penn foster’s machinist apprenticeship program

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Penn Foster’s Machinist Apprenticeship program

Course PF Course Course Title Number Price Duration

Year 1:

Trades Safety: Getting Started 186104 $75.00 5 hours

Working Safely with Chemicals 186105 $75.00 5 hours

Fire Safety 186106 $75.00 5 hours

Material Handling Safety 186109 $75.00 5 hours

Linear and Distance Measurement 186125 $75.00 5 hours

Basic Industrial Math Block X31 $450.00 30 hours

Addition and Subtraction 186303 ($75.00) (5 hours)

Multiplication and Division 186304 ($75.00) (5 hours)

Fractions, Percents, Proportions, and Angles 186305 ($75.00) (5 hours)

Metric System 186306 ($75.00) (5 hours)

Formulas 186307 ($75.00) (5 hours)

Introduction to Algebra 186308 ($75.00) (5 hours)

Applied Geometry 186085 $75.00 6 hours

Practical Trigonometry 186086 $75.00 6 hours

Introduction to Print Reading 186325 $75.00 8 hours

Abbreviations & Symbols 186326 $75.00 8 hours

Dimensions & Tolerancing 186327 $75.00 8 hours

Reading Shop Prints, Parts 1 & 2 386043, 386044 $150.00 20 hours

Geometric Dimensioning/Tolerancing STP194 $175.00 20 hours Bench Work 5004A-C $225.00 30 hours Precision Measuring Instruments, Part 1 186188 $75.00 10 hours

Precision Measuring Instruments, Part 2 186189 $75.00 10 hours

Precision Measuring Instruments, Part 3 186190 $75.00 10 hours

Jobs, Companies, and the Economy: Basic Concepts

for Employees 186191 $75.00 5 hours

Quality Concepts: Tools and Applications 186036 $75.00 5 hours

Metal Processing 186087 $75.00 3 hours

Ferrous Metals 186088 $75.00 3 hours

Nonferrous Metals 186089 $75.00 3 hours

Identification of Metals 186090 $75.00 3 hours

Layout 3501 $75.00 10 hours

Year 2:

Basic Machining Skills Block X08 $1,050.00 56 hours

Practical Shop Math, Part 1 X0801 ($75.00) (4 hours)

Practical Shop Math, Part 2 X0802 ($75.00) (4 hours)

Practical Shop Measurement X0803 ($75.00) (4 hours)

Safe Shop Practices X0804 ($75.00) (4 hours)

Properties and Classifications of Metals X0805 ($75.00) (4 hours)

Progress Examination X0821 ($0.00) (0 hour)

Using Shop Drawings, Process, and Routing

Sheets, Part 1 X0806 ($75.00) (4 hours)

Using Shop Drawings, Process, and Routing

Sheets, Part 2 X0807 ($75.00) (4 hours)

Layout X0808 ($75.00) (4 hours)


Metal Cutting and Machine Tooling, Part 1 X0809 ($75.00) (4 hours)

Metal Cutting and Machine Tooling, Part 2 X0810 ($75.00) (4 hours)

Metal Cutting Machinery, Part 1 X0811 ($75.00) (4 hours)


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Metal Cutting Machinery, Part 2 X0812 ($75.00) (4 hours)

Fundamentals of Grinding X0813 ($75.00) (4 hours)

CNC Machine Tool Features and Applications X0814 ($75.00) (4 hours)


Progress Examination Booklet X0820 ($0.00) (0 hour)

Drilling, Parts 1 & 2 386050, 386051 $150.00 20 hours

Lubrication, Part 1 286091 $75.00 10 hours

Lubrication, Part 2 286092 $75.00 10 hours

Fasteners 286095 $75.00 10 hours

Milling Machine Fundamentals 386031 $75.00 10 hours

Milling Machine Cutting Tools 386032 $75.00 10 hours

Milling Machine Practice and Operation, Part 1 386033 $75.00 10 hours

Milling Machine Practice and Operation, Part 2 386034 $75.00 10 hours

Milling Machine Indexing and Spiral Work 386035 $75.00 10 hours

Lathes, Part 1 386036 $75.00 10 hours





Year 3:

Fundamentals of Metal Cutting 386030 $75.00 10 hours

Machine Safety 186110 $75.00 5 hours

Automatic Screw Machines 3530A-B $150.00 20 hours

Turret Lathes 3525A $75.00 10 hours

Turret Lathe Tools and Setups 2213 $75.00 10 hours

Fundamentals of Grinding 386016 $75.00 10 hours

Cylindrical Grinding, Part 1 386010 $75.00 10 hours

Cylindrical Grinding, Part 2 386011 $75.00 10 hours

Surface Grinding, Part 1 386012 $75.00 10 hours

Surface Grinding, Part 2 386013 $75.00 10 hours

Inspection of Shop Products 5962 $75.00 10 hours

Quality Control for the Technician 386E02 $365.00 70 hours

Boring Mills 5636A $75.00 10 hours

Planers 6118 $75.00 10 hours

Year 4:

Broaching 6091 $75.00 10 hours

Shapers, Slotters, and Keyseaters 2222 $75.00 10 hours

Nontraditional Machining Technologies 386029 $75.00 10 hours

Hardening and Tempering 3195 $75.00 10 hours

Tool Grinding 386017 $75.00 10 hours

Tool Dressing 3194 $75.00 10 hours

Gear Calculations 2243 $75.00 10 hours

Gear Making 5532A-B $150.00 20 hours

Manufacturing Processes, Part 1 186075 $75.00 10 hours




CNC Technology & Programming (replaces 066903) 386E06 $350.00 45 hours

Toolholding Systems 386028 $75.00 10 hours

CNC Turning 386041 $75.00 10 hours

CNC Milling 386042 $75.00 10 hours

Optional: Tool & Die Maker Skills

Mechanics of Materials 5282A-C $225.00 30 hours

Heat Treatment 3541A-D $300.00 40 hours

Dies and Die Making 5101A-B $150.00 20 hours

Forging Dies 3199 $75.00 10 hours

Making Forging Dies 3197 $75.00 10 hours

Toolmaking 2540A-C $225.00 30 hours


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Gage Making 5098 $75.00 10 hours

Jigs and Fixtures 5099 $75.00 10 hours

Jig and Fixture Making 5100 $75.00 10 hours

Estimated Total Curriculum Duration (not including Optional courses): 839 hours

Number of Exams (not including Optional courses): 104

***SEE FULL COURSE DESCRIPTIONS BELOW


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186104 Trades Safety: Getting Started

Duration: 5 hours (includes 1 test)

What Students Learn: Preview

A thorough knowledge of safe practices is an important part of

working in any industrial setting. Every industrial worker

should be familiar with accident prevention techniques, fire

safety mehods, and the use of personal protective equipment.

Injuries in the workplace cost many millions of dollars in

medical costs, lost wages, and production losses each year.

Many injuries can be prevented by understanding how

accidents and injuries can occur. This study unit is designed

to help trainees understand why safety is so important, and to

present students with information about safety that goes

beyond common sense.

Objectives

When a student completes this study unit, he and she will be

able to:

• Name the agencies that make and enforce safety

regulations and explain an employee’s responsibilities

under those regulations.

• List the physical hazards associated with chemicals and

describe how to avoid those hazards.

• Name several electrical shock hazards and the

techniques used to prevent shocks.

• List the steps in a lock-out / tag-out procedure.

• Explain the importance of machine guarding and name

several types of machine guards.

• Name the four classes of fire and how to extinguish

each of them.

• Describe the proper technique used to lift a heavy load.

• Explain how to avoid hand injuries when using hand

and power tools.

• List some of the hazards involved in welding and hot

cutting operations and how to prevent them.

• Explain how job analysis and the science of ergonomics

are used to improve the workplace.

• Explain the importance of personal protective

equipment and name several types of PPE.

Contents

Introduction; Safety Regulations; Key safety Issues;

Protecting Yourself and Your Co-workers.

186105 Working Safely with Chemicals



This study unit deals with the safe use of chemicals in the

workplace. The two primary causes of chemical accidents are

the misuse of chemicals and the improper disposal of chemical

wastes. Understanding the hazards that chemicals can create

is the first step in protecting people from harm.

The main goal of this study unit is to provide students with

sound, practical knowledge about chemical use and disposal,

both in the workplace and at home. You will learn how to

recognize common chemical hazards and how to deal with

them. Trainees will learn how to perform a job analysis to

look for potential chemical dangers in your daily taks. Finally,

people will learn how to take precautions to avoid chemical

accidents and make all jobs as safe as possible.

