ED 401 433
TITLE
INSTITUTIONSPONS AGENCY
PUB DATECONTRACTNOTE
AVAILABLE FROMPUB TYPE
EDRS PRICEDESCRIPTORS
ABSTRACT
DOCUMENT RESUME
CE 072 926
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)
achine Tool
dvancedkillsethnology
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
TECHNICALINS T IT U T E
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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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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
MANUFACTURING ENGINEERING TECHNOLOGYMACHINING OPTION
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
MANUFACTURING ENGINEERING TECHNOLOGYMACHINING OPTION
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
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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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MACHINIST: CERTIFICATE se
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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.
Machine Tool Advanced SkillsTechnology 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
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
gages)d. Measure with direct measuring instruments (e.g.,
instruments)e. Measure with fixed gages (go and not go gages)
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
Machine Tool Advanced SkillsTechnology Program
COURSE SYLLABUS
PRECISION TOOLS & MEASUREMENTS
49
MAST PROGRAMCOURSE SYLLABUS
PRECISION TOOLS & MEASUREMENTS
Lecture hours/week: 2
COURSE DESCRIPTION:
Lab hours/week: 4 Credit hours: 3
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
REQUIRED COURSE MATERIALS:
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.
METHODS OF INSTRUCTION:
Lecture: Didactic presentations will include lecture, video and demonstrations.
Laboratory: Laboratory will consist of "hands-on" activities.
50
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. 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
LECTURE OUTLINE:Lecture Topics Text Reference Page Contact Hrs.
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
Total Lecture Hours 24
LAB OUTLINE:Lab Topics Contact Hrs.
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
COURSE OBJECTIVES: TECHNICAL COMPETENCIES
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
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)
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 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
D. Systems: Understands complex inter-relationships1. demonstrate knowledge of the following systems:
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
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 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
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 4
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 metrology labB. 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. 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
knowledge5. Reasoning: Discovers a rule or principle underlying the relationship
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
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 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
contributions toward common goals3. Sociability: Demonstrates understanding, friendliness, adaptability,
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
Appropriate Reference Materials:
1. Machinery's Handbook, Industrial Press2. Mathematics for Machine Technology; Robert Smith, Delmar Publishers
hiE71103
01/060596
Machine Tool Advanced SkillsTechnology Program
COURSE SYLLABUS
INDUSTRIAL SPECIFICATIONS ANDSAFETY
57
MAST PROGRAMCOURSE SYLLABUS
INDUSTRIAL SPECIFICATIONS AND SAFETY
Lecture hours/week: 2
COURSE DESCRIPTION:
Lab hours/week: 4 Credit hours: 3
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
REQUIRED COURSE MATERIALS:
Textbook/Lab Manual: B ueprint Reading for Manufacturing, Edward Hoffman and PaulWallach, Delmar Publishers, Latest Edition.
Student Tool List **/Quantity Required: None
** A complete list of recommended capital equipment, tools and supplies (to be furnished bythe school) may be found in Tab 5 of this volume.
METHODS OF INSTRUCTION:
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.
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 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
COURSE OBJECTIVES: TECHNICAL COMPETENCIES
After the successful completion of this course the student will be able to:A. PRACTICE SAFETY
1. Follow Safety Manuals and All Safety Regulations/Requirementsa. 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
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 part
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.
61
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. 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
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. 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
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
skillB. 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. 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
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. 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
preventive actionsd. takes initiative when needed to gain resources or assistance to
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
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
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
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 classroom
during examination, and on classroom exercisesd. understand the consequences of unethical behaviors
Appropriate Reference Materials:
1. Machinery's Handbook, Industrial Press2. Technology of Machine Tools, 4th Ed. McGraw Hill Publishers
N1E-11603
01/060596
Machine Tool Advanced SkillsTechnology Program
COURSE SYLLABUS
MACHINE TOOL PRACTICES IIPrerequisite: MACHINE TOOL PRACTICES I
S5
MAST PROGRAMCOURSE SYLLABUS
MACHINE TOOL PRACTICES II
Lecture hours/week: 3
COURSE DESCRIPTION:
Lab hours/week: 9 Credit hours: 6
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
REQUIRED COURSE MATERIALS:
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.
** A complete list of recommended capital equipment, tools and supplies (to be furnished bythe school) may be found in Tab 5 of this volume.
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. 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
LECTURE OUTLINE:Lecture Topics Text Reference Page Contact Hrs.
Introduction to the Course 1
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
Total Lecture Hours 36
*(15-20 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 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
COURSE OBJECTIVES: TECHNICAL COMPETENCIES
After the successful completion of this course the student will be able to:A. PRACTICE SAFETY
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
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
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
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
H. FOUNDATION SKILLSA. Basic Skills: Reads, writes, performs arithmetic and mathematical operations,
listens and speaks.1. Reading: Locates, understands, and interprets written information in
prose and in documents such as manuals, graphs, and schedulesa. read/studies textbookb. studies student laboratory manualc. 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 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
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 15-20 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 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
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 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
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 workb. 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 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 laboratory,
during examination, and on outside assignmentsd. understand the consequences of unethical behaviors
Appropriate Reference Materials:
I. Machinery's H .andbook, Industrial Press2. Technology of Machine Tools, 4th Ed., McGraw Hill Publishers
MET20001/072396
Machine Tool Advanced SkillsTechnology Program
COURSE SYLLABUS
SURVEY OF WELDING PROCESSES ANDAPPLICATIONS
73
MAST PROGRAMCOURSE SYLLABUS
SURVEY OF WELDING PROCESSES ANDAPPLICATIONS
Lecture hours/week: 3
COURSE DESCRIPTION:
Lab hours/week: 3 Credit hours: 4
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
REQUIRED COURSE MATERIALS:
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
** A complete list of recommended capital equipment, tools and supplies (to be furnished bythe school) may be found in Tab 5 of this volume.
METHODS OF INSTRUCTION:
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.
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. 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 Text Reference Page Contact Hrs.
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
Total Lecture Hours 36
LAB OUTLINE:Lab Topics Contact Hrs.
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
COURSE OBJECTIVES: TECHNICAL COMPETENCIES
After the successful completion of this course the student will be able to:A. PRACTICE SAFETY
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
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 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
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 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
standardsE. Technology: Works with a variety of technologies
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
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 manualc. interprets welding symbolsd. 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 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
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 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
apply 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 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
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 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 (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
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. 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
Machine Tool Advanced SkillsTechnology Program
COURSE SYLLABUS
MACHINE TOOL PRACTICES IIIPrerequisite: MACHINE TOOL PRACTICES II
82
MAST PROGRAMCOURSE SYLLABUS
MACHINE TOOL PRACTICES III
Lecture hours/week: 3
COURSE DESCRIPTION:
Lab hours/week: 12 Credit hours: 7
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
REQUIRED COURSE MATERIALS:
Textbook:Lab Manual:
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
** A complete list of recommended capital equipment, tools and supplies (to be furnished bythe school) may be found in Tab 5 of this volume.
