32420326Machine Tool 5
Course Information
Description
Skills and knowledge necessary for advanced setups and procedures on milling machines, grinders, and lathes. Introduces both tool and cutter grinding and the selection and use of carbide tooling. Special emphasis is given to Electrical Discharge Machine and electrode development. CNC machining applications to complete course projects is enhanced. Safety, precision measurement and craftsmanship are stressed.
Total Credits
4
Course Competencies
  1. Use safety practices in all machine and hand work operations
    Assessment Strategies
    Test, Skill Demonstration in Lab
    Criteria
    you pass safety test
    demonstrate safety procedures
    operate machines with all required guards in place
    maintain clean and organized work environment
    wear appropriate clothing and Personal Protective Equipment (PPE)
    explain proper lock-out tag-out procedures

  2. Operate a CNC Wire EDM
    Assessment Strategies
    Skill Demonstration in Lab
    Using the Makino CNC Wire EDM
    On small V-Block
    Criteria
    load correct program, and activate the proper screens
    check program, and activate graphics screen to plot and verify the geometry path
    set fixture offsets
    initiate cycle start and monitor burn process
    measure part as per blueprint specifications
    properly shut down machine
    follow all safety practices – both general and specific to CNC Wire EDM machines
    machine detail or part conforms to blueprint specifications

  3. Gain skills in the understanding and use of carbide tooling
    Assessment Strategies
    Skill Demonstration in Lab
    Using the Machinery’s handbook and a calculator
    With carbide inserts and tool holders selected by the student
    On manual mills, lathes, and CNC machines
    On R-8 cutter, precision vise, and kant twist clamp projects
    Criteria
    explain the ASA carbide insert identification number
    explain the different geometries of carbide inserts in regard to strength, lead, and rake angles
    select the correct carbide insert and tool holder for a given application
    calculate the feed, speed, and depth of cut for a given application
    describe the basic types of tool wear and corrective actions
    turn, bore, and mill using carbide tooling

  4. Set up a tool and cutter grinder
    Assessment Strategies
    Test, Skill Demonstration in Lab
    With the Cincinnati universal tool and cutter grinder
    With the Weldon air flow fixture
    With the index head and centers
    With tools selected by the student
    Criteria
    you pass written tool and cutter grinding test
    Weldon air flow fixture is properly positioned, and the finger is the correct location of the grinding wheel and end mill
    mount the index fixture to the table and position the end mill in the correct location to the grinding wheel
    mount the end mill fixture on the surface grinder and position primary and secondary angles in relation to the grinding wheel
    position the wheel guard in a safe location, and ensure the correct rotational direction of the wheel

  5. Operate a tool and cutter grinder
    Assessment Strategies
    Skill Demonstration in Lab
    With a cutter clearance and relief chart
    Using tools selected by the student
    Using the Weldon air flow fixture
    Using the index fixture and centers
    Grinding a reamer between centers – Group demonstration
    Grinding the bottom of 2 end mills using the proper cutting clearance for the primary and secondary relief
    Grinding 2 end mills on the outside periphery using the proper cutting clearance for the primary and secondary relief
    Making a test cut in a piece of steel
    Criteria
    grind the bottom of an end mill with the proper primary and secondary relief angles
    grind the periphery of an end mill with the proper primary and secondary relief angles
    sharpened cutter passes a test cut
    cutter has been ground to designated size
    grind an end mill with proper clearances, and the cutter will efficiently cut when applied to a test cut
    describe a reamer with the correct edge relief and chamfer angle
    verify clearance angles using the indicator drop method and the cutter clearance gage
    follow all safety practices – both general and specific to the tool and cutter grinder

  6. Setup a CNC turning center
    Assessment Strategies
    Skill Demonstration in Lab
    With Dousan and Okuma CNC turning center and reference manual
    Using lab equipment selected by the student
    On R-8 carbide cutter and Kant Twist projects
    Criteria
    choose proper collet and rigidly mounts workpiece to the headstock
    grid or reference machine
    select and load the turret with the proper tooling for the job
    set tool length offsets for X (diameters)
    set tool length offsets for Z (zeroes)

  7. Program a CNC turning center
    Assessment Strategies
    Skill Demonstration in Lab
    With Dousan and Okuma CNC turning center
    Using Fanuc controller
    On R-8 carbide cutter & Kant Twist projects
    Criteria
    use Mastercam Lathe software to draw the part geometry
    assign the proper tool for a specific operation (generate tool path)
    use reference manual to look up and key in tool library information
    edit part geometry and tool path
    assign a filename and post processes the file
    demonstrate file management techniques

  8. Operate a CNC turning center
    Assessment Strategies
    Skill Demonstration in Lab
    With Dousan and Okuma CNC turning center
    Using lab equipment selected by the student
    On R-8 carbide cutter & Kant Twist projects
    Criteria
    load NC file from computer memory
    demonstrate file management techniques
    adjust feed and speed overrides, and activate program
    measure workpiece and adjusts tool offsets to compensate for diameter and length discrepancies
    verify finished part to blueprint specifications
    properly shut down machine
    follow all safety practices – both general and specific to the CNC turning center
    machined part matches blueprint specifications

  9. Setup a CNC machining center
    Assessment Strategies
    Skill Demonstration in Lab
    With the Haas and Dousan CNC machining centers and manuals
    Using lab equipment selected by student
    On precision vise, and kant twist clamps
    Criteria
    use proper work holding devices and rigidly mount workpiece to machine table
    tram workpiece to machine axes and set zero point
    set clear and reference points
    select and load correct program
    install tools into holders, and set tool length offsets

