

Tea

mC

onve

ne in

the

Tec

hnic

al L

angu

age

of th

e T

rade

Kno

wle

dge

of O

ccup

atio

nal O

ppor

tuni

ties

Kno

wle

dge

ofE

mpl

oyee

lEm

ploy

er R

espo

nsib

ilitie

sK

now

ledg

e of

Com

pany

Qua

lity

Ass

uran

ce A

ctiv

ities

Prac

tice

Qua

lity-

Com

ciou

snes

s in

Per

form

ance

of

the

lob

TE

XA

S ST

AT

E T

EC

HN

ICA

L C

OL

LE

GE

WA

CO

MA

ST P

RO

GR

AM

RE

PRE

SEN

TA

TIV

ES

DR

HU

GH

RO

GE

RS

Dis

eser

DR

JO

N B

OT

SFO

RD

Mei

= d

reie

r

TE

RR

Y S

AW

MA

Res

ent C

amel

eer

WA

LL

AC

E P

EL

TO

NSi

ts C

ando

r"

Fael

liate

d B

y:

DR

. JO

N B

OT

SFO

RD

Ass

ista

nt D

irec

tor

Mac

hine

Too

l Adv

ance

d Sk

ills

Tec

hnol

ogy

Prog

ram

(M

AST

)

Teg

tIV

iege

b 1.

TR

AIT

S A

ND

AT

TIT

UD

ES

Stro

ng W

ork

Eth

ickf

terp

eivo

nal S

kills

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(V.1

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What follows is a narrative of the pilot program which was conducted for this particularoccupational specialty.

18i

Machine Tool Advanced SkillsTechnology Program (MAST)

3801 Campus Dr. Waco, Texas 76705817/867-4849 FAX: 817/867-3380

http://machinetool.tstc.edu/

7.Texas State

Technical CollegeWaco

MAST STUDENT PILOT PROGRAMDESCRIPTION/NARRATIVE

The following narrative describes the one year pilot program which was conducted at Texas StateTechnical College - Waco, during the 1995-96 school year.

APPLICATION AND SELECTION PROCESS

Recruiting efforts were begun in January 1995. Letters were sent and visits were made to theseand other local area high schools. Connally High School, La Vega High School, Waco HighSchool, Marlin High School, Killeen High School, and Midway High School. At each schoolMAST project staff discussed the MAST program with both faculty, counselors and students.Applications were given out and, when possible, tours to the college were arranged. (Examplesof these letters and other correspondence is located at the end of this section.) MAST projectstaff also made presentations to numerous industries and to regional secondary schoolconferences in an attempt to recruit students for the MAST program. MAST project staff alsoarranged "in home" visits with some families when possible. MAST project staff madepresentations whenever student tours were arranged on our college campus.

MAST project staff also contracted with the video production arm of TSTC to produce arecruiting video for the Manufacturing Engineering Technology Department. This video has beendistributed to a number of local school counselors, faculty and administrators. (A copy of thisvideo has been included as part of the MAST project deliverables.)

182

Machine Tool Advanced Skills Technology Prograr---1.' MASTTexas State Technical College-3801 Campus Dr. Waco, Texas 767057k817/867-3526 FAX 817/867-3221

March 27, 1995

Ms. GrayVocational CounselorLa Vega High School555 N. Loop 340Waco, Texas 76705

Ms. Gray;

I wish to reaffi rm my offer to visit the La Vega High School campus, and speak with you, your staff, anyinterested teachers, and prospective students concerning the special opportunities which are related to theMAST grant at TSTC. I am always grateful for the opportunity to speak about the resources of Texas StateTechnical College at La Vega since I am a product of the La Vega Independent School District. I also lookforward to having you and your students visit our campus, tour our facilities, and explore career opportunitiesavailable at Texas State Technical College.

The following will provide you with an overview of the MAST project:

Texas State Technical College has been awarded a $1,472,000 grant by the U.S. Department of Education todevelop and implement training curriculum model to overcome skill shortages in the machine tool and metalsrelated industries. This grant project is titled "Machine Tool Advanced Skills Technology" Program orM.A.S.T. The goals of the grant project are:

1. define national skills standards for those persons entering the machine trades areas;2. develop curriculum materials to support these skill standards;3. increase awareness and identify career opportunities in the machine tool and metal related

industries;4. develop school-to-work programs with secondary school students and industrial partners;5. offer out-of-school underemployed and existing industry employees the opportunity to learn

new skills and upgrade existing skills;6. to develop internship/apprenticeship programs with industrial partners as a capstone

experience in both certificate and Associate of Applied Science (AAS) programs;7. conduct a one year "pilot" program with 25 selected students at each college curriculum

development center to evaluate curriculum content and effectiveness;8. identify skill competencies of program applicants at point of entrance and exit;9. compile and package the program model in multi-media from for national dissemination

including course syllabi, textbooks, handbooks, laboratory manuals, recommendedequipment, and standardized examinations and evaluative tools.