METHODS OF INSTRUCTION:
Lecture: Didactic presentations will include lecture, video and demonstrations.
Laboratory: Laboratory will be a "hands-on" machining process.
83
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. 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 Text Reference Page Contact Hrs.
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
LAB OUTLINE:Lab Topics Contact Hrs.
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
COURSE OBJECTIVES: TECHNICAL COMPETENCIES
After the successful completion of this course the student will be able to:A. PRACTICE SAFETY
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
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 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
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. 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
D. Systems: Understands complex inter-relationships1. demonstrate knowledge of the following systems:
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
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
8
H. FOUNDATION SKILLSA. Basic Skills: Reads, writes, performs arithmetic and mathematicaloperations,
listens and speaks.1. Reading: Locates, understands, and interprets written information in
prose and in documents such as manuals, graphs, and schedulesa. read/studies textbookb. interprets blueprints and technical drawingsc. 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. 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
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 laboratoryB. 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. 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
apply 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 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
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 workb. 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 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
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
MET30001/060696
Machine Tool Advanced SkillsTechnology Program
COURSE SYLLABUS
MANUFACTURING PROCESSES
90
MAST PROGRAMCOURSE SYLLABUS
MANUFACTURING PROCESSES
Lecture hours/week: 3
COURSE DESCRIPTION:
Lab hours/week: 3 Credit hours: 4
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
REQUIRED COURSE MATERIALS:
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
** A complete list of recommended capital equipment, tools and supplies (to be furnished bythe school) may be found in Tab 5 of this volume.
METHODS OF INSTRUCTION:
Lecture: Didactic presentations will include lecture, video and demonstrations.
Laboratory: Laboratory will consist of "hands-on" activities. Students will operate variousconventional metalworking machines to manufacture a product.
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. 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
LECTURE OUTLINE:Lecture Topics Text Reference Page Contact Hrs.
Introduction to the Course 1
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 OUTLINE:Lab Topics Contact Hrs.
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
Total Lecture Hours 36
COURSE OBJECTIVES: TECHNICAL COMPETENCIES
After the successful completion of this course the student will be able to:A. PRACTICE SAFETY
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
2. Use Standards to Verify Requirementsa. Discuss the purpose of standardsb. Discuss source locations for standards
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
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
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 requiredby industry. SCANS ismade up of five competencies and a three-part foundation of skills and personalqualities 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. 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
D. Systems: Understands complex inter-relationships1. demonstrate knowledge of the following systems:
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
standardsE. Technology: Works with a variety of technologies
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
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 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
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 laboratoryB. 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. 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
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. 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
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 workb. 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 manufactured component
partsb. 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 laboratory,
during examination, and on outside assignmentsd. understand the consequences of unethical behaviors
Appropriate Reference Materials:
I. Machinery's Handbook, Industrial Press2. Technology of Machine Tools, 4th Ed. McGraw Hill Publishers
MET30101/060796
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Machine Tool Advanced SkillsTechnology Program
COURSE SYLLABUS
INTRODUCTION TO CNC
97
MAST PROGRAMCOURSE SYLLABUS
INTRODUCTION TO CNC
Lecture hours/week: 2
COURSE DESCRIPTION:
Lab hours/week: 4 Credit hours: 3
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
REQUIRED COURSE MATERIALS:
Textbook:Lab Manual:
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.
** A complete list of recommended capital equipment, tools and supplies (to be furnished bythe school) may be found in Tab 5 of this volume.
METHODS OF INSTRUCTION:
Lecture: Didactic presentations will include lecture, video and demonstrations
Laboratory: Laboratory will be a "hands-on" activities relating to CNC programming
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. 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
Total Lecture Hours 24
LAB OUTLINE:Lab Topics Contact Hrs.
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
COURSE OBJECTIVES: TECHNICAL COMPETENCIES
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
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 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
D. Systems: Understands complex inter-relationships1. 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 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
standardsE. Technology: Works with a variety of technologies
1. chooses procedure required to program a part using CNC2. applies appropriate procedures to program a part using CNC
II. FOUNDATION SKILLSA. Basic Skills: Reads, writes, performs arithmetic and mathematical operations,
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
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 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 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
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
generate desired features in raw stock in order to plan machinesetups and sequence of machining operations
d. visualize cutter path and position of clamps and workholdingdevices while preparing CNC programs
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 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
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
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
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, 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
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 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 Publishers3. Computer Numerical Control by Warren S. Seams, Delmar Publishers
MET230301/060796
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Machine Tool Advanced SkillsTechnology Program
COURSE SYLLABUS
MACHINE TOOL PRACTICES IVPrerequisite: MACHINE TOOL PRACTICES III
1O3
MAST PROGRAMCOURSE SYLLABUS
MACHINE TOOL PRACTICES IV
Lecture hours/week: 3
COURSE DESCRIPTION:
Lab hours/week: 15 Credit hours: 8
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
REQUIRED COURSE MATERIALS:
Textbook:Lab Manual:
Machine Tool Practices, Kibbe, Neely, and Meyer, Wiley Pub., 4th Ed.Instructor Prepared Lessons/Modules
REQUIRED COURSE MATERIALS:
Student Tool List **. Tools are the same as those used in Machine Tool Practices I, IIand III.
106
** A complete list of recommended capital equipment, tools and supplies (to be furnished bythe school) may be found in Tab 5 of this volume.
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. 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 Text Reference Page Contact Hrs.
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
Total Lecture Hours 36
107
LAB OUTLINE:Lab Topics Contact Hrs.
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
COURSE OBJECTIVES: TECHNICAL COMPETENCIES
After the successful completion of this course the student will be able to:A. PRACTICE SAFETY
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
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. 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
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 process through the
EDM 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
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 classroom handoutsc. 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. 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
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 laboratoryB. 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. 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,
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 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
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 workb. 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 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 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
MET40001/060796
111
Machine Tool Advanced SkillsTechnology Program
COURSE SYLLABUS
ADVANCED CNCPrerequisite: INTRODUCTION TO CNC
12
MAST PROGRAMCOURSE SYLLABUS
ADVANCED CNC
Lecture hours/week: 3
COURSE DESCRIPTION:
Lab hours/week: 9 Credit hours: 6
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
REQUIRED COURSE MATERIALS:
Textbook: NoneLab Manual: None
Student Tool List **: Tools will be the same as required for Introduction to CNC
** A complete list of recommended capital equipment, tools and supplies (to be furnished bythe school) may be found in Tab 5 of this volume.
METHODS OF INSTRUCTION:
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.
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 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)
Total Lecture Hours 36
LAB OUTLINE:Lab Topics Contact Hrs.