Objectives


able to:

• Recognize the six different ways in which a chemical

can cause physical injury.

• Name the routes or paths of entry by which chemicals

can enter the body.

• Describe the types of injuries caused by chemicals. • Identify potential chemical dangers in your workplace.

• Describe how to identify, store and label hazardous

chemicals.

• List several methods used to prevent chemical

accidents.

• Explain why proper training is important to chemical

handling.

• Describe the types of personal protective equipment

used and worn when handling chemicals.

• Explain the role of governmental agencies in enforcing

chemical regulations.

Contents

Introduction: Living with Chemicals; Chemical Injuries;

Accident Prevention; Handling Hazardous Wastes.

186106 Fire Safety



Fires are the most destructive and expensive of all accidents.

However, fires can be effectvely prevented through the

combined use of technology and common sense. By

understanding how fires get started and how to extinguish

them, students will have much of the knowledge needed to

protect people from fire. This study unit will introduce

trainees to the information you need to practice fire safety and

prevention in the workplace.


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Objectives


able to:

• Describe the types of property losses and injuries

associated with fires.

• Explain how fires are ignited.

• Identify the four classes of fire.

• Describe the primary fire hazards found in the

workplace.

• Explain the various ways in which fires can be

prevented.

• Describe the operation of several different fixed fire

protection systems.

• Identify the proper type of portable fire extinguisher to

use on a fire.

• Describe the operation of several different types of fire

extinguishers.

• Explain how to defend yourself and others in a fire

situation.

• Describe how to safely evacuate a burning building.

Contents

Introduction to Fire; Fire Hazards in the Workplace;

Preventing Fires; Fixed Fire Protection Equipment;

Portable Fire Extinguishers; Fire Protection Techniques.

186109 Material Handling Safety



This study unit introduces the safe techniques and work

practices commonly used when handling manufacturing and

industrial materials. Trainees will learn the procedures

necessary to avoid physical injury to yourself and those

working with you, for both manual handling methods and

mechanical handling methods. You will also learn procedures

that minimize damage to the materials being moved and to

facility property. Knowing the proper procedures will also

give you the insight to decide when mechanical handling is

necessary, or preferred, over traditional physical handling.

Objectives


able to:

• Recognize the hazards associated with handling

materials.

• Know the types of injuries that can be caused by these

hazards.

• Understand how to effectively use safe material

handling practices.

• Know how to avoid physical injury when handling

loads.

• Know and follow the rules for safe operation of

powered industrial material handling equipment.

• Understand and respect the limits and restrictions placed

on powered material handling mechanisms.

Contents

Introduction to Material Handling; Housekeeping and

Storage; Material Handling Equipment; Hoists and

Cranes.

186125 Linear and Distance Measurement


What Students Learn: • Recognize the difference between English and metric

units of length.

• Find the perimeter of rectangular, square, or triangular

areas or objects, such as rooms or machine bases, after

measuring the sides.

• Calculate the circumference of circular objects like

pipes of tanks after measuring the diameter.

• Measure lengths with the aid of rigid and flexible rules,

thickness gauges and screw pitch gauges.

• Read a typical vernier scale and micrometer to take

precise measurements.

Block X31 Basic Industrial Math

Duration: 30 hours (includes 6 tests)

What Students Learn: This module of six study units offers the trainee arithmetic and

basic mathematics, metric measurement, and calculator

fundamentals. The Metric System is an introductory unit

which includes metric conversions. Problem exercises and

examples in this module are presented in on-the-job scenarios

with applications drawn from the industrial context.

Special Notes: This updated course replaces lessons contained within

Practical Math and Measurements, Block X01. Each study

unit contains a progress examination.

Components: Addition and Subtraction (186303)

Multiplication and Division (186304)

Fractions, Percents, Proportions, and Angles (186305)

Metric System (186306)

Formulas (186307)

Introduction to Algebra (186308)


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186303 Addition and Subtraction

Objectives: • Define the terms: whole number, numeral, digit,

decimal, place value, addend, sum, minuend,

subtrahend, and difference.

• Explain the significance of the digit zero in a number.

• Differentiate between concrete and abstract numbers.

• Properly prepare numbers for addition and subtraction.

• Perform addition and subtraction on numbers.

• How to check your answers to both addition and

subtraction problems.

• How to use a calculator to add and subtract numbers.

186304 Multiplication and Division

Objectives: • Define the terms: factor, multiplicand, multiplier, partial

product, dividend, divisor, quotient, and remainder.

• Recognize the various signs used for multiplication and

division.

• Properly prepare numbers for multiplication and

division.

• Perform multiplication and division on whole numbers

and decimals.

• How to check your answers to both multiplication and

division problems.

• How to find the average of a group of numbers.

• How to use a calculator to multiply and divide numbers.

186305 Fractions, Percents, Proportions, and Angles

Objectives: • Define the terms: fraction, proper fraction, improper

fraction, lowest common denominator, percent, ratio,

and proportion.

• How to add, subtract, multiply, and divide fractions and

decimals.

• How to change fractions to decimals and decimals to

fractions.

• Solve problems involving percent.

• How to use a protractor to measure angles.

• Lay out templates for checking angles.

• How to use a calculator to solve percent problems and

to convert fractions to decimals.

186306 Metric System

Objectives: • Name the base units most commonly used in the metric

system.

• Identify metric prefixes and their values.

• Apply conversion factors to increase or decrease metric

base units.

• Estimate lengths in metric units.

• Express temperature in degrees Celsius.

• Define the terms: mass, density, force, torque, and

pressure. Identify the metric units used to measure each

one.

• How to use a calculator to convert one metric unit to

another.

186307 Formulas

Objectives: • Explain the use of letters in formulas.

• Prepare and use formulas to solve problems.

• The use of formulas to calculate the perimeter of a

triangle and rectangle, distance, area of a triangle,

rectangle, and circle, volume of a pyramid, current in a

circuit, and volume of a sphere.

• How to use a calculator to find square root and solve

formulas.

• Transform and solve an equation.

• Perform basic arithmetic operations with signed terms.

• Substitute given numerical values for letters in a

formula and find the unknown quantity.

186308 Introduction to Algebra

Objectives: • Define the terms: term, constant, coefficient, exponent,

monomial, trinomial, and polynomial.

• Identify and combine like terms in an expression.

• Multiply and divide terms containing exponents.

• Remove parentheses from an expression and simplify

the expression.

• Perform basic arithmetic operations with signed terms.

186085 Applied Geometry

Duration: 6 hours

Course Prerequisites: Basic Industrial Math (Block X31)

Practical Measurements (Block X32)

What Students Learn:


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• Recognize characteristics of angles and closed plane

figures.

• Distinguish between common geometric solids.

• Apply the Pythagorean theorem.

• Calculate perimeters and areas of a polygon, circle, and

ellipse.

• Apply the formula for area and volume of geometric

solids.

186086 Practical Trigonometry

Duration: 6 hours



What Students Learn: • Define trigonometric functions.

• Use trigonometric tables and apply interpolation.

• Solve right triangles.

• Apply the laws of sines and cosines in solving oblique

triangles.

__________________________________________________

186325 Introduction to Print Reading What Students Learn: • Describe the basic format for conveying technical information in a drawing • Interpret the various drawing views used in technical drawings • Extract information from notes and title blocks • Recognize and interpret the different line types used in drawings • Understand the concept of drawing scale and how it affects information shown in the drawing • Identify various types of building, electrical, and mechanical drawings ________________________________________________________________________

186326 Print Reading Symbols and Abbreviations Course Prerequisite: Introduction to Print Reading (186080)

What Students Learn: • Recognize, understand, and interpret the most common abbreviations used on a wide range of drawing types used in construction and maintenance trades • Understand and interpret the various symbols and notations used on drawings for electrical, architectural, mechanical, welding, fluid power, and other types of applications

• Explain how symbols are used to show standard materials, parts, and assemblies __________________________________________________________________________

186327 Dimensioning and Tolerancing Course Prerequisite: Introduction to Print Reading (186080)

What Students Learn: • Recognize the international standards and conventions that apply to drawings • Explain how different numbering systems were developed and how they are applied to prints • Read and interpret various systems of dimensions and tolerances on drawings • Recognize and interpret common symbols and nomenclature used in geometric dimensioning and tolerancing (GD&T) systems __________________________________________________

386043 Reading Shop Prints, Part 1 Duration: 10 hours (includes 1 test)

What Students Learn: • Interpret working drawings • Evaluate various systems of dimensions and tolerances • Recognize symbols, notes, and specifications called out on detail and assembly prints • Identify material requirements as specified on a print • Evaluate a print to determine the proper procedure to make a simple part

Special Note: • This study unit takes the place of study unit 6720A. __________________________________________________________________________

386044 Reading Shop Prints, Part 2 Duration: 10 hours (includes 1 test)

Course Prerequisite: Reading Shop Prints, Part 1 (386043)

What Students Learn: • Interpret more complex working drawings • Define and use cam, gear, and thread terminology • Interpret cam, gear, and thread specifications on shop prints • Work with various sectioning techniques • Read and interpret a bill of materials • Evaluate more complex prints to determine the best order of machining

Special Note: • This study unit takes the place of study unit 6720B.

