CREDITS: 6-8/year (may count for math credits; inquire with your high school)
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1 MACHINING TECHNOLOGY Gregory W. Carmack Instructor 1005 Franklin Valparaiso, IN Fx COURSE SYLLABUS CREDITS: 6-8/year (may count for math credits; inquire with your high school) CONTACT HOURS: 540/1080 hours (35% lecture, 65% machine shop) DATE OF LAST REVISION: Aug. 20, 2008 COURSE DESCRIPTION: Modern Machining Technology is a high school vocational technical program that teaches students machining, CNC machining, computer aided machining (CAM), manufacturing, quality and basic mechanics. Our program is offered to high school junior and senior boys and girls and is a 2 year program that will prepare students for a career after high school or for advancement in a college related programs such as manufacturing, mechanical, production or quality engineering. Modern Machining Technology is available to any and all students. Every student has a right to learn what they desire in an environment that encourages them to discover their capabilities. MAJOR COURSE LEARNING OBJECTIVES: Upon successful completion of this program, students will be able to: 1. Demonstrate personal, occupational and environmental safety in a manufacturing environment on a daily basis. 2. Read and interpret mechanical blueprints, including an interpretation of Geometric Dimensioning & Tolerancing. 3. Successfully machine parts to blueprints/engineering specifications. 4. Successfully choose the most productive and precise type of manufacture available to them to produce parts. 5. Demonstrate proper selection and use of tools, machinery and measuring devices used in manufacturing. 6. Have a technical and academic advantage over students without a career and technical educational. 7. Possess the knowledge and continually practice an exceptional work ethic that keeps them employed and in demand for what ever career they choose. 8. Think and make successful decisions on their own in regards to career and life choices. 9. Overcome the fear of failure to try new things. 10. Be ready for a career and/or post secondary education before they graduate high school. Page 1 of 8
2 LECTURE/SHOP TOPICS FIRST YEAR PROGRAM: BLUE PRINT READING BPR-CH2 DRAW MISSING VIEW BPR-CH3 LINE USAGE/IDENTIFY SURFACES IN DIFFERENT VIEWS BPR-CH4 TITLE BLOCKS BPR-CH5 WORKING DRAWINGS/NUMBER OF VIEWS BPR-CH6 HOLES BPR-CH7 THREADS Pg BPR-CH8- CONTOURS Pg BPR-CH9 SECTION VIEW DRAW MISSING VIEW Pg BPR-CH9B SECTION VIEW QUESTIONS Pg BPR-CH10 ANGLES Pg BPR-CH11 MACHINING DETAILS Pg BPR-CH11 MACHINING DETAILS Pg BPR-GD&T PG ** SHOP MATH TALKING LIKE A MACHINIST 1 (.xxx decimal nomenclature) DECIMALS & FRACTIONS DIAMETER/RADIUS WORKSHEET MULTIPLY/DIVIDE DECIMALS & ROUNDING CALCULATING RPM AND FEED RATES SCREW THREADS/3 WIRE CALCULATION CALCULATING BAR STOCK POSITIVE & NEGATIVE NUMBERS ANGLE PUZZLES #1 W/GEOMETRY HAND OUT ANGLE PUZZLES #2 DEGREES/MIN/SEC TO DECIMAL DEGREES CONVERSION PERCENTAGES CALCULATING INTEREST RATES EXPONENTS NUMBERS IN PARENTHESES Page 2 of 8