An important component of the project is to "pilot test" the Machinist Certificate curriculum at Texas StateTechnical College by enrolling twenty five (25) interested students to evaluate and validate curriculumcontent and effectiveness. The grant proposal includes funds for student scholarships. This money isavailable for tuition, fees, and books for students entering the program. Students applying for thesescholarships will need to meet our normal entrance requirements as outlined in the current TSTC catalog.

183

These students would be required to enroll in the one year Machining Option, which is part of theManufacturing Engineering Technology Department. Student achievement will be followed as they progressthrough the curriculum, ob placement, and in the workplace as a part of the terms of the scholarship.

I ask for your assistance in identifying those students who will be graduating before Fall 1995 orrecent graduates (past 2-5 years) who might be interested in participating in this project. There are currentlymany excellent career opportunities available for young people interested in the manufacturing technologies.TSTC would like to become a partner with you and La Vega High School to identify students interested inparticipating in this project and preparing people for well paying careers.

I have included a MAST Program Interest Form and respectfully request that you inform potential students ofthe program, its goals, and available scholarship support. Please return any completed forms in the enclosedpostage prepaid envelope and I will send additional information and application for the program to anyinterested students. If you have any questions please feel free to call me at (817) 867-3526. Thank you foryour support in this educational endeavor and I look forward to a successful partnership with La Vega HighSchool and Texas State Technical College.

Sincerely,

Wallace PeltonSite Coordinator: MAST ProgramTexas State Technical College3801 Campus Dr.Waco, Texas 76705(817) 867-3526

encl: student interest formpostage prepaid envelope

184

Machine Tool Advanced Skills Technology PrograrS-4! MASTTexas State Technical College-3801 Campus Dr. Waco, Texas .76705%"817/867-3526 FAX: 817/867-3221

MAST Program Interest Form

Please return completed forms to the MAST office at Texas State Technical College. A postage paidreturn envelope is enclosed for your convenience. Please photocopy as required. I understand thatinterested students will be mailed information about the MAST program within the next few weeks.

The following students have expressed an interest in participating in the MAST curriculum project for theFall 1995 entering class in the Machinist Certificate Program.

Name Age Home Phone

Home Address City/State ZIP

Graduation Year Parent/Guardian Phone

Name Age Home Phone



Name Age Home Phone



Name Age Home Phone

Home Address City/State ZIP _


From:

Teacher /Counselor Name

Position:

School School Phone Number

185




Waco

Dear Interested Student,

Thank you for your interest in the Machine Tool Advanced Skills Technology Program (MAST) at TexasState Technical College.

Texas State Technical College has been awarded a $1,472,000 grant by the U.S. Department of Education todevelop and implement a training curriculum model to overcome skill shortages in the machine tool andmetals related industries. This grant project is titled "Machine Tool Advanced Skills TechnologyProgram"or M.A.S.T. The goals of the grant project are:

1. to define national skills standards for those persons entering the machine trades areas;2. develop curriculum materials to support these skill standards;3. increase awareness and identify career opportunities in the machine tool and metal related

industries;4. develop school-to-work programs with secondary school students and industrial partners;5. offer out-of-school underemployed and existing industry employees the opportunity to learn

new skills and upgrade existing skills;6. to develop internship/apprenticeship programs with industrial partners as a capstone

experience in both certificate and Associate of Applied Science (AAS)programs;7. conduct a one year "pilot" program with 25 selected students at each college curriculum

development center to evaluate curriculum content and effectiveness;8. identify skill competencies of program applicants at point of entrance and exit;9. compile and package the program model in multi-media form for national dissemination,

including course syllabi, textbooks, handbooks, laboratory manuals, recommendedequipment, and standardized examinations and evaluative tools.

An important component of the project is to "pilot test" the Machinist Certificate curriculum at Texas StateTechnical College by enrolling twenty-five (25) interested students to evaluate and validate curriculumcontent and effectiveness. Scholarship money is available to pay for tuition, fees, and books for thosestudents accepted into the program. As a student applying for this scholarship you will need to meet ournormal entrance requirements as outlined in the current TSTC catalogue. You will be required to enroll inthe one year Machining Option, which is part of the Manufacturing Engineering TechnologyDepartment. Aspart of the terms of the scholarship, your achievements will be followed as you progress through thecurriculum and into the workplace.