STP194


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Geometric Dimensioning and Tolerancing

This course will cover important and fundamental concepts in geometric dimensioning and tolerancing (GD&T) in four parts. First, you'll work through the basics by studying the various symbols, dimensions, tolerances, annotations, and views of shop prints. Once you can recognize these elements of prints, you'll be able to more easily understand identify datum features, symbols, and terminology used in the manufacturing industry.

The second half of this course will help you recognize various types of orientation tolerances, geometric form tolerances, and runout geometric controls. You'll also learn about various concepts such as concentricity and symmetry. You'll end your study of GD&T with simple and composite forms of locational tolerances as they relate to true position.



Reading Prints and Schematics (Block X25)

Course Objectives:

· Identify various symbols, dimensions, tolerances, annotations, and views found in shop prints

· Summarize the proper use of datum features, symbols, and terminology used in manufacturing

· Recognize various types of orientation tolerances and geometric form tolerances

· Explain the concepts of runout geometric controls, concentricity, symmetry, and locational tolerances

What Students Learn: Lesson 1 (386125): Geometric Dimensioning and Tolerancing, Part 1 Overview: This lesson introduces you to geometric dimensioning and tolerancing, or GDT. GDT is a collection of definitions, rules, symbols, and methods of application employed throughout modern manufacturing. The

lesson begins by reviewing the basic skills you probably already use when interpreting shop drawings. After this refresher, you’ll begin to learn the basics of GDT drawing systems. You’ll study some GDT symbols and learn to recognize and interpret them when they’re inserted into a drawing. Finally, this lesson serves as a foundation onto which you’ll add more knowledge as you progress through additional GDT-related training topics. Lesson 2 (386126): Geometric Dimensioning and Tolerancing, Part 2 Overview: Datums and material condition modifiers will now be covered in greater depth. With any measurement, the location of a feature is referenced or measured from a theoretical perfect plane, point, line, axis, or surface called a datum. Datums may be physical features on a part, such as steps or edges, or theoretical features such as the center of a hole or the centerline of a slot. Understanding how a datum is defined is critical for properly setting up the part’s machining or inspection operations. The material condition modifier concepts of maximum material condition, least material condition, and regardless of feature size are also explained in this lesson. Along with the dimensional limits covered earlier, the material condition modifiers are used to vary, or modify, a dimension’s nominal tolerance. You’ll learn how properly using these material conditions allows for a wider variation in dimensions (compared to conventional dimensioning) while still providing proper fit and function of the assembled parts. Lesson 3 (386127): Geometric Dimensioning and Tolerancing, Part 3 Overview: In this lesson you’ll learn about tolerances that relate to part profiles, forms and orientation. Many parts have functional features that can’t be fully specified by geometric tolerances and material modifiers. Parts may have surfaces, profiles, and features oriented to a datum plane or have profiles and surfaces that must retain a defined shape. Round parts may be more accurately produced when tolerances are specified for cylindricity and circularity along with the size tolerances. Machined parts might be specified using size and location tolerances while benefiting from increased controls for flatness or straightness. Lesson 4 (386128): Geometric Dimensioning and Tolerancing, Part 4 Overview: In this lesson, you’ll learn about the geometric characteristics of location including position tolerances,


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symmetry tolerances, and runout tolerances as well as the concept of concentricity. Locational tolerances specify the position, concentricity, and symmetry of features on a part. Most mating or assembled components make use of location tolerances to ensure interchangeability among parts in a production run. The tolerances are commonly used on everything from standard fasteners such as screws, nuts, bolts, and pins to manufactured brackets, plates, and machine components. The proper use of location tolerances makes the manufacture and inspection of symmetric parts more efficient. Location tolerances also help control patterns of features such as a grid of holes, or features around the diameter of a part, while reducing the need for very close conventional tolerances.

Special Notes: This course replaces 386E01.

5004A-C Bench Work


What Students Learn: PART 1 (5004A). Introduction to Bench Work; Wrenches,

Hammers, Pliers, and Screwdrivers; Punches, Twist Drills,

Reamers, and Broaches; Saws, Chisels, and Snips; Finishing

and Grinding Tools; Files, Scrapers, and Abrasives.

PART 2 (5004B). Threaded Fasteners; Bolts, Screws, and

Studs; Thread Systems; Hole Preparation for Threaded

Fasteners; Mechanical Fasteners; Rivets, Keys, and Pins;

Threading with Hand Tools; Taps: Tap Drills; Tap Wrenches;

Removal of Broken Taps; Repairing Damaged Threads.

PART 3 (5004C). Fitting Practice; Tolerance, Allowance,

Clearance, and Fit; Babbitting; Hack Saw; Band Saw

Machine; Clamping Work for Sawing; Soldering; Soft Solder;

Soldering Copper; Sweat Soldering; Brazing; Hand Solders

and Fluxes; Torch Brazing; Induction Brazing; Furnace

Brazing.

186188 Precision Measuring Instruments, Part 1


What Students Learn: Purpose and Language of Measurement; Scale Instruments

and Accessories; Vernier Caliper; Micrometers, Gages, and

Protractors.



What Students Learn: Indicators; Shop Gages; Gage Blocks; Fundamentals of

Trigonometry; Sine Bar and Sine Plate.



What Students Learn: Optical Comparators; Optical Flats Light Beams for

Alignment and Measurement; Digital Readout Measuring;

Special Measuring Systems; Materials Testing.

186191 Jobs, Companies, and the Economy: Basic Concepts for Employees


What Students Learn: • Recognition of how the economy affects the actions of

companies, employees, consumers, and investors.

• The concept of capitalism and the principles of supply

and demand.

• How government policies affect the amounts of saving,

spending, and investing by companies and individuals.

• Understand economic measuring tools such as the

inflation rate, the unemployment rate and Gross

Domestic Product (GDP).

• How labor is divided into three employment sectors and

how wages are set, including the influence of labor

unions and the benefits of a multi-functional workforce.

• Recognition of how both the employee and the company

must compete in an increasingly international

marketplace.

Special Notes: This updated course replaces How Our Economic System

Works, study unit 6606, and Economics Today, study unit

186034.


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186036 Quality Concepts: Tools and Applications


What Students Learn: • Describe how job roles change as a company evolves in

its quality consciousness.

• Explain several ways in which you can support TQM.

• Identify approaches, practices and skills associated with

positive organizational change.

• Differentiate between the "change process" at the

company level and the manufacturing processes that

require improvement.

• Describe major causes of process variation and give

examples of how they may affect you in your job.

• Explain why and how the reduction of variability is a

key factor in process improvement.

• Describe why and how quality and process

improvement depend on data-driven decision making.

• Identify seven quality tools and explain their uses.

186087 Metal Processing

Duration: 3 hours



What Students Learn: • Identify industrial metals by their names and chemical

symbols.

• Define in basic terms the characteristics and properties

of metals.

• Explain the various metal-processing methods used in

producing industrial metals.

• Explain how metals are extracted from their ores found

in the earth and then refined.

186088 Ferrous Metals

Duration: 3 hours




• Identify the features of a blast furnace.

• Recognize cast irons by their fractures and other

properties.

• Describe the major steelmaking processes.

• Discuss the hot-working and cold-working methods

used to shape steel.

• Classify the types of steel, according to both processing

method and carbon content.

• Relate certain grade numbers to the types of steel they

identify.

186089 Nonferrous Metals

Duration: 3 hours



What Students Learn: • Explain how the various metals are extracted from their

ores.

• Describe how the addition of certain elements affects

the physical properties of the base metals.

• Select the metal alloy most suitable for a given job.

• Recognize whether a copper alloy is a brass or a bronze.

186090 Identification of Metals

Duration: 3 hours



What Students Learn: • Identify a metal by making a file, test magnetic test,

temperature test, chip test, or spark test.