3 MACHINING/MANUFACTURING SAFETY VIDEOS/FIRST AID TRAINING-GORY VIDEOS FOR EYE AND HAND INJURY, HAND AND POWER TOOL SAFETY, MACHINE SHOP SAFETY, FIRST AID MACHINING VIDEOS MODERN MARVELS-MACHINE TOOLS GAUGING-READING MICROMETERS.XXX MF-Ch4 MEASUREMENT MF-Ch13 LATHE & LATHE VIDEO 26 min/parts/rules, GRIND LATHE BITS 3 EA. MF-CH17 THE MILL MF-CH6 HAND TOOLS DRILL/TAP CHART EXERCISE MF-CH5 LAYOUT WORK, LAYOUT & CUT T-SLOT CLEANER MF-CH12 SAWING & CUT OFF MACHINES MF-Ch14 CUTTING TAPERS & THREADS ON LATHE ** MF-CH10 DRILLS & DRILLING MACHINES, GRIND DRILL BIT MF-CH20 BAND MACHINING, VIDEO, WELDING BLADES GAGE READING VERNIER SCALES MF-CH 18 MILLING MACHINE OPERATIONS GAUGING-READING DIAL CALIPERS GAUGING-READING MICROMETER REVIEW.XXX MF-CH7 FASTENERS GAUGING-READING DIAL INDICATORS GAUGING-READING DEPTH MICROMETERS MF-Ch11 OFFHAND GRINDING CARBIDE INSERT CODE READING WORKSHEET MF-CH19 PRECISION GRINDING GRINDING WHEEL IDENTIFICATION DECODING GENERAL SHOP SKILLS FOLD BAND SAW BLADE, WELD BANDSAW BLADE, TRAM MILL HEAD, INDICATE TAILSTOCK, INDICATE 4 JAW CHUCK MF-Ch10 DRILLS & DRILLING MACHINES, VIDEO, GRINDING DRILL BIT MF-CH 15 OTHER LATHE OPERATIONS MF-CH16 BROACHING OPERATIONS ** * MF is for Machining Fundamentals the text we use in class Page 3 of 8
4 CAREER BUILDING DRUGS & DRUG SCREENING SEXUAL HARASSMENT & DISCRIMINATION 25 POINTS EXTRA FOR GETTING DRIVER'S LICENSE SUBMITTING REAL APPLICATION 25 POINTS MACH.TECH.RESUME MACH.TECH. APPLICATION MACH.TECH. COVER LETTER MACH.TECH. FOLLOW UP LETTER MACH.TECH. DECLINE LETTER 25 POINTS EXTRA CREDIT FOR GETTING A JOB ESSAY- GAME PLAN FOR LIFE AFTER HIGH SCHOOL JOB SHADOWING FIELD TRIPS (3 minimum per year) SHOP PROJECTS** 1 ST QUARTER THREADED JOURNAL LATHE MILL PRACTICE PART STEPPED BLOCK CENTER PUNCH CLAMP ON VISE STOP BALL PEEN HAMMER HSS BIT TOOL HOLDER FOR LATHE 3 RD QUARTER CARBIDE SCRIBER PEN SM or LG TAP WRENCH QC TOOL HOLDER FOR LATHES TAP DRIVER DIE HOLDER HARDENED CENTER FOR TURNING FACEPLATES FOR ELECTRONICS SKILLS USA 2 ND QUARTER SPRING LOADED TAP GUIDE CIRCUIT BOARDS MASTERCAM BORING EXERCISE LATHE HACK SAW INDICATOR BASE CHRISTMAS ORNAMENT/TAG - MASTERCAM BATTLE TOPS 4 TH QUARTER ZACH S TAP WRENCH MINI MACHINIST S VISE FLY CUTTER or FLY CUTTER SET W/BASE SLITTING SAW ARBOR DIGITAL CLOCK & BASE ** To keep the program up to date and exciting for the students, the projects will change each year with the exception of the GD&T projects and beginner/practice parts for first year students. Projects are selected based on skill level and time. Page 4 of 8
5 LECTURE/SHOP TOPICS SECOND YEAR PROGRAM: BLUE PRINT READING BPR-GD&T PG BPR-GD&T REVIEW Pg BPR-CALCULATING BONUS TOLERANCES/MMC, LMC, RFS GD&T PROJECT NO1 BIG RING GD&T PROJECT NO2 CONCENTRICITY OD-OD JOURNAL GD&T PROJECT NO3 CONCENTRICITY ID-OD ADAPTER WITH BORE GD&T PROJECT NO4 CONCENTRICITY/RUN OUT MULTI ID/OD GD&T PROJECT NO5 PARALLEL/POSITION/ANGULARITY MILL BLOCK GD&T PROJECT NO6 PARALLEL/POSITION/ANGULARITY MILL PLATE ** 2 nd year machining/inspection project, students submit an inspection report SHOP MATH TALKING LIKE A MACHINIST 2 (.xxxx decimal nomenclature) COST ESTIMATION WITH BAR STOCK CALCS METRIC CONVERSION MM/INCH DIVIDING/INDEXING HEAD CALCULATIONS CALCULATING AREAS IN SQUARE INCHES NO1, NO2 TRIGONOMETRY-IDENTIFYING TRIANGLE SIDES TRIGONOMETRY #1 SIMPLE TRIG TRIGONOMETRY-IDENTIFYING TRIANGLE SIDES REVIEW GAGE BLOCK STACK UP CALCULATIONS 5in SINE BAR CALCULATIONS TRIGONOMETRY-AND CALCULATING TAPERS REARRANGING EQUATIONS/FRACTIONS TRIGONOMETRY-WITH REARRANGING TRIGONOMETRY-#3 PRACTICE TRIGONOMETRY-CIRCULAR BOLT HOLE PATTERN TRIGONOMETRY-TANGENT POINTS STRENGTH OF MATERIALS VIDEO MODERN MARVELS METALS MF-CH 24 METAL CHARACTERISTICS MF-CH 25 HEAT TREATMENT OF METALS SofM-MATERIAL PROPERTIES RESEARCH SofM-TENSILE CALCULATIONS SofM-SHEAR CALCULATIONS SofM-BOLT CALCULATIONS, SHEAR & TENSILE SofM-FORD TRUCK BED BOLT CALCULATION SofM-THERMAL EXPANSION & STRESS SofM-TORQUE CALCULATION Page 5 of 8
