32420327Machine Tool 6
Course Information
Description
Provides the student with the skills and knowledge necessary for advanced setups and procedures on milling machines, grinders, and lathes. Students are also introduced 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 also enhanced. Building a stamp die. Safety, precision measurement and craftsmanship are stressed.
Total Credits
5
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. Setup a CNC machining center
    Assessment Strategies
    Skill Demonstration in Lab
    With the Haas, Dousan, and Okuma CNC machining centers and manuals
    Using lab equipment selected by student
    On vise and stamp die projects by instructor specified date
    Criteria
    use proper workholding devices and rigidly mount workpiece to machine table
    tram workpiece to machine axes and set zero point
    select and load correct program
    install tools into holders and set tool length offsets

  3. Program a CNC machining center
    Assessment Strategies
    Skill Demonstration in the Lab
    Using the Haas, Dousan, and Okuma CNC machining centers
    On vise and stamp die projects by instructor specified date
    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

  4. Operate a CNC machining center
    Assessment Strategies
    Skill Demonstration in Lab
    Using the Haas, Dousan, and Okuma CNC machining centers and reference manuals
    On vise and stamp die projects by instructor specified date
    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

  5. 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 stamp die and precision vise projects by instructor specified date
    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

  6. Use advanced setups and procedures on manual vertical and horizontal milling machines
    Assessment Strategies
    Skill Demonstration in Lab
    With bridgeport vertical mill
    With horizontal mill
    With the Machinery’s handbook and a calculator
    Using cutting tool selected by the student
    Using an offset boring head
    On stamp die and precision vise projects by instructor specified date
    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, 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

  7. Demonstrate skills in using machine tool accessories
    Assessment Strategies
    Skill Demonstration in Lab
    Using the Haas, Dousan, and Okuma CNC machines
    Using tools and equipment selected by the student
    On vise and stamp die projects by instructor specified date
    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, rotary tables, and index heads
    use magnetic chucks, v-blocks, and parallels
    use offset boring heads
    use DRO (digital readout systems)

  8. Develop and machine an electrode for EDM machining
    Assessment Strategies
    Skill Demonstration in Lab
    Using lab equipment selected by the student
    On electrodes for precision vise project by instructor specified date
    Criteria
    select the appropriate electrode material
    complete electrode size worksheet
    generate the geometry and sizes necessary to produce the cavity detail
    machine finishing electrode to the blueprint specifications
    machine roughing electrode to blueprint specifications
    electrode is machined to the proper undersize to achieve blueprint specifications

  9. Setup a CNC EDM sinker
    Assessment Strategies
    Skill Demonstration in Lab
    With the Makino CNC EDM machine and reference manuals
    Using lab equipment selected by student
    On precision vise project by instructor specified date
    Criteria
    select a work holding device and rigidly mount the workpiece to the machine table
    tram or edge find the workpiece to establish the datum point
    mount the electrode to a holder and the machine ram
    select and load the correct technology file for the burn
    attach the flushing lines
    set flushing levels, pressures, and locations

  10. Operate a CNC EDM sinker
    Assessment Strategies
    Skill Demonstration in Lab
    With the Makino CNC EDM machine and reference manual
    Using tools and equipment selected by the student
    On the precision vise project by instructor specified date
    Criteria
    load and activate the correct technology file for the specific burn
    fill dielectric tank, set float level, and activate flushing
    initiate the burn cycle, and monitor the process making adjustments as necessary
    verify burn depth and size – adjusting if necessary to achieve blueprint specifications
    properly shut down machine
    follow all safety practices – both general and specific to the EDM machine

  11. Build and assemble small stamping die
    Assessment Strategies
    Skill Demonstration in Lab
    With tools and equipment selected by the student
    On canned stamp die project
    Criteria
    use prints
    apply machining techniques required to build a stamping die
    assemble, and fit the stamp die

  12. Setup a CNC wire EDM
    Assessment Strategies
    Skill Demonstration in Lab
    With the Makino CNC wire EDM and reference manual
    Using lab equipment selected by the student
    On stamp die or special machining project by instructor specified date
    Criteria
    use proper work holding devices and rigidly mount workpiece to machine table
    thread wire through wire rollers and initiate auto threading cycle
    position upper guide to correct height
    select the proper screens and operation keys to position the wire for edge finding part
    select and execute edge find and center find programs to establish part zero
    select and download correct part program

  13. Operate a CNC wire EDM
    Assessment Strategies
    Skill Demonstration in Lab
    Using the Makino CNC wire EDM machine
    On stamp die
    Criteria
    activate the proper screens and load the correct program
    check program
    activate proper CNC program, wire, and technology files
    activate graphics screen to plot wire geometry path on CNC control screen
    use Model Plan and Data book to create a technology file for roughing, and finish cuts
    check setup and Data pages to create a technology file for roughing, and finish cuts
    check operation page to monitor burn process
    properly shut down machine
    follow all safety practices both general and specific to the CNC wire EDM machined detail or part conforms to blueprint specifications

  14. 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

  15. Proof a stamping die using a stamp press
    Assessment Strategies
    Skill Demonstration in Lab
    Using the equipment and tools provided by the instructor
    With the stamping press
    On stamp die
    Criteria
    mount the die to the press bed
    work with the instructor on press operation parameters and setup
    run several piece parts, and verify dimensions and appearance to blueprint specifications
    make adjustments to the die and machine as necessary
    work with the instructor on machine shut down and die removal

  16. 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 vise and stamp die projects by instructor specified date
    Criteria
    measure dimensional accuracy of the part on the machine using indicators, outsidemicrometers, 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