SAN DIEGO COMMUNITY COLLEGE DISTRICT CITY COLLEGE ASSOCIATE DEGREE COURSE OUTLINE

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Calvin Gallagher
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1 SAN DIEGO COMMUNITY COLLEGE DISTRICT CITY COLLEGE ASSOCIATE DEGREE COURSE OUTLINE SECTION I SUBJECT AREA AND COURSE NUMBER: Machine Technology 140 COURSE TITLE: Machine Technology UNITS: 4.00 Grade O nly CATALOG COURSE DESCRIPTION: This course is an introduction to the M achine Technology field. Emphasis is placed o n safety, measurements, common formulas, machining applications, drawings, and career opportunities in the field. This course is designed for students planning to major in the occupational field of machine technology. REQUISITES: Advisory: ENGL 051 and ENGL 056, each with a grade of "C" or better, or equivalent, or W5/R5. Advisory: Completion of or concurrent enrollment in MATH 095 with a grade of "C" or better, or equivalent, or M40. FIELD TR IP REQUIREMENTS: May be required TRANSFER APPLICABILITY: Associate Degree Credit & transfer to CSU and/or private colleges and universities. CAN DATA: None LECTURE HOURS PER WEEK: 3.00 LAB HOURS PER WEEK: 3.00 STUDENT LEARNING OUTCO MES: Upon successful completion of the course the student will be able to: 1. Describe the history of machines and identify machine trade careers, professions and trade organizations. 2. Identify safety eq uipment and explain safe work practices in the mac hine shop. 3. Illustrate an understanding of the lines and symbols on engineering drawings and plan the sequence of operations for machining round work and flat workpieces. 4. Use a variety of measuring instruments such as squares, surface plates, vernier calipers, micrometers, gages, com parators, to measure given workpieces. 5. Prepare a work surface for layout, use the combination square and surface gage to layout straight lines, and make precision layo uts using the sine bar and gage blocks. 6. Select appropriate tools for holding, assembling and dismantling workpieces and for sawing a variety of materials, and identify and exp lain the purpose of several types of hand reamers and bearings. 7. Identify the applications of various types of cutting-tool materials, set up a tool and machine for cutting with various tools, and apply cutting fluids efficiently for a variety of ma chining ope rations. 8. Use a bandsaw to cut off work to an accurate length, explain the purpose the main operative parts of a contour-cutting bandsaw, and set up a contour b andsaw to file a layout.

2 9. Distinguish among the four types of drilling presses based on each one's purp ose, use a drill grinder to grind proper angles and clearances on a twist drill and use a drill press to make accurately-sized holes in workpieces. Calculate the reaming allowance required for given reamers. 10. Explain purposes of the main operative parts of the lathe, list the necessary safety precautions required to run a lathe, and set up the following: a workpiece for machining between centers, a cutting tool for turning operations, a lathe to cut a variety of threads and a lathe chuck to hold a workpiece to b e cut. 11. Recognize and explain the purposes of standard milling machines and milling cutters, calculate the proper feeds for various cutters and materials, set up a milling machine for face, side, straddle and gang milling, and calculate the indexing necessary with a wide-range divider. 12. Identify the purposes of the main operative parts of a jig borer, calculate hole locations, and select the wheels and grinding methods required for jig-grinding holes. 13. Select the proper grinding wheel for given work materials and jobs and set up various workpieces for surface, cylindrical and internal grinding. 14. Describe the chemical composition of steel, choose the proper grade of tool steel for a given workpiece, and test a given piece of stee l for hardness. 15. Use mathematical formulas commonly found in machining technology to calculate speeds and feeds on mills and lathes, and calculate the layout and positioning o f angles and angular hole p atterns. SECTIO N II 1. COURSE OUTLINE AND SCOPE A. OUTLINE OF TOPICS: The following topics are included in the framework of the course but are not intended as limits on content. The order o f presentation and relative emphasis will vary with each instructor. 1. Introduction to machine tools and trades a. The history of machines i. Common machine to ols ii. Standard machine tools iii. Computer numerical control machines iv. Major developments in metalworking b. Machine trade opportunities i. Careers in the metalworking industry ii. Apprenticeship training iii. Professions iv. Trade organizations 2. Safety in the machine shop a. Safety equipment b. Safe work practices c. Proper clothing and hygiene d. Proper laboratory cleaning e. Chemicals and fire hazards 3. Mathematical Computations with Calculator a. Using mathematics in machining b. Scientific pocket calculator c. Calculating Fractions and Decimals with scientific Calculator 4. Converting Metric and US Standard Units of Measure a. Metric system b. Converting U.S. system units to metric system units c. Converting metric system units to U.S. system units 5. Performing RPM Calculations a. Prop erly calc ulat ing R PM 's

