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Penn Foster’s Machinist Apprenticeship program
Course PF Course Course Title Number Price Duration
Year 1:
Trades Safety: Getting Started 186104 $75.00 5 hours
Working Safely with Chemicals 186105 $75.00 5 hours
Fire Safety 186106 $75.00 5 hours
Material Handling Safety 186109 $75.00 5 hours
Linear and Distance Measurement 186125 $75.00 5 hours
Basic Industrial Math Block X31 $450.00 30 hours
Addition and Subtraction 186303 ($75.00) (5 hours)
Multiplication and Division 186304 ($75.00) (5 hours)
Fractions, Percents, Proportions, and Angles 186305 ($75.00) (5 hours)
Metric System 186306 ($75.00) (5 hours)
Formulas 186307 ($75.00) (5 hours)
Introduction to Algebra 186308 ($75.00) (5 hours)
Applied Geometry 186085 $75.00 6 hours
Practical Trigonometry 186086 $75.00 6 hours
Introduction to Print Reading 186325 $75.00 8 hours
Abbreviations & Symbols 186326 $75.00 8 hours
Dimensions & Tolerancing 186327 $75.00 8 hours
Reading Shop Prints, Parts 1 & 2 386043, 386044 $150.00 20 hours
Geometric Dimensioning/Tolerancing STP194 $175.00 20 hours Bench Work 5004A-C $225.00 30 hours Precision Measuring Instruments, Part 1 186188 $75.00 10 hours
Precision Measuring Instruments, Part 2 186189 $75.00 10 hours
Precision Measuring Instruments, Part 3 186190 $75.00 10 hours
Jobs, Companies, and the Economy: Basic Concepts
for Employees 186191 $75.00 5 hours
Quality Concepts: Tools and Applications 186036 $75.00 5 hours
Metal Processing 186087 $75.00 3 hours
Ferrous Metals 186088 $75.00 3 hours
Nonferrous Metals 186089 $75.00 3 hours
Identification of Metals 186090 $75.00 3 hours
Layout 3501 $75.00 10 hours
Year 2:
Basic Machining Skills Block X08 $1,050.00 56 hours
Practical Shop Math, Part 1 X0801 ($75.00) (4 hours)
Practical Shop Math, Part 2 X0802 ($75.00) (4 hours)
Practical Shop Measurement X0803 ($75.00) (4 hours)
Safe Shop Practices X0804 ($75.00) (4 hours)
Properties and Classifications of Metals X0805 ($75.00) (4 hours)
Progress Examination X0821 ($0.00) (0 hour)
Using Shop Drawings, Process, and Routing
Sheets, Part 1 X0806 ($75.00) (4 hours)
Using Shop Drawings, Process, and Routing
Sheets, Part 2 X0807 ($75.00) (4 hours)
Layout X0808 ($75.00) (4 hours)
Progress Examination X0822 ($0.00) (0 hour)
Metal Cutting and Machine Tooling, Part 1 X0809 ($75.00) (4 hours)
Metal Cutting and Machine Tooling, Part 2 X0810 ($75.00) (4 hours)
Metal Cutting Machinery, Part 1 X0811 ($75.00) (4 hours)
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Metal Cutting Machinery, Part 2 X0812 ($75.00) (4 hours)
Fundamentals of Grinding X0813 ($75.00) (4 hours)
CNC Machine Tool Features and Applications X0814 ($75.00) (4 hours)
Progress Examination X0823 ($0.00) (0 hour)
Progress Examination Booklet X0820 ($0.00) (0 hour)
Drilling, Parts 1 & 2 386050, 386051 $150.00 20 hours
Lubrication, Part 1 286091 $75.00 10 hours
Lubrication, Part 2 286092 $75.00 10 hours
Fasteners 286095 $75.00 10 hours
Milling Machine Fundamentals 386031 $75.00 10 hours
Milling Machine Cutting Tools 386032 $75.00 10 hours
Milling Machine Practice and Operation, Part 1 386033 $75.00 10 hours
Milling Machine Practice and Operation, Part 2 386034 $75.00 10 hours
Milling Machine Indexing and Spiral Work 386035 $75.00 10 hours
Lathes, Part 1 386036 $75.00 10 hours
Lathes, Part 2 386037 $75.00 10 hours
Lathes, Part 3 386038 $75.00 10 hours
Lathes, Part 4 386039 $75.00 10 hours
Lathes, Part 5 386040 $75.00 10 hours
Year 3:
Fundamentals of Metal Cutting 386030 $75.00 10 hours
Machine Safety 186110 $75.00 5 hours
Automatic Screw Machines 3530A-B $150.00 20 hours
Turret Lathes 3525A $75.00 10 hours
Turret Lathe Tools and Setups 2213 $75.00 10 hours
Fundamentals of Grinding 386016 $75.00 10 hours
Cylindrical Grinding, Part 1 386010 $75.00 10 hours
Cylindrical Grinding, Part 2 386011 $75.00 10 hours
Surface Grinding, Part 1 386012 $75.00 10 hours
Surface Grinding, Part 2 386013 $75.00 10 hours
Inspection of Shop Products 5962 $75.00 10 hours
Quality Control for the Technician 386E02 $365.00 70 hours
Boring Mills 5636A $75.00 10 hours
Planers 6118 $75.00 10 hours
Year 4:
Broaching 6091 $75.00 10 hours
Shapers, Slotters, and Keyseaters 2222 $75.00 10 hours
Nontraditional Machining Technologies 386029 $75.00 10 hours
Hardening and Tempering 3195 $75.00 10 hours
Tool Grinding 386017 $75.00 10 hours
Tool Dressing 3194 $75.00 10 hours
Gear Calculations 2243 $75.00 10 hours
Gear Making 5532A-B $150.00 20 hours
Manufacturing Processes, Part 1 186075 $75.00 10 hours
Manufacturing Processes, Part 2 186076 $75.00 10 hours
Manufacturing Processes, Part 3 186077 $75.00 10 hours
Manufacturing Processes, Part 4 186078 $75.00 10 hours
CNC Technology & Programming (replaces 066903) 386E06 $350.00 45 hours
Toolholding Systems 386028 $75.00 10 hours
CNC Turning 386041 $75.00 10 hours
CNC Milling 386042 $75.00 10 hours
Optional: Tool & Die Maker Skills
Mechanics of Materials 5282A-C $225.00 30 hours
Heat Treatment 3541A-D $300.00 40 hours
Dies and Die Making 5101A-B $150.00 20 hours
Forging Dies 3199 $75.00 10 hours
Making Forging Dies 3197 $75.00 10 hours
Toolmaking 2540A-C $225.00 30 hours
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Gage Making 5098 $75.00 10 hours
Jigs and Fixtures 5099 $75.00 10 hours
Jig and Fixture Making 5100 $75.00 10 hours
Estimated Total Curriculum Duration (not including Optional courses): 839 hours
Number of Exams (not including Optional courses): 104
***SEE FULL COURSE DESCRIPTIONS BELOW
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186104 Trades Safety: Getting Started
Duration: 5 hours (includes 1 test)
What Students Learn: Preview
A thorough knowledge of safe practices is an important part of
working in any industrial setting. Every industrial worker
should be familiar with accident prevention techniques, fire
safety mehods, and the use of personal protective equipment.
Injuries in the workplace cost many millions of dollars in
medical costs, lost wages, and production losses each year.
Many injuries can be prevented by understanding how
accidents and injuries can occur. This study unit is designed
to help trainees understand why safety is so important, and to
present students with information about safety that goes
beyond common sense.
Objectives
When a student completes this study unit, he and she will be
able to:
• Name the agencies that make and enforce safety
regulations and explain an employee’s responsibilities
under those regulations.
• List the physical hazards associated with chemicals and
describe how to avoid those hazards.
• Name several electrical shock hazards and the
techniques used to prevent shocks.
• List the steps in a lock-out / tag-out procedure.
• Explain the importance of machine guarding and name
several types of machine guards.
• Name the four classes of fire and how to extinguish
each of them.
• Describe the proper technique used to lift a heavy load.
• Explain how to avoid hand injuries when using hand
and power tools.
• List some of the hazards involved in welding and hot
cutting operations and how to prevent them.
• Explain how job analysis and the science of ergonomics
are used to improve the workplace.
• Explain the importance of personal protective
equipment and name several types of PPE.
Contents
Introduction; Safety Regulations; Key safety Issues;
Protecting Yourself and Your Co-workers.
186105 Working Safely with Chemicals
Duration: 5 hours (includes 1 test)
What Students Learn: Preview
This study unit deals with the safe use of chemicals in the
workplace. The two primary causes of chemical accidents are
the misuse of chemicals and the improper disposal of chemical
wastes. Understanding the hazards that chemicals can create
is the first step in protecting people from harm.
The main goal of this study unit is to provide students with
sound, practical knowledge about chemical use and disposal,
both in the workplace and at home. You will learn how to
recognize common chemical hazards and how to deal with
them. Trainees will learn how to perform a job analysis to
look for potential chemical dangers in your daily taks. Finally,
people will learn how to take precautions to avoid chemical
accidents and make all jobs as safe as possible.
Objectives
When a student completes this study unit, he and she will be
able to:
• Recognize the six different ways in which a chemical
can cause physical injury.
• Name the routes or paths of entry by which chemicals
can enter the body.
• Describe the types of injuries caused by chemicals. • Identify potential chemical dangers in your workplace.
• Describe how to identify, store and label hazardous
chemicals.
• List several methods used to prevent chemical
accidents.
• Explain why proper training is important to chemical
handling.
• Describe the types of personal protective equipment
used and worn when handling chemicals.
• Explain the role of governmental agencies in enforcing
chemical regulations.
Contents
Introduction: Living with Chemicals; Chemical Injuries;
Accident Prevention; Handling Hazardous Wastes.
186106 Fire Safety
Duration: 5 hours (includes 1 test)
What Students Learn: Preview
Fires are the most destructive and expensive of all accidents.
However, fires can be effectvely prevented through the
combined use of technology and common sense. By
understanding how fires get started and how to extinguish
them, students will have much of the knowledge needed to
protect people from fire. This study unit will introduce
trainees to the information you need to practice fire safety and
prevention in the workplace.
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Objectives
When a student completes this study unit, he and she will be
able to:
• Describe the types of property losses and injuries
associated with fires.
• Explain how fires are ignited.
• Identify the four classes of fire.
• Describe the primary fire hazards found in the
workplace.
• Explain the various ways in which fires can be
prevented.
• Describe the operation of several different fixed fire
protection systems.
• Identify the proper type of portable fire extinguisher to
use on a fire.
• Describe the operation of several different types of fire
extinguishers.
• Explain how to defend yourself and others in a fire
situation.
• Describe how to safely evacuate a burning building.
Contents
Introduction to Fire; Fire Hazards in the Workplace;
Preventing Fires; Fixed Fire Protection Equipment;
Portable Fire Extinguishers; Fire Protection Techniques.
186109 Material Handling Safety
Duration: 5 hours (includes 1 test)
What Students Learn: Preview
This study unit introduces the safe techniques and work
practices commonly used when handling manufacturing and
industrial materials. Trainees will learn the procedures
necessary to avoid physical injury to yourself and those
working with you, for both manual handling methods and
mechanical handling methods. You will also learn procedures
that minimize damage to the materials being moved and to
facility property. Knowing the proper procedures will also
give you the insight to decide when mechanical handling is
necessary, or preferred, over traditional physical handling.
Objectives
When a student completes this study unit, he and she will be
able to:
• Recognize the hazards associated with handling
materials.
• Know the types of injuries that can be caused by these
hazards.
• Understand how to effectively use safe material
handling practices.
• Know how to avoid physical injury when handling
loads.
• Know and follow the rules for safe operation of
powered industrial material handling equipment.
• Understand and respect the limits and restrictions placed
on powered material handling mechanisms.
Contents
Introduction to Material Handling; Housekeeping and
Storage; Material Handling Equipment; Hoists and
Cranes.
186125 Linear and Distance Measurement
Duration: 5 hours (includes 1 test)
What Students Learn: • Recognize the difference between English and metric
units of length.