• Find the hardness of a metal by using a Brinell-

Rockwell Monotron, a Vickers-Herbert Pendulum, or a

scieroscope hardness-testing machine.

Block X08 Basic Machining Skills


Course Prerequisites: Introduction to Algebra, Geometry, and Trigonometry (Block

X02)


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Industrial Safety (Block X23)

Hand and Power Tools (Block X24)

What Students Learn: This block presents the trainee with a broad overview of the

basic industrial skills and knowledge needed by an entry level

machinist. Skilled workers, such as electricians, pipefitters,

and mechanics, whose duties include the maintenance and

repair of machine tools, can benefit through cross training,

from taking this course. The course starts with shop math and

measurements, and applies these concepts to shop drawings,

blueprint reading, layout, and metal cutting. On-the-job tasks,

such as working with metal cutting machinery - milling

machines, drilling machines, lathes, grinders, and CNC

machine tools - are described in detail. Safety procedures

relating to job tasks using metal shop machinery are an

essential part of this course.

Components: Practical Shop Math, Part 1 (X0801)

Practical Shop Math, Part 2 (X0802)

Practical Shop Measurement (X0803)

Safe Shop Practices (X0804)

Properties and Classifications of Metals (X0805)

Progress Examination (X0821)

Using Shop Drawings, Process, and Routing Sheets, Part 1

(X0806)

Using Shop Drawings, Process, and Routing Sheets, Part 2

(X0807)

Layout (X0808)


Metal Cutting and Machine Tooling, Part 1 (X0809)

Metal Cutting and Machine Tooling, Part 2 (X0810)

Metal Cutting Machinery, Part 1 (X0811)

Metal Cutting Machinery, Part 2 (X0812)

Fundamentals of Grinding (X0813)

CNC Machine Tool Features and Applications (X0814)


Progress Examination Booklet (X0820)

X0801 Practical Shop Math, Part 1

Objectives: • Learn the basics of shop mathematics as they relate to

machine technology.

• Add, subtract, multiply, and divide fractions and

decimal values of whole units such as inches, and feet.

• Derive the square root of fractions and decimals.

• Compute a machine drive ratio for a given speed.

• Make calculations using the metric or SI system of

measurement.

X0802 Practical Shop Math, Part 2

Objectives:

• Learn the fundamentals of geometry and trigonometry

as they apply to machine shop calculations.

• Compute the areas of rectangles, triangles, circles,

parallelograms, and other common shapes.

• Compute the volumes of solid figures such as cubes,

cylinders, cones, rectangles, and combinations of these.

• Use the principles of geometry and trigonometry to

analyze and solve various kinds of triangles and their

parts.

• Plot coordinates of a point using both the rectangular

(Cartesian) and the polar systems.

• Present the fundamentals of calculator operations as

they apply to shop work.

X0803 Practical Shop Measurement

Objectives: • Teach the terminology of linear (length) and angular

dimensioning.

• Learn which tools and measuring instruments are

commonly used to determine the size and dimensions of

a sample workpiece.

• Use a steel rule to measure the length of a part in inches

or millimeters.

• Measure the sizes of parts to 1/10,000 inch using a

vernier caliper.

• Use a micrometer to measure diameters and thicknesses

of workpieces.

• Make angular measurements using various instruments.

X0804 Safe Shop Practices

Objectives: • List the proper safety equipment to be worn when

performing machine shop tasks.

• State the environmental hazards most commonly

encountered in a machine shop.

• Teach the fundamental safety measures for the machine

shop environment and for the more popular types of

machine tools used across industry.

• State the method used to remove stock from a

workpiece mounted in a lathe, milling machine, and

drill press.

• Name one method used to protect the worker from

harmful fumes when cutting fluids are used.

X0805 Properties and Classifications of Metals

Objectives:


12

• Understand the four basic methods of manufacturing

iron and steel.

• Discuss the fundamental properties of metals.

• Recognize standard identification of various steels and

alloys.

• Know the characteristics and applications of particular

steels and alloys.

• Realize the effects and limitations of heat treatment.

• Be familiar with materials testing methods.

• Differentiate between hot-working and cold-working

metal processes.

X0821 Progress Examination

X0806 Using Shop Drawings, Process, and Routing Sheets, Part 1

Objectives: • Understand the uses of industrial blueprints.

• Learn how to read shop drawings, process, and routing

sheets.

• Recognize surfaces, object lines, and object points on a

blueprint.

• Recognize front, top, and right-side views of an object.

• Identify lines on a drawing and explain their use.

• Read and understand sectional views and apply

information from them to other views.

• Identify and read auxiliary and double auxiliary lines.

• Understand tolerances and apply them to dimensions,

and read different tolerancing systems.

• Introduce the trainee to the language of print reading.

X0807 Using Shop Drawings, Process, and Routing Sheets, Part 2

Objectives: • Recognize and read a geometric drawing.

• Understand the system of geometric dimensioning and

tolerancing used in industrial shop drawings.

• Understand variations used on geometric drawings.

• Locate and correctly read a drawing block, and apply its

information to a drawing.

• Recognize and read a process sheet, and use the

information it contains.

• Understand the baseline dimensioning system.

• Understand the Cartesian coordinate system.

• Understand the fixed or floating zero system.

X0808

Layout

Objectives: • Prepare a work surface and know the types and uses of

layout compounds.

• Identify and use common layout tools.

• Identify and use measuring instruments used in layout.

• Identify and use precision layout tools.

• Perform basic layout operations and construct various

geometric shapes.


X0809 Metal Cutting and Machine Tooling, Part 1

Objectives: • Describe metal cutting, how it is accomplished, and

whether a cutting tool is performing properly.

• Identify a variety of cutting tools.

• Understand how a cutting tool cuts and separates

material by using the three kinds of cutting edges.

• Identify the three major types of chips a cutting tool

produces.

• Name the key parts of a twist drill.

• Describe the applications of a counterbore, countersink,

and combination countersink/centerdrill. • State the differences between reamers for machine and

hand use.

• Explain the differences between taps used for hand

tapping and machine tapping methods.

• Describe the dies used to produce threads by both hand

and machine methods.

• Identify the different machine attachments and tooling

components needed for tap and die threading on

production machinery.

X0810 Metal Cutting and Machine Tooling, Part 2

Objectives: • Define the major parts of a lathe tool bit.

• Identify the types and applications of turning, boring,

and milling tools used in machining operations.

• Describe the different styles of end mills available.

• Identify the different horizontal end mills.

• Explain the difference between the mounting methods

used for horizontal and end mill style cutters.

• Understand the differences among the various cutting

tool materials used.


13

• Describe the reasons for using a tool coating on a

cutting tool or cutting insert.

• Describe the effects of coolants on the cutting point.

• Identify the major methods of applying cutting fluids.

X0811 Metal Cutting Machinery, Part 1

Objectives: • Identify the different types and applications of drilling

machines used in industry and their important operating

parts.

• Describe the major accessories and workholders used on

drilling machines.

• Explain the difference between horizontal and vertical

milling machines.

• Describe the different types of horizontal and vertical

milling machines available.

• Understand numerical control and computerized

numerical control of machine tools and differentiate

between them.

• Distinguish a machining center from an ordinary milling

machine.

• Understand the differences among the four designs of

automatic toolchangers.

X0812 Metal Cutting Machinery, Part 2

Objectives: • Describe basic lathe construction.

• Describe the manual and automated turning machines

used by industry.

• Recognize the uses of turning centers for mass-

production applications.

• Differentiate between bar and chucking types of

automatic screw machines.

• Identify turning machine accessories and workholders.

• State the differences between horizontal and vertical

bandsaw configurations.

• Interpret the different tooth styles of bandsaws and the

applications for each style.

• Describe conventional and vertical bandsaw cutting

operations.

• Explain circular cold sawing, abrasive cutting, and

friction sawing techniques.

X0813 Fundamentals of Grinding

Objectives:

• Explain the physical characteristics, setup, and

operation of grinding wheels.

• Name the different types of abrasives and bonds.

• Define how structure applies to the grinding process.

• Recognize Standard Marking System symbols to choose

the correct grinding wheel.

• Describe the major wheel types by shape and list

specific applications for each.

• Describe how to put a grinding wheel into operation and

keep it in good working order.

• State the various types of grinding fluids, what they are

used for, and the different methods of applying them.

• List uses and nomenclature associated with utility

grinders, surface grinders, and cylindrical grinders.

• Demonstrate safe practices when using grinders.

X0814 CNC Machine Tool Features and Applications

Objectives: • Name the common machines adapted to computer

numerical control.

• Describe how CNC machines operate and what

processes they are capable of performing.