3 b. Changing variables in machining formulas c. Effec ts of different alloys and cutting tool s on RPM's d. Correct use of formulas to achieve proper RPM 6. Feed Calculations a. Proper feed calculations b. Variables in feed equations c. Negative effects of improper RPM, feed, and depth of cut on tool life, production and profitability d. Benefits of increased production related to increased profit for proper feed calculations e. Differences between inch per revolution (IPR) and inch per minute (IPM) f. Proper application of IPR and IPM g. Chip load per tooth for roughing ve rses finishing of different materials 7. Pythagorean Theorem Calculations a. Limitations of Pythagorean Theorem b. Equations for the Pythagorean Theorem c. Pythagorean equations in machining processes 8. Trigonometry used in machining technology a. Combined methods to solve missing lengths b. Combined methods to solve missing angles c. Applications of sine function to machining sine bar 9. Trigonometric polar to rectangluar coordinate conversions a. Benefits of not being limited to 90 degree solutions b. Using scientific calculator to perform polar to rectangluar coordinate conversions c. Time benefits using polar coordinates to calculate locations d. Proper use of Polar trigonometry to calculate locations on a bolt hole circle e. Translation of a reference relative to a known point in a cartesian coordinate system 10. Job planning a. Engineering drawings i. Types of drawings and lines ii. Drafting terms and symbols iii. Surface symbols b. Machining procedures for various workpieces i. Machining procedures for round work ii. Workpieces held in a chuck iii. Machining flat workpieces 11. Measurement a. Basic measurement i. Inch system ii. Metric system iii. Fractional measurement iv. Metric steel rules v. Fractional steel rules vi. Outside calipers vii. Inside calipers b. Squares and surface plates i. Machinist's combination square ii. Precision squares iii. Beveled-edge squares iv. Toolmaker's surface plate square v. Cylindrical squares

4 vi. Adjustable squares vii. Adjustable micrometer square viii. Straightedges ix. Surface plates c. Micrometers i. Principle of the inch micrometer ii. Vernier micrometer iii. Metric micrometer iv. Metric vernier micrometer v. Combination inch-metric micrometer vi. Micrometer adjustments vii. Testing the accuracy of micrometers viii. Special-purpose micrometers ix. Screw thread micrometers d. Vernier calipers i. Parts of the vernier caliper ii. Measuring a workpiece iii. Reading the metric vernier caliper iv. Direct-reading dial caliper e. Inside-measuring instruments i. Inside micrometer calipers ii. Inside micrometers iii. Small hole gages iv. Telescope gages v. Dial bore gages f. Depth-measuring instruments i. Micrometer depth gage ii. Vernier depth gages g. Height-mea suring instruments i. Vernier height gage ii. Measuring height with gage blocks iii. Precision height gage h. Gage blocks i. Gage block manufacture ii. Gage block sets i. Angular measurement i. The universal bevel protractor ii. The sine bar iii. The comp ound sine p late or table j. Gages i. Fixed gages ii. Cylindrical plug gages iii. Plain ring gages iv. Taper plug gages v. Taper ring gages vi. Thread plug gages vii. Thread ring gages viii. Snap gages k. Comparison measurement i. Comparators ii. Dial indicators iii. Mechanical and electronic comparators iv. Optical comparators v. Mechanical-optical comparators vi. Air gages or pneumatic comparators l. The coordinate measuring system