• Find the perimeter of rectangular, square, or triangular
areas or objects, such as rooms or machine bases, after
measuring the sides.
• Calculate the circumference of circular objects like
pipes of tanks after measuring the diameter.
• Measure lengths with the aid of rigid and flexible rules,
thickness gauges and screw pitch gauges.
• Read a typical vernier scale and micrometer to take
precise measurements.
Block X31 Basic Industrial Math
Duration: 30 hours (includes 6 tests)
What Students Learn: This module of six study units offers the trainee arithmetic and
basic mathematics, metric measurement, and calculator
fundamentals. The Metric System is an introductory unit
which includes metric conversions. Problem exercises and
examples in this module are presented in on-the-job scenarios
with applications drawn from the industrial context.
Special Notes: This updated course replaces lessons contained within
Practical Math and Measurements, Block X01. Each study
unit contains a progress examination.
Components: Addition and Subtraction (186303)
Multiplication and Division (186304)
Fractions, Percents, Proportions, and Angles (186305)
Metric System (186306)
Formulas (186307)
Introduction to Algebra (186308)
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186303 Addition and Subtraction
Objectives: • Define the terms: whole number, numeral, digit,
decimal, place value, addend, sum, minuend,
subtrahend, and difference.
• Explain the significance of the digit zero in a number.
• Differentiate between concrete and abstract numbers.
• Properly prepare numbers for addition and subtraction.
• Perform addition and subtraction on numbers.
• How to check your answers to both addition and
subtraction problems.
• How to use a calculator to add and subtract numbers.
186304 Multiplication and Division
Objectives: • Define the terms: factor, multiplicand, multiplier, partial
product, dividend, divisor, quotient, and remainder.
• Recognize the various signs used for multiplication and
division.
• Properly prepare numbers for multiplication and
division.
• Perform multiplication and division on whole numbers
and decimals.
• How to check your answers to both multiplication and
division problems.
• How to find the average of a group of numbers.
• How to use a calculator to multiply and divide numbers.
186305 Fractions, Percents, Proportions, and Angles
Objectives: • Define the terms: fraction, proper fraction, improper
fraction, lowest common denominator, percent, ratio,
and proportion.
• How to add, subtract, multiply, and divide fractions and
decimals.
• How to change fractions to decimals and decimals to
fractions.
• Solve problems involving percent.
• How to use a protractor to measure angles.
• Lay out templates for checking angles.
• How to use a calculator to solve percent problems and
to convert fractions to decimals.
186306 Metric System
Objectives: • Name the base units most commonly used in the metric
system.
• Identify metric prefixes and their values.
• Apply conversion factors to increase or decrease metric
base units.
• Estimate lengths in metric units.
• Express temperature in degrees Celsius.
• Define the terms: mass, density, force, torque, and
pressure. Identify the metric units used to measure each
one.
• How to use a calculator to convert one metric unit to
another.
186307 Formulas
Objectives: • Explain the use of letters in formulas.
• Prepare and use formulas to solve problems.
• The use of formulas to calculate the perimeter of a
triangle and rectangle, distance, area of a triangle,
rectangle, and circle, volume of a pyramid, current in a
circuit, and volume of a sphere.
• How to use a calculator to find square root and solve
formulas.
• Transform and solve an equation.
• Perform basic arithmetic operations with signed terms.
• Substitute given numerical values for letters in a
formula and find the unknown quantity.
186308 Introduction to Algebra
Objectives: • Define the terms: term, constant, coefficient, exponent,
monomial, trinomial, and polynomial.
• Identify and combine like terms in an expression.
• Multiply and divide terms containing exponents.
• Remove parentheses from an expression and simplify
the expression.
• Perform basic arithmetic operations with signed terms.
186085 Applied Geometry
Duration: 6 hours
Course Prerequisites: Basic Industrial Math (Block X31)
Practical Measurements (Block X32)
What Students Learn:
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• Recognize characteristics of angles and closed plane
figures.
• Distinguish between common geometric solids.
• Apply the Pythagorean theorem.
• Calculate perimeters and areas of a polygon, circle, and
ellipse.
• Apply the formula for area and volume of geometric
solids.
186086 Practical Trigonometry
Duration: 6 hours
Course Prerequisites: Basic Industrial Math (Block X31)
Practical Measurements (Block X32)
What Students Learn: • Define trigonometric functions.
• Use trigonometric tables and apply interpolation.
• Solve right triangles.
• Apply the laws of sines and cosines in solving oblique
triangles.
__________________________________________________
186325 Introduction to Print Reading What Students Learn: • Describe the basic format for conveying technical information in a drawing • Interpret the various drawing views used in technical drawings • Extract information from notes and title blocks • Recognize and interpret the different line types used in drawings • Understand the concept of drawing scale and how it affects information shown in the drawing • Identify various types of building, electrical, and mechanical drawings ________________________________________________________________________
186326 Print Reading Symbols and Abbreviations Course Prerequisite: Introduction to Print Reading (186080)
What Students Learn: • Recognize, understand, and interpret the most common abbreviations used on a wide range of drawing types used in construction and maintenance trades • Understand and interpret the various symbols and notations used on drawings for electrical, architectural, mechanical, welding, fluid power, and other types of applications
• Explain how symbols are used to show standard materials, parts, and assemblies __________________________________________________________________________
186327 Dimensioning and Tolerancing Course Prerequisite: Introduction to Print Reading (186080)
What Students Learn: • Recognize the international standards and conventions that apply to drawings • Explain how different numbering systems were developed and how they are applied to prints • Read and interpret various systems of dimensions and tolerances on drawings • Recognize and interpret common symbols and nomenclature used in geometric dimensioning and tolerancing (GD&T) systems __________________________________________________
386043 Reading Shop Prints, Part 1 Duration: 10 hours (includes 1 test)
What Students Learn: • Interpret working drawings • Evaluate various systems of dimensions and tolerances • Recognize symbols, notes, and specifications called out on detail and assembly prints • Identify material requirements as specified on a print • Evaluate a print to determine the proper procedure to make a simple part
Special Note: • This study unit takes the place of study unit 6720A. __________________________________________________________________________
386044 Reading Shop Prints, Part 2 Duration: 10 hours (includes 1 test)
Course Prerequisite: Reading Shop Prints, Part 1 (386043)
What Students Learn: • Interpret more complex working drawings • Define and use cam, gear, and thread terminology • Interpret cam, gear, and thread specifications on shop prints • Work with various sectioning techniques • Read and interpret a bill of materials • Evaluate more complex prints to determine the best order of machining
Special Note: • This study unit takes the place of study unit 6720B.
STP194
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Geometric Dimensioning and Tolerancing
This course will cover important and fundamental concepts in geometric dimensioning and tolerancing (GD&T) in four parts. First, you'll work through the basics by studying the various symbols, dimensions, tolerances, annotations, and views of shop prints. Once you can recognize these elements of prints, you'll be able to more easily understand identify datum features, symbols, and terminology used in the manufacturing industry.
The second half of this course will help you recognize various types of orientation tolerances, geometric form tolerances, and runout geometric controls. You'll also learn about various concepts such as concentricity and symmetry. You'll end your study of GD&T with simple and composite forms of locational tolerances as they relate to true position.
Duration: 20 hours (includes 4 tests)
Course Prerequisites: Basic Industrial Math (Block X21)
Reading Prints and Schematics (Block X25)
Course Objectives:
· Identify various symbols, dimensions, tolerances, annotations, and views found in shop prints
· Summarize the proper use of datum features, symbols, and terminology used in manufacturing
· Recognize various types of orientation tolerances and geometric form tolerances
· Explain the concepts of runout geometric controls, concentricity, symmetry, and locational tolerances
What Students Learn: Lesson 1 (386125): Geometric Dimensioning and Tolerancing, Part 1 Overview: This lesson introduces you to geometric dimensioning and tolerancing, or GDT. GDT is a collection of definitions, rules, symbols, and methods of application employed throughout modern manufacturing. The
lesson begins by reviewing the basic skills you probably already use when interpreting shop drawings. After this refresher, you’ll begin to learn the basics of GDT drawing systems. You’ll study some GDT symbols and learn to recognize and interpret them when they’re inserted into a drawing. Finally, this lesson serves as a foundation onto which you’ll add more knowledge as you progress through additional GDT-related training topics. Lesson 2 (386126): Geometric Dimensioning and Tolerancing, Part 2 Overview: Datums and material condition modifiers will now be covered in greater depth. With any measurement, the location of a feature is referenced or measured from a theoretical perfect plane, point, line, axis, or surface called a datum. Datums may be physical features on a part, such as steps or edges, or theoretical features such as the center of a hole or the centerline of a slot. Understanding how a datum is defined is critical for properly setting up the part’s machining or inspection operations. The material condition modifier concepts of maximum material condition, least material condition, and regardless of feature size are also explained in this lesson. Along with the dimensional limits covered earlier, the material condition modifiers are used to vary, or modify, a dimension’s nominal tolerance. You’ll learn how properly using these material conditions allows for a wider variation in dimensions (compared to conventional dimensioning) while still providing proper fit and function of the assembled parts. Lesson 3 (386127): Geometric Dimensioning and Tolerancing, Part 3 Overview: In this lesson you’ll learn about tolerances that relate to part profiles, forms and orientation. Many parts have functional features that can’t be fully specified by geometric tolerances and material modifiers. Parts may have surfaces, profiles, and features oriented to a datum plane or have profiles and surfaces that must retain a defined shape. Round parts may be more accurately produced when tolerances are specified for cylindricity and circularity along with the size tolerances. Machined parts might be specified using size and location tolerances while benefiting from increased controls for flatness or straightness. Lesson 4 (386128): Geometric Dimensioning and Tolerancing, Part 4 Overview: In this lesson, you’ll learn about the geometric characteristics of location including position tolerances,
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symmetry tolerances, and runout tolerances as well as the concept of concentricity. Locational tolerances specify the position, concentricity, and symmetry of features on a part. Most mating or assembled components make use of location tolerances to ensure interchangeability among parts in a production run. The tolerances are commonly used on everything from standard fasteners such as screws, nuts, bolts, and pins to manufactured brackets, plates, and machine components. The proper use of location tolerances makes the manufacture and inspection of symmetric parts more efficient. Location tolerances also help control patterns of features such as a grid of holes, or features around the diameter of a part, while reducing the need for very close conventional tolerances.
Special Notes: This course replaces 386E01.
5004A-C Bench Work
Duration: 30 hours (includes 3 tests)
What Students Learn: PART 1 (5004A). Introduction to Bench Work; Wrenches,
Hammers, Pliers, and Screwdrivers; Punches, Twist Drills,
Reamers, and Broaches; Saws, Chisels, and Snips; Finishing
and Grinding Tools; Files, Scrapers, and Abrasives.
PART 2 (5004B). Threaded Fasteners; Bolts, Screws, and
Studs; Thread Systems; Hole Preparation for Threaded
Fasteners; Mechanical Fasteners; Rivets, Keys, and Pins;
Threading with Hand Tools; Taps: Tap Drills; Tap Wrenches;
Removal of Broken Taps; Repairing Damaged Threads.
PART 3 (5004C). Fitting Practice; Tolerance, Allowance,
Clearance, and Fit; Babbitting; Hack Saw; Band Saw
Machine; Clamping Work for Sawing; Soldering; Soft Solder;
Soldering Copper; Sweat Soldering; Brazing; Hand Solders
and Fluxes; Torch Brazing; Induction Brazing; Furnace
Brazing.
186188 Precision Measuring Instruments, Part 1
Duration: 10 hours (includes 1 test)
What Students Learn: Purpose and Language of Measurement; Scale Instruments
and Accessories; Vernier Caliper; Micrometers, Gages, and
Protractors.
186189 Precision Measuring Instruments, Part 2
Duration: 10 hours (includes 1 test)
What Students Learn: Indicators; Shop Gages; Gage Blocks; Fundamentals of
Trigonometry; Sine Bar and Sine Plate.