186

Currently there are many excellent career opportunities available for trained, skilled technicians in theManufacturing Technologies. The State of Texas is facing a severe shortage of skilled technicians in themachine and manufacturing trades. Additionally, the employment potential for skilled technicians is great. Iinvite you and your parents to visit the TSTC campus, tour our facilities, learn more about the Machinistcurriculum, identify the opportunities available through the MAST program, and the career potential inmachining technology. I encourage you to apply for a scholarship and complete the MAST ProgramApplication in Manufacturing Engineering Technology, Machinist Certificate Option. ScholarshipApplication deadline is July 1, 1995 for Fall 1995 enrollment. Please complete the application as soon aspossible and return it to: .

Mast Program; ITC 134Texas State Technical College

3801 Campus DriveWaco, Texas 76705

If you would like to make an appointment to visit the campus, tour our facilities, and learn more about thecurriculum and the MAST program please call me at (817) 867-3526.

Sincerely,

Terry SawmaResearch CoordinatorTexas State Technical College3801 Campus Dr.Waco, Texas 76705(817) 867-3526

MAST student application

wp/ ts revisedMAST 040595student application/letter

187

Wallace PeltonSite Coordinator: MAST ProgramTexas State Technical College3801 Campus Dr.Waco, Texas 76705(817) 867-3526

FUNDING AUGMENTATIONS

As part of the MAST grant, the MAST Project Director offered to fund twenty five (25)scholarships for the school year 1995-96 to assist in recruiting students to pilot test the MASTcurriculum. The scholarships would be for a period of 1 year (4 quarters) and would pay fortuition, fees and books for each of the students selected to receive the scholarship. Criteria forscholarship eligibility were determined and a scholarship application form was created anddistributed to all interested young people by the MAST staff. (Scholarship-related documentationis found at the end of this section.)

By August 1, 1995 MAST had received 31 scholarship applications. MAST project staff met andselected 25 students to participate in the scholarship program. (A complete listing of thesestudents is found at the end of this section.) These students were notified by letter and bytelephone. These students, along with their parents, were invited to our campus on July 14, 1995for a tour and an information session. (A copy of the student's program booklet is found at theend of this section.) At this time the students were provided information about registration,housing, registration, and information about the MAST program. Students were then introducedto MAST bUsiness and industry partners at the MAST Steering Committee meeting which hadbeen scheduled to coincide with the students visit to our campus. The day concluded with acampus tour.

Students were enrolled, tuition and fees paid, and books purchased in time for classes to begin inthe Fall 1995.

APPRENTICESHIP, COOP AND/OR INTERNSHIP PARTICIPATION

No formal apprenticeships, coops or internships have been established at this time although manycompanies expressed an interest in participating in one of these programs at a later time.

188


3801 Campus Dr. Waco, Texas 76705817/867-3526 FAX: 817/867-3221 Texas State


MAST Program ApplicationManufacturing Engineering Technology: Machinist Certificate Option

Please return completed forms to the MAST Office, ITC 134, at Texas State Technical College, Waco.

Please complete all requested information to apply for a MAST scholarship in Manufacturing EngineeringTechnology, Machinist Certificate Option. The information will be used in preparing your permanentrecords. Please complete all information accurately and return by July 1, 1995.

Personal Data:

1. Name-Last First MI

2. Permanent Address

3. City 4. County

5. State 6. Zip Code 7. Country (If other than USA)

8. Social Security Number

9. Sex: Male Female 10. Birthdate

11. Phone Number

Enrollment Information:

12. Are you a Texas Resident ? Yes No

13. High School Attended

14. High School Graduate GED Junior College Graduate College Graduate

189

15. Do you hold a college degree ? Yes No

If Yes, Name of College or University

Major Name of Degree

Date of Graduation

Employment Status;

16. Employed: Full-Time Part-Time

Unemployed, Seeking work Unemployed, Not Seeking Work

17. In your own handwriting, please explain why you would like to be considered for acceptanceinto the MAST program's Manufacturing Engineering Technology MachinistOption at TexasState Technical College. Describe your long term goals and expectations.