• State advantages of CNC over manual control.

• Name various CNC components and describe what each

does.

• Explain the function of a feedback device.

• Understand the Cartesian coordinate system of

measurement.

• Define tool length compensation and describe the

process of zeroing a CNC machine.

• Demonstrate safe practices when operating CNC

machines.

• Describe the job responsibilities of people involved in

CNC operations.


X0820 Progress Examination Booklet

3501 Layout

Duration:


14

10 hours (includes 1 test)

What Students Learn: Marking Devices: Punches, Scribers, Dividers, Calipers,

Gages, Beam Trammels, Combination Sets, Bevel Protractors,

Keyseat Clamps; Scribing Problems; Use of Bench Plates,

Surface Plates, Parallels, V Blocks, and Arbors; How to Draw

Horizontal, Vertical, and Inclined Lines; How to Draw a

Circle or Circular Arc; Layout Problems: Location of Holes in

a Plate; Location of Boundaries of Flat Surfaces; Marking of

Lines on Curved Surfaces; Locating the Center of a Circle in

an Opening; Subdividing a Circle into a Number of Equal

Parts; Determining Required Length of Stock for Forming a

Bent Part; Laying Out of Keyways, Templates, Castings,

Cams, and Sprockets.

Special Notes: Covers subject at an advanced, in-depth level.

386050, 386051 Drilling, Parts 1 & 2


What Students Learn: PART 1 (386050).

• Identify the parts of and explain how to use basic

drill presses.

• Identify and use various types of drill tools for

counterboring, countersinking, spot facing,

reaming, tapping, and hole sawing.

• Explain how to set up various workpieces on a drill

press.

• Selecting and using tool holders and workholding

devices.• Understand how to recondition drilling

tools and maintain equipment.

PART 2 (386051).

• Explain how to set up more complex drilling

equipment included automated and CNC equipment.

• Select and use various types of auxiliary tools with

drill equipment.

• Set up more advanced work on a drill press.

• Select and modify drills for different materials and

cutting conditions.

• Determine the correct speeds, feeds, and coolant for a

given operation.

• Diagnose quality, tolerance, and tool-life problems,

and find solutions for them.

Special Note:

• This course replaces 3521-B.

286091 Lubrication, Part 1



Since the development of machinery, there has been a war

against friction. Friction causes machinery to vibrate

excessively, sound louder, use more energy to do a given job,

and, most importantly, wear out faster. To counter friction,

lubricants have been developed.

Lubricants were once basic animal fats and plant oils used on

simple machines. Today's lubricants are chemical

compositions specially designed for specific types of machines

and their work environment. There are now hundreds of types

of oils and grease to select from, each tailored specifically for

the machine or an individual component of any given

machine.

This study unit is designed to give students the information

they need to understand how lubricants are blended into these

very special compounds and how they are selected for various

applications.

Objectives


able to:

• Describe the various types of friction.

• Discuss how materials wear.

• List the various functions lubricants perform in industry.

• Explain how lubricants reduce friction.

• Classify lubricants depending upon their composition,

properties, and additives.

• Understand why certain lubricants are chosen for certain

tasks.

• Explain how to safely handle and store lubricants.

Contents

Friction and Wear; The Purpose of Lubricants; How

Lubricants are Classified; How Lubricants Work;

Proper Lubricant Selection; Handling and Storing

Lubricants Safely.

Special Notes: This updated course replaces 2531A.

286092


15

Lubrication, Part 2



Lubricating equipment is one of the most important industrial

maintenance activities performed. Lubricants reduce friction,

which saves on energy costs. They reduce wear, which saves

on equipment maintenance costs. Proper lubrication

significantly reduces machine downtime resulting from broken

or worn out components. In addition, proper lubricating

practices help keep a machine in tolerance for a longer period

of time.

In today's world of twenty-four-hour-a-day, seven-days-a-

week, plant operation, the role of lubrication takes on even

greater importance. Equipment must be lubricated on a timely

schedule, in the proper amounts, and with the correct

lubricants to sustain long work cycles between planned

shutdowns. This study unit will show you how to properly

apply lubrication and maintain lubrication systems.

Objectives


able to:

• Explain how to manually apply various types of

lubricants in an industrial environment.

• Describe total-loss lubrication.

• Identify a nonloss lubrication system's components and

describe their operation.

• Explain how to maintain a nonloss lubrication system.

• Identify the proper lubrication procedures to use for

special industrial applications including sealed bearings,

oil-impregnated bearings and food-processing plants.

• Explain how lubricant-conditioning systems work and

how to maintain them.

• Describe how automatic lubrication systems work and

how to maintain them.

• List the tasks involved in preventive and predictive

lubrication maintenance.

Contents

Manual Methods of Lubrication; Lubricating Total-Loss

Systems; Nonloss Lubrication Systems; Lubrication in

Special Environments; Lubrication Conditioning;

Automatic Lubrication Systems; Preventive and

Predictive Lubrication Maintenance.

Special Notes: This updated course replaces 2531B.

286095 Fasteners



This study unit explains the use and properties of specialty and

common fasteners used by maintenance technicians. It also

covers many of those fasteners installed during automated

assembly processes.

Objectives


able to:

• Identify the types and properties of fastener material.

• Describe the components of threaded fastener systems

including bolts, nuts, screws and washers.

• Discuss the anchoring systems used in industry.

• Identify rivets and riveting tools.

• Describe other non-threaded fasteners including keys,

pins and retaining rings.

• Display fastener installation techniques including

tensioning, torquing and lubrication.

• Discuss how to troubleshoot fastener failure.

Contents

Introduction to Fasteners; Fastener Materials; Threaded

Designs; Threaded Fastening Systems; Nonthreaded

Fasteners; Installing and Removing Fasteners; Industrial Adhesives.

Special Notes: This updated course replaces 2542.

386031 Milling Machine Fundamentals


Course Prerequisites: Basic Machining Skills (Block X08)


This study unit focuses on the fundamentals of milling

machines. It begins with a brief historical overview of milling

machines. Then, students will learn basic milling concepts,

such as peripheral and face milling, the milling machine

coordinate system, and feed, speed, and depth of cut. You will

also learn about the basic features and common parts of a mill.

This study unit explores the various types of mills, starting

with the most prevalent column- and knee-type machines.

The bed-type and planer-type are reviewed next, followed by a

discussion of special milling machines.

A milling machine by itself usually can’t complete a milling

job. An attachment or accessory is usually required to

perform the task. Therefore, a portion of this unit is devoted

to common attachments and accessories that enhance the

mill’s capabilities.


16

In the final section, trainees will learn about automation of

milling machines and modern computer-controlled machining

centers. You should find this study unit to be a valuable

introduction to the milling process, and a useful reference for

understanding the basic operation of mills.

Objectives


able to:

• Understand the application of a Cartesian coordinate

system to the milling operation.

• Describe the construction, sizes, and the basic

components of milling machines.

• Identify the classifications, characteristics, and

functions of different milling machines.

• Describe how the knee, horizontal, and vertical milling

machines operate.

• Discuss the numerous attachments and accessories that

increase the effectiveness of milling machines.

• Explain the application of NC and CNC to milling

machines.

Contents

Introduction to the Milling Process: Definition of Milling;

History of Milling Machines; Early Milling Cutters and

Drivers; Peripheral Milling and Face Milling; Depth and

Width of Cut; Direction of Feed; Cutter Feeds and

Speeds; Coordinate System for Milling; General

Construction of Milling Machines: Basic Parts of the

Milling Machine; Standard Milling Machine Sizes;

Milling Machine Types: Manual Milling Machine

Classifications; Knee-Type Milling Machines; Bed-

Type Milling Machines; Planer-Type Milling Machines;

Special Milling Machines; Attachments and

Accessories: Purpose of Attachments and Accessories;

Arbors; Arbor Tapers; Arbor Supports; Draw-in Bolts;

Quick-Change Adapters; Bearing and Spacing Collars;

Overarms; Collets and Adapters; Machine Conversion

Attachments; Slotting Attachments; Rack-Milling

Attachments; Rotary Tables; Vises, Fixtures, Clamps,

and Other Hold-Down Devices; Universal Indexing

Heads; Digital Read Out Systems; Milling Machine

Automation: Numerically Controlled Machining;

Computer Controlled Machining; Machining Centers.

386032 Milling Machine Cutting Tools



Milling Machine Fundamentals (426031)


In your previous studies, you learned about the fundamentals

of metal cutting, including basic concepts of feed, speed, and

depth of cut. You also learned about types of cutting tools and

tool materials, such as high-speed steels and carbides.