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
COURSE OBJECTIVES: TECHNICAL COMPETENCIES
After the successful completion of this course the student will be able to:A. PRACTICE SAFETY
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
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 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
standardsE. Technology: Works with a variety of technologies
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
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 CNC machine operating and programming manualsb. interprets blueprints and technical drawingsc. 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 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
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 CNC labB. 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. 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,
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
d. visualize cutter path and position of clamps and workholdingdevices while preparing CNC programs
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 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
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 workb. 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, computers 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 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 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 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.
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Mac
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l Adv
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d Sk
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Tec
hnol
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Prog
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sort
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(V.1
99J4
0008
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Ted
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Bel
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icop
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XT
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BE
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AV
AIL
AB
LE
1 26
MA
CH
INIS
T...
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n, la
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, set
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and
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tool
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Und
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s to
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Sel
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ess
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ect
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tool
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C4
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nglis
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Per
form
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s8-
3 O
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wer
saw
s0-
4 O
pera
te d
rill
pram
s0-
5 O
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grin
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D-9
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jig
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achi
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D-I
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pmen
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E-I
Pro
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achi
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mac
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CN
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-5 O
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E4
Dow
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pes
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ary
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ds
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atio
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-7 O
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F-8
Ope
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bob
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mac
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s
F-9
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fini
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gm
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0-1
Wel
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PA
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Eng
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Sup
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Exp
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achi
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128
BE
ST
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AV
AIL
AB
LE
SKIL
LS
AN
D K
NO
WL
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Con
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in th
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aniz
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kills
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ompa
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Mita
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Wac
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129
TR
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Stro
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Eth
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TO
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S A
ND
EQ
UIP
ME
NT
Ele
ctri
cian
's T
ools
(lin
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stri
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s,sc
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driv
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etc
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lect
ric
Dri
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eadi
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FUT
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E
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Prep
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By
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WaC
O
130
MA
CH
INIS
T...
. pla
n, la
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, set
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and
ope
rate
han
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achi
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ols
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achi
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wor
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B
Per
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Mea
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Mai
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1113
Viro
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mea
t
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Rev
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Iden
tify
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pes
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ach
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C-6
Des
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neer
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ings
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C-7
Use
stan
dard
s to
verit
y re
quire
-m
erits
C4
Ana
lyze
tall
of m
ater
ials
(BO
M)
D-1
Iden
tify
mat
eria
ls w
ithde
sire
dpr
oper
ties
D-2
. Des
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at tr
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Des
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erm
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4 D
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-m
esh
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ect
prop
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easu
rem
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tool
s
E-3
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ly p
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rm
easu
ring
tech
niqu
es
E4
the
Met
rican
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nglis
hab
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r& o
fm
easu
rem
ent
E-5
Per
form
mea
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tsw
ith h
and
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Mau
mee
F-I
Pre
pare
and
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achi
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atio
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Use
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-3 O
pera
te &
El
pres
ses
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Oss
eove
rtic
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iltin
gm
achi
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F4
Ope
rate
horiz
onta
lm
illin
g m
achi
nes
F6
Ope
rate
met
al c
uttin
gba
thes
F-7
Ope
rate
grin
ding
/abr
asiv
em
achi
nes
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1 O
pera
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barr
ing
equi
pmen
t
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Ope
rate
vert
ical
turn
ing
mac
hine
(Bol
lard
)
F-W
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rate
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l bon
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ill
F-1
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pera
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drau
lic p
ress
esF
-12
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rate
broa
chin
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achi
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and
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ers
F-1
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pera
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wer
han
gm
achi
nes
F-1
4 O
pera
tetr
epam
ing
mac
hine
F-1
5 O
pera
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ck b
ore
mac
hine
F-1
6 P
erfo
rmfr
eeha
nd c
utte
rgr
indi
ng
0-1
Pre
pare
and
plea
Re
CN
Cm
achi
ning
oper
atio
ns
O-2
Sel
ect a
ndm
e C
NC
tool
ing
syst
ems
0-3
Ope
rate
CN
C m
achi
ning
cent
ers
(mill
s)
0-4
Ope
rate
CN
C tu
ning
cent
ers
(lath
es)
H-1
Des
crib
eth
e di
ffere
ntty
pes
of g
ears
H-2
Und
erst
and
gear
teem
sH
-3 U
se r
otar
yta
bles
and
divi
ding
hea
ds
H-4
Dis
cuss
gea
rin
spec
tion
and
mea
sure
men
t
H-5
Meh
l=m
ar p
a
132
BE
ST C
OPY
AV
AIL
AB
LE
SKIL
LS
AN
D K
NO
WL
ED
GE
Com
mun
icat
ion
Skill
sU
se M
easu
rem
ent T
ools
Use
Ins
pect
ion
Dev
ices
Mat
hem
atic
al S
kills
Rea
ding
AV
ritin
g Sk
ills
Kno
wle
dge
of S
afet
y R
egul
atio
nsPr
actic
e Sa
fety
in th
e W
orkp
lace
Org
aniz
atio
nal S
kills
Kno
wle
dge
of C
ompa
ny P
olic
ies/
Proc
edur
esM
echa
nica
l Apt
itude
Abi
lity
to C
ompr
ehen
d W
ritte
n/V
erba
l Ins
truc
tions
Kno
wle
dge
of C
uttin
g Fl
uids
/Lub
rica
nts
Bas
ic K
now
ledg
e of
Fas
tene
rsA
bilit
y to
Wor
k as
Par
t of
a T
eam
Con
vers
e 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
/Em
ploy
er R
espo
nsib
ilitie
sK
now
ledg
e of
Com
pany
Qua
lity
Ass
uran
ce A
ctiv
ities
Prac
tice
Qua
lity-
Con
scio
usne
ss in
Per
form
ance
of
the
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
Dic
ctor
DR
. IO
N B
OT
SFO
RD
Ass
istir
t Oka
da
JOE
PE
NIC
Kho
ject
Coo
reitw
or
TE
RR
Y S
AW
MA
Res
earc
h C
oard
into
r
WA
LL
AC
E P
EL
TO
NC
oard
into
r
RO
SE M
AR
Y T
IMM
ON
SSa
ricr
Ste
rol:A
unt:i
ce!)
Furn
ishe
d B
y:
GR
EG
LA
SKY
Mod
ena
Nbrr 13
3
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
s
Safe
ty C
onsc
ient
ious
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
Mac
hini
st's
Too
ls (
e.g.
, cal
iper
s. d
ial i
ndic
ator
s.m
agne
tic to
ol h
olde
rs, e
tc.)