5 i. Parts of the measuring unit ii. Operation of the measuring unit m. Measuring with light waves i. Measuring with optical flats ii. Measurement with alsers iii. The lasermike n. Surface finish measurement 12. Layout tools and procedures a. Basic layout materials, tools and accessories i. Layout solutions ii. Layout tables and surface plates iii. Scribers iv. Dividers and trammels v. Hermaphrodite calipers vi. Squares vii. The combination set viii. Surface gage ix. Layout or prick punches and center punches b. Basic or semiprecision layout i. How to lay out hole locations, slots and rad ii ii. How to lay out a casting having a cored hole iii. How to lay out a keyseat in shaft c. Precision layout i. The vernier height gage ii. How to make a precision layout using a sine bare, gage blocks and a vernier height gage 13. Hand tools and bench work a. Holding, striking and assembling tools i. The bench vise ii. Hammers iii. Screwdrivers iv. Wrenches v. Pliers b. Hand-type cutting tools i. Sawing, filing and scraping ii. The hand hacksaw iii. Files iv. Scapers c. Thread-cutting tools and procedures i. Hand taps ii. Threading dies d. Finishing processes - reaming, broaching and lapping i. Hand reamers ii. Broaching iii. Lapping 14. Metal-cutting technology a. Physics of metal cutting i. Metal-cutting technology ii. Plastic flow of metal iii. Chip types b. Machinability of metals i. Grain structure - low- and high-carbon steel, alloy steel, cast iron, aluminum, copper ii. The effects of temperature and friction iii. Surface finish

6 iv. Effects of cutting fluids c. Cutting tools i. Cutting-tool materials - types of toolb its ii. Cutting-tool nomenclature iii. Lathe toolbit angles and clearances iv. Cutting-tool shape v. Tool life vi. Principles of machining - turning, planing, plain, end and face milling and drilling d. Operating conditions and tool life i. Depth of cut, feed rate and cutting speed ii. Effects of changing operating conditions iii. General operating condition rules iv. Economic performance v. Machining cost analysis e. Carbide cutting tools i. Manufacture of cemented carbides ii. Cemented-carbide applications iii. Grades of cemented carbides iv. Tool geometry - cutting-tool angles and clearances v. Cutting speeds and feeds vi. Machining with carbide tools vii. Grinding cem ented-carb ide tools f. Diamond cutting tools i. Manufactured diamonds ii. Advantages iii. Use, cutting speeds and feeds g. Ceramic cutting tools i. Manufacture ii. Applications iii. Factors affecting performance iv. Advantages and disadvantages v. Geometry vi. Cutting speeds h. Cermet cutting tools i. Types and characteristics ii. Advantages and uses i. Polycrystalline cutting tools i. Manufacture ii. Polycrystalline cubic boron nitride (PCB N) tools iii. Polycrystalline diam ond (PC D) tools iv. Diamond -coated too ls j. Cutting fluids - types and applications i. Characteristics of a good cutting fluid ii. Types of cutting fluids iii. Functions of a cutting fluid iv. Application of a cutting fluid 15. Metal-cutting saws a. Types of metal saws i. Methods of cutting off material ii. Horizontal bandsaw parts iii. Saw blades iv. Sawing b. Contour bandsaw parts and accessories i. Contour bandsaw parts ii. Bandsaw applications

7 iii. Coolants iv. Power feed v. Bandsaw blade types and applications c. Contour bandsaw operations i. Sawing external sections ii. Sawing internal sections iii. Friction sawing iv. Band filing 16. Drilling machines a. Drill presses i. Standard operations ii. Sensitive drill presses iii. Upright drilling machine iv. Radial drilling machine v. Numerical control drilling machine b. Drilling machine accessories i. Tool-holding devices ii. Work-holding devices iii. Clamping stresses c. Twist drills i. Twist drill parts ii. Drill point characteristics iii. Systems of drill sizes iv. Types of drills d. Cutting speeds and feeds e. Drilling holes i. Drill press safety ii. Lathe center holes iii. Spotting a hole location with a center drill iv. Drilling work held in a vise v. Drilling to an accurate layout vi. Drilling large holes vii. Drilling round work in a v-block f. Reaming i. Reamers ii. Reaming allowances iii. Reaming speeds and feeds iv. Reaming a straight hole v. Reaming a tapered ho le g. Drill press operations i. Counterboring ii. Countersinking iii. Tapping iv. Transferring hole locations v. Drill jigs 17. The lathe a. Engine lathe parts i. Parts of the lathe ii. Setting speeds on a lathe iii. Setting feeds iv. Shear pins and clutches b. Lath accessories i. Work-holding devices ii. Cutting-tool-holding devices

