Course Description

USE OF HAND AND BENCH TOOLS

Hand tools

Cut threads with taps and dies.

Remove threaded fasteners and repair threads.

Deburr parts.

Sharpen and polish tools using abrasive stones.

Disassemble, assemble, and straighten parts using arbor press.

Disassemble, fit, and reassemble parts.

Work materials with hand tools.

Demonstrate correct use of files.

Use other tools (hacksaws, chisels, screwdrivers, punches, hand wrenches, and pliers).

Cut keyways with broach.

USE OF POWER TOOLS

Portable power tools

Demonstrate safe use and handling of portable power tools (drill, grinders).

Finishing parts

Polish parts using coated abrasives.

Finish parts with hand grinders.

Polish and buff parts with portable hand tools.

Set up and use hone to apply specified surface in hole and fit to part or size.

Work materials with portable power tools.

ANALYSIS OF MEASUREMENTS

Inspection

Inspect parts with precision measuring tools.

Inspect parts with comparison measuring tools.

Set up and inspect parts using dial indicators.

Inspect and measure keyways.

Inspect surface finish of parts.

Inspect parts according to quality control and inspection standards and procedures.

Inspect machined parts.

Inspect assemblies.

Inspect parts with metric measuring instruments.

Verification

Measure parts using optical comparators.

Measure parts using electronic measuring tools.

Verify dimensions.

Verify alignments.

Verify clearance fit or interference fit.

Analysis and action

Define steps to be taken to correct procedures that have resulted in faulty or rejected parts.

Explain the use of Pareto and fishbone charts.

SAFETY AND TERMINOLOGY

SAW AND BLADE SELECTION

Type of machine

Explain the various types of saws (cold saws, vertical and horizontal band saws, and power hacksaws).

Determine which type of saw should be used to cut the workpiece to blueprint specifications.

Geometry of workpiece

Describe how the geometric shape of the workpiece would affect the machine selection and workholding device.

Type of material

Explain how the type of material dictates the type of blade, pitch, and machine which would be used in cut-off operations.

Types of blades available for a specific function

Use H.S.S. and bi-metal band saw blade tables.

List the types of hacksaw and circular saw blades that are available.

Pitch and set

Define pitch, set, and the variations of pitch or set that are available on the cut-off and band saw.

Use correct pitch for size and type of material.

FEED AND SPEEDS DETERMINATION

Feed and speed tables

Use feed and speed tables to set up machines.

Feed and speed calculations via Machinist's Handbook formulas

Calculate and set cutting feed and speed rate for sawing.

USE OF COOLANTS

Coolants

Use and maintain coolant system for sawing.

SAW AND BLADE MAINTENANCE

Maintenance

Remove and replace saw blades.

Cut and weld band saw blades.

Set up and use stops and guides to control dimension of cuts.

Perform basic saw maintenance.

SAWING OPERATIONS    

Planning

Plan sequence of sawing operations.

Lay out workpiece with dye, scribed lines, and points.

Vertical band saws

Saw straight, curved, and irregular lines on vertical band saw.

Use of jigs and fixtures

Set up workpiece in sawing machine using jigs and fixtures.

Horizontal band saws

Saw materials to layout on vertical band saw.

Vertical band saws

Set up and use vertical band saw for interior contour sawing.

Set up and use vertical band saw to file parts.

Cut straight lines on vertical band saw using automatic feed.

Cut angles on vertical band saw by tilting table.

Slot, groove, miter, and trim parts on saw.

Set up and use power hacksaw for production work.

Set up and use horizontal band saw for production work.

Set up and use friction saw for production work.

Set up and use rubber disk saw for production work.

DRILLING SET UP AND OPERATION

Proper tool determination

Select drills using drill chart.

Use and maintain coolant system for drilling.

Sequence of operations determination

Change drills and tool holders.

Calculate and set drilling speeds, feeds, and depth of cut.

Drill maintenance

Align workpiece, jigs, and fixtures with drill spindle.

Speeds, feeds, and depth of cut calculation

Align tools with drill guide bushings.

Position spindle over hole location by swinging radial arm.

Drill setup

Perform basic drilling machine maintenance.

Plan sequence of drilling operation.

Set up drill press.

Sharpen drills.

Determine operation and location from blueprint.

Drilling operations

Center drill and drill holes to size.

Other drill press operations

Countersink, counterbore, and spot face parts to specifications.

Drill blind holes to specifications.

Drill deep holes to specifications.

Drill holes to specifications using special drills.

Thread parts using tapping attachment.

Ream holes to size.

Set up drill to layout using edge finder.

ISO 9000       

Definition

Explain the procedures that are put in place in an ISO 9000 company.

Define the guidelines in the ISO 9000 documentation.

Benefits

Explain the benefits of participation in the ISO 9000 program.

DEMING'S QUALITY THEORY

Management

Recall Deming’s 14 points for management.

Define Single Sourcing.

Employee participation

State several ways machine tool technologists might participate in decision making.

Inspection

Summarize Deming’s philosophy on inspection of incoming or outgoing goods.

QUALITY GOALS AND OBJECTIVES

Organization for quality

Define responsibilities for quality.

Describe the quality function and the quality manager’s responsibilities.

Give examples of the composition of quality councils, committees, and teams.

Planning for quality

Give examples of flow charts.

Describe planning for just-in-time management.

Construct a model for measuring customer (dis)satisfaction.