Students have been introduced to milling operations and

equipment, including different types of mills, attachments, and

accessories.

In this study unit, trainees will learn about milling machine

cutters in more detail. You will be presented with in-depth

information about tool design and materials. At the end of this

unit, metal cutting theory, the principles of tool wear, and

milling economics are discussed.

Objectives


able to:

• Discuss the primary function of different types of

milling cutters.

• Describe the heat treatment process for making tool

steels.

• Explain how cemented carbide cutting tools are made.

• Interpret the standardized lettering/numbering system

for carbide cutters.

• Understand the geometry of carbide inserts and

toolholders and the methods used to attach inserts to

tools.

• Explain tool wear and methods for extending tool life.

• Recognize basic milling econometrics concepts.

Contents

Tool Design and Construction: Introduction; Tool

Materials; Standard- and Formed-Tooth Cutters:

General Guidelines; Standard-Tooth Cutters; Formed-

Tooth Cutters; Inserted-Tooth Cutters: Common Types

of Inserted-Tooth Cutters; Milling Cutter Inserts; Insert

Holders; Setting and Replacing Inserts; Tool

Performance and Econometrics: The Metal-Cutting

Process; Tool Wear and Econometrics.

386033 Milling Machine Practice and Operation, Part 1




Milling Machine Cutting Tools (426032)



17

Previous study units in the milling series focused on the

fundamentals of metal cutting, including basic concepts of

feed, speed, and depth of cut. These units introduced concepts

of milling machine design, milling cutters, attachments, and

accessories. This study unit is the first of a series of units that

put these theories into practice by describing milling

operations.

This study unit uses both English and metric units of

measurement. Generally, the English unit is presented,

followed by the approximate metric equivalent in parentheses.

In some cases, only English units are given, particularly when

including the metric unit would be confusing. For example,

when citing specific dimensions and their tolerances or when

describing objects (such as gage blocks) whose properties are

based on standard English dimensions, students will only see

the English unit of measurement.

Objectives


able to:

• Explain the function of layout tools.

• Perform basic layout operations.

• Understand machine setup guidelines.

• Use a variety of vises, clamps, and fixtures to securely

hold workpieces.

• Square up work holders on a milling machine table.

• Select machine speeds and feeds.

• Plan a sequence of milling operations.

Contents

Getting Started: Milling Machine Practice and Operation;

Work Orders and Drawings; Dimensional Measurement

Issues; Work Layout; Setting Up the Work: General

Principles of Milling Table Setups; Work-Holding

Devices; Setting Up the Milling Machine: Determining

the Milling Method; Selecting the Milling Cutter;

Selecting Cutting Speeds and Feeds; Squaring the Vise

to the Milling Machine; Setting the Work to the Cutter.

386034 Milling Machine Practice and Operation, Part 2


Course Prerequisites: Milling Machine Fundamentals (426031)


Basic Machining Skills (Block X08)


In previous study units in the milling series, you learned about

the fundamentals of metal cutting, including concepts of feed,

speed, and depth of cut. You learned basic information about

milling machine design, milling cutters, attachments, and

accessories. In addition, you learned about workpiece layout,

cutter selection, work holding, and machine setup. This study

unit addresses milling machine practice and operation.

Today, many machine shops use programmable machines,

such as CNC mills or machining centers, to perform milling

operations. However, this study unit discusses conventional

mills with manual controls. Most machinists first learn on

these machines, which remain in widespread use.

This study unit uses both English and metric units of

measurement. Generally, the English unit is presented,

followed by the approximate metric equivalent in parentheses.

In some cases, only English units are given, particularly when

including the metric unit would be confusing. For example,

when citing specific dimensions and their tolerances or when

describing objects (such as gage blocks) whose properties are

based on standard English dimensions, students will only see

the English unit of measurement.

Objectives


able to:

• Set the cutter exactly on the workpiece surface.

• Square the workpiece.

• Mill shoulders, steps, slots, angled surfaces, dovetails,

keyseats, and pockets.

• Perform sawing and slitting work on the mill.

• Maintain and troubleshoot mills.

Contents

Preparation for Milling: Safety; Workpiece Layout; Work

Holding; Machine Design Overview; Milling Machine

Controls; Cutting Fluids; Basic Milling Operations:

Setting the Cutter to the Work; Squaring the Work;

Milling a Shoulder or Step; Milling a Slot or Groove;

Milling an Angled Surface; Sawing on a Mill; Milling

Holes (Drilling and Boring); Milling a Pocket or

Internal Opening; Other Milling Issues: Completing the

Milling Process; Troubleshooting; Maintenance; A

Sample Project: Preparation for Milling; Squaring the

Workpiece; Milling the Slots; Drilling the Holes;

Milling the Internal Opening; Milling the Angles

Surfaces; Milling the Radii.

386035 Milling Machine Indexing and Spiral Work


Course Prerequisites: Milling Machine Fundamentals (426031)


18


Milling Machine Practice and Operation, Part 1 (426033)




This study unit describes how to mill certain types of complex

shapes. This type of milling work might be used for

manufacturing gears or cams.

Indexing, or repeatedly milling a feature at uniform intervals,

and spiral work were once performed exclusively on manual

milling machines. In a modern shop, these tasks are most

often performed using CNC equipment. However, the

techniques and tooling used to manually perform indexing and

spiral work are still encountered in many workplaces.

After introducing the principles of index milling and spiral

work, this study unit explains the manual techniques used to

produce these features. It concludes with a discussion of how

these features are more efficiently milled using CNC

equipment and reviews some sample programming code.

Objectives

When a student completes this study unit, he and she will be able to:

• Explain direct, linear, circular, compound, and

differential indexing.

• Describe the basic operation of indexing head.

• Discuss how to select the correct indexing circle and to

calculate the number of index crank turns.

• Explain how change gears are used.

• Explain how to mill a helix.

• Describe the rotation of a workpiece during helical

milling and how to compensate for the tool shape by

adjusting the table angle.

• Explain the role of CNC milling machines in modern

indexing and spiral machining.

Contents

Indexing: Linear Indexing; Circular Indexing; Direct

Indexing; Indirect Indexing; Compound Indexing;

Differential Indexing; Conventional Helical Milling:

Basic Principles; Setting up the Mill for Helical Milling;

Cutting Helices on the Milling Machine; CNC Helical

Milling: CNC Overview; CNC Programming Codes and

Helical Motion.

386036 Lathes, Part 1




Preview

This study unit is a basic introduction to the lathe. Trainees

will become familiar with general terminology, and you will

learn about the lathe’s operation. This unit is the first in a

series of units on lathes. Each unit progressively discusses

lathes in more detail. This unit is designed to give you

background information, which equips you with a basic

understanding of how to operate a lathe safely and efficiently.

If you have just begun to work with lathes, you will find this

basic information very helpful.

This unit uses both the English and Metric standards of

measurement. Most examples use the English standard

system, with the Metric equivalents listed. Not all conversions

are held to a close tolerance. In cases where there are ranges

of numbers, the nominal metric equivalents are given rather

than the actual converted number. Trainees will find that, in

practice, dimensions on a print will need to be converted

directly. However, stock sizes, standard sizes, and ratings

generally have nominal metric values close but not equal to

English values.

Objectives


able to:

• Describe the modern lathe.

• Explain the differences among various types of modern

lathes.

• Interpret the size ratings of a lathe.

• Describe common work-holding devices.

• Explain the range of operations of the lathe.

• Describe various tool styles, materials, and holders.

• Understand turning parameters and their effects on the

machining process.

Contents

Introduction to the Lathe: What is a Lathe?; The History of

the Lathe; Early Improvements in the Lathe; The

Modern Lathe; Size Ratings; Types of Lathes: Engine

Lathes; Benchtop Lathes; Toolroom Lathes; Turret

Lathes; CNC Lathes; Special Purpose Lathes; Work-

Holding Devices: Chucks; Collets; Mandrels; Centers;

Lathe Dogs and Drive Plates; Lathe Operations: Basic

Lathe Operations; Special Attachments; Tool Types:

Basic Tool Types; Tool Geometry; Materials; Holders;

Turning Parameters: Speed and Feed Selection; Depth

of Cut; Metal Removal Rates.






19

Lathes, Part 2 is designed to provide trainees with a basic

introduction to external lathe operations. This unit is the

second in a series of units that progressively discuss these

operations in more detail. You will gain an understanding of

lathe operations, including facing, diameter turning, shoulder

turning, forming, necking, and parting. Apprentices, machine

shop personnel, and students who are just starting to use a

lathe can benefit from this study unit. Further study and

practice should complement this text, giving you reference

material enhancing your shop floor experience.