6 MACHINING/MANUFACTURING SAFETY VIDEOS/FIRST AID TRAINING-GORY VIDEOS FOR EYE AND HAND INJURY, HAND AND POWER TOOL SAFETY, MACHINE SHOP SAFETY, FIRST AID MACHINING VIDEOS MODERN MARVELS-MACHINE TOOLS GAUGING-READING MICROMETERS.XXXX TECHNICAL WRITING MACHINE MANUALS MF-CH8 JIGS & FIXTURES CH9 CUTTING FLUIDS CH16 BROACHING CH26 METAL FINISHING GAUGING-READING MICROMETER REVIEW.XXXX MACHINERY S HANDBOOK RESEARCH GAUGING-MEASURING ANGULARITY ON SINE BAR SURFACE PLATE MEASURING-TFT CASTING PART SKETCH/PRINT CREATION PROCESS ROUTING EXERCISE * MF is for Machining Fundamentals the text we use in class G-CODE PROGRAMMING (manual input without the use of Mastercam) MF-Ch 21 COMPUTER NUMERICAL CONTROL RECTANGULAR/ABSOLUTE PLOTTING INCREMENTAL PLOTTING POLAR COORDINATE PLOTTING PROGRAM #1 SIMPLE CONTOUR MILL, G0,G1,G2,G3,IJ PROGRAM #2.375 OFFSET CONTOUR-MILL, G0,G1,G2,G3,IJ PROGRAM # BORE INTERPOLATION-MILL, G0,G1,G2,G3,IJ PROGRAM #3B HOLE PATTERN DRILL-MILL, G81,G98 PROGRAM #4 DRILLING 100 HOLES-MILL, G91,G83,G98, L PROGRAM #5 COMBO-CONTOUR/DRILL/BORE &TRIG PROGRAM #6 TURNING ODs, G0,G1,G2,G3,IJ PROGRAM #7 TURNING ODs #2,G0,G1,G2,G3,IJ,G42,G73, G71 PROGRAM #8 CUTTER COMP-MILL, G42/G42 Page 6 of 8
7 CAREER BUILDING DRUGS & DRUG SCREENING SEXUAL HARASSMENT & DISCRIMINATION 25 POINTS EXTRA CREDIT FOR GETTING DRIVER'S LICENSE REAL APPLICATION - EXTRA CREDIT 25 POINTS MACH.TECH.RESUME MACH.TECH. APPLICATION MACH.TECH. 3 LETTERS/RESUMES FOR JOBS 25 POINTS EXTRA CREDIT FOR JOB APPLICATION 25 POINTS EXTRA CREDIT FOR GETTING A JOB ESSAY- STUDENT CAREER INTERVIEW WITH PARENT JOB SHADOWING SCHOOL TO WORK INTERNSHIP FIELD TRIPS (3 minimum per year) STATISTICAL MATHEMATICS SPC POWERBALL HISTOGRAM TEEN STATISTICS, APPLYING NATIONAL AVERAGES/PERCENTAGES TO OUR CLASS SIZE AVERAGES AND FREQUENCIES, MODE & MEAN TFT BAFFLE CAPABILITY EVALUATION (100 PARTS FOR DATA) Page 7 of 8
8 SHOP PROJECTS** 1 ST QUARTER PROGRAM #1 SIMPLE CONTOUR MILL, G0,G1,G2,G3,IJ PROGRAM #2.375 OFFSET CONTOUR-MILL, G0,G1,G2,G3,IJ PROGRAM # BORE INTERPOLATION-MILL, G0,G1,G2,G3,IJ PROGRAM #3B HOLE PATTERN DRILL-MILL, G81,G98 PROGRAM #4 DRILLING 100 HOLES-MILL, G91,G83,G98, L PROGRAM #5 COMBO-CONTOUR/DRILL/BORE &TRIG PROGRAM #6 TURNING ODs, G0,G1,G2,G3,IJ PROGRAM #7 TURNING ODs #2,G0,G1,G2,G3,IJ,G42,G73, G71 PROGRAM #8 CUTTER COMP-MILL, G42/G42 2 ND QUARTER GD&T PART No.1 r fb g GD&T PART No.2 r GD&T PART No.3 r GD&T PART No.4 rht GD&T PART No.5 r b fj GD&T PART No.6 j fb rk 3 RD QUARTER TOOL KIT - INDICATOR SWIVEL T-BASE FOR CALIPERS OAK BOX FOR KIT MASTERCAM 5 SINE BAR SKILLSUSA NIMS ALTERNATIVE PROJECTS SCHOOL TO WORK INTERNSHIP 4 TH QUARTER LG or SM V-BLOCK SET 5C COLLET BLOCK SET DIGITAL CLOCK & BASE (ELECTRONICS LAB) NIMS ALTERNATIVE PROJECTS TESTING! SCHOOL TO WORK INTERNSHIP ** To keep the program up to date and exciting for the students, the projects will change each year with the exception of the GD&T projects and beginner/practice parts for first year students. Projects are selected based on skill level and time. Page 8 of 8
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