186190 Precision Measuring Instruments, Part 3
Duration: 10 hours (includes 1 test)
What Students Learn: Optical Comparators; Optical Flats Light Beams for
Alignment and Measurement; Digital Readout Measuring;
Special Measuring Systems; Materials Testing.
186191 Jobs, Companies, and the Economy: Basic Concepts for Employees
Duration: 5 hours (includes 1 test)
What Students Learn: • Recognition of how the economy affects the actions of
companies, employees, consumers, and investors.
• The concept of capitalism and the principles of supply
and demand.
• How government policies affect the amounts of saving,
spending, and investing by companies and individuals.
• Understand economic measuring tools such as the
inflation rate, the unemployment rate and Gross
Domestic Product (GDP).
• How labor is divided into three employment sectors and
how wages are set, including the influence of labor
unions and the benefits of a multi-functional workforce.
• Recognition of how both the employee and the company
must compete in an increasingly international
marketplace.
Special Notes: This updated course replaces How Our Economic System
Works, study unit 6606, and Economics Today, study unit
186034.
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186036 Quality Concepts: Tools and Applications
Duration: 5 hours (includes 1 test)
What Students Learn: • Describe how job roles change as a company evolves in
its quality consciousness.
• Explain several ways in which you can support TQM.
• Identify approaches, practices and skills associated with
positive organizational change.
• Differentiate between the "change process" at the
company level and the manufacturing processes that
require improvement.
• Describe major causes of process variation and give
examples of how they may affect you in your job.
• Explain why and how the reduction of variability is a
key factor in process improvement.
• Describe why and how quality and process
improvement depend on data-driven decision making.
• Identify seven quality tools and explain their uses.
186087 Metal Processing
Duration: 3 hours
Course Prerequisites: Basic Industrial Math (Block X21)
Practical Measurements (Block X22)
What Students Learn: • Identify industrial metals by their names and chemical
symbols.
• Define in basic terms the characteristics and properties
of metals.
• Explain the various metal-processing methods used in
producing industrial metals.
• Explain how metals are extracted from their ores found
in the earth and then refined.
186088 Ferrous Metals
Duration: 3 hours
Course Prerequisites: Basic Industrial Math (Block X21)
Practical Measurements (Block X22)
What Students Learn:
• Identify the features of a blast furnace.
• Recognize cast irons by their fractures and other
properties.
• Describe the major steelmaking processes.
• Discuss the hot-working and cold-working methods
used to shape steel.
• Classify the types of steel, according to both processing
method and carbon content.
• Relate certain grade numbers to the types of steel they
identify.
186089 Nonferrous Metals
Duration: 3 hours
Course Prerequisites: Basic Industrial Math (Block X21)
Practical Measurements (Block X22)
What Students Learn: • Explain how the various metals are extracted from their
ores.
• Describe how the addition of certain elements affects
the physical properties of the base metals.
• Select the metal alloy most suitable for a given job.
• Recognize whether a copper alloy is a brass or a bronze.
186090 Identification of Metals
Duration: 3 hours
Course Prerequisites: Basic Industrial Math (Block X21)
Practical Measurements (Block X22)
What Students Learn: • Identify a metal by making a file, test magnetic test,
temperature test, chip test, or spark test.
• Find the hardness of a metal by using a Brinell-
Rockwell Monotron, a Vickers-Herbert Pendulum, or a
scieroscope hardness-testing machine.
Block X08 Basic Machining Skills
Duration: 56 hours (includes 3 tests)
Course Prerequisites: Introduction to Algebra, Geometry, and Trigonometry (Block
X02)
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Industrial Safety (Block X23)
Hand and Power Tools (Block X24)
What Students Learn: This block presents the trainee with a broad overview of the
basic industrial skills and knowledge needed by an entry level
machinist. Skilled workers, such as electricians, pipefitters,
and mechanics, whose duties include the maintenance and
repair of machine tools, can benefit through cross training,
from taking this course. The course starts with shop math and
measurements, and applies these concepts to shop drawings,
blueprint reading, layout, and metal cutting. On-the-job tasks,
such as working with metal cutting machinery - milling
machines, drilling machines, lathes, grinders, and CNC
machine tools - are described in detail. Safety procedures
relating to job tasks using metal shop machinery are an
essential part of this course.
Components: Practical Shop Math, Part 1 (X0801)
Practical Shop Math, Part 2 (X0802)
Practical Shop Measurement (X0803)
Safe Shop Practices (X0804)
Properties and Classifications of Metals (X0805)
Progress Examination (X0821)
Using Shop Drawings, Process, and Routing Sheets, Part 1
(X0806)
Using Shop Drawings, Process, and Routing Sheets, Part 2
(X0807)
Layout (X0808)
Progress Examination (X0822)
Metal Cutting and Machine Tooling, Part 1 (X0809)
Metal Cutting and Machine Tooling, Part 2 (X0810)
Metal Cutting Machinery, Part 1 (X0811)
Metal Cutting Machinery, Part 2 (X0812)
Fundamentals of Grinding (X0813)
CNC Machine Tool Features and Applications (X0814)
Progress Examination (X0823)
Progress Examination Booklet (X0820)
X0801 Practical Shop Math, Part 1
Objectives: • Learn the basics of shop mathematics as they relate to
machine technology.
• Add, subtract, multiply, and divide fractions and
decimal values of whole units such as inches, and feet.
• Derive the square root of fractions and decimals.
• Compute a machine drive ratio for a given speed.
• Make calculations using the metric or SI system of
measurement.
X0802 Practical Shop Math, Part 2
Objectives:
• Learn the fundamentals of geometry and trigonometry
as they apply to machine shop calculations.
• Compute the areas of rectangles, triangles, circles,
parallelograms, and other common shapes.
• Compute the volumes of solid figures such as cubes,
cylinders, cones, rectangles, and combinations of these.
• Use the principles of geometry and trigonometry to
analyze and solve various kinds of triangles and their
parts.
• Plot coordinates of a point using both the rectangular
(Cartesian) and the polar systems.
• Present the fundamentals of calculator operations as
they apply to shop work.
X0803 Practical Shop Measurement
Objectives: • Teach the terminology of linear (length) and angular
dimensioning.
• Learn which tools and measuring instruments are
commonly used to determine the size and dimensions of
a sample workpiece.
• Use a steel rule to measure the length of a part in inches
or millimeters.
• Measure the sizes of parts to 1/10,000 inch using a
vernier caliper.
• Use a micrometer to measure diameters and thicknesses
of workpieces.
• Make angular measurements using various instruments.
X0804 Safe Shop Practices
Objectives: • List the proper safety equipment to be worn when
performing machine shop tasks.
• State the environmental hazards most commonly
encountered in a machine shop.
• Teach the fundamental safety measures for the machine
shop environment and for the more popular types of
machine tools used across industry.
• State the method used to remove stock from a
workpiece mounted in a lathe, milling machine, and
drill press.
• Name one method used to protect the worker from
harmful fumes when cutting fluids are used.
X0805 Properties and Classifications of Metals
Objectives:
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• Understand the four basic methods of manufacturing
iron and steel.
• Discuss the fundamental properties of metals.
• Recognize standard identification of various steels and
alloys.
• Know the characteristics and applications of particular
steels and alloys.
• Realize the effects and limitations of heat treatment.
• Be familiar with materials testing methods.
• Differentiate between hot-working and cold-working
metal processes.
X0821 Progress Examination
X0806 Using Shop Drawings, Process, and Routing Sheets, Part 1
Objectives: • Understand the uses of industrial blueprints.
• Learn how to read shop drawings, process, and routing
sheets.
• Recognize surfaces, object lines, and object points on a
blueprint.
• Recognize front, top, and right-side views of an object.
• Identify lines on a drawing and explain their use.
• Read and understand sectional views and apply
information from them to other views.
• Identify and read auxiliary and double auxiliary lines.
• Understand tolerances and apply them to dimensions,
and read different tolerancing systems.
• Introduce the trainee to the language of print reading.
X0807 Using Shop Drawings, Process, and Routing Sheets, Part 2
Objectives: • Recognize and read a geometric drawing.
• Understand the system of geometric dimensioning and
tolerancing used in industrial shop drawings.
• Understand variations used on geometric drawings.
• Locate and correctly read a drawing block, and apply its
information to a drawing.
• Recognize and read a process sheet, and use the
information it contains.
• Understand the baseline dimensioning system.
• Understand the Cartesian coordinate system.
• Understand the fixed or floating zero system.
X0808
Layout
Objectives: • Prepare a work surface and know the types and uses of
layout compounds.
• Identify and use common layout tools.
• Identify and use measuring instruments used in layout.
• Identify and use precision layout tools.
• Perform basic layout operations and construct various
geometric shapes.
X0822 Progress Examination
X0809 Metal Cutting and Machine Tooling, Part 1
Objectives: • Describe metal cutting, how it is accomplished, and
whether a cutting tool is performing properly.
• Identify a variety of cutting tools.
• Understand how a cutting tool cuts and separates
material by using the three kinds of cutting edges.
• Identify the three major types of chips a cutting tool
produces.
• Name the key parts of a twist drill.
• Describe the applications of a counterbore, countersink,
and combination countersink/centerdrill. • State the differences between reamers for machine and
hand use.
• Explain the differences between taps used for hand
tapping and machine tapping methods.
• Describe the dies used to produce threads by both hand
and machine methods.
• Identify the different machine attachments and tooling
components needed for tap and die threading on
production machinery.
X0810 Metal Cutting and Machine Tooling, Part 2
Objectives: • Define the major parts of a lathe tool bit.
• Identify the types and applications of turning, boring,
and milling tools used in machining operations.
• Describe the different styles of end mills available.
• Identify the different horizontal end mills.
• Explain the difference between the mounting methods
used for horizontal and end mill style cutters.
• Understand the differences among the various cutting
tool materials used.
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• Describe the reasons for using a tool coating on a
cutting tool or cutting insert.
• Describe the effects of coolants on the cutting point.
• Identify the major methods of applying cutting fluids.
X0811 Metal Cutting Machinery, Part 1
Objectives: • Identify the different types and applications of drilling
machines used in industry and their important operating
parts.
• Describe the major accessories and workholders used on
drilling machines.
• Explain the difference between horizontal and vertical
milling machines.
• Describe the different types of horizontal and vertical
milling machines available.
• Understand numerical control and computerized
numerical control of machine tools and differentiate
between them.
• Distinguish a machining center from an ordinary milling
machine.
• Understand the differences among the four designs of
automatic toolchangers.
X0812 Metal Cutting Machinery, Part 2
Objectives: • Describe basic lathe construction.
• Describe the manual and automated turning machines
used by industry.
• Recognize the uses of turning centers for mass-
production applications.
• Differentiate between bar and chucking types of
automatic screw machines.
• Identify turning machine accessories and workholders.
• State the differences between horizontal and vertical
bandsaw configurations.
• Interpret the different tooth styles of bandsaws and the
applications for each style.
• Describe conventional and vertical bandsaw cutting
operations.
• Explain circular cold sawing, abrasive cutting, and
friction sawing techniques.
X0813 Fundamentals of Grinding
Objectives:
• Explain the physical characteristics, setup, and
operation of grinding wheels.
• Name the different types of abrasives and bonds.
• Define how structure applies to the grinding process.
• Recognize Standard Marking System symbols to choose
the correct grinding wheel.
• Describe the major wheel types by shape and list
specific applications for each.
• Describe how to put a grinding wheel into operation and
keep it in good working order.
• State the various types of grinding fluids, what they are
used for, and the different methods of applying them.
• List uses and nomenclature associated with utility
grinders, surface grinders, and cylindrical grinders.
• Demonstrate safe practices when using grinders.
X0814 CNC Machine Tool Features and Applications
Objectives: • Name the common machines adapted to computer
numerical control.
• Describe how CNC machines operate and what
processes they are capable of performing.
• State advantages of CNC over manual control.
• Name various CNC components and describe what each
does.
• Explain the function of a feedback device.
• Understand the Cartesian coordinate system of
measurement.
• Define tool length compensation and describe the
process of zeroing a CNC machine.