Mea
suri
ng T
ools
Pow
er T
ools
Met
al L
athe
with
Atta
chm
ents
Dri
ll Pr
esse
sV
ertic
al M
ill w
ith A
ttach
men
tsPo
wer
Saw
sPo
wer
Dri
llsH
ydra
ulic
/Arb
or P
ress
Hea
t Tre
atm
ent E
quip
men
t
Har
dnes
s T
estin
g E
quip
men
tG
rind
ing
Mac
hine
s w
ith A
ttach
men
tsC
NC
Mac
hini
ng C
ente
r an
d T
urni
ng C
ente
rG
ear
Prod
ucin
g M
achi
nes
with
Atta
chm
ents
Alig
rune
nt/C
alib
mtio
n T
ools
Coo
lant
Rec
over
y E
quip
men
tC
ompu
ter
Ven
tilat
ion
Equ
ipm
ent
Fork
lift
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
Stat
istic
al P
roce
ss C
ontr
olT
rain
ing
to O
pera
te N
ew A
dvan
ced
Equ
ipm
ent
Adv
ance
d C
ompu
ter
App
licat
ions
Rob
otim
Env
iron
men
tal C
once
rns
Fast
s. 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
EM
achi
nist
BE
ST
CO
PY
AV
AIL
AB
LE
Con
duct
ed B
yM
.A.S
.T.
Mac
hine
Too
l Adv
ance
d Sk
ills
Tec
hnol
ogy
Prog
ram
and
Con
sort
ia P
artn
ers
(V.1
99J4
0008
)
Tep
nitisSA
aWL
oneg
eW
aco
C R
YS
LER
UN
EN
GI E
134
MA
CH
INIS
T...
. pla
n, la
yout
, set
up,
and
ope
rate
han
d an
d m
achi
ne to
ols
to p
erfo
rm m
achi
ning
oper
atio
ns n
eces
sary
to p
rodu
ce a
wor
kple
ce to
ref
eren
ced
engi
neer
ing
stan
dard
s.
4D
utie
s
B F
Inte
rpre
tE
ngin
eerl
ag D
raw
-in
gs a
nd C
ontr
olD
ocum
ents
Rec
ogni
seD
IPM
anuf
actu
ring
Mat
eria
ls a
ndPr
oces
ses
Perf
orm
Adv
ance
d
GM
achi
ning
Proc
esse
s
I
136
onm
scan
oro
snor
nion
s
Perf
orm
Gea
rC
uttin
gO
pera
tion
Tas
ksA
-I F
ollo
wsa
fety
man
uals
,an
d al
l saf
ety
regu
latio
ns/
requ
irem
ents
A-2
Use
pro
tec-
tive
equi
pmen
tA
-3 F
ollo
w s
afe
oper
atin
gpr
oced
ure.
for
hand
and
mac
hine
tool
s
A-4
Mai
ntai
ncl
ean
and
safe
wor
k en
viro
n-m
eat
B-I
Per
form
bale
ari
thm
etic
func
tions
B-2
Int
erco
nver
tfr
actio
ns/
deci
mal
s
13-3
htte
rcon
vert
Met
ric/
Eng
lish
mea
sure
men
ts
13-4
Per
form
basi
ctr
igon
omet
ric
fini
ctio
ns
B-3
Cal
cula
tesp
eeds
and
fee
dsfo
r m
achi
ning
B-6
Loc
ate
mac
hini
ng p
oint
sfr
om a
dat
umpo
int
B-7
Per
form
calc
ulat
ions
for
sine
bar
and
sin
epl
ate
B-8
Cal
cula
tefo
r di
rect
,si
mpl
e, a
ndan
gula
r in
dexi
ng
13-9
Per
form
calc
ulat
ions
nece
ssar
y fo
rtu
rnin
g ta
pers
8-10
Sol
ve f
orlit
tle 'h
"
C-I
Rev
iew
blue
prin
t not
esan
d di
men
sion
s
C-2
Ide
ntity
basi
c la
yout
of
draw
ings
C-3
Ide
ntif
yba
sic
type
s of
draw
ings
C-4
Lid
the
purp
ose
of e
ach
type
of
draw
ing
C-5
Ver
ify
draw
ing
elem
ents
C-6
Pra
ctic
egr
oMet
ric
&m
en'
sion
ing
and
tole
ranc
ing
03D
AT
) m
etho
dol
ogy
C-7
Des
crib
e th
ere
latio
nshi
p of
engi
neer
ing
draw
ings
todr
awin
gs
C-8
Use
stan
dard
s to
veri
fy r
equi
re-
mea
t,
C-9
Ana
lyze
bill
of m
ater
ials
(BO
M)
C-I
0 U
nder
-st
and
and
use
qual
ity s
yste
ms
13-1
Ide
ntif
ym
ater
ial,
with
desi
red
prop
ertie
s
D-2
Des
crib
eth
e he
at tr
eatin
gpr
oces
s
D-3
Per
form
heat
trea
ting
oper
atio
ns
15-4
Tar
t met
alsa
mpl
es f
orha
rdne
ss
D-5
Ide
ntif
yty
pes
of p
last
icm
ater
ials
and
proc
esse
s.
E-I
Ide
ntif
yty
pes
of m
easu
re-
men
ts
E-2
Sel
ect
prop
erm
easu
rem
ent
tool
s
E-3
App
ly p
rope
rm
eal r
ing
tech
niqu
es
E-4
Use
Met
ric
and
Eng
lish
stan
dard
s of
mea
sure
men
t
E-5
Per
form
mea
sure
men
tsw
ith h
and
held
inst
rum
ents
E-6
Per
form
mea
sure
men
ts o
nsu
rfac
e pl
ate
E-7
Per
form
insp
ectio
ns u
sing
stat
iona
ryeq
uipm
ent
F-1
Prep
are
and
plan
for
mac
hini
ngop
erat
ions
F-2
Use
pro
per
hand
tool
sF-
3 O
pera
tepo
wer
WM
F-4
Ope
rate
dri
llpr
esse
sF-
3 O
pera
teve
rtic
al m
illin
gm
achi
nes
F-6
Ope
rate
hori
zont
alm
illin
g m
achi
nes
F-7
Ope
rate
met
al c
uttin
gla
thes
F-8
Ope
rate
grin
ding
/abr
asiv
em
achi
nes
F-9
Ope
rate
jig
bori
ng m
achi
nes
F-10
Ope
rate
debu
rrin
geq
uipm
ent
0-1
Prep
are
and
plan
for
CN
Cm
achi
ning
oper
atio
ns
0-2
Sele
ct a
ndus
e C
NC
tool
ing
ryst
erns
0-3
Prog
ram
CN
C m
achi
nes
0-4
Ope
rate
CN
C m
achi
ning
cent
ers
(mill
s)
0-5
Ope
rate
CN
C tu
rnin
gce
nter
s (b
athe
s)
0-6
Ope
rate
elec
tric
aldi
scha
rge
mac
hine
s
H-I
Des
crib
eth
e di
ffer
ent
type
s of
gea
rs
H-2
Und
erst
and
gear
term
sH
-3 U
se r
otar
yta
bles
and
divi
ding
hea
ds
H-4
Dis
cuss
gea
rin
spec
tion
and
mea
sure
men
t
H-3
Mac
hine
asp
ur g
ear
I-I
Wel
d w
ithSh
ield
ed M
etal
Arc
Wel
ding
(SM
AW
) pr
oces
s
1-2
Wel
d/cu
tw
ith o
xyac
ety-
lens
1-3
Wel
d w
ithO
ss T
ungs
ten
Arc
Wel
ding
(OT
AW
)(H
elia
rc)
I-4
Wel
d w
ithO
as M
etal
Arc
Wel
ding
(OM
AW
Y(M
it)&
Fla
x C
ore
Arc
Wel
ding
(FC
AW
)
s.