1 0




Waco

To: MAST Scholarship RecipientsManufacturing Engineering TechnologyMachinist Certificate Option

From: Joe PenickMAST Project Director

Subject: Conditions of MAST Scholarship

Date: November 6, 1995

Conditions of the MAST Scholarship are as follows:

1. enrollment in all required courses in the machining certificate program for the currentquarter semester;

2. successful completion of all required courses in each quarter semester with acumulative grade point average (GPA) of 2.0.

We would like for you to register for courses each Quarter during Early Registration week. Once you havesigned up for your courses at the MET office, please bring your class schedule to the MAST office, 100 FifthStreet. One of the MAST staff will assist you in the completion of the registration process. If you have anyquestions about the MAST scholarship, course registration, academic advisement, financial aid, campushousing, facilities, etc., please stop by the MAST office and visit with Mr. Pelton, Mr. Sawma, or Ms.Timmons or call (817) 867-3526.

Again, congratulations and I hope you will enjoy your experiences at TSTC.

191



7-7Texas State


October 31, 1995

Mr. Christopher Pitts

Congratulations!

You have been selected as a scholarship recipient for the Manufacturing Engineering TechnologyMachinist Certificate Program at Texas State Technical College, Waco, Texas. This scholarshipwill cover the cost of tuition, books and fees for the next three quarters.

After you have signed up for classes in the MET office, please bring your paperwork to theMAST building.

If you have any questions please don't hesitate to call this office at (817) 867-3526. Once again,Congratulations.

Sincerely,

Joe PenickProject Director

192




Waco

Congratulations to MAST Scholarship Recipients,

You have applied for, and been selected, to participate in a very special program at TexasState Technical College. The program is called MAST and it stands for Machine Tool AdvancedSkills Technology Program. The MAST grant was awarded to TSTC by the U.S. Department ofEducation. Our goals are (1) to identify national skills standards for several metalworkingoccupations, (2) to develop curriculum which would provide training to persons interested inpursuing careers in these fields, and (3) to make young people more aware of the careeropportunities in the areas of manufactUring and metal working.

The cornerstone of all metalworking occupations is the Machinist. The machinist is theskilled technician who is responsible for the metal molds from which plastic parts are molded.The machinist is the person who builds the tools and dies which are used in manufacturing plantsthroughout the world. The machinist is the person who performs many of the precision machiningoperations which are required to produce every conceivable type of product from automobiles tocomputers to space shuttles. As you can see, the machinist plays a very important role in makingAmerica one of the greatest nations of the world. The countries which possess the greatestmanufacturing resources also have the capability to produce the greatest wealth.

The duties of the machinist have changed greatly the last 25 years. While the machinisttrade was once considered to be a dirty, monotonous job; it has evolved into an highly skilledoccupation which requires the use of computers, sophisticated multi-axis computer controlledmilling and turning centers, and many other high technology advancements. Where products wereonce manufactured to tolerances which were measured in thousands of an inch, tolerances withina few millionths of an inch are now common. As you can see, these changes will require a newtype of machinist. Not only must he or she be familiar with the conventional metal workingmachines and tools, but he or she must also be "conversational" with many of the new computercontrolled measuring and machining tools which are now commonplace on the shop floor.

Remember that the goals of the MAST Program are to identify the required duties andtasks for a machinist in today's workplace, and to develop a curriculum (training program) whichwill prepare a person to enter that workplace with confidence. All of this sounds wonderful sofar; but, the best is yet to come.

This is where you come in. Without you, MAST could have been just a lot of talk and alot of paper. You have been awarded an opportunity to receive training which will equip you towork in virtually any city or in any state where manufacturing operations are performed. Not onlyhave you received a scholarship valued at about $2000.00, but you can expect rewards which aremany times greater than the value of the scholarship. You will be learning the same exact skillswhich industry has told us are the most important for their employees. When you graduate youwill be offered many opportunities for employment at starting wages which are much higher thanfor students who choose not to go school. And the best part is that you will have excellent

193

technical skills which you will be able to market the rest of your working life. The skills whichyou are about to learn at TSTC will enable you to make enough money to buy that new pickup, orthat new home, or begin a family, or anything else that you want to do. The number of youngpeople entering the machinist occupation is far short of the number of machinists which areneeded to support American industry. Therefore you can expect many opportunities foradvancement and promotion in the years to come. Congratulations!

