32420395Tool Making Theory 2
Course Information
Description
Lecture and demonstration course supporting lab activities in Machine Tool 4. Major emphasis is on nomenclature, theory, construction features, design, and the technology of Mold Dies. The seven molding processes will be introduced. Students will also design and plan a special mold, tool, or CNC project to be constructed in Machine Tool 4.
Total Credits
2
Course Competencies
  1. Explain common plastics and the injection molding process
    Assessment Strategies
    when the learner completes assigned questions from text
    in the MATC classroom
    when the learner completes the plastics cross reference worksheet
    when the learner completes the slide calculations worksheet
    when the learner can pass the written evaluation
    Criteria
    learner summarizes the word plastics
    learner discusses the history of plastics
    learner explains the injection molding processes
    learner explains the difference between thermosetting and thermoplastics materials
    learner identifies some common plastics and their properties
    learner cross references common plastics and their trade names
    learner compares plunger and reciprocating screw injection molding machines
    learner explains a three plate mold
    learner explains the principle of hot runner systems
    learner explains the principles of slides
    learner explains the slide construction features
    learner performs calculations for proper slide operation

  2. Explain mold life, the steels used, and heat treatment of these steels in mold making
    Assessment Strategies
    when the learner completes assigned questions from text
    in the MATC classroom
    when the learner passes the written evaluation
    Criteria
    learner summarizes what is mold life
    learner identifies steels used in plastic molding
    learner identifies steels used for die casting
    learner explains the advantage of using prehardened steels
    learner explains the following heat treatment processes: normalizing, annealing, stress relieving , hardening, tempering, cyaniding, carburizing, and nitriding

  3. Identify mold components
    Assessment Strategies
    when the learner completes assigned questions from text
    in the MATC classroom
    when the learner can sketch the basic ejector system
    when the learner can pass the written evaluation
    Criteria
    learner identifies standard mold components
    learner explains the six methods of mounting/retaining of cavity and core inserts
    learner identifies two methods of preventing round inserts from rotating
    learner explains a conventional ejector system
    learner determines ejector pin location relative to core
    learner explains the function of ejector blades and sleeves
    learner explains the purpose of guide pins and bushings in ejector mechanisms
    learner explains the function of cam blocks
    learner explains the purpose of stripper plates and rings
    learner explains the action of a top ejection unit
    learner explains the differences between an integral and loaded insert

  4. Utilize industrial catalogs to select standard components for purchase
    Assessment Strategies
    in the MATC classroom
    when the learner completes the DME catalog worksheet
    when the learner completes the worksheet for sketching and dimensioning the following components:sprue bushing, locating ring, ejector pins, ejector sleeve, leader pins, and bushings
    Criteria
    learner explains the economics of standardization
    learner identifies the DME steel numbering system
    learner explains the DME catalog numbering system for components
    learner uses the numbering system to order a mold
    learner compares the A and AR series mold bases
    learner compares the A and B series mold bases
    learner compares mold bases for zinc and aluminum die casting
    learner explains the difference between C and CX core pins
    learner explains the design of ejector sleeves

  5. Compare the different methods of heating and cooling molds
    Assessment Strategies
    when the learner completes assigned questions from text
    in the MATC classroom
    when the learner can sketch the basic heating and cooling system
    when the learner can pass the written evaluation
    Criteria
    learner identifies the primary means of heating and cooling molds
    learner compares common mold heating and cooling patterns
    learner explains the use of baffles and bubblers in the cooling system
    learner explains the use of O rings
    learner explains the use of diverting plugs
    learner explains construction for plugs and quick disconnects

  6. Examine different runner and gate designs
    Assessment Strategies
    when the learner completes assigned questions from text
    in the MATC classroom
    when the learner can pass the written evaluation
    Criteria
    learner explains the purpose of a runner system
    learner compares runner cross-sectional shape with plastic flow
    learner explains the properties of a well designed gate pattern
    learner identifies the cause of a weld line
    learner explains a balanced runner system
    learner explains the function of a cold slug well
    learner explores the application of the different gating designs
    learner explains the purpose of venting

  7. Summarize the methods of producing cores, cavities and mold bases
    Assessment Strategies
    when the learner completes assigned questions from text
    in the MATC classroom
    when the learner can sketch the basic heating and cooling system
    when the learner can pass the written evaluation
    when the learner can sketch and dimension cavity insert rounds
    when the learner completes the EDM electrode worksheet
    when the learner can pass the written evaluation
    Criteria
    learner explains the principles of duplicating machines
    learner explains the hobbing process
    learner explains the pressure casting process
    learner explains the EDM process
    learner identifies the AISI number for the types of steels used in the production of mold bases
    learner explains the advantages of the flame cutting process
    learner explains the purpose of rough machining
    learner summarizes the process of drilling, boring and reaming leader or guide pin holes
    learner explains the process of transferring ejector pin holes
    learner explains the function of support pillars

  8. Demonstrate the polishing of molds
    Assessment Strategies
    when the learner completes assigned questions from text
    in the MATC classroom
    when the learner can pass the written evaluation
    Criteria
    learner explains why polishing is necessary
    learner explains polishing methods and processes
    learner determines the proper surface finish for a hob
    learner qualifies specific finishes for certain materials
    learner explains polishing relative to parting lines, slots,and runners

  9. Develop sketches for canned mold/project
    Assessment Strategies
    in the MATC Classroom
    with canned mold A and B plate geometries
    with CAD/CAM software and a computer
    by end of the semester
    Criteria
    learner chooses a plastic part to produce
    learner generates a plastic piece part print
    learner modifies A and B plate drawings to accommodate his/her part
    learner generates the ejector system drawing
    learner dimensions drawings

  10. Compare thermoforming, expansion, extrusion, and blow molding
    Assessment Strategies
    in the MATC classroom
    when the learner can pass the written evaluation
    Criteria
    learner explains the principles of thermoforming
    learner explains the principles of expansion molding
    learner explains the principles of extrusion molding
    learner explains the principles of blow molding

  11. Explain rubber molding
    Assessment Strategies
    when the learner completes assigned questions from text
    in the MATC classroom
    when the learner can pass the written evaluation
    Criteria
    learner explains the principles of rubber molding
    learner explains the two different types of rubber molds
    learner explains the construction features of rubber molds

  12. Explain zinc and aluminum die casting
    Assessment Strategies
    when the learner completes assigned questions from text
    in the MATC classroom
    when the learner can pass the written evaluation
    Criteria
    learner explains the principles of zinc die casting
    learner explains the principles of aluminum die casting
    learner explains the construction features of zinc die casting
    learner explains the construction features of aluminum die casting
    learner explains the principles of push through and compound trim dies
    learner explains the construction features of trim dies

  13. Explain the mold press set up and operation
    Assessment Strategies
    in the MATC molding lab
    with the Cincinnati molding machine and manual
    with with the necessary tools and supplies
    with the assistance of the instructor
    Criteria
    learner attends mold setup and operation demonstration
    learner associates safety precautions, attitudes, and actions for proper working conditions
    learner properly installs mold and clamps
    learner operates the control to setup the mold clamp, pressures, shot size, time, etc
    learner cycles the molding press to produce their part
    learner properly shuts down the machine