8 iii. Compound rest tooling systems c. Cutting speed, feed and depth cut i. Cutting speed ii. Depth of cut iii. Graduated micrometer collars iv. Calculating machining time d. Lathe safety precautions e. Mounting, removing and aligning lathe centers f. Grinding lathe cutting tools g. Facing between centers i. Setting up a cutting tool for machining ii. Mounting work between centers iii. Facing between centers h. Machining between centers i. Setting up a cutting tool ii. Mounting work between centers iii. Parallel turning iv. Rough turning v. Finish turning vi. Filing in a lathe vii. Polishing in a lathe viii. Turning to a shoulder i. Knurling, grooving and form turning j. Tapers, taper turning and taper calculations k. Threads and thread cutting i. Thread calculations ii. Thread-chasing dial iii. Thread cutting l. Steady rests, follower rests and mandrels m. Machining in a chuck i. Mounting and removing lathe chucks ii. Mounting work in a chuck iii. To rough- and finish-turn work in a chuck iv. Turning hardened stee l with PCB N tools v. Cutting off work in a chuck n. Drilling, boring, reaming and tapping 18. Milling machines a. Milling machines and accessories i. Horizontal milling machines ii. Manufacturing-type milling machines iii. Knee-and-column-type milling machines iv. Parts of the milling machine v. Milling machine accessories b. Milling cutters i. Milling cutter materials ii. Types of milling cutters c. Cutting speed, feed and depth of cut i. Cutting speed ii. Calculations iii. Milling feed and depth of cut iv. Advantages and disadvantages of climb milling v. Milling cutter failure d. Milling machine setups i. Milling machine safety ii. Mounting and removing a milling machine arbor

9 iii. Mounting and removing milling cutters iv. Aligning the table on a universal milling machine v. Aligning the milling machine vise e. Milling operations i. Setting the cutter to the work surface ii. Milling a flat surface iii. Face milling iv. Side milling v. Straddle milling vi. Gang milling vii. Sawing and slitting f. The indexing or dividing head i. Index head p arts ii. Methods of indexing iii. The wide-range dividing head iv. Linear graduating g. Gears i. Types of gears ii. Gear terminology h. Gear cutting i. Involute gear cutters ii. Metric gears and gear cutting iii. Gear tooth measurement i. Helical milling i. Helical terms ii. Determining the helix angle iii. Determining the direction to sw ing the table iv. Calculations v. Cutting short lead helices j. Cam, rack, worm and clutch milling i. Cam and cam milling ii. Rack milling iii. Worms and worm gears iv. Clutches k. The vertical milling machine - construction and operation i. Types of vertical milling machines ii. Parts of the ram-type vertical mill iii. Aligning the vertical head iv. Aligning the vise v. Mounting and removing the cutters vi. Machining a block square and parallel vii. Machining the ends square viii. Milling hardened steel with P CBN tools ix. Producing the finishing holes x. Cutting slots and keyseats l. Special milling operations i. The rotary table ii. Radius milling iii. Jig boring on a vertical milling machine 19. The jig borer and jig grinder a. The jig borer b. Jig-boring holes i. Setting up the work ii. Methods of locating an edge iii. The coordinate locating system

10 iv. Measurement and inspection of holes c. The jig grinder i. Jig grinder parts ii. Grinding head outfeed iii. Grinding methods iv. Grinding wheels v. Grinding allowances vi. Grinding sequence vii. Jig grinding with cubic boron nitride wheels 20. Grinding a. Abrasives i. Types ii. Grinding wheels iii. Selecting a grinding wheel for a specific job iv. Diamond wheels v. Cubic boron nitride (CBN) wheels vi. Coated abrasives b. Surface grinders and accessories i. The grinding process ii. Surface grinding iii. Grinding wheel care iv. Work-holding devices v. Grinding fluids vi. Surface finish c. Surface-grinding operations i. Mounting the workpiece for grinding ii. Grinder safety iii. Grinding operations iv. Grinding a flat surface with a CBN wheel v. Form grinding vi. Cutting-off operations d. Cylindrical grinders i. Center-type cylindrical grinders ii. Machine preparation for grinding iii. Internal grinders iv. Centerless grinders v. Methods of centerless grinding e. Universal cutter and tool grinder i. Parts of the universal cutter and tool grinder ii. Accessories and attachments iii. Milling cutter nomenclature iv. Cutter clearance angles v. Methods of grinding clearance on cutters vi. Methods of checking clearance angles vii. Cutter grinding operations and setups 21. Metallurgy a. Manufacture and properties of steel i. Physical properties of metals ii. Manufacture of ferrous metals iii. Direct ironmaking iv. Direct steelmaking v. Minimills vi. Chemical composition of steel vii. Classification of steel