• Demonstrate safe practices when operating CNC
machines.
• Describe the job responsibilities of people involved in
CNC operations.
X0823 Progress Examination
X0820 Progress Examination Booklet
3501 Layout
Duration:
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10 hours (includes 1 test)
What Students Learn: Marking Devices: Punches, Scribers, Dividers, Calipers,
Gages, Beam Trammels, Combination Sets, Bevel Protractors,
Keyseat Clamps; Scribing Problems; Use of Bench Plates,
Surface Plates, Parallels, V Blocks, and Arbors; How to Draw
Horizontal, Vertical, and Inclined Lines; How to Draw a
Circle or Circular Arc; Layout Problems: Location of Holes in
a Plate; Location of Boundaries of Flat Surfaces; Marking of
Lines on Curved Surfaces; Locating the Center of a Circle in
an Opening; Subdividing a Circle into a Number of Equal
Parts; Determining Required Length of Stock for Forming a
Bent Part; Laying Out of Keyways, Templates, Castings,
Cams, and Sprockets.
Special Notes: Covers subject at an advanced, in-depth level.
386050, 386051 Drilling, Parts 1 & 2
Duration: 20 hours (includes 2 tests)
What Students Learn: PART 1 (386050).
• Identify the parts of and explain how to use basic
drill presses.
• Identify and use various types of drill tools for
counterboring, countersinking, spot facing,
reaming, tapping, and hole sawing.
• Explain how to set up various workpieces on a drill
press.
• Selecting and using tool holders and workholding
devices.• Understand how to recondition drilling
tools and maintain equipment.
PART 2 (386051).
• Explain how to set up more complex drilling
equipment included automated and CNC equipment.
• Select and use various types of auxiliary tools with
drill equipment.
• Set up more advanced work on a drill press.
• Select and modify drills for different materials and
cutting conditions.
• Determine the correct speeds, feeds, and coolant for a
given operation.
• Diagnose quality, tolerance, and tool-life problems,
and find solutions for them.
Special Note:
• This course replaces 3521-B.
286091 Lubrication, Part 1
Duration: 10 hours (includes 1 test)
What Students Learn: Preview
Since the development of machinery, there has been a war
against friction. Friction causes machinery to vibrate
excessively, sound louder, use more energy to do a given job,
and, most importantly, wear out faster. To counter friction,
lubricants have been developed.
Lubricants were once basic animal fats and plant oils used on
simple machines. Today's lubricants are chemical
compositions specially designed for specific types of machines
and their work environment. There are now hundreds of types
of oils and grease to select from, each tailored specifically for
the machine or an individual component of any given
machine.
This study unit is designed to give students the information
they need to understand how lubricants are blended into these
very special compounds and how they are selected for various
applications.
Objectives
When a student completes this study unit, he and she will be
able to:
• Describe the various types of friction.
• Discuss how materials wear.
• List the various functions lubricants perform in industry.
• Explain how lubricants reduce friction.
• Classify lubricants depending upon their composition,
properties, and additives.
• Understand why certain lubricants are chosen for certain
tasks.
• Explain how to safely handle and store lubricants.
Contents
Friction and Wear; The Purpose of Lubricants; How
Lubricants are Classified; How Lubricants Work;
Proper Lubricant Selection; Handling and Storing
Lubricants Safely.
Special Notes: This updated course replaces 2531A.
286092
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15
Lubrication, Part 2
Duration: 10 hours (includes 1 test)
What Students Learn: Preview
Lubricating equipment is one of the most important industrial
maintenance activities performed. Lubricants reduce friction,
which saves on energy costs. They reduce wear, which saves
on equipment maintenance costs. Proper lubrication
significantly reduces machine downtime resulting from broken
or worn out components. In addition, proper lubricating
practices help keep a machine in tolerance for a longer period
of time.
In today's world of twenty-four-hour-a-day, seven-days-a-
week, plant operation, the role of lubrication takes on even
greater importance. Equipment must be lubricated on a timely
schedule, in the proper amounts, and with the correct
lubricants to sustain long work cycles between planned
shutdowns. This study unit will show you how to properly
apply lubrication and maintain lubrication systems.
Objectives
When a student completes this study unit, he and she will be
able to:
• Explain how to manually apply various types of
lubricants in an industrial environment.
• Describe total-loss lubrication.
• Identify a nonloss lubrication system's components and
describe their operation.
• Explain how to maintain a nonloss lubrication system.
• Identify the proper lubrication procedures to use for
special industrial applications including sealed bearings,
oil-impregnated bearings and food-processing plants.
• Explain how lubricant-conditioning systems work and
how to maintain them.
• Describe how automatic lubrication systems work and
how to maintain them.
• List the tasks involved in preventive and predictive
lubrication maintenance.
Contents
Manual Methods of Lubrication; Lubricating Total-Loss
Systems; Nonloss Lubrication Systems; Lubrication in
Special Environments; Lubrication Conditioning;
Automatic Lubrication Systems; Preventive and
Predictive Lubrication Maintenance.
Special Notes: This updated course replaces 2531B.
286095 Fasteners
Duration: 10 hours (includes 1 test)
What Students Learn: Preview
This study unit explains the use and properties of specialty and
common fasteners used by maintenance technicians. It also
covers many of those fasteners installed during automated
assembly processes.
Objectives
When a student completes this study unit, he and she will be
able to:
• Identify the types and properties of fastener material.
• Describe the components of threaded fastener systems
including bolts, nuts, screws and washers.
• Discuss the anchoring systems used in industry.
• Identify rivets and riveting tools.
• Describe other non-threaded fasteners including keys,
pins and retaining rings.
• Display fastener installation techniques including
tensioning, torquing and lubrication.
• Discuss how to troubleshoot fastener failure.
Contents
Introduction to Fasteners; Fastener Materials; Threaded
Designs; Threaded Fastening Systems; Nonthreaded
Fasteners; Installing and Removing Fasteners; Industrial Adhesives.
Special Notes: This updated course replaces 2542.
386031 Milling Machine Fundamentals
Duration: 10 hours (includes 1 test)
Course Prerequisites: Basic Machining Skills (Block X08)
What Students Learn: Preview
This study unit focuses on the fundamentals of milling
machines. It begins with a brief historical overview of milling
machines. Then, students will learn basic milling concepts,
such as peripheral and face milling, the milling machine
coordinate system, and feed, speed, and depth of cut. You will
also learn about the basic features and common parts of a mill.
This study unit explores the various types of mills, starting
with the most prevalent column- and knee-type machines.
The bed-type and planer-type are reviewed next, followed by a
discussion of special milling machines.
A milling machine by itself usually can’t complete a milling
job. An attachment or accessory is usually required to
perform the task. Therefore, a portion of this unit is devoted
to common attachments and accessories that enhance the
mill’s capabilities.
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In the final section, trainees will learn about automation of
milling machines and modern computer-controlled machining
centers. You should find this study unit to be a valuable
introduction to the milling process, and a useful reference for
understanding the basic operation of mills.
Objectives
When a student completes this study unit, he and she will be
able to:
• Understand the application of a Cartesian coordinate
system to the milling operation.
• Describe the construction, sizes, and the basic
components of milling machines.
• Identify the classifications, characteristics, and
functions of different milling machines.
• Describe how the knee, horizontal, and vertical milling
machines operate.
• Discuss the numerous attachments and accessories that
increase the effectiveness of milling machines.
• Explain the application of NC and CNC to milling
machines.
Contents
Introduction to the Milling Process: Definition of Milling;
History of Milling Machines; Early Milling Cutters and
Drivers; Peripheral Milling and Face Milling; Depth and
Width of Cut; Direction of Feed; Cutter Feeds and
Speeds; Coordinate System for Milling; General
Construction of Milling Machines: Basic Parts of the
Milling Machine; Standard Milling Machine Sizes;
Milling Machine Types: Manual Milling Machine
Classifications; Knee-Type Milling Machines; Bed-
Type Milling Machines; Planer-Type Milling Machines;
Special Milling Machines; Attachments and
Accessories: Purpose of Attachments and Accessories;
Arbors; Arbor Tapers; Arbor Supports; Draw-in Bolts;
Quick-Change Adapters; Bearing and Spacing Collars;
Overarms; Collets and Adapters; Machine Conversion
Attachments; Slotting Attachments; Rack-Milling
Attachments; Rotary Tables; Vises, Fixtures, Clamps,
and Other Hold-Down Devices; Universal Indexing
Heads; Digital Read Out Systems; Milling Machine
Automation: Numerically Controlled Machining;
Computer Controlled Machining; Machining Centers.
386032 Milling Machine Cutting Tools
Duration: 10 hours (includes 1 test)
Course Prerequisites: Basic Machining Skills (Block X08)
Milling Machine Fundamentals (426031)
What Students Learn: Preview
In your previous studies, you learned about the fundamentals
of metal cutting, including basic concepts of feed, speed, and
depth of cut. You also learned about types of cutting tools and
tool materials, such as high-speed steels and carbides.
Students have been introduced to milling operations and
equipment, including different types of mills, attachments, and
accessories.
In this study unit, trainees will learn about milling machine
cutters in more detail. You will be presented with in-depth
information about tool design and materials. At the end of this
unit, metal cutting theory, the principles of tool wear, and
milling economics are discussed.
Objectives
When a student completes this study unit, he and she will be
able to:
• Discuss the primary function of different types of
milling cutters.
• Describe the heat treatment process for making tool
steels.
• Explain how cemented carbide cutting tools are made.
• Interpret the standardized lettering/numbering system
for carbide cutters.
• Understand the geometry of carbide inserts and
toolholders and the methods used to attach inserts to
tools.
• Explain tool wear and methods for extending tool life.
• Recognize basic milling econometrics concepts.
Contents
Tool Design and Construction: Introduction; Tool
Materials; Standard- and Formed-Tooth Cutters:
General Guidelines; Standard-Tooth Cutters; Formed-
Tooth Cutters; Inserted-Tooth Cutters: Common Types
of Inserted-Tooth Cutters; Milling Cutter Inserts; Insert
Holders; Setting and Replacing Inserts; Tool
Performance and Econometrics: The Metal-Cutting
Process; Tool Wear and Econometrics.
386033 Milling Machine Practice and Operation, Part 1
Duration: 10 hours (includes 1 test)
Course Prerequisites: Basic Machining Skills (Block X08)
Milling Machine Fundamentals (426031)
Milling Machine Cutting Tools (426032)
What Students Learn: Preview
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17
Previous study units in the milling series focused on the
fundamentals of metal cutting, including basic concepts of
feed, speed, and depth of cut. These units introduced concepts
of milling machine design, milling cutters, attachments, and
accessories. This study unit is the first of a series of units that
put these theories into practice by describing milling
operations.
This study unit uses both English and metric units of
measurement. Generally, the English unit is presented,
followed by the approximate metric equivalent in parentheses.
In some cases, only English units are given, particularly when
including the metric unit would be confusing. For example,
when citing specific dimensions and their tolerances or when
describing objects (such as gage blocks) whose properties are
based on standard English dimensions, students will only see
the English unit of measurement.
Objectives
When a student completes this study unit, he and she will be
able to:
• Explain the function of layout tools.
• Perform basic layout operations.
• Understand machine setup guidelines.
• Use a variety of vises, clamps, and fixtures to securely
hold workpieces.
• Square up work holders on a milling machine table.
• Select machine speeds and feeds.
• Plan a sequence of milling operations.
Contents
Getting Started: Milling Machine Practice and Operation;
Work Orders and Drawings; Dimensional Measurement
Issues; Work Layout; Setting Up the Work: General
Principles of Milling Table Setups; Work-Holding
Devices; Setting Up the Milling Machine: Determining
the Milling Method; Selecting the Milling Cutter;
Selecting Cutting Speeds and Feeds; Squaring the Vise
to the Milling Machine; Setting the Work to the Cutter.