136
SKIL
LS
AN
D K
NO
WL
ED
GE
Com
nam
icat
ice
Skill
sU
se M
easu
rem
ent T
ools
Use
Ins
pect
ion
Dev
ice.
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
sTro
cedu
res
Mec
hani
cal A
ptitu
deA
bilit
y to
Com
preh
end
Wri
tten/
Ver
bal I
nane
:nom
Kno
wle
dge
of C
uttin
g Fl
uida
/Lub
rica
nts
Bas
ic K
now
ledg
e of
Fas
tene
rsA
bilit
y to
Wor
k as
Par
t of
a T
eam
Con
vers
e 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
oyea
/Ern
ploy
er R
espo
nsth
ilitie
sK
now
ledg
e of
Com
pany
Qua
lity
Ass
uran
ce A
ctiv
ities
Prac
tice
Qua
lity-
Con
scio
usne
ss in
Per
forn
aace
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
GH
RO
GE
RS
Dan
n(
DR
JO
N B
OO
RD
JOE
PE
NIC
KM
en C
ordi
nolo
r
TE
RR
Y S
AW
MA
Mor
el C
oord
inat
or
WA
LL
AC
E F
EL
TO
NSt
e C
eert
eato
r
RO
SE M
AR
Y T
IMM
ON
Ssa
kese
crea
ryau
dalc
ia
Fund
slss
el B
y:
JER
RY
CR
AW
FOR
DM
adan
Moa
n
RIC
HA
RD
GR
IFFI
NM
arot
entr
ie4
Wag
er
KA
YL
E R
OW
LE
EA
tedi
ront
eiai
loaS
hcp
Sum
ner
Ted
tntie
geVWCn
137
TR
AIT
S A
ND
AT
TIT
UD
ES
Stro
ng W
ork
Eth
icIn
terp
erso
nal S
kills
Punc
tual
ityD
epen
dabi
lity
Hon
esty
Nea
tnes
sSa
fety
Con
seic
etio
tsM
otiv
atio
nR
espo
nsib
lePh
ysic
al A
bilit
yPr
ofes
sion
al
Tru
stw
orth
yC
usto
mer
Rel
atio
nsPe
rson
al E
thic
s
TO
OL
S A
ND
EQ
UIP
ME
NT
Mac
hini
sts
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
ries
Hea
t Tre
atm
ent E
quip
men
t
Har
dnes
s T
estin
g E
quip
men
tG
rind
ing
Mac
hine
s w
ith A
ttach
men
tsW
eldi
ng E
quip
men
t (SM
AW
, OM
AW
. FC
AW
)C
NC
Mac
hini
ng C
ente
r en
d T
urni
ng C
ente
rG
ear
Prod
ucin
g M
achi
nes
with
Atta
chm
ents
Alig
nmen
t/Cal
ibra
tion
Too
l,C
oola
nt R
ecov
ery
Equ
ipm
ent
Com
pute
rV
entil
atio
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
Stat
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
s13
nvir
omne
ntal
Con
cern
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
ng
CO
MPE
TE
NC
Y P
RO
FIL
EM
achi
nist
Con
duct
ed B
yM
.A.S
.T.
Mac
hine
Too
l Adv
ance
d S
kills
Tec
hnol
ogy
Pro
gram
and
Con
sort
ia P
artn
ers
(V.1
99J4
0008
)
lecZ
nale
gev.
tico
40.,
CH
RY
SLE
RT
EC
H O
LOG
IES
AIR
BO
RN
E S
YS
TE
MS
, IN
C.
133
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.
4T
asks
Dut
ies
Inte
rpre
tE
ngin
eerin
g D
raw
-in
gs a
nd C
entr
alD
ocum
ent
Per
form
Con
vead
omal
FM
achi
ning rim
s
Per
form
Adv
ance
d
GM
erid
ians
Pro
cess
es
I
CT
ASI
AC
HIS
13
WSD
01/4
711,
1
A-I
Fol
low
mfe
ty m
anua
ls,
and
all m
fety
regu
letio
ns/
requ
irem
ents
flizz
Com
. Aril
A-2
Um
pro
les-
five
equi
pmen
tA
-3 F
ollo
w s
afe
oper
atin
gpr
oced
ures
fix
hand
and
=ch
ins
tool
s
A-4
Mai
ntai
ncl
ean
and
safe
wor
k go
yim
-m
eat
B-I
Per
form
basi
c ar
ithm
etic
Run
times
13-2
Inta
ccav
ert
auct
ions
/de
cim
al.
13-3
tide
:con
vert
Met
ric/E
nglid
tm
easu
rem
ent
8-4
Per
form
Laic
trig
onom
etric
lb:id
iom
B-5
Cat
calls
spee
ds a
nd fe
eds
for
=di
ning
8-6
Loca
tem
achi
ning
poi
nts
ftom
datu
m
Poi
nt
B-7
Per
form
raku
latio
ns fo
rsi
ne te
r an
d si
ne
plat
e
8-8
Cal
cula
tefo
r di
rect
sim
ple,
and
angu
lar
inde
8-9
Per
form
cala
datio
nsne
cess
ary
foe
turn
ing
tape
rs
B-I
0 S
olve
for
little
"h"
C-I
Rev
iew
blue
prin
t not
esan
d di
men
sion
s
C-2
Iden
tity
belie
layo
ut o
fdr
awin
gs
C-3
Idea
l*ba
sic
type
s of
draw
ings
C-4
Lis
t the
purp
ose
of e
ach
type
of d
raw
ing
C-5
Ver
itydr
awin
gel
emen
ts
C-6
Pra
ctic
eP
onte
tlio
anon
-sk
imps
sad
mm
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
chas
sis a
nd b
odyw
ork
Tas
ksA
-1 D
emon
-m
aw u
nder
.st
andi
ng o
fsa
fety
rul
es
A-2
Ass
ume
pers
onal
saf
ety
stan
dard
s fo
rse
lf a
nd o
ther
s
A-3
Sup
port
all p
ract
ice.
