32420328Machine Tool 7
Course Information
Description
Set-up and operate a CNC EDM machine, CNC machining center, and select and use superabrasives for grinding and machining. Advanced machining setups, procedures, and operations will be covered to enable students to accomplish the machining projects. 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
    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. Develop and machine an electrode for EDM machining
    Assessment Strategies
    Skill demonstration in the lab
    Using lab equipment selected by the student
    When electrode is machined to the proper undersize to achieve blueprint specifications
    On electrodes for dovetail project
    Criteria
    Select the appropriate electrode material
    Complete electrode size worksheet
    Generate the geometry and size necessary to produce the cavity detail
    Machine finishing electrode to the blueprint specifications
    Machine roughing electrode to blueprint specifications

  3. Setup a CNC EDM machine
    Assessment Strategies
    Select the appropriate electrode material
    Complete electrode size worksheet
    Generate the geometry and size necessary to produce the cavity detail
    Machine finishing electrode to the blueprint specifications
    Machine roughing electrode to blueprint specifications
    Criteria
    Choose proper workholding devices and rigidly mount workpiece to machine table
    Activate proper screens to position electrode and workpiece
    Execute centering or edge finding program
    Tram workpiece to machine axes and set zero point
    Select and load correct program and technology file
    Attach flushing lines
    Set flushing levels, pressure, and locations

  4. Program a CNC EDM machine
    Assessment Strategies
    In class programming assignment
    With Makino graphite technology chart and handouts
    With computer selected by student
    On vise dovetail project
    By 4th week of the semester
    Criteria
    Recognize and use preform commands in programming
    Use both absolute and incremental positioning
    Calculate frontal surface area of electrode
    Use Makino worksheet to determine surface finish, number of electrodes, and rough settings
    Use graphite technology chart to calculate generator settings and electrode undersize for both down and orb commands
    Generate a complete program with multiple tool changes
    Key in program on a computer with ASCII format or Makino control

  5. Operate a CNC EDM machine
    Assessment Strategies
    Skill demonstration in the lab
    With the Makino CNC EDM and reference manual
    Using the lab equipment selected by the student
    Using fixturing provided
    By verifying the size and depth of burn and adjusting if necessary to achieve blueprint specifications
    On vise dovetail project
    Criteria
    Mount the workpiece to the fixture, and set fixture locations
    Load electrodes into toolchanger and set tool length offsets
    Load and activate correct technology file for the specific burn
    Fill dielectric tank, set float level
    Load and execute correct program from memory or thumb drive
    Demonstrate file management techniques
    Select the proper computer screens to monitor positions and burn progress
    Adjust flushing to achieve maximum burn and safety
    Activate correct screens and commands to change successive (multiple) tools
    Activate correct screens to edit program file for multiple burn locations
    Verify burn depth and diameters – adjusting if necessary to achieve blueprint specifications
    Shut down machine after completion of program
    Follow all safety practices – both general and specific to the CNC EDM

  6. Setup a CNC machining center
    Assessment Strategies
    Skill demonstration in the lab
    With the Haas, Doosan, and Okuma CNC machining center and reference manual
    Using lab equipment selected by student
    On vise dovetail, R8, and indicator projects
    Criteria
    Use proper workholding devices and rigidly mount workpiece to machine table
    Tram workpiece to machine axes and set zero point
    Install tools into holders, and set fixture and tool length offsets
    Select and load correct program

  7. Program a CNC machining center
    Assessment Strategies
    Skill demonstration in the lab
    Using the Haas, Doosan, and Okuma CNC machines
    On vise dovetail, R8, and indicator projects
    When machined part or detail matches blueprint specifications
    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
    Assign the proper tool for a specific operation
    Choose the proper cutter entry and exit position/path
    Select the appropriate tool change position
    Edit part geometry and toolpath
    Proof toolpath through back plotting
    Assign a filename and post processes the file