386034 Milling Machine Practice and Operation, Part 2
Duration: 10 hours (includes 1 test)
Course Prerequisites: Milling Machine Fundamentals (426031)
Milling Machine Cutting Tools (426032)
Basic Machining Skills (Block X08)
What Students Learn: Preview
In previous study units in the milling series, you learned about
the fundamentals of metal cutting, including concepts of feed,
speed, and depth of cut. You learned basic information about
milling machine design, milling cutters, attachments, and
accessories. In addition, you learned about workpiece layout,
cutter selection, work holding, and machine setup. This study
unit addresses milling machine practice and operation.
Today, many machine shops use programmable machines,
such as CNC mills or machining centers, to perform milling
operations. However, this study unit discusses conventional
mills with manual controls. Most machinists first learn on
these machines, which remain in widespread use.
This study unit uses both English and metric units of
measurement. Generally, the English unit is presented,
followed by the approximate metric equivalent in parentheses.
In some cases, only English units are given, particularly when
including the metric unit would be confusing. For example,
when citing specific dimensions and their tolerances or when
describing objects (such as gage blocks) whose properties are
based on standard English dimensions, students will only see
the English unit of measurement.
Objectives
When a student completes this study unit, he and she will be
able to:
• Set the cutter exactly on the workpiece surface.
• Square the workpiece.
• Mill shoulders, steps, slots, angled surfaces, dovetails,
keyseats, and pockets.
• Perform sawing and slitting work on the mill.
• Maintain and troubleshoot mills.
Contents
Preparation for Milling: Safety; Workpiece Layout; Work
Holding; Machine Design Overview; Milling Machine
Controls; Cutting Fluids; Basic Milling Operations:
Setting the Cutter to the Work; Squaring the Work;
Milling a Shoulder or Step; Milling a Slot or Groove;
Milling an Angled Surface; Sawing on a Mill; Milling
Holes (Drilling and Boring); Milling a Pocket or
Internal Opening; Other Milling Issues: Completing the
Milling Process; Troubleshooting; Maintenance; A
Sample Project: Preparation for Milling; Squaring the
Workpiece; Milling the Slots; Drilling the Holes;
Milling the Internal Opening; Milling the Angles
Surfaces; Milling the Radii.
386035 Milling Machine Indexing and Spiral Work
Duration: 10 hours (includes 1 test)
Course Prerequisites: Milling Machine Fundamentals (426031)
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Milling Machine Cutting Tools (426032)
Milling Machine Practice and Operation, Part 1 (426033)
Milling Machine Practice and Operation, Part 2 (426034)
Basic Machining Skills (Block X08)
What Students Learn: Preview
This study unit describes how to mill certain types of complex
shapes. This type of milling work might be used for
manufacturing gears or cams.
Indexing, or repeatedly milling a feature at uniform intervals,
and spiral work were once performed exclusively on manual
milling machines. In a modern shop, these tasks are most
often performed using CNC equipment. However, the
techniques and tooling used to manually perform indexing and
spiral work are still encountered in many workplaces.
After introducing the principles of index milling and spiral
work, this study unit explains the manual techniques used to
produce these features. It concludes with a discussion of how
these features are more efficiently milled using CNC
equipment and reviews some sample programming code.
Objectives
When a student completes this study unit, he and she will be able to:
• Explain direct, linear, circular, compound, and
differential indexing.
• Describe the basic operation of indexing head.
• Discuss how to select the correct indexing circle and to
calculate the number of index crank turns.
• Explain how change gears are used.
• Explain how to mill a helix.
• Describe the rotation of a workpiece during helical
milling and how to compensate for the tool shape by
adjusting the table angle.
• Explain the role of CNC milling machines in modern
indexing and spiral machining.
Contents
Indexing: Linear Indexing; Circular Indexing; Direct
Indexing; Indirect Indexing; Compound Indexing;
Differential Indexing; Conventional Helical Milling:
Basic Principles; Setting up the Mill for Helical Milling;
Cutting Helices on the Milling Machine; CNC Helical
Milling: CNC Overview; CNC Programming Codes and
Helical Motion.
386036 Lathes, Part 1
Duration: 10 hours (includes 1 test)
Course Prerequisites: Basic Machining Skills (Block X08)
What Students Learn:
Preview
This study unit is a basic introduction to the lathe. Trainees
will become familiar with general terminology, and you will
learn about the lathe’s operation. This unit is the first in a
series of units on lathes. Each unit progressively discusses
lathes in more detail. This unit is designed to give you
background information, which equips you with a basic
understanding of how to operate a lathe safely and efficiently.
If you have just begun to work with lathes, you will find this
basic information very helpful.
This unit uses both the English and Metric standards of
measurement. Most examples use the English standard
system, with the Metric equivalents listed. Not all conversions
are held to a close tolerance. In cases where there are ranges
of numbers, the nominal metric equivalents are given rather
than the actual converted number. Trainees will find that, in
practice, dimensions on a print will need to be converted
directly. However, stock sizes, standard sizes, and ratings
generally have nominal metric values close but not equal to
English values.
Objectives
When a student completes this study unit, he and she will be
able to:
• Describe the modern lathe.
• Explain the differences among various types of modern
lathes.
• Interpret the size ratings of a lathe.
• Describe common work-holding devices.
• Explain the range of operations of the lathe.
• Describe various tool styles, materials, and holders.
• Understand turning parameters and their effects on the
machining process.
Contents
Introduction to the Lathe: What is a Lathe?; The History of
the Lathe; Early Improvements in the Lathe; The
Modern Lathe; Size Ratings; Types of Lathes: Engine
Lathes; Benchtop Lathes; Toolroom Lathes; Turret
Lathes; CNC Lathes; Special Purpose Lathes; Work-
Holding Devices: Chucks; Collets; Mandrels; Centers;
Lathe Dogs and Drive Plates; Lathe Operations: Basic
Lathe Operations; Special Attachments; Tool Types:
Basic Tool Types; Tool Geometry; Materials; Holders;
Turning Parameters: Speed and Feed Selection; Depth
of Cut; Metal Removal Rates.
386037 Lathes, Part 2
Duration: 10 hours (includes 1 test)
Course Prerequisites: Basic Machining Skills (Block X08)
What Students Learn: Preview
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19
Lathes, Part 2 is designed to provide trainees with a basic
introduction to external lathe operations. This unit is the
second in a series of units that progressively discuss these
operations in more detail. You will gain an understanding of
lathe operations, including facing, diameter turning, shoulder
turning, forming, necking, and parting. Apprentices, machine
shop personnel, and students who are just starting to use a
lathe can benefit from this study unit. Further study and
practice should complement this text, giving you reference
material enhancing your shop floor experience.
This study unit uses both the English and metric standards of
measurement. Most of the examples are given in English units
with the metric equivalents listed in parentheses. Not all
conversions are held to a close tolerance Therefore, in cases
where ranges of numbers are used, the nominal metric
equivalents rather than the actual converted number are
provided. In practice, dimensions on a print will need to be
converted directly (1 inch = 25.4 mm). However, stock sizes,
standard sizes, and ratings generally have nominal metric
values close but not equal to the English values.
Objectives
When a student completes this study unit, he and she will be
able to:
• Set up a lathe using various work holders and auxiliary
equipment.
• Choose the correct tool material, type, and geometry for
a particular operation.
• Set the correct feed, speed, and depth of cut for external
machining operations.
• Explain facing, diameter turning, and shoulder turning.
• Describe forming, including the fillet radius and
chamfer forming.
• Explain necking and groove cutting, parting, and
knurling.
• Discuss finishing operations, including filing and
polishing.
Contents
Preparation for Machining: Safety; Maintenance; External
Operations; Tool Selection: Tool Material; Types of
Tools; Tool Geometry; Speed and Feed; Depth of Cut;
Lubricants and Coolants; Basic External Machining
Operations: Analyzing the Part and Setup; Facing;
Center Drilling; Straight or Diameter Turning; Shoulder
Turning; Turning Tips; Special External Machining
Operations: Forming; Shapes and Chamfers; Necking
and Form Groove Cutting; Parting; Knurling; Filing and
Polishing.
386038 Lathes, Part 3
Duration: 10 hours (includes 1 test)
Course Prerequisites: Basic Machining Skills (Block X08)
What Students Learn: Preview
This study unit is designed to provide trainees with a basic
introduction to internal lathe operations. This unit is the third
in a series of units that will progressively discuss lathe
operations in more detail. You will develop a basic
understanding necessary to accomplish a variety of lathe
operations, including boring, counterboring, tailstock
operations (drilling, reaming, and tapping), and special
operations (tracing, grinding, eccentrics, and others).
This study unit uses both the English and metric standards of
measurement. Most of the examples are given in English units
with the metric equivalents listed in parentheses. Not all
conversions are held to a close tolerance. Therefore, in cases
where ranges of numbers are used, the nominal metric
equivalents are provided instead of the actual converted. In
practice, dimensions on a print will need to be converted
directly (1 inch = 25.4 millimeters). However, stock sizes,
standard sizes, and ratings generally have nominal metric
values close but not equal to the English values.
Objectives
When a student completes this study unit, he and she will be
able to: • Machine boring operations, internal shoulders, internal
grooves, and recesses.
• Machine offset bushings, eccentrics, off-center, and
milling operations.
• Improve workpiece finish and reduce chatter.
• Measure inside forms, including bored holes and
internal grooves.
• Understand tailstock operations, including drilling,
reaming, and tapping.
• Describe the functions of different types of drills.
Contents
Boring: Boring Tools; Setting up Boring Operations;
Boring Procedure; Measuring Internal Forms;
Counterboring; Tips and Chatter Reduction; Recessing /
Grooving: Tailstock Operations: Drilling; Reaming;
Tapping; Special Operations: Tracing; Grinding
Operations; Offset Bushings and Eccentrics; Milling
Operations; Off-Center Work; Substitute Lathe
Operations.
386039 Lathes, Part 4
Duration: 10 hours (includes 1 test)
Course Prerequisites: Basic Machining Skills (Block X08)
What Students Learn: Preview
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20
This study unit is designed to provide trainees with an
introduction to tapers and taper turning on the lathe. This unit
is the fourth in a series of units that progressively discusses
lathe operations in more detail. You will develop a basic
understanding necessary to identify taper types and sizes,
machine tapers on the lathe, and measure tapers. Experience,
further study, and practice should complement this study unit,
providing you with a broad range of reference material.
This study unit relies on the English standard of measurement.
Most examples are given with English units, without the
metric equivalents listed. Tapers are often measured in inches
of taper per foot of length. Generally, there isn’t a
corresponding metric taper that converts directly from the
English standard.
Objectives
When a student completes this study unit, he and she will be
able to:
• Identify various types of tapers and their uses.
• Describe methods of producing tapers.
• Calculate the required dimensions and setups required
to machine tapers.
• Set up and machine tapers following various methods.
• Calculate tapers measured in inches per foot and their
corresponding taper angles.
• Measure and inspect tapers.
Contents
Tapers: Basic Definitions and Calculations; Finding Taper
Dimensions; Taper Tables; Types of Tapers: Basic
Styles; Morse Tapers; Brown and Sharpe Tapers; Jarno
Tapers; American National Standard Machine Tapers;
British Standard Tapers; Taper Pin Tapers; Jacobs
Tapers; Oversize Tapers; Fast Tapers and Tapers for
Machine Tool Spindles; Identifying Tapers; Taper
Turning: Common Methods to Produce Tapers;
Template Tracing; Plunge Formed Tapers and
Chamfers; Tapers Using Compound Rests; Taper
Angles; Tapers Using Tailstock Offsets; Using a Taper
Attachment; Tips for Cutting Tapers; Machining a
Lathe Half-Center; Measuring Tapers and Inspection:
Tools to Measure Tapers; Using a Sine Plate.
386040 Lathes, Part 5
Duration: 10 hours (includes 1 test)
Course Prerequisites: Basic Machining Skills (Block X08)
What Students Learn: Preview
This study unit is a basic introduction to threads and thread
chasing on the lathe. This unit is the fifth in a series of units
that have progressively discussed lathe operations in more
detail. This study unit provides the background necessary to
identify thread forms, functions, and classifications, to
machine threads on the lathe, and to measure threads.