The MAST staff at TSTC want to welcome you to our campus, and want to help makeyour entry into college go as smoothly as possible. When you come on to our campus to register,we would like for you to stop by our office first (ITC Building, Room 134). Remember that youmust have completed your Application for Admission into TSTC prior to registering forclasses. Also remember that the dates for Early Registration are August 7-11 and thatRegular Registration is September 6, with September 5th being set aside for new studentorientation. One of our staff will assist you in getting to the right place to register for yourclasses and then getting to the Business Office to get proper credit for your MAST scholarship.We would like to help insure that the registration process goes as smoothly as possible for you.Once you are registered and are attending classes, please feel free to stop by, or call our office(817) 867-3526 when you have questions relating to life on campus. We may not know all theanswers but we will certainly be glad to assist in any way that we can. Once again,congratulations and we thank you for participating in MAST with us.

You truly,

demtx /21,Wallace Pelton, Site Coordinator - MAST

The MAST staff at TSTC

Dr. Hugh K. RogersJoe PenickTerry SawmaWallace PeltonRose Mary Timmons

Project DirectorProject CoordinatorResearch CoordinatorSite CoordinatorSenior Secretary/Statistician

194

STUDENT ASSESSMENT/RESULTS ANALYSIS

1. MAST Consortia Partner College name:Texas State Technical College at Waco, TX.

2. Number and category of those enrolled in the program:

Started Finished

25 21 84% Completion Rate

24 20 Male

1 1 Female

21 17 White

1 1 Black

2 2 Hispanic

0 0 Asian

0 0 Native American

1 1 Foreign

*Please note that in the following section that some students fell into more than one category.

1 1 Single head of household

2 2 Single parent

0 0 Disability (Physical or Mental)

17 15 Social/Economic Status (gross familyincome of $22,800 or less)

All students were pre-tested during the first quarter of their enrollment at TSTC. A 50 questionmultiple choice test was prepared. The test covered general mechanical knowledge and a numberof topics which are specific to the machine trades. (A copy of this pre-test, along with a summaryof student scores, may be found at the end of this section.) Each student also completed a generalmechanical aptitude test at our college counseling center. (A copy of this test, along with asummary of the results, may also be found at the end of this section.) Students were post-testedduring the summer of 1996, which was the last quarter of the pilot program. Students were giventhe same test that was used for pre-testing. Comparisons and analysis were then performed. (Asummary of student scores may be found at the end of this section along with a comparison of thepre-test and the post-test results.)

195



http: / /machinetool.tstc.edu/ NAME:

aiiizege

PRE/POST - TEST for MACHINE TOOL STUDENTS

Directions: Circle the letter beside the best answer for each of the questions below. (2 pts.each)

1. The smallest graduation on a rule with No.4 graduations is:a. .5mmb. 4thsc. 1/64"d. quarters

2. A surface plate:a. is a referenceb. measures surface finishc. is made of steeld. has four point suspension

3. There are threads on a spindle of an inch micrometer.a. 25b. 100c. 40d. 15

4.

5.

The value of each line on the sleeve or barrel is:a. .100"b. .025"c. .050"d. .001"

The value of each line on the thimble is:a. .100"b. .025"c. .050"d. .001"

6. Surface finishes are important to:a. prolong the life of partsb. make products attractivec. speed up productiond. lower cost

7. The angle of a center punch should be:a. 90°b. 45°c. 60°d. 30° 196

8. Dividers are used to:a. scribe arcsb. scribe circlesc. transfer measurementsd. all of the above

9. The most common hammer used by machinists is the:a. clawb. ball peenc. straight peend. cross peen

10. Open-end wrenches are offset about 15° to:a. prevent slippingb. fit several sizesc. get into close placesd. fit neatly into tool boxes

11. One precaution to observe when using an adjustable wrench is to:a. use only on hex nutsb. adjust tightly to the nutc. use only on square nutsd. none of the above

12. The cross-sectional shape of an Allen wrench is:a. squareb. roundc. hexagonald. rectangular

13. The permissible variation is called the:a. toleranceb. sizec. basic dimensiond. none of the above

14. How far can a 1" diameter piece of stock safely stick out of a lathe chuck unsupported?a. 1" -b. 2"c. 3"d. 4"

15. The difference between the "reading" of an outside micrometer and a depth micrometer is:a. the outside mike is easierb. the depth mike is backwardc. the depth mike reads in .001"d. the outside mike reads direct

Page - 2 1 97

16. Enlarging a previously drilled hole using a single point cutting tool is called:a. counterboringb. boringc. reamingd. countersinking

17. To fit a small tapered shank tool into a large tapered spindle you use:a. a drill driftb. a tapered sleevec. a drill socketd. a #4 morse

18.

19.