  10. Program a CNC machining center
    Assessment Strategies
    Skill Demonstration in Lab
    Using the Haas and Dousan machining centers
    On precision vise, and kant twist clamps
    Criteria
    manually program part geometry
    use off-line programming software to draw the part geometry
    use off-line programming software to generate the tool path
    choose the proper cutter entry and exit position/path
    assign the proper tool for a specific operation
    edit part geometry and toolpath
    proof toolpath through back plotting
    assign a filename and post process the file
    machined part or detail matches blueprint specifications

  11. Operate a CNC machining center
    Assessment Strategies
    Skill Demonstration in Lab
    Using the Haas and Dousan CNC machining centers and reference manuals
    On precision vise and kant twist clamps
    Criteria
    load correct program
    check program
    demonstrate file management techniques
    initiate cycle start and adjust feeds and speeds as necessary
    measure part as per blueprint specifications, and adjust tool lengths and offsets as required
    follow all safety practices – both general and specific to the CNC machining center
    properly shut down machine
    machined detail or part conforms to blueprint specifications

  12. Use advanced setups and procedures on surface grinders
    Assessment Strategies
    Skill Demonstration in Lab
    Using tools and equipment selected by the student
    On three different surface grinders
    Using precision angle plates, magnetic sine chuck, and magnetic parallels
    On precision vise project
    Criteria
    select the proper grinding wheel for a given application
    check and stone off magnetic chuck
    mount and dress the grinding wheel
    parallel grind and square workpiece to blueprint specifications
    properly remove grind stock relative to detail and hole locations
    set up magnetic sine chuck and grind angled surfaces both square and parallel to datum edges
    square a shoulder using the sidewheel method
    follow all safety practices – both general and specific to surface grinders

  13. Use advance setups and procedures on manual vertical milling machines
    Assessment Strategies
    Skill Demonstration in Lab
    With bridgeport vertical mill
    With digital readout
    With the Machinery’s handbook and a calculator
    Using cutting tool selected by the student
    Using an offset boring head
    On kant twist clamp and precision vise projects
    Criteria
    choose proper work holding devices and rigidly mount workpiece to machine table
    edge find or tram workpiece to establish datum position
    select the proper size cutting tool for the application
    calculate the proper feed and speed for a variety of cutting tools
    parallel mill and square workpieces to blueprint specifications
    spot drill, drill, chamfer, and ream holes to blueprint specifications
    center drill, drill, chamfer, and tap holes to blueprint specifications
    bore hole locations and diameter to blueprint specifications
    line bore hole locations and diameters to blue print specifications
    mill slots, angles, radii, and chamfer to blueprint specifications
    mill pockets to blueprint specifications
    follow all safety practices – both general and specific to the milling machine

  14. Setup and operate manual horizontal milling machines
    Assessment Strategies
    Skill Demonstration in Lab
    Using tools and equipment selected by the student
    With horizontal mill
    On precision vise project
    Criteria
    choose the proper work holding device and rigidly mounts the workpiece to the machine table
    edge find or tram the workpiece to establish the datum position
    select the proper cutting tool and arbor for the application
    calculate the proper feed and speed for a variety of cutting tools
    parallel mill and square the workpiece to blueprint specifications
    mount milling cutters on arbors using an overarm support
    straddle mill, mill slot, and mill grooves
    follow all safety practices – both general and specific to the horizontal mill

  15. Use advanced setups and procedures on manual lathes
    Assessment Strategies
    Skill Demonstration in Lab
    With manual lathe
    With Machinery’s handbook and calculator
    Using cutting tools and holders selected by the student
    On kant twist clamps, R-8 cutter, and precision vise projects
    Criteria
    use proper work holding device to mount the workpiece to the machine spindle
    establish the datum or machining location
    select the proper cutting tool for the application
    calculate the correct feed and speed for all cutting tools
    turn diameters, shoulders, and angles to blueprint specifications
    center, drill, chamfer, and tap holes to blueprint specification
    spot drill, drill, and ream holes to blueprint specifications
    bore and counterbore hole diameters to blueprint specifications
    chase threads to blueprint specifications
    follow all safety practices – both general and specific to the lathe

  16. Demonstrate skills in using machine tool accessories
    Assessment Strategies
    Skill Demonstration in Lab
    Using manual machines and the CNC machines
    Using tools and equipment selected by the student
    On vise and kant twist clamp projects
    Criteria
    mount workpiece to and use milling vises
    mount work pieces to the machine table using parallels, vise stops, table stops, and strap clamps
    mount work pieces to the machine table using fixtures
    use sine bars, sine chucks, angle plates, angle vises, v-blocks, and index heads
    use magnetic chucks, v-blocks, and parallels
    use offset boring heads
    use DRO (digital readout systems)

  17. Heat treats project steels using sound metallurgical practices
    Assessment Strategies
    Skill Demonstration in Lab
    Using the manufacturer’s heat treating specification charts
    Using the heat treat and tempering furnaces
    Using a Rockwell hardness tester
    Criteria
    determine the correct temperature, length of time, and quenching medium for hardening the workpiece
    determine the tempering temperature and soak time to achieve the desired Rockwell hardness
    visually inspect and Rockwell hardness test the workpiece

  18. Verify accuracy of machining using dimensional metrology practices and equipment
    Assessment Strategies
    Skill Demonstration in Lab
    Using tools and equipment selected by the student
    While part is still mounted to the machine
    In the gage lab
    On a surface plate
    On V-block, kant twist clamps, and R-8 carbide cutter
    Criteria
    measure dimensional accuracy of the part on the machine using indicators, outside micrometers, depth micrometers, inside micrometers, calipers, telescoping gages, small hole gages, plug gages, and mating parts
    measure dimensional accuracy of the part on a surface plate using indicators, gage blocks, height gages, sine bars, angle plates, plug gages, and cylindrical squares
    measure length, width, height, locations, sizes, and angles using a CMM