This study unit uses both English and metric standards. Most
examples are given in English units, without the metric
equivalents listed. When discussing metric threads, the
English equivalent is not listed. Threads are often measured in
threads per inch (English) or in millimeters of pitch (metric).
There’s usually no corresponding metric thread that converts
directly from the English standard, and no English thread can
be converted from the metric thread.
Objectives
When a student completes this study unit, he and she will be
able to:
• Describe the functions of various thread types.
• Understand the differences among thread standards.
• Calculate the required dimensions and setups for
machining threads.
• Explain common methods of producing threads.
• Set up, machine, measure, and inspect threads.
Contents
Threading: Basic Definitions; Thread Function and
Classification; Thread Terminology; Thread Standards;
Thread Classes; Thread Notations; Thread Styles: Sharp
V Thread; American National Thread; Unified Thread;
American National Acme Thread; Tapered Threads;
International Metric Thread; Special Threads; Thread
Chasing: Threading Tools; Gearing for Threads;
Thread-Chasing Dial; Setting up for Chasing; Chasing
Technique; Chasing Left Hand Threads; Terminating a
Thread; Picking up a Thread; Dragging a Thread;
Chasing Internal Threads; Chasing Tips; Square Thread
Tips; Chasing Metric Threads; Chasing Multiple
Threads; Inspecting Threads: Measuring Pitch
Diameter; Checking Threads; Finding Pitch; Inspecting
Multiple Threads.
386030 Fundamentals of Metal Cutting
Duration: 10 hours (includes 1 test)
Course Prerequisites: Basic Machining Skills (Block X08)
What Students Learn: Preview
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21
In this study unit, students learn about the fundamental
methods and principles related to machining metal. The study
unit begins with a brief historical review of the evolution of
machining. Then, you will be introduced to three key factors
that are used to define all metal cutting operations: feed, depth
of cut, and speed. These factors have interrelated roles in
shaping metals. Students will then learn about the critical role
of the cutting tool itself and how cutting tools are designed to
improve metal cutting performance and to reduce tool wear.
The study unit discusses a broad variety of materials from
which cutting tools are made; steels, carbides, ceramics,
diamond, and others, and explains which tool materials are
best suited to certain machining jobs.
Trainees will then learn about single-point cutting tools and
how small changes in tool design and construction can have a
great effect on cutting effectiveness and on the quality of the
machined part. Lathe tools are the primary focus of the study
of single-point cutting tools, but the unit also describes
shaping, planning, boring, and some special-purpose tools.
Multiple-point cutting tools are introduced. There is an
extensive section on milling tools and all their variations. In
addition to milling tools, this study unit covers other varieties
of multiple-point cutting tools, including taps, reamers,
broaches, saws, files, gear cutters, and many types of drills.
You will learn how to use guidebooks and other information
to help you plan your machining tasks and how to work
successfully when you don’t have written guidance. Finally,
students will learn about the role of cutting fluids in various
machining operations and how to select and use cutting fluids
to improve machining performance.
Objectives
When a student completes this study unit, he and she will be
able to:
• Describe the metal-cutting process and cutting tool
requirements.
• Explain the role of feed, speed, and depth-of-cut in
machining.
• Explain the advantages and limitations of carbon steel
and carbide cutting tools.
• Describe the principles of single-point cutting tools and
the factors governing tool wear.
• Explain multiple-point cutting tools and their uses.
• Describe the difference between lathe turning and
milling.
• Explain tapping, threading, reaming, and broaching.
• Explain the role of cutting fluids in machining
operations.
Contents
Introduction to Metal Cutting: Safety; Historical
Perspective; New Developments; Metal Cutting
Fundamentals; Cutting Tool Fundamentals; Cutting
Tool Properties: Tool Material Requirements; Tool
Materials; Single-Point Cutting Tools: Lathe Tools;
Other Single-Point Cutting Tools; Multiple-Point
Cutting Tools: Milling Tools; Other Multiple-Point
Cutting Tools; Cutting Fluids: Advantages of Cutting
Fluids; Other Considerations; Types of Cutting Fluids;
Cutting Fluid Application.
186110 Machine Safety
Duration: 5 hours (includes 1 test)
What Students Learn: Preview
In this study unit, trainees will gain a better understanding of
the work practices necessary to operate industrial machinery,
such as a bench-top drill press or a ten ton mechancial poewer
press, safely. You will learn how the principles and practices
used to keep ypu safe from injury can be incorporated into
your daily routine.
Providing a safe work enviornment is the responsibility of the
employer. It is the employees responsibility to work safely at
all times, especially when using power driven machinery.
Awareness and sound practice of the safety procedures you'll
learn offer your best defense against workplace injuries. In
this study unit, students will learn the skills needed to become
a productive and safe industrial machine operator.
Objectives
When a student completes this study unit, he and she will be
able to:
• Recognize the basic machine motions that can present a
hazard to workers.
• Recognize the types of machinery most likely to be
hazardous to workers.
• Understand the types of injuries caused by accidents
commonly associated with unsafe machine operating
procedures.
• Discuss the importance of machine guarding and how to
incorporate methods of guarding to avoid physical
injury.
• Recognize the four basic types of machine guards
commonly used in industry.
• Control various forms of hazardous machine energy
through the use of lockout / tagout procedures.
• Understand how and why to properly use personal
protective equipment for added protection when using
industrial equipment.
Contents
Introduction to Machine Safety; Machine Safeguarding;
Types of Machinery; Machine Controls and Control
Equipment; Protective Equipment and Procedures.
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3530A-B Automatic Screw Machines
Duration: 20 hours (includes 2 tests)
Course Prerequisites: Basic Machining Skills (Block X08)
Turret Lathes (3525A)
Turret Lathe Tools and Setups (2213)
What Students Learn: PART 1 (3530A). Types of Automatic Screw Machines;
Single-Spindle Chucking Lathe; Multiple-Spindle Chucking
Lathe; Bar-Type Lathes.
PART 2 (3530B). Tools and Setups; Single-Spindle Chucking
Lathe; Multiple-Spindle Chucking Lathe; Single-Spindle Bar
Machine; Swiss-Type Automatic Lathe; Single-Spindle Bar
Lathe; Multiple-Spindle Bar Lathe.
3525A Turret Lathes
Duration: 10 hours (includes 1 test)
Course Prerequisites: Basic Machining Skills (Block X08)
What Students Learn: Turret Lathe Design; Ram-Type Turret Lathes; Saddle-Type
Turret Lathes; Electronically Controlled Turret Lathes; Turret-
Lathe Basic Maintenance; Work-Holding and Work-Feeding
Devices.
2213 Turret Lathe Tools and Setups
Duration: 10 hours (includes 1 test)
Course Prerequisites: Turret Lathes (3525A)
What Students Learn:
Hexagon Turret Tool-Holding Provisions; Flanged,
Adjustable, and Floating Holders; Duplex Holder; Center
Drilling Tool; Knee Tool; Stock Stop Box Tools; End Former;
Taper Turner; Taper Forming Box Tool; Chamfering Tools;
Multiple Turning Head; Slide Tools; Boring Bars; Rack Tool;
Knurling Tool; Collapsing Taps; Self-Opening Dies; Cross
Slide Tool-Holding Provisions; Square Turret; Single Point
Cutters and Holders; Tool Posts; Forming Cutters and
Holders; Threading Toolholder; Tooling Principles;
Economics of Turret Lathe Setups; Bar Setups; Chucking
Setups.
386016 Fundamentals of Grinding
Duration: 10 hours (includes 1 test)
Course Prerequisites: Basic Machining Skills (Block X08)
What Students Learn: Forms of Abrasives; Classification of Abrasives; Abrasive
Grinding Processes and Machines; Standard Wheel Marking
System; Abrasive Types; Grain Size; Wheel Grade, Wheel
Structure, Wheel Bonds; Diamond and Cubic Boron Nitride
Wheels; Wheel Grinding Machines; Wheel Shapes; Grinding
Wheel Testing and Maintenance; Grinding Fluids or Coolants
Coated Abrasives; Applications and Characteristics of Coated
Abrasives; Factors Affecting Stock Removal and Finish; Safe
Practices for Grinding.
Special Notes: • Covers subject at an advanced, in-depth level.
• This updated course replaces course 5023.
386010 Cylindrical Grinding, Part 1
Duration: 10 hours (includes 1 test)
Course Prerequisites: Basic Machining Skills (Block X08)
What Students Learn: Types of Cylindrical Grinding Machines; Major Units of
Center-Type Grinders; Grinding Machine Controls; Grinding
Wheels; Coolants.
Special Notes: • This updated course replaces course 3560A.
• The entire course consists of study units 426010-
426011.
386011
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Cylindrical Grinding, Part 2
Duration: 10 hours (includes 1 test)
Course Prerequisites: Basic Machining Skills (Block X08)
What Students Learn: General Safety Information; Machine Setup Procedure;
Production Grinding; Roll Grinding; Grinding Applications;
Troubleshooting in Cylindrical Grinding.
Special Notes: • This updated course replaces course 3560B.
• The entire course consists of study units 426010-
426011.
386012 Surface Grinding, Part 1
Duration: 10 hours (includes 1 test)
Course Prerequisites: Fundamentals of Grinding (426016)
What Students Learn: Introduction to Surface Grinding; Types of Surface-Grinding
Machines; Components of Surface-Grinding Machines.
Special Notes: • This updated course replaces course 5024A.
• The entire course consists of study units 426012-
426013.
386013 Surface Grinding, Part 2
Duration: 10 hours (includes 1 test)
Course Prerequisites: Fundamentals of Grinding (426016)
What Students Learn: Preparing the Abrasive Wheel for Surface Grinding; Surface
Grinder Operations; Surface Finish and Measurement.
Special Notes: • This updated course replaces course 5024B.
• The entire course consists of study units 426012-
426013.
5962
Inspection of Shop Products
Duration: 10 hours (includes 1 test)
Course Prerequisites: Introduction to Algebra, Geometry, and Trigonometry (Block
X02)
What Students Learn: Specifications for Inspection; Tolerances, and Allowances;
Standards; First-Piece Inspection; Automatic Machine-Product
Inspection; Patrol Inspection; Batch Inspection; Final
Inspection; Screw Inspection; Measuring Threads; Three-Wire
Methods; Thread Gages; Comparators; Measuring Spur Gears;
Gaging Odd Teeth; Recurring Inspection; Ultrasonic
Equipment; Dynamic Balances; Inspection of Machined
Castings; Spectrographic Testing.
386E02 Quality Control for the Technician
Duration: 70 hours (includes 7 tests)
Course Prerequisites: Basic Industrial Math (Block X21)
What Students Learn: Part 1 (426026). Lesson 1 - Total Quality Management for
Technicians:
• Quality Systems, Communication, and Motivation;
Total Quality Management (TQM) Tools,
Responsibilities and Systems; Quality Costs:
Identifying, Controlling, Minimizing, Reporting and
Analysis; Planning and Conducting Audits; Inspection
Systems and Planning.
Lesson 2 - Blueprint and GD&T System Interpretation for
Inspection:
• Using Engineering Prints for Inspection; Working with
Geometric Dimensioning and Tolerancing Systems;
Graphical Inspection Analysis Procedures and
Advantages.
Part 2 (426027). Lesson 3 - Common Inspection Tools:
• Measurement Tools, Accuracy and Errors; Spring
Calipers; Gage Blocks; Indicators; Micrometers and
Vernier Instruments; Hole, Attribute, and Radius Gages;
Tapered Parallels; Measuring Threads; Calibration
Techniques.
Lesson 4 - Surface Plate Inspection Methods:
• Surface Plates and Gages: Care of Equipment;
Measuring Various Attributes with Surface Plates.
Lesson 5 - Special Measurement Equipment and
Techniques:
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• Digital Measuring Equipment; Using Optical Flats;
Measuring Surface Finish; Pneumatic Comparators;
Circularity and Cylindricity; Optical Comparators;
Coordinate Measurement Machines (CMM’s); Hardness
Testing.