  8. Operate a CNC machining center
    Assessment Strategies
    Skill demonstration in the lab
    Using the Haas, Doosan, and Okuma CNC machines
    On vise dovetail, R8, and indicator projects
    When machined detail or part conforms to blueprint specifications
    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
    Shut down machine properly
    Follow all safety practices – both general and specific to the CNC machining center

  9. Use Cubic Boron Nitride and Diamond superabrasives for grinding
    Assessment Strategies
    Skill demonstration in the lab
    Given a superabrasive grinding wheel, brake controlled truing device, and aluminum oxide dressing stick
    With a surface grinder
    On selected tool steels
    Criteria
    Pass superabrasive grinding test
    Select and use the proper type of wheel for grinding on a variety of tool steels
    Select the proper type of wheel for grinding on non-ferrous materials.
    Mount a superabrasive grinding wheel on the grinder
    Condition the grinding wheel using both trueing and dressing procedures

  10. Use advanced setups and procedures on manual vertical and horizontal milling machines
    Assessment Strategies
    Skill demonstration in the lab
    With Bridgeport vertical mill
    With horizontal mill
    With the Machineries handbook and a calculator
    Using cutting tool selected by the student
    Using an offset boring head
    On vise dovetail, R8, and indicator projects
    Criteria
    Choose proper workholding 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 diameters to blueprint specifications
    Bore hole locations and tap holes to blueprint specifications
    Line bore hole locations and diameters to blue print specifications
    Mill slots, pockets, angles, radii, and chamfers to blueprint specifications
    Follow all safety practices – both general and specific to milling machines

  11. Use advanced setups and procedures on manual lathes
    Assessment Strategies
    Skill demonstration in the lab
    With manual lathe
    With Machineries handbook and calculator
    Using cutting tools and holders selected by the student
    On R8 and indicator projects
    Criteria
    Use proper workholding 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 specification
    Center drill, drill, chamfer, and tap holes to blueprint specifications
    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 lathes

  12. Use advanced setups and procedures on surface grinders
    Assessment Strategies
    Skill demonstration in the lab
    Using tools and equipment selected by the student
    On the surface grinders
    Using precision angle plates, magnetic sine chuck, and magnetic parallels
    On vise dovetail and indicator projects
    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
    Follow all safety practices – both general and specific to surface grinders

  13. Operate a CNC wire EDM
    Assessment Strategies
    Skill demonstration in the lab
    Using the Makino wire EDM machine
    On indicator holder project
    When machined detail or part conforms to blueprint specifications
    Criteria
    activate the proper screens and load the correct program
    Check program
    Use Model Plan to create a technology file for roughing, and finish cuts
    Activate proper CNC program, wire, and technology files
    Check user and EDM parameters page
    Activate graphics screen to plot wire geometry path on CNC control screen
    Check info page to monitor burn process
    Shut down machine properly
    Follow all safety practices – both general and specific to the CNC wire EDM

  14. Verify accuracy of machining using dimensional metrology practices and equipment
    Assessment Strategies
    Skill demonstration in the 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 dovetail, R8, and indicator projects
    Criteria
    Measure dimensional accuracy of the part on the machine using indicators, outside micrometers, depth micrometers, inside micrometers, calipers, telescoping gages, small hole 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

  15. Heat treats various tool steels using sound metallurgical practices
    Assessment Strategies
    Skill demonstration in the lab
    With the manufacturers heat treating specifications chart
    Using tempering and heat treating furnaces
    Using tools and equipment selected by the student
    Using a Rockwell hardness tester
    On vise dovetail or special project
    Criteria
    Decipher the appropriate time to heat treat within a manufacturing sequence
    Determine the correct temperature, length of time, and quenching medium for hardening the workpiece
    Determine the temperature and soak time for the tempering process based on the desired Rockwell hardness
    Perform visual inspection and Rockwell hardness test on the workpiece to determine heat treating success