32420329Machine Tool 8
Course Information
Description
Set-up and operate a CNC EDM machining center, and select and use superabrasives for grinding and machining. Includes advances machining setups, procedures, and operations to accomplish the machining of a small MUD plastic injection mold or special machining project. Safety, precision measurement, and craftsmanship are stressed.
Total Credits
5
Course Competencies
  1. Use safety practice 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. Setup a CNC EDM machine
    Assessment Strategies
    Skill demonstration in the lab
    With the Makino CNC EDM and reference manual
    Using lab equipment selected by the student
    On the mold die project
    By the 15th week of semester
    Criteria
    Choose proper work holding devices and rigidly mount work piece to machine table
    Activate proper screens to position electrode and work piece
    Execute centering or edge finding program
    Tram work-piece to machine axes and set zero point
    Select and load correct program and technology file
    Attach flushing lines
    Set flushing levels, pressures, and locations

  3. Program a CNC EDM machine
    Assessment Strategies
    In the class programming assignment
    With the Makino Data Book
    With computer selected by student
    On the mold die project
    By the 15th week of semester
    Criteria
    Recognize and use standard commands in programming
    Use both absolute and incremental positioning
    Calculate frontal surface area of electrode
    Use Makino Data Book to determine surface finish, number of electrodes, and rough and finish settings
    Use Makino Data Book 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 Model Plan

  4. Operate a CNC EDM machine
    Assessment Strategies
    Skill demonstration in the lab
    With the Makino CNC EDM and reference manual
    Using 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
    Criteria
    Load and activate correct technology file for the specific bum
    Fill dielectric tank, set float level, and turn on flushing
    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

  5. Setup a CNC machining center
    Assessment Strategies
    Skill demonstration in the lab
    With the Haas,  Dousan, or Okuma CNC machining center and reference manual
    Using lab equipment selected by the student
    On injection mold or special machining project
    Criteria
    Choose proper work holding devices and rigidly mount work piece to machine table
    Tram work piece to machine axes and set zero point
    Set fixture offsets
    Select and load correct program
    Install tools into holders, and set tool length offsets

  6. Program a CNC machining center - A
    Assessment Strategies
    Skill demonstration in the lab
    Using the Haas,  Dousan, or Okuma CNC machines
    On injection mold or special project
    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 tool path
    Proof tool path through back plotting
    Assign a filename and post processes the file

  7. 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 bar
    With horizontal mill
    With the Machineries handbook and a calculator
    Using cutting tool selected by the student
    Using an offset boring head
    On injection mold or special machining project
    Criteria
    Choose proper workholding devices and rigidly mounth 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 diameters to blueprint specifications
    Line bore hole locations and diameters to blueprint specifications
    Mill slots, pockets, angles, radii, and chamfers to blueprint specifications
    Follow all safety practices – both general and specific to milling machines

  8. Use advanced setups and procedures on manual lathes
    Assessment Strategies
    Skill demonstration in the lab
    With manual lathe
    With the Machineries handbook and a calculator
    Using cutting tools and holders selected by the student
    On injection mold or special machining project
    Criteria
    Use proper workholding devices to mount the workpiece to the machine spindle
    Establish the datum or machining location
    Select the proper size cutting tool for the application
    Calculate the proper feed and speed for a variety of 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 hole locations and diameters to blueprint specifications
    Chase threads to blueprint specifications
    Follow all safety practices – both general and specific to lathes

  9. 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 injection mold or special machining 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
    Follow all safety practices – both general and specific to surface grinders
    Grind angled surfaces

  10. Use PCBN and PCD superabrasive cutting tools for milling and turning
    Assessment Strategies
    Skill demonstration in the lab
    On a manual or CNC lathe
    On a manual or CNC mill
    Using cutting tool selected by the student
    With the superabrasives feed and speed chart and a calculator
    On hardened tool steel samples
    Criteria
    Pass superabrasives milling and turning test
    Evaluate the application and select the proper cutting tool for a variety of tool steels
    Mount PCBN and PCD inserts in tool holder
    Calculate the feed and speed for all cutting tools
    Turn diameters on hardened steel to the proper diameter and surface finish
    Mill hardened steels to the proper thickness and surface finish

  11. Use handling techniques for large work
    Assessment Strategies
    Skill demonstration in the lab
    Using tools and equipment selected by the student
    With a hydraulic die cart
    With an overhead crane
    On injection mold or special machining project
    Criteria
    Move large blocks from machine to machine using a die cart
    Drill and tap lifting holes in the centroid of various large workpieces, and insure 75%
    Thread contact with at least 1-1/2 – 2 diameters of thread engagement
    Install handling eyebolts in large workpieces insuring full engagement of the thread length
    Lift and position large workpieces using the overhead crane
    Use chains and safety straps properly

  12. Operate a CNC wire EDM
    Assessment Strategies
    Skill demonstration in the lab
    Using the Makino wire EDM machine
    On injection mold or special machining 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 operations page to monitor burn process
    Shut down machine properly
    Follow all safety practices – both general and specific to the CNC wire EDM
    Setup and check data pages to insure correct work offsets and generator settings

  13. Build and assemble a small MUD injection mold
    Assessment Strategies
    Skill demonstration in the lab
    With tools and equipment selected by the student
    On canned Mud injection mold project
    By the 17th week of the semester
    Criteria
    Use prints generated in Tool Making Theory 2
    Apply machining techniques required to build a small MUD injection mold
    Polish, assemble and fit the injection mold

  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 injection mold or special machining project
    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

  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 injection mold 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

  16. Proof injection mold in a molding machine
    Assessment Strategies
    Skill demonstration in the lab
    Using equipment and tools provided by the instructor
    With the plastic injection molding machine
    On injection mold
    Criteria
    Mount mold to injection machine platten
    Work with instructor on injection mold operation parameters and setup
    Run several piece parts, and verify dimensions and appearance to blueprint specifications
    Make adjustments to the mold and machines as necessary
    Work with instructor on the machine shut down and mold removal