Lesson 6 - Lot by Lot Acceptance:
• Basic Probability; Sampling Verses 100% Inspection;
Lot-by-Lot, Process Control and Random Sampling;
Using Mil-Std-105E for Sampling; Dodge-Romig
Tables; Mil-Std-414; Variable Sampling Tables;
Operating Characteristic Curves.
Lesson 7 - Statistical Process Control in Practice:
• Objectives and Tools for Process Control; Computing
Average, Range and Standard Deviation; Control and
Specification Limits; Identifying Processes In-Control;
Plotting Techniques; Control Charts and Pattern
Analysis; Process Capability.
Special Notes: • This course consists of a textbook and two supplemental
study guides. We recommend the course be purchased
in its entirety. However, if needed due to targeted
training, study guides (Parts 1 and 2) can be purchased
separately, with or without the textbook. Note that the
textbook is required for the Part 1 study guide. Call
Customer Service for pricing and ordering information.
5636A Boring Mills
Duration: 10 hours (includes 1 test)
What Students Learn: Fundamentals of Boring Mills; Basic Functions; Vertical
Boring Mills; Horizontal Boring Mills; Attachments and
Accessories; Special Boring Mills; Boring Mill Motions;
Boring Operations.
6118 Planers
Duration: 10 hours (includes 1 test)
Course Prerequisites: Shapers, Slotters, and Keyseaters (2222)
What Students Learn: Planer Cutting Action; Bed and Table Construction; Drive and
Lubrication Systems; Column, Crossrail, and Toolhead
Construction; Counterbalancing and Power Swiveling System;
Automatic Feed and Rapid-Power Traverse Systems;
Elevating and Clamping Mechanisms; Pendant Stations;
Cutters; Feeds and Speeds; Work-Setting Equipment; Planer
Practice.
6091 Broaching
Duration: 10 hours (includes 1 test)
What Students Learn: Broaching Principle; Broaching Tools; Internal Broaching;
Pull and Push Broaches; Chip Breakers; Burnishers; Manual
and Automatic Broach Pullers; Surface Broaches; Broaching
Machines; Broaching Press; Broaching Fixtures; Broaching
Practice; Cutting Speeds; Cutting Oils; Chip Disposal;
Dislodging a Stuck Broach.
2222 Shapers, Slotters, and Keyseaters
Duration: 10 hours (includes 1 test)
What Students Learn: Horizontal Reciprocating Equipment; Crank-Driven Shapers;
Stroke Length; Ram Quick-Return Motions; Stroke Area;
Rapid-Power Traverse; Universal Shaper; Hydraulic Shaper;
Draw-Cut Shaper; Work-Holding Devices; Automatic Tool
Lifter; Index Centers; Cutting Tools; Setting Length and
Position of Stroke; Overtravel and Machine Time; Speeds and
Feeds; Horizontal, Vertical, and Angular Shaping;
Duplicating; Slotters and Slotter Practice; Keyseaters;
Keyseater Bars and Cutters.
386029 Nontraditional Machining Technologies
Duration: 10 hours (includes 1 test)
Course Prerequisites: Toolmaking (2540A-C)
What Students Learn: Preview
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25
Think of the types of energy used in most manufacturing
processes. A lathe employs mechanical energy to remove
material from the work piece. The tool makes contact with the
work piece and the resulting shear causes the material to flow
over the tool. All traditional forms of metal cutting use shear
as the primary method of material removal. The primary
source of energy in traditional manufacturing is mechanical.
However, there are other sources of energy at work. Chemical
energy has a significant effect on every turning operation.
Think of the effect that different kinds of coolants have on the
cutting action of a tool. Some amount of chemical energy is
being used in most metal cutting operations. All forms of
manufacturing use more than one type of energy.
Nontraditional machining can be thought of as operations that
do not use shear as their primary source of energy. For
example, abrasive water jet operations use mechanical energy,
but material is removed by erosion. In this study unit, students
will learn more about nontraditional machining technologies.
When a student completes this study unit, he and she will be
able to:
• Explain how electrical discharge machining (EDM)
works.
• Describe the difference between wire and ram EDM.
• Explain how laser light is produced and how lasers are
used in industrial settings.
• Explain why a plasma cutting torch is so much hotter
than other types of cutting torches.
• Describe the difference between chemical and electro-
chemical machining.
• Explain how water can be made to cut steel.
• Describe the common manufacturing methods of rapid
prototyping.
Contents
Introduction to Machining Technologies; Electrical
Discharge Machining; Plasma Arc Cutting; Laser
Machining; Water Jet Machining; Chemical Machining;
Ultrasonic, Abrasive Flow, and Thermal Deburring;
Rapid Prototyping and Manufacturing.
3195 Hardening and Tempering
Duration: 10 hours (includes 1 test)
What Students Learn:
Methods of Heat Treatment; Gas-Fired and Electric Furnaces;
Controlled Atmospheres; Heating Baths; Crucible Furnace;
Oil and Air Tempering Furnaces; Quenching Baths;
Quenching Tanks; Heat-Treating Operations; Composition,
Properties, and Uses of Carbon Tool Steel; Heating and
Cooling for Annealing; Heating for Hardening; Oil-Hardening
Steels; Air-Hardening Steels; High-Carbon, High-Chromium
Tool Steels; Chisel Steels; Hardening and Tempering Taps
and Reamers; Twist Drills; High-Speed Steel Saws; Springs
and Chromium-Steel Rolls; Heat Treatment of Dies, Forged
Chisels, and Rock Drills; Structures of Alloy Steels; High-
Frequency Hardening; Dielectric Heating.
386017 Tool Grinding
Duration: 10 hours (includes 1 test)
Course Prerequisites: Fundamentals of Grinding (426016)
What Students Learn: Wheel Selection and Shapes; Oilstones; Honing Cutting
Tools; Grinding Single-Point Tools; Angle Calculations;
Universal Grinder; Drill Grinding; Testing Drill Points;
Grinding Milling Cutters; Clearance Grinding; Tooth Rest;
Grinding Side, Shank Angular, Inserted-Blade, and Helical
Cutters; Grinding Circular Saws, Formed Cutters, Gear
Cutters, Hobs, Reamers, Taps, Radial, and Tangential
Chasers; Grinding Carbide Tools; Grinding Internal and Slab
Broaches.
Special Notes: This updated course replaces course 5349.
3194 Tool Dressing
Duration: 10 hours (includes 1 test)
What Students Learn: Inspection of Steels; Cutting and Heating Tool Steel; Forging
Tools; Tipping Forged Tools; Annealing, Hardening, and
Tempering; Colors Corresponding to Hardening
Temperatures; Heating Furnaces; Heating Baths; Tempering
Furnace; Quenching Baths; Annealing, Hardening, and
Tempering High-Speed Steel.
2243 Gear Calculations
Duration: 10 hours (includes 1 test)
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26
What Students Learn: Kinds of Gears; Spur Gears; Spur-Gear Calculations in
Circular-Pitch System and in Diametral-Pitch System;
Involute System; Form of Helical Gear; Helical-Gear
Calculations; Bevel Gears; Laying Out Bevel Gears; Spiral-
Bevel Gears; Worms and Worm Gears; Worm-Gear and
Worm Calculations; Spiral Gears; Spiral-Gear Calculations.
5532A-B Gear Making
Duration: 20 hours (includes 2 tests)
Course Prerequisites: Practical Measurements (Block X22)
Plane Trigonometry (2309A-B)
Milling Machine Fundamentals (426031)
Milling Machine Indexing and Spiral Work (426035)
Gear Calculations (2243)
Milling Machine Cutting Tools (426032)
Milling Machine Practice and Operation, Part 1 (426033)
Milling Machine Practice and Operation, Part 2 (426034)
What Students Learn: PART 1 (5532A). Processes; Cutters; Tooth Dimensions;
Milling Spur Gear; Helical Gears; Bevel Gears; Worm Gears;
Internal Gears; Planning; Generating; Herringbone Gears.
PART 2 (5532B). Hobbing; Spiral Bevels; Hypoids; Gear
Finishing; Rack Shaving; Rotary Shaving; Curve Shaving;
Burnishing; Lapping; Grinding; Gear Inspection; Gear
Materials; Heat Treatment; Flame Hardening.
186075 Manufacturing Processes, Part 1
Duration: 10 hours (includes 1 test)
What Students Learn:
• Relate historical trends in manufacturing to
modern ones
• Describe the development and importance of
modern quality systems
• Explain how available material types shape
manufacturing processes
• Describe early factory systems and their impact
on modern systems
• Classify modern manufacturing systems by type
and abilities This course replaces 2520A
186076 Manufacturing Processes, Part 2
Duration: 10 hours (includes 1 test) \
What Students Learn:
• Explain the relationship between atomic
structure and material properties
• Classify materials used in manufacturing based on physical and mechanical
properties
• Identify benefits and drawbacks of
specific materials for a given application
• Interpret the classifications of various
metallic materials
• Compare properties of various metallic
materials
• Identify properties of and applications for
various nonmetallic materials
NOTE: This course replaces 2520B
186077 Manufacturing Processes, Part 3
Duration: 10 hours (includes 1 test)
What Students Learn:
• Describe common methods and applications for
casting metals and plastics
• Describe and contrast various forming processes
including forging, drawing, and others
• Differentiate between the benefits and costs of
casting and forming processes
• Explain how the various conventional metal-
©Sep-20 Education Direct, All Rights Reserved.
27
removal technologies are used in
manufacturing
• Identify the benefits of and range of applications
for robotics and CNC systems in
manufacturing
• Describe the benefits and costs of non-contact
metal removal and shaping processes
NOTE: This course replaces 2520C
186078 Manufacturing Processes, Part 4
Duration: 10 hours (includes 1 test)
What Students Learn:
• Relate the factors of production to how a given
manufacturing organization is structured
• List the types of manufacturing production
systems
• Suggest modifications of equipment layout to
improve productivity
• Evaluating automation strategies and problems
• Benefits of quality management methods
• Describe their role in JIT, Lean, and e
Manufacturing systems
NOTE: This course replaces 2520D
086E06 CNC Technology and Programming
Duration: 45 hours (includes 3 tests)
Course Prerequisites: Basic Machining Skills (Block X08)
What Students Learn:
• Introduction to Computer Numerical Control: History
of Numerical Control; Types of Numerical Control
Machines; Point-to-Point vs. Continuous Path; Machine
Tool Axes; Components of CNC Machines; Why
CNC?; Axes and Coordinate Systems; Absolute and
Incremental Programming.
• Fundamentals of Programming: Word Address
Programming; Part Programming; Programming
Procedures; Incremental Positioning; Circular
Interpolation; Tool Length Offset; Tool Diameter
Offsets.
• Basic Trigonometry: Pythagorean Theorem; Sine,
Cosine, and Tangent.
• Carbide Fundamentals: Fundamentals of Carbide
Tooling; Insert Selection; Insert Selection Practice; Tool
Holder Style and Identification; Chip Control;
Troubleshooting.
• Machining Centers: Types of Machining Centers; Parts
of the Machining Center; Axes of Motion; Work
Holding Devices; Tools and Tool Holders; Tools for
Milling; Climb and Conventional Milling; Cutting
Speed, Feed, and Depth of Cut; Machining Center
Operation; Safety; Machine Control Features;
Workpiece Coordinate Setting; Other Control Features;
Conversational Programming.
• Programming Machining Centers: Planning the
Program; Canned Cycles for Machining Centers.
• CNC Turning Machines: Introduction to Turning
Centers; Types; Components of CNC Lathes; Turning
Machine Axes Identification; Work Holding; Cutting
Tools; Presetting Tools; Offsets; Material Handling;
Machine Control Operation; Manual Control; Program
Editing; Diagnostics; Conversational Programming.
• Programming CNC Turning Machines: Review of
Turning Centers; Planning the Program; Quick Review
of Programming; Circular Interpolation; Canned Cycles
for Turning Centers.
• Electrical Discharge Machining (EDM): Introduction to
EDM; Cutting With EDM; Types of Wire EDM
Machines; Parts of the Wire-Feed EDM; Machine
Setup; Programming.