and
use
of p
rote
ctiv
eeq
uipm
ent
A-4
Dan
n-'tr
ite a
n un
der-
awai
t of
prop
er b
uwdo
usm
ater
ial h
urdl
ing
A-5
Kno
w f
irst
aid
and
CPR
A-6
Fol
low
safe
ty m
anua
l,an
d al
l saf
ety
regu
latio
ns/
requ
irem
ents
A-7
Use
pro
les-
five
equ
ipm
ent
A-8
Fol
low
safe
ope
ratin
gpr
oced
ures
for
hand
and
mac
hine
tool
s
A-9
Mai
ntai
n a
clam
and
saf
ew
ork
envi
ronm
ent
B-I
App
lypr
inci
ples
and
tool
s of
con
tain
-ou
s qu
ality
impr
ovem
ent
B-2
Und
erst
and
the
impo
rtan
ceof
qua
lity
in th
em
amfa
ctur
ing
proc
esse
s
B-3
Im
plem
ent
conc
epts
of
qual
ity in
the
wor
kpla
ce
B-4
Fol
low
the
Qua
lity
Plan
and
reco
mm
end
ion-
prov
erne
nts
inw
ork
met
hods
or
tool
ing
B-5
Est
ablis
hm
etho
d', p
lans
and
proc
edur
es to
mai
ntai
n qu
ality
C-1
Be
prom
ptan
d on
the
job
in a
owed
ance
with
wor
ksc
hedu
le
C-2
Wne
hone
st w
ork
ethi
cs e
ndre
spon
sibi
lity
inth
e w
orkp
lace
C-3
Dem
on-
stat
e hi
ghm
oral
val
ues
C-4
Dis
play
ane
at a
nd c
lam
wor
kpla
ce
C-5
Pra
ctic
eca
refu
l use
and
mai
nten
ance
of
tool
s an
deq
uipm
ent
C-6
Be
com
mit-
ted
to e
xcel
lenc
ean
d qu
ality
C-7
Pre
sent
ago
od c
ompa
nyim
age
in a
ttire
end
attit
ude
C-8
Sup
port
apo
sitiv
e w
ork
envi
ronm
ent
C-9
Pra
ctic
e a
posi
tive
attit
ude
D-1
Be
anac
tive
liste
ner
D-2
Dem
on-
skat
ego
odre
adin
g,co
mpr
ehen
sion
,an
d w
ritin
g sk
ills
13-3
Dem
on-
stra
ta a
bilit
y to
prep
are
scam
-m
eada
troa
for
cont
inua
l:"im
mur
emen
t
D-4
Sum
mar
ize
and
prio
ritiz
ew
ork
resp
onsi
bilit
ies
,
D-5
Exp
ress
idea
s cl
earl
yD
-6 D
emon
-st
rata
abi
lity
togi
ve a
nd f
ollo
win
tera
ctio
ns
13-7
Acc
ept
cons
truc
tive
athe
ism
D-8
Dem
on-
stra
ta a
bilit
y to
com
mun
icat
ew
ith c
o-w
orke
rean
d m
anag
emen
t
E1
Und
erst
and
the
role
s of
co-w
orke
rs
E-2
Res
pect
peer
rel
atio
n-sh
ips
E-3
Sha
rere
sour
ces
toac
com
plis
hne
cess
ary
task
s
E-4
Fac
ilita
teth
ew
ork
ethi
cby
com
plet
ing
task
s on
tim
ean
d ac
cura
tely
E-5
Be
invo
lved
in p
robl
emso
lvin
g
E-6
App
lycr
eativ
e th
inki
ngE
-7 S
uppo
rt a
posi
tive
attit
ude
E-8
Enc
oura
gego
od f
eelin
gsan
d na
rele
E-9
Und
erst
and
the
pupa
e en
dgo
als
of th
eor
gani
zatio
n
E-1
0 Pl
an a
ndor
gani
ze w
ork
as a
team
E-1
1 B
e w
illin
gto
lead
in a
reas
of k
now
ledg
ean
d ex
pert
ise
E-1
2 D
emon
-st
rata
will
ing-
nee"
to le
arn
new
met
hods
and
"kill
s
E-l
3 D
emon
-st
rata
goo
dpe
rson
alre
talia
te s
kills
F-1
Exh
ibit
unde
rsta
ndin
gof
bas
ic w
ith-
met
ic [
mot
ions
F-2
Exh
ibit
unde
rsta
ndin
gof
con
vert
ing
Ruc
tions
and
deci
mal
s
F-3
Dem
on-
skat
e pr
actic
alm
athe
mat
ic*
inth
e m
e of
ure
a-oa
rsm
an to
ols
F4 I
nter
-co
nver
t Met
ric/
Eng
lish
mea
sure
-m
ew
F-5
Perf
orm
Prac
tical
mat
h-en
uttic
alw
hoa-
dons
rel
evan
t to
area
of
wor
k
F-6
Use
app
lied
Kai
aks.
FPO
&an
d da
rts
Paw
ns o
fm
al7d
i and
prob
lem
- s
olvi
ng0-
1 R
evie
wbl
uepr
int n
otes
and
dim
ensi
ons
0-2
Iden
tity
basi
c la
yout
of
draw
ing"
0-3
Iden
tity
basi
c ty
pes
ofdr
awin
gs
0-4
Lis
t the
purp
ose
of e
ach
type
of
draw
ing
0-5
Ver
ify
draw
ing
elem
ents
0-6
Prac
tice
Geo
met
ric
Dim
ensi
onin
&an
d "D
ilem
ma
(OD
&T
)M
etho
dolo
gy
0-7
Rea
d/In
terp
ret p
rint
she
m d
iffe
rent
Tra
de,il
ocee
pe.
lions
H-1
Ide
ntif
yty
pes
ofm
easu
rem
ent
H-2
Sel
ect
prop
erm
easu
rem
ent
ne&
H-3
App
lypr
oper
man
urin
gte
chni
ques
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
ent,
H-6
Ver
ily th
atto
ol c
alib
ratio
nfe
lls w
ithin
ca-
bast
ion
sche
dule
I-1
Use
arb
oran
d sh
oppr
esse
s
1-2
Sele
ctne
cess
ary
wor
k-ho
ldin
g de
vice
.an
d ha
nd to
ols
as n
eede
d
1-3
Sele
ct a
ndus
e ha
nd f
iles
1-4
Iden
tify
and
use
hand
ream
er.
1-6
Follo
wta
ppin
gpr
oced
ures
topr
oduc
ein
tern
al th
read
s.
1-7
Use
thre
ad-
cutti
ng d
ies
topr
oduc
e ex
tern
alth
read
s
1.8
Ope
rate
benc
h an
dpe
dest
algr
inde
rs s
afel
y
1.9
Inst
all
helic
al,
1-10
Use
impa
ctw
renc
hes
I-1
I U
seto
rque
wre
nche
s
1-12
Use
gask
et c
utte
rsI-
13 I
dent
ify
& u
se c
orre
ctco
rros
ion
cont
rol
proc
edur
es a
ndm
ater
ials
1 -I
Lat
heO
pera
tions
1-2
Mill
ing
Mac
hine
Ope
ratio
ns
1-3
Dri
ll Pr
ess
1-4
Punc
hPr
ess,
She
ar.
