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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
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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
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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
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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
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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
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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
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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
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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
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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
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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
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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
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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
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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
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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
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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
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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