This study unit uses both the English and metric standards of

measurement. Most of the examples are given in English units

with the metric equivalents listed in parentheses. Not all

conversions are held to a close tolerance Therefore, in cases

where ranges of numbers are used, the nominal metric

equivalents rather than the actual converted number are

provided. In practice, dimensions on a print will need to be

converted directly (1 inch = 25.4 mm). However, stock sizes,

standard sizes, and ratings generally have nominal metric

values close but not equal to the English values.

Objectives


able to:

• Set up a lathe using various work holders and auxiliary

equipment.

• Choose the correct tool material, type, and geometry for

a particular operation.

• Set the correct feed, speed, and depth of cut for external

machining operations.

• Explain facing, diameter turning, and shoulder turning.

• Describe forming, including the fillet radius and

chamfer forming.

• Explain necking and groove cutting, parting, and

knurling.

• Discuss finishing operations, including filing and

polishing.

Contents

Preparation for Machining: Safety; Maintenance; External

Operations; Tool Selection: Tool Material; Types of

Tools; Tool Geometry; Speed and Feed; Depth of Cut;

Lubricants and Coolants; Basic External Machining

Operations: Analyzing the Part and Setup; Facing;

Center Drilling; Straight or Diameter Turning; Shoulder

Turning; Turning Tips; Special External Machining

Operations: Forming; Shapes and Chamfers; Necking

and Form Groove Cutting; Parting; Knurling; Filing and

Polishing.





This study unit is designed to provide trainees with a basic

introduction to internal lathe operations. This unit is the third

in a series of units that will progressively discuss lathe

operations in more detail. You will develop a basic

understanding necessary to accomplish a variety of lathe

operations, including boring, counterboring, tailstock

operations (drilling, reaming, and tapping), and special

operations (tracing, grinding, eccentrics, and others).

This study unit uses both the English and metric standards of

measurement. Most of the examples are given in English units

with the metric equivalents listed in parentheses. Not all

conversions are held to a close tolerance. Therefore, in cases

where ranges of numbers are used, the nominal metric

equivalents are provided instead of the actual converted. In

practice, dimensions on a print will need to be converted

directly (1 inch = 25.4 millimeters). However, stock sizes,

standard sizes, and ratings generally have nominal metric

values close but not equal to the English values.

Objectives


able to: • Machine boring operations, internal shoulders, internal

grooves, and recesses.

• Machine offset bushings, eccentrics, off-center, and

milling operations.

• Improve workpiece finish and reduce chatter.

• Measure inside forms, including bored holes and

internal grooves.

• Understand tailstock operations, including drilling,

reaming, and tapping.

• Describe the functions of different types of drills.

Contents

Boring: Boring Tools; Setting up Boring Operations;

Boring Procedure; Measuring Internal Forms;

Counterboring; Tips and Chatter Reduction; Recessing /

Grooving: Tailstock Operations: Drilling; Reaming;

Tapping; Special Operations: Tracing; Grinding

Operations; Offset Bushings and Eccentrics; Milling

Operations; Off-Center Work; Substitute Lathe

Operations.






20

This study unit is designed to provide trainees with an

introduction to tapers and taper turning on the lathe. This unit

is the fourth in a series of units that progressively discusses

lathe operations in more detail. You will develop a basic

understanding necessary to identify taper types and sizes,

machine tapers on the lathe, and measure tapers. Experience,

further study, and practice should complement this study unit,

providing you with a broad range of reference material.

This study unit relies on the English standard of measurement.

Most examples are given with English units, without the

metric equivalents listed. Tapers are often measured in inches

of taper per foot of length. Generally, there isn’t a

corresponding metric taper that converts directly from the

English standard.

Objectives


able to:

• Identify various types of tapers and their uses.

• Describe methods of producing tapers.

• Calculate the required dimensions and setups required

to machine tapers.

• Set up and machine tapers following various methods.

• Calculate tapers measured in inches per foot and their

corresponding taper angles.

• Measure and inspect tapers.

Contents

Tapers: Basic Definitions and Calculations; Finding Taper

Dimensions; Taper Tables; Types of Tapers: Basic

Styles; Morse Tapers; Brown and Sharpe Tapers; Jarno

Tapers; American National Standard Machine Tapers;

British Standard Tapers; Taper Pin Tapers; Jacobs

Tapers; Oversize Tapers; Fast Tapers and Tapers for

Machine Tool Spindles; Identifying Tapers; Taper

Turning: Common Methods to Produce Tapers;

Template Tracing; Plunge Formed Tapers and

Chamfers; Tapers Using Compound Rests; Taper

Angles; Tapers Using Tailstock Offsets; Using a Taper

Attachment; Tips for Cutting Tapers; Machining a

Lathe Half-Center; Measuring Tapers and Inspection:

Tools to Measure Tapers; Using a Sine Plate.





This study unit is a basic introduction to threads and thread

chasing on the lathe. This unit is the fifth in a series of units

that have progressively discussed lathe operations in more

detail. This study unit provides the background necessary to

identify thread forms, functions, and classifications, to

machine threads on the lathe, and to measure threads.

This study unit uses both English and metric standards. Most

examples are given in English units, without the metric

equivalents listed. When discussing metric threads, the

English equivalent is not listed. Threads are often measured in

threads per inch (English) or in millimeters of pitch (metric).

There’s usually no corresponding metric thread that converts

directly from the English standard, and no English thread can

be converted from the metric thread.

Objectives


able to:

• Describe the functions of various thread types.

• Understand the differences among thread standards.

• Calculate the required dimensions and setups for

machining threads.

• Explain common methods of producing threads.

• Set up, machine, measure, and inspect threads.

Contents

Threading: Basic Definitions; Thread Function and

Classification; Thread Terminology; Thread Standards;

Thread Classes; Thread Notations; Thread Styles: Sharp

V Thread; American National Thread; Unified Thread;

American National Acme Thread; Tapered Threads;

International Metric Thread; Special Threads; Thread

Chasing: Threading Tools; Gearing for Threads;

Thread-Chasing Dial; Setting up for Chasing; Chasing

Technique; Chasing Left Hand Threads; Terminating a

Thread; Picking up a Thread; Dragging a Thread;

Chasing Internal Threads; Chasing Tips; Square Thread

Tips; Chasing Metric Threads; Chasing Multiple

Threads; Inspecting Threads: Measuring Pitch

Diameter; Checking Threads; Finding Pitch; Inspecting

Multiple Threads.

386030 Fundamentals of Metal Cutting





21

In this study unit, students learn about the fundamental

methods and principles related to machining metal. The study

unit begins with a brief historical review of the evolution of

machining. Then, you will be introduced to three key factors

that are used to define all metal cutting operations: feed, depth

of cut, and speed. These factors have interrelated roles in

shaping metals. Students will then learn about the critical role

of the cutting tool itself and how cutting tools are designed to

improve metal cutting performance and to reduce tool wear.

The study unit discusses a broad variety of materials from

which cutting tools are made; steels, carbides, ceramics,

diamond, and others, and explains which tool materials are

best suited to certain machining jobs.

Trainees will then learn about single-point cutting tools and

how small changes in tool design and construction can have a

great effect on cutting effectiveness and on the quality of the

machined part. Lathe tools are the primary focus of the study

of single-point cutting tools, but the unit also describes

shaping, planning, boring, and some special-purpose tools.

Multiple-point cutting tools are introduced. There is an

extensive section on milling tools and all their variations. In

addition to milling tools, this study unit covers other varieties

of multiple-point cutting tools, including taps, reamers,

broaches, saws, files, gear cutters, and many types of drills.

You will learn how to use guidebooks and other information

to help you plan your machining tasks and how to work

successfully when you don’t have written guidance. Finally,

students will learn about the role of cutting fluids in various

machining operations and how to select and use cutting fluids

to improve machining performance.

Objectives


able to:

• Describe the metal-cutting process and cutting tool

requirements.

• Explain the role of feed, speed, and depth-of-cut in

machining.

• Explain the advantages and limitations of carbon steel

and carbide cutting tools.

• Describe the principles of single-point cutting tools and

the factors governing tool wear.

• Explain multiple-point cutting tools and their uses.

• Describe the difference between lathe turning and

milling.

• Explain tapping, threading, reaming, and broaching.

• Explain the role of cutting fluids in machining

operations.