& B
rake
s
1-5
Rou
tine/
Dai
ly M
aint
e-m
ince
Act
iviti
es
BE
ST C
OPY
AV
AIL
AB
LE
Dut
ies
1011
1.7A
N P
IO
AST
1011
0.13
111
K
FAB
RIC
AT
ION
OPE
RA
TO
R..c
ontin
ued
Tas
ksK
-1 D
isci
.), a
gene
ral u
nder
-'M
ang
ofem
erge
ncy
edge
'ste
rmin
olog
y
K-2
Und
o:at
:end
the
func
tions
of
equi
poor
nent
bein
g as
sem
bled
K-3
Und
erst
and
how
com
pone
nts
rela
te a
sto
tal
syst
em
L-1
Dem
on-
L-2
Dem
on-
L.-
3 A
bilit
y to
1.-4
Dis
play
abi
l-L
-5 P
rese
nt a
L-6
App
lyst
ate
abili
ty to
skat
e ab
ility
tow
ork
from
var
ious
ity to
wor
khi
stor
y of
wel
lnes
slif
t 30
poun
dsto
lera
te h
eigh
taPo
sitio
ns T
abin
hot
/col
ddo
cum
ente
din
form
atio
nup
to 1
00 f
eet
stan
ding
on
Con
-en
viro
nmen
t for
regu
lar
atte
n-to
life
styl
e to
met
e fo
r ad
eade
dpe
riod
s84
0 ho
ueda
nce
at w
ork
mai
ntai
n he
alth
BE
ST
CO
PY
AV
AIL
AB
LE
1.50
SKIL
LS
AN
D K
NO
WL
ED
GE
TR
AIT
S A
ND
AT
TIT
UD
ES
Com
num
iaai
on S
kills
Stro
ng W
ork
Eth
icU
se M
easu
rem
ent T
ools
Inte
rper
sona
l Ski
llsU
se I
nspe
ctio
n D
evic
esPu
nctu
ality
Mat
hem
atic
al S
kills
Dep
enda
bilit
yR
eedi
ng/W
ritin
g Sk
ills
Hon
esty
Kno
wle
dge
of S
afet
y R
egul
atio
nsN
eatn
ess
Prac
tice
Safe
ty in
the
Wor
kpla
ceSa
fety
Aw
aren
ess
Org
anim
tiona
l Ski
llsM
otiv
atio
nM
echa
nica
l Apt
itude
Res
pons
ible
Abi
lity
to C
ompr
ehen
d W
ritte
n/V
erba
l Ins
truc
tions
Phys
ical
Abi
lity
Bas
ic K
now
ledg
e of
Fas
tene
rsPr
ofes
sion
alA
bilit
y to
Wor
k as
Par
t of
a T
eam
Tru
stw
orth
yC
onve
rse
in th
e T
echn
ical
lang
uage
of
the
Tra
deC
usto
mer
Rel
atio
nsK
now
ledg
e of
Occ
upat
iona
l Opp
ortu
nitie
sPe
rson
al E
thic
sK
now
ledg
e of
Em
ploy
aam
ploy
er R
espo
nsib
ilitie
sK
now
ledg
e of
Com
pany
Qua
lity
Impr
ovem
ent A
ctiv
ities
Prac
tice
Qua
lity-
Con
scio
usne
ss in
Per
form
ance
of
the
Job
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
Dea
nfre
ettil
et1
Edu
catio
n
MIK
E F
OX
Dir
ecto
r/In
dust
ry S
ervi
ces
LA
RR
YM
YFO
RD
Coo
rdau
tor/
Man
ufac
tiain
g T
echn
olog
y
KE
N D
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/Man
ufac
turi
ngR
OD
NIE
MA
NN
, Pla
nt M
anag
er/B
ody
Plan
tR
ON
ST
EPH
EN
S, H
uman
Res
ourc
es M
anag
erE
LA
INE
SW
IOA
RT
, Hum
an R
esou
rces
Sup
ervi
sor
DO
NN
A T
AC
ICE
TT
, Hea
lth 8
c Sa
fety
Sup
ervi
sor
A. S
MIT
H, P
lam
Man
ager
/Aer
ial P
lant
It L
HE
UR
EU
X, S
uper
viso
r
151
TO
OL
S A
ND
EQ
UIP
ME
NT
Mac
hine
Too
ls (
man
ual &
CN
C):
Lat
hes
Mill
ing
Mac
hine
sD
rill
Pres
sSu
rfac
e G
rind
erC
ut-o
ff S
awG
rind
ers
Tap
ping
Hea
dB
orin
g H
ead
Han
d T
ools
:H
acks
aws
Han
d T
appi
ngFi
les
Gri
nder
sA
rbor
Pre
ss (
Hyd
raul
ic o
r m
anua
l)
FUT
UR
E T
RE
ND
S A
ND
CO
NC
ER
NS
CN
C M
achi
nes
- Se
tup
and
Ope
ratio
nM
ulti-
axis
pro
gram
min
g/m
achi
ning
BE
ST
CO
PY
AV
AIL
AB
LE
CO
MPE
TE
NC
Y P
RO
FIL
E
Mac
hini
st
Prep
ared
by
Cen
tral
Flo
rida
Com
mun
ity C
olle
ge
and
Em
erge
ncy
One
, Inc
.
Dec
embe
r 19
95
152
Dut
ies
10/1
EM
AC
Pan
ILL
STR
I710
.ta
Dem
onst
rate
Com
mun
icat
ion
Skill
s
App
lyM
athe
mat
ical
Con
cept
Eng
inee
ring
Dra
win
gsan
d C
ontr
olD
ocum
ents
MA
CH
INIS
T...
plan
, lay
out,
setu
p, a
nd o
pera
te h
and
and
mac
hine
tool
s to
per
form
mac
hini
ng o
pera
tions
nece
ssar
y to
pro
duce
a w
orkp
iece
to r
efer
ence
den
gine
erin
g st
anda
rds.