A plug tap has imperfect threads on it.a. . 7b. 1

c. 3

d. 9

The tap drill for a 3/8-16-NC thread is:a. 5/16"b. 3/8"c. 17/32"d. .299"

20. A hand reamer:a. removes 1/32"b. leaves the hole smoothc. has a tapered shankd. all of the above

21. A sine bar is used for:a. measuring anglesb. machining tapersc. layout workd. all of the above

22.

23.

The complimentary angle of 35° is:a. 65°b. 35°c. 90°d. 55°

The conventional drill point angle is:a. 118°b. 110°c. 90°d. 60°

Page - 3

198

24. The part on the ends of a taper shank drill bit that helps drive it is the:a. tangb. flutec. margind. driver

25. If a drill bit has unequal lip length, then:a. the hole will be too smallb. the hole will be too deepc. the hole will be too bigd. the hole will be too shallow

26. What speed is required to drill a 1" hole in aluminum at 300 feet per minute?a. 400 RPMb. 800 RPMc. 1200 RPMd. 1600 RPM

27. What speed is required to drill a 1" hole in mild steel at 100 feet per minute?a. 100 RPMb. 200 RPMc. 300 RPMd. 400 RPM

28. The note T.I.R. on a drawing means:a. The internal radiusb. Total indicated run-outc. Test in reversed. Texas Industrial Requirements

29. To produce a hole suitable for a socket head cap screw to fit in flush is called:a. treepanningb. counterboringc. drilling outd. none of the above

30. What hand tool is used to cut an external thread?a. a threading fileb. a threading tapc. a threading died. a threading arbor

31. The smallest graduation on a metric rule is:a. 1mmb. .5mmc. .25mmd. lcm

Page - 4 1 99

32. To change speeds on a variable speed lathe or mill, the spindle must be:a. completely stoppedb. in neutralc. turningd. none of the above

33. The half-nut lever on a lathe is:a. used for facingb. used for turningc. used for threadingd. used for reversing the feed direction

34. As a rule carbide cutting tools can be runa. fasterb. slowerc. more aggressivelyd. less aggressively

than high speed cutting tools.

35. Feed on a drill press is based on:a. inches per minuteb. inches per revolution of the spindlec. inches per footd. none of the above

36. When lathe centers are out of line on a lathe, the resulting work will be:a. straightb. wavyc. hopelessd. tapered

37. A dial indicator is used for:a. alignment of work holding devicesb. alignment of workpiecesc. inspection of work in progressd. all of the above

38. Knurling is used to:a. improve appearanceb. provide a good gripping surfacec. increase size for press fitsd. all of the above

39. Holes to be drilled are "spotted" with a:a. center finderb. center drillc. combination square and scribed. a magnifying glass

200Page - 5

40. A shear pin is:a. for punching 1/4" holesb. a safety devicec. hardened for strengthd. none of the above

41. When should safety glasses be worn in the shop?a. when the light is poorb. when you are working on extremely precision partsc. at all timesd. when you are working on hazardous materials

42. Which tools should not be mounted in a drilling chuck?a. a drill bitb. an end millc. a tapd. a reamer

43. Drill bits are sized under four common systems: fractional, number, metric, anda. oversizeb. undersizec. letterd. ultra-precision

44. The letters CNC stand for:a. computerized nitride coatingb. calculated numbering centerc. computer numerical controld. cut no corners

45. A sheet metal brake is used for:a. stamping sheet metalb. cutting sheet metalc. stopping metal from moving in an emergencyd. bending sheet metal

46. Surface grinders are use for:a. producing precision flat surfacesb. producing precision parallel surfacesc. producing precision right angle surfacesd. all of the above

47. Computer controlled machines are usually used:a. for production workb. for prototype workc. for precision workd. all of the above

Page - 6 201

48. The "Bridgeport" type machine is:a. a horizontal milling machineb. a vertical milling machinec. a jig bore machined. a drill press

49. Which lathe workholding device is the best to use for holding round stock?a. a 3-jaw chuckb. a 4-jaw chuckc. a faceplated. a collet chuck

50. Always a machine before measuring, cleaning or making adjustments.a. oilb. slow downc. stopd. none of the above

Page -7 202

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BEST COPY AVAILABLE

For more information:

MAST Program DirectorTexas State Technical College3801 Campus DriveWaco, TX 76705

(817) 867-4849FAX (817) 867-33801-800-792-8784http://machinetool.tstc.edu

(9/92)

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Machine Tool Advanced Skills Technology

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