• Fundamentals of Communications: Introduction;
Levels of Plant Communication; Local Area Networks
(LANs); CNC Communications; Cabling
Configurations; A Simple Communication Network.
• Fundamentals of Statistical Process Control:
Introduction to Statistical Process Control; Types of
Data; Coding Data; Graphic Representation of Data;
Basics of Variation; Chance and Assignable Variation;
Average (mean); Measures of Variation; Normal
Distribution.
• Statistical Process Control: Process Capability; Benefits
of Charting; Charting Processes; Analyzing the Chart.
• Introduction to ISO 9000: Introduction to ISO 9000
Basics; The ISO 9000 Standards; Levels of
Documentation; Benefits of a Quality System; ISO
Elements; ISO Implementation; Certification; QS 9000.
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• Fundamentals of CAD/CAM: Introduction to
CAD/CAM; Design; Computer-Aided Design (CAD);
Use of CAD; Advantages of CAD; Computer-Aided
Part Programming (CAPP); Post-Processors;
Simulation; Downloading CNC Programs; The Future
of Design.
386028 Toolholding Systems
Duration: 10 hours (includes 1 test)
Course Prerequisites: Toolmaking (2540A-C)
What Students Learn: Preview
Trainees have studied the process of machining and the
various types of machine tools that are used in manufacturing.
In this study unit, they will take a closer look at the interface
between the machine tools and the work piece, the toolholder.
In today's modern manufacturing environment, many
sophisticated machine tools are available, including standard
types and CNC machines with special accessories to aid high-
speed machining. Many of these new machine tools are very
expensive and have the ability to machine quickly and
precisely. However, if a careless decision is made regarding a
cutting tool and its toolholder, a poor product quality will
result, no matter how sophisticated the machine. In this study
unit, trainees will learn some of the fundamental
characteristics that most toolholders have in common, and
what information is needed to select the proper toolholder.
Objectives
When a student completes this study unit, he and she will be
able to:
• Understand the fundamental characteristics of
toolholders required for various machine tools.
• Understand and describe how the toolholder affects the
quality of the machining operation.
• Interpret national standards for tool and toolholder
identification systems.
• Recognize the differences in toolholder tapers and the
proper applications for each type of taper.
• Explain the effects of toolholder concentricity and
imbalance.
• Find additional information from manufacturers
concerning toolholder selection.
Contents
Overview of Machine Tools; Toolholders for Conventional
Machine Tools; Toolholders for Computerized
Numerical Control (CNC) Applications; Safety with
Toolholders and Cutting Tools.
386041 CNC Turning
Duration: 10 hours (includes 1 test)
Course Prerequisites: Basic Machining Skills (Block X08)
CNC Technology and Programming (066903)
What Students Learn: Preview
This study unit is designed to provide the trainee with an
advanced discussion on CNC turning. This unit may be used
as an advanced supplement to a basic introduction to CNC
turning. Apprentices, machine shop personnel, and students
with basic CNC turning experience can use this unit. The
information in this unit will briefly review the basics, and then
continue with more in-depth discussions of advanced CNC
topics.
This unit uses both the English and Metric standards. Program
examples will be provided for both standards without
conversions between the two. Generally, programs are written
in either standard, depending on the requirements of the
particular job. If a Metric print is provided, then the program
is usually written in Metric format, without conversion. The
same is true for a print provided in English dimensions.
Objectives
When a student completes this study unit, he and she will be
able to:
• Apply basic concepts to advanced turning programs.
• Understand the application of canned cycles,
subroutines, loops, and other advanced concepts.
• Understand how special codes are used to automate
complete jobs, including dual turret turning centers.
• Understand how speeds and feeds are affected by CNC
operations.
• Understand how to correct common problems such as
part size and
feature locations that are out of tolerance.
Contents
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CNC Safety Procedures: Axis and Coordinate Systems:
Axis Systems and Machine Axis Orientation; Cartesian
vs. Polar Coordinates; Absolute vs. Incremental Moves;
Origins; Machine Zero; Part or Program Zero; Local
Zero; Introduction to G AND M Coded Programs: Basic
Codes and Definitions; Miscellaneous Codes and
Program Control; Speeds and Feeds: Constant RPM
versus Constant Surface Speed; Feed per Minute versus
Feed per Revolution; 2-Axis Lathe Programming: Lathe
Examples with Rotary Axis; Canned Cycles for Lathes:
Metal Removal; Threading; Advanced Lathe
Programming: Subroutines; Loops; Dual Turrets; Math,
Logic, and Variables; Reference Points, Offset and
Correcting for Common Problems: Locating Zero and
Reference Points: Shifting Reference Points: Cutter
Compensation: X and Z Offsets; Tool Nose Radius and
Tool Type; Wear Offsets; Correcting Common
Problems.
386042 CNC Milling
Duration: 10 hours (includes 1 test)
Course Prerequisites: CNC Technology and Programming (066903)
What Students Learn:
• Apply of canned cycles, subroutines, and loops in
real-world programming applications.
• Modify and adapt basic programs and commands to
develop advanced milling programs.
• Use special codes to automate complete jobs,
including programming for maximum production
efficiency.
• Affect of some CNC operations on cutting speeds
and feed rates.
• Correct common problems such as unacceptable part
size and out-of- tolerance feature locations.
Optional: Tool & Die Maker
Skills
5282A-C Mechanics of Materials
Duration: 30 hours (includes 3 tests)
Course Prerequisites:
Introduction to Algebra, Geometry, and Trigonometry (Block
X02)
What Students Learn: PART 1 (5282A). Comparison of Materials; Simple Stresses;
Reactions; Deformation; Elastic Properties of Materials;
Allowable Unit Stresses; Factor of Safety; Investigation and
Design of Simple Tension and Compression Members;
Members Subjected to Shear; Hollow Thin Cylinders;
Temperature Stresses; Riveted Joints; Welded Joints; Bolted
Connections in Steel Fastenings for Timber.
PART 2 (5282B). Fixed and Moving Loads on Beams;
Reactions at Beam Supports; Cantilever; Simple and
Overhanging Beams; Continuous Beams and Beams with
Fixed Ends; Points of Inflection; Maximum Shear and
Bending Moment in Beams; Shear and Bending Moment
Diagrams.
PART 3 (5282C). Flexural Stresses in Beams; Moment of
Inertia and Section Modulus; Shearing Stresses in Beams;
Stresses Due to Torsion; Torsion and Bending in Circular
Shafts; Deflections of Beams; Investigation and Design of
Beams; Theory of Column Design Radius of Gyration;
Investigation and Design of Columns.
3541A-D Heat Treatment
Duration: 40 hours (includes 4 tests)
Course Prerequisites: Practical Measurements (Block X22)
Elements of Chemistry (5011)
What Students Learn: PART 1 (3541A). Steel Ingots; Hot Working of Steel; Effects
of Hot Working on Microstructure; Cold Working of Steel;
Heat-Treating Equipment; Cooling Mediums and Devices;
Temperature Measurement and Control; Miscellaneous
Equipment; Metric System Conversion Information.
PART 2 (3541B). Composition of Carbon Steels; Heat-
Treating Processes; Heat-Treating Equipment.
PART 3 (3541C). Composition of Alloy Steels; Heat
Treatment of Alloy Steels; Properties of Low-Alloy Steels;
Special Steels; Case Hardening; Furnace Atmospheres.
PART 4 (3541D). Classification and Description of Tool
Materials; Inspection, Test, and General Heat-Treating
Processes; Heat-Treating Equipment; Typical Procedures of
Heat-Treating Tool Steels.
5101A-B Dies and Die Making
Duration: 20 hours (includes 2 tests)
Course Prerequisites:
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Basic Machining Skills (Block X08)
What Students Learn: PART 1 (5101A). Dies for Sheet-Metal Work; Cutting Dies;
Punch Presses; Speeds of Punch Presses; Attaching Dies to
Presses; Examples of Die Work; Machine Tool Equipment for
Die Making; Making Cutting Dies; Selecting Materials for
Dies; Preparation of Die Blanks; Layout of Die; Making
Templets; Machining of Die Blank; Making Stripper and
Punch Plate; Forms of Cutting Dies; Shear of Dies; Making
Progressive Cutting Dies; Making Subpress Cutting Dies.
PART 2 (5101B). Making Shaping Dies; Drawing Dies; Size
of Blanks; Deep Cylindrical and Non-Cylindrical Cups;
Redrawing Dies; Making Dies for Curling, Wiring, Seaming,
Coining, Extruding, and Embossing; Making Combination
Dies; Cutting, Drawing, and Embossing Combination Dies;
Combination Forming and Swaging Dies; Combination
Blanking, Piercing, and Swaging Dies; Progressive
Combination Dies; Hardening and Tempering of Dies;
Prevention of Cracks; Die Setting Estimating Capacity of
Press; Lubrication of Dies; Mechanical Feeds for Punch
Presses.
3199 Forging Dies
Duration: 10 hours (includes 1 test)
Course Prerequisites: Dies and Die Making (5101A-B)
What Students Learn: Construction and Use of Drop-Forging Dies; Nature and
Construction of Press-Forging Dies; Bending Dies.
3197 Making Forging Dies
Duration: 10 hours (includes 1 test)
Course Prerequisites: Dies and Die Making (5101A-B)
What Students Learn: Kinds of Steel Used in Making Forging Dies; Annealing,
Hardening, and Tempering Treatment of Die Blocks; Machine
Tools Used in Working with Die Sinkers; Using Hand Tools
in the Diemaking Practice; Laying Out and Machining Die
Blocks; Handwork on Die Impressions; Making Breakdowns
and Trimming Dies.
2540A-C Toolmaking
Duration: 30 hours (includes 3 tests)
Course Prerequisites: Basic Machining Skills (Block X08)
What Students Learn: PART 1 (2540A). General Toolroom Work; Materials and
Equipment; Procedure and Measurements; Limitations of
Toolmaking; Examples of Toolmaking and Toolmaking
Operations.
PART 2 (2540B). Cutting Tools; Hand Taps; Machine Taps;
Taper Taps; Hobs; Dies for Thread Cutting; Die Holders;
Reamers; Theory of Cutting Tools.
PART 3 (2540C). Counterbores; Hollow Mills; Milling
Cutters; Screw Machine, Turret Lathe, and Broaching Tools.
5098 Gage Making
Duration: 10 hours (includes 1 test)
Course Prerequisites: Basic Machining Skills (Block X08)
What Students Learn: Classification, Accuracy, and Tolerances; Materials for Gages;
Proportions of Gages; Grinding and Lapping Gages; Making
Thread Gages; Making End-Measuring Gages; Making
Caliper Gages; Limit Gages; Flat-Surface Gages; Angular
Gages; Making Straightedges; Making Taper Gages; Contour
Gages; Pin Gages; Cylindrical Square; Indicator Gages; Ball
Gages; Gaging Teeth of Spur Gears; Gaging Compound
Angles; Sine-Bar Angles for Lathe Tools, Templets, and
Templet Making.
5099 Jigs and Fixtures
Duration: 10 hours (includes 1 test)
Course Prerequisites: Basic Machining Skills (Block X08)
What Students Learn: Types of Jigs; Examples of Jigs; Jig Parts and Accessories;
Bushings; Jig Covers and Clamps; Miscellaneous Details of
Jigs; Fixtures; Common Vise Fixture; Special Vise Fixture;
Bolted Fixture: Combination Jig and Fixture; Trunnion
Fixture; Roller Fixture; Broaching Fixture.
5100 Jig and Fixture Making
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Duration: 10 hours (includes 1 test)
Course Prerequisites: Basic Machining Skills (Block X08)
What Students Learn: Processes in Jig and Fixture Making; Planning; Machining;
Locating and Producing Holes; Locating Centers by Buttons;
Locating by Calculation; Locating Buttons by Rings and
Disks; Micrometer Measurements with Rings; Locating Holes;
Examples of Jig Making; Making Jig Bushings; Master Plates;
Continuous Dialing; Setting Up Indexing Jigs: Making Jigs on
Drilling Machines; Checking Jigs; Making Plate Jigs; Making
Fixtures.