Tas
ksA
-I D
emon
-nu
b) u
nder
-st
andi
ng o
fsa
fety
rul
es
A-2
Ass
ume
pers
onal
saf
ety
stan
dard
s fo
rse
lf a
nd o
ther
'
A-3
Sup
port
all p
ract
ices
and
use
of p
rote
ctiv
eeq
uipm
ent
A-4
Dem
on-
stra
ta e
n un
der-
stun
ting
ofpr
oper
haz
ard-
mu
mat
erie
lhe
adlin
e
A-5
Kno
w tu
tai
d en
d C
PRA
-6 F
ollo
wsa
fety
man
uals
and
all s
afet
yre
gula
tions
end
requ
irem
ents
A-7
Use
pro
tec-
tive
equi
pmen
tA
-8 F
ollo
w s
afe
oper
atin
gpr
oced
ures
for
hand
end
mac
hine
tool
s
A-9
Mai
ntai
n a
clea
ns:4
saf
ew
ork
envi
ron-
mee
t
B-1
App
lypr
inci
ples
and
tool
s of
=U
m-
cut q
ualit
yim
prov
emen
t
B-2
Unc
le/s
teel
the
impo
rtan
ceof
qua
lity
in th
em
anuf
acha
ing
proc
ess
B-3
Im
plem
ent
conc
ept.
ofqu
ality
in th
ew
orkp
lace
B-4
Fol
low
the
Qua
lity
Plan
and
reco
mm
ende
dim
pove
men
ts in
wor
k m
etho
dsor
Mol
ine
B-5
Est
ablis
hm
etho
ds, p
lans
,an
d pr
oced
ures
to m
aint
ain
qual
ity
C-I
Be
prom
ptan
d on
the
job
in a
ccor
danc
ew
ith w
ork
sche
dule
C-2
Val
ueho
nest
wor
ket
hics
and
resp
onsi
bilit
y in
the
wor
kpla
ce
C-3
Dem
on-
Mut
e hi
ghm
oral
val
ues
C-4
Dis
play
ane
at a
nd c
lean
wor
kpla
ce
C-5
Pra
ctic
eca
refa
lues
and
mai
:am
mo,
of
tool
s en
d eq
uip-
mar
t
C-6
Be
com
mit-
ted
to e
xcel
lenc
ean
d qu
ality
C-7
Pre
sent
ago
od c
ompa
nyim
age
in a
ttire
end
attit
ude
C-8
Sup
port
posi
tive
win
ken
viro
nmen
t
C-9
Pra
ctic
epo
sitiv
e at
titud
e
D-I
Be
anac
tive
liste
ner
D-2
Dem
on-
Ann
e go
odre
adin
g,co
mpr
ehen
sion
,an
d w
ritin
gsk
ills
D-3
Sum
mar
ize
and
prio
ritiz
ew
ork
resp
onse
.ta
ta
D-4
Exp
ress
idea
s cl
earl
yD
-5 D
emon
-st
rata
abi
lity
togi
ve a
nd f
ollo
win
druc
tions
D4
Acc
ept
cons
truc
tive
criti
cism
E4
Und
ers
tand
the
role
s of
co-w
orke
rs
E-2
Res
pect
peer
tele
text
-sh
ips
E-3
Sha
rere
sour
ces
toac
com
plis
hne
cess
ity ta
sks
E4
Faci
litat
eth
e w
ork
ethi
cby
com
plet
ing
teas
on
time
and
accu
rate
ly-
E4
Be
invo
lved
with
pro
blem
solv
ing
E-6
App
lycr
eativ
e th
inki
ngE
-7 S
uppo
rtpo
sitiv
e at
titud
eE
-8 E
ncou
age
good
&di
ms
and
mor
ale
E-9
Und
er-
stan
d pu
rpos
ean
d go
al, o
f th
eor
gani
zatio
n
E-1
0 Pl
an a
ndor
geni
re w
ork
m a
team
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
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
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ool A
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Skill
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echn
olog
y Pr
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man
dC
onso
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tner
s(V
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J400
08)
t
BE
ST
CO
PY
AV
AIL
AB
LE
166
iI
II
0.
II
4.4
II ,II
iti
11I
II
.-
.
III
I-
1r;
.
1
SKIL
LS
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D K
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se M
easu
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Mas
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Mac
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an
Pm_
idtn
age
169
TR
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S A
ND
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UD
ES
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ork
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kills
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rson
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thic
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S A
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hini
st's
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ls (
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ools
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athe
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ger,
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Y P
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nist
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Mac
hine
Too
l Adv
ance
d Sk
ills
Tec
hnol
ogy
Prog
ram
and
Con
sort
ia P
artn
ers
(V.1
99J4
0008
)
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dia
Nat
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ollo
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feed
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r m
achi
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sfr
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form
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for
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bar
end
sin
e
plat
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dan
gula
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form
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no:te
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tape
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olve
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blue
prin
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men
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basi
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t the
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etod
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neer
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draw
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seet
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to
veril
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-m
ints
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lyze
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ater
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(BO
M)
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nder
-st
and
and
use
qual
ity s
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ms
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tify
mat
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ithde
sire
d
prop
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s
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proc
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form
heat
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ting
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atio
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t met
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type
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D-7
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proc
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vibr
atio
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tc)
-
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type
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mea
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-m
ents
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prop
erm
easu
rem
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tool
s
E-3
App
ly p
rope
rm
easu
ring
tech
niqu
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E-4
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rican
d E
nglis
hst
anda
rds
ofm
easu
rem
ent
E-5
Per
form
mea
sure
men
tsw
ith h
and
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inst
rum
ents
E-6
Per
form
mea
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men
ts o
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ate
E-7
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form
insp
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stat
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.
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Pre
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plan
for
mac
hini
ngop
erat
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F-2
Use
pro
per
hand
tool
sF
-3 O
pera
tepo
wer
saw
sF
-4 O
pera
te d
ull
pres
ses
F-5
Ope
rate
vert
ical
mill
ing
mac
hine
s
F-6
Ope
rate
horiz
onta
lm
illin
g m
achi
nes
F-7
Ope
rate
met
al c
uttin
gla
thes
F-8
Ope
rate
grin
ding
/abr
asiv
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F-9
Ope
rate
jig
borin
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achi
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F-I
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AV
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AB
LE
APPENDIX B - PILOT PROGRAM NARRATIVE
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
Home Address City/State ZIP
Graduation Year Parent/Guardian Phone
Name Age Home Phone
Home Address City/State ZIP
Graduation Year Parent/Guardian Phone
Name Age Home Phone
Home Address City/State ZIP _
Graduation Year Parent/Guardian Phone
From:
Teacher /Counselor Name
Position:
School School Phone Number
185
Machine Tool Advanced SkillsTechnology Program (MAST)
3801 Campus Dr. Waco, Texas 76705817/867-3526 FAX: 817/867-3221
Texas StateTechnical College
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
Machine Tool Advanced SkillsTechnology Program (MAST)
3801 Campus Dr. Waco, Texas 76705817/867-3526 FAX: 817/867-3221 Texas State
Technical CollegeWaco
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
Machine Tool Advanced SkillsTechnology Program (MAST)
3801 Campus Dr. Waco, Texas 76705817/867-3526 FAX: 817/867-3221
Texas StateTechnical College
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
Machine Tool Advanced SkillsTechnology Program (MAST)
3801 Campus Dr. Waco, Texas 76705817/867-3526 FAX: 817/867-3221
7-7Texas State
Technical CollegeWaco
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
Machine Tool Advanced SkillsTechnology Program (MAST)
3801 Campus Dr. Waco, Texas 76705817/867-3526 FAX: 817/867-3221
Texas StateTechnical College
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
Machine Tool Advanced SkillsTechnology Program (MAST)
3801 Campus Dr. Waco, Texas 76705817/867-4849 FAX: 817/867-3380
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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