11 b. Heat treatment of steel i. Heat-treating equipment ii. Heat-treatment terms iii. Selection of tool steel iv. Classification of steel v. Heat treatment of carbon steel vi. Case-hardening methods vii. Surface hardening of med ium-carbon steels c. Testing of metals and nonferrous metals i. Hardness testing ii. Destructive testing iii. Nonferrous m etals and alloys B. READING ASSIGNM ENTS: Reading assignments are required and may include but, are not limited to, the following: 1. The assigned text bo ok, laboratory and/or m anuals 2. Machine T echnology industry and/or trade publications such as: a. Modern Machine Shop b. Production Machining 3. Selections from Internet sites, including: a. b. c. d. C. WRITING ASSIGNMENTS: Writing assignments are required and may include, but are not limited to, the following: 1. Prepare process documents detailing machine shop equipment and procedures required for given jobs 2. Maintenance of a machine shop notebook 3. Short answers to questions dealing with a variety of issues related to materials, equipment and procedures used in the machine shop D. APPROPRIATE OUTSIDE ASSIGNMENTS: Outside assignments ma y include, but are not limited to, the following: 1. Reading and writing assignments as specified in the course syllabus 2. Field assignments designed to familiarize students with functioning machine shops and career opportunities in the field of machine technology 3. Research projects that relate to and enhance the student's understanding of upcoming in-class projects related to recent developments in machine technology techniques

12 E. APPROPRIATE ASSIGNMENTS THAT DEMONSTRATE CRITICAL THINKING: Critical thinking assignments are required and may include, but are not limited to, the following: 1. Interpret, analyze and evaluate assigned readings, machine shop instructions, blueprints and drawings 2. Prepare milling machines, lathes and drill presses to perform a wide variety of machine shop jobs 3. Assess current and future career options in the machine technology field 2. METHODS OF EVALUATION: A student's grade will be based on multiple measures of performance unless the course requires no grade. Multiple m easures may include, but are not limited to, the following: 1. Performance o n manipulative skills as demonstrated through a wide range of laboratory assignments 2. Performance on written, oral and practical examinations 3. Perform ance on outside assignments including writing assignments 4. Class attendance and participation 3. METHODS OF INSTRUCTION: Methods of instruction may include, but are not limited to, the following: * Lecture * Computer Assisted Instruction * Lecture-Lab Combination * Collaborative Learning * Other (Specify) 1. Lectures and demonstrations dealing with machine shop safety, equipment, materials and procedures 2. Group problem solving, discussion and/or critiques related to blueprints and drawings, use of equipment such as the lathe and milling machines, and/or efficient execution of machine shop assignments 3. Instructor-assisted, hands-on, independent learning based on trial and error processes in which students perform calculations req uired to set up a project, p repare machines, set up workpieces and complete assigned jobs 4. Field trips or field assignments related to practical and business applications of machine technology 4. REQUIRED TEXTS AND SUPPLIES: Textbooks may include, but are not limited to: 1. Krar, Steve, et al. Machine Tool Technology Basics, 1st Edition, Industrial Press, 2002, ISBN: Oberg, Erik, et al. Machinery's Handbook, 26th Edition, Industrial Press, 2000, ISBN: Krar, Steve F. and Albert F. Check Technology of Machine Tools, 5th Edition, McGraw Hill, 1996, ISBN: Krar, Steve F. and Albert F. Check Workbook for Technology of Machine Tools, 5th Edition, McGraw Hill, 1999, ISBN: SUPPLIES: None ORIG INAT OR: Jack Bollinger, John Bollinger

Tool and Die Maker Level 2

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