Contents

Introduction to Metal Cutting: Safety; Historical

Perspective; New Developments; Metal Cutting

Fundamentals; Cutting Tool Fundamentals; Cutting

Tool Properties: Tool Material Requirements; Tool

Materials; Single-Point Cutting Tools: Lathe Tools;

Other Single-Point Cutting Tools; Multiple-Point

Cutting Tools: Milling Tools; Other Multiple-Point

Cutting Tools; Cutting Fluids: Advantages of Cutting

Fluids; Other Considerations; Types of Cutting Fluids;

Cutting Fluid Application.

186110 Machine Safety



In this study unit, trainees will gain a better understanding of

the work practices necessary to operate industrial machinery,

such as a bench-top drill press or a ten ton mechancial poewer

press, safely. You will learn how the principles and practices

used to keep ypu safe from injury can be incorporated into

your daily routine.

Providing a safe work enviornment is the responsibility of the

employer. It is the employees responsibility to work safely at

all times, especially when using power driven machinery.

Awareness and sound practice of the safety procedures you'll

learn offer your best defense against workplace injuries. In

this study unit, students will learn the skills needed to become

a productive and safe industrial machine operator.

Objectives


able to:

• Recognize the basic machine motions that can present a

hazard to workers.

• Recognize the types of machinery most likely to be

hazardous to workers.

• Understand the types of injuries caused by accidents

commonly associated with unsafe machine operating

procedures.

• Discuss the importance of machine guarding and how to

incorporate methods of guarding to avoid physical

injury.

• Recognize the four basic types of machine guards

commonly used in industry.

• Control various forms of hazardous machine energy

through the use of lockout / tagout procedures.

• Understand how and why to properly use personal

protective equipment for added protection when using

industrial equipment.

Contents

Introduction to Machine Safety; Machine Safeguarding;

Types of Machinery; Machine Controls and Control

Equipment; Protective Equipment and Procedures.


22

3530A-B Automatic Screw Machines



Turret Lathes (3525A)

Turret Lathe Tools and Setups (2213)

What Students Learn: PART 1 (3530A). Types of Automatic Screw Machines;

Single-Spindle Chucking Lathe; Multiple-Spindle Chucking

Lathe; Bar-Type Lathes.

PART 2 (3530B). Tools and Setups; Single-Spindle Chucking

Lathe; Multiple-Spindle Chucking Lathe; Single-Spindle Bar

Machine; Swiss-Type Automatic Lathe; Single-Spindle Bar

Lathe; Multiple-Spindle Bar Lathe.

3525A Turret Lathes



What Students Learn: Turret Lathe Design; Ram-Type Turret Lathes; Saddle-Type

Turret Lathes; Electronically Controlled Turret Lathes; Turret-

Lathe Basic Maintenance; Work-Holding and Work-Feeding

Devices.

2213 Turret Lathe Tools and Setups


Course Prerequisites: Turret Lathes (3525A)


Hexagon Turret Tool-Holding Provisions; Flanged,

Adjustable, and Floating Holders; Duplex Holder; Center

Drilling Tool; Knee Tool; Stock Stop Box Tools; End Former;

Taper Turner; Taper Forming Box Tool; Chamfering Tools;

Multiple Turning Head; Slide Tools; Boring Bars; Rack Tool;

Knurling Tool; Collapsing Taps; Self-Opening Dies; Cross

Slide Tool-Holding Provisions; Square Turret; Single Point

Cutters and Holders; Tool Posts; Forming Cutters and

Holders; Threading Toolholder; Tooling Principles;

Economics of Turret Lathe Setups; Bar Setups; Chucking

Setups.

386016 Fundamentals of Grinding



What Students Learn: Forms of Abrasives; Classification of Abrasives; Abrasive

Grinding Processes and Machines; Standard Wheel Marking

System; Abrasive Types; Grain Size; Wheel Grade, Wheel

Structure, Wheel Bonds; Diamond and Cubic Boron Nitride

Wheels; Wheel Grinding Machines; Wheel Shapes; Grinding

Wheel Testing and Maintenance; Grinding Fluids or Coolants

Coated Abrasives; Applications and Characteristics of Coated

Abrasives; Factors Affecting Stock Removal and Finish; Safe

Practices for Grinding.

Special Notes: • Covers subject at an advanced, in-depth level.

• This updated course replaces course 5023.

386010 Cylindrical Grinding, Part 1



What Students Learn: Types of Cylindrical Grinding Machines; Major Units of

Center-Type Grinders; Grinding Machine Controls; Grinding

Wheels; Coolants.

Special Notes: • This updated course replaces course 3560A.

• The entire course consists of study units 426010-

426011.

386011


23

Cylindrical Grinding, Part 2



What Students Learn: General Safety Information; Machine Setup Procedure;

Production Grinding; Roll Grinding; Grinding Applications;

Troubleshooting in Cylindrical Grinding.

Special Notes: • This updated course replaces course 3560B.


426011.

386012 Surface Grinding, Part 1


Course Prerequisites: Fundamentals of Grinding (426016)

What Students Learn: Introduction to Surface Grinding; Types of Surface-Grinding

Machines; Components of Surface-Grinding Machines.

Special Notes: • This updated course replaces course 5024A.


426013.

386013 Surface Grinding, Part 2



What Students Learn: Preparing the Abrasive Wheel for Surface Grinding; Surface

Grinder Operations; Surface Finish and Measurement.

Special Notes: • This updated course replaces course 5024B.


426013.

5962

Inspection of Shop Products


Course Prerequisites: Introduction to Algebra, Geometry, and Trigonometry (Block

X02)

What Students Learn: Specifications for Inspection; Tolerances, and Allowances;

Standards; First-Piece Inspection; Automatic Machine-Product

Inspection; Patrol Inspection; Batch Inspection; Final

Inspection; Screw Inspection; Measuring Threads; Three-Wire

Methods; Thread Gages; Comparators; Measuring Spur Gears;

Gaging Odd Teeth; Recurring Inspection; Ultrasonic

Equipment; Dynamic Balances; Inspection of Machined

Castings; Spectrographic Testing.

386E02 Quality Control for the Technician



What Students Learn: Part 1 (426026). Lesson 1 - Total Quality Management for

Technicians:

• Quality Systems, Communication, and Motivation;

Total Quality Management (TQM) Tools,

Responsibilities and Systems; Quality Costs:

Identifying, Controlling, Minimizing, Reporting and

Analysis; Planning and Conducting Audits; Inspection

Systems and Planning.

Lesson 2 - Blueprint and GD&T System Interpretation for

Inspection:

• Using Engineering Prints for Inspection; Working with

Geometric Dimensioning and Tolerancing Systems;

Graphical Inspection Analysis Procedures and

Advantages.

Part 2 (426027). Lesson 3 - Common Inspection Tools:

• Measurement Tools, Accuracy and Errors; Spring

Calipers; Gage Blocks; Indicators; Micrometers and

Vernier Instruments; Hole, Attribute, and Radius Gages;

Tapered Parallels; Measuring Threads; Calibration

Techniques.

Lesson 4 - Surface Plate Inspection Methods:

• Surface Plates and Gages: Care of Equipment;

Measuring Various Attributes with Surface Plates.

Lesson 5 - Special Measurement Equipment and

Techniques:


24

• Digital Measuring Equipment; Using Optical Flats;

Measuring Surface Finish; Pneumatic Comparators;

Circularity and Cylindricity; Optical Comparators;

Coordinate Measurement Machines (CMM’s); Hardness

Testing.

Lesson 6 - Lot by Lot Acceptance:

• Basic Probability; Sampling Verses 100% Inspection;

Lot-by-Lot, Process Control and Random Sampling;

Using Mil-Std-105E for Sampling; Dodge-Romig

Tables; Mil-Std-414; Variable Sampling Tables;

Operating Characteristic Curves.

Lesson 7 - Statistical Process Control in Practice:

• Objectives and Tools for Process Control; Computing

Average, Range and Standard Deviation; Control and

Specification Limits; Identifying Processes In-Control;

Plotting Techniques; Control Charts and Pattern

Analysis; Process Capability.

Special Notes: • This course consists of a textbook and two supplemental

study guides. We recommend the course be purchased

in its entirety. However, if needed due to targeted

training, study guides (Parts 1 and 2) can be purchased

separately, with or without the textbook. Note that the

textbook is required for the Part 1 study guide. Call

Customer Service for pricing and ordering information.

5636A Boring Mills


What Students Learn: Fundamentals of Boring Mills; Basic Functions; Vertical

Boring Mills; Horizontal Boring Mills; Attachments and

Accessories; Special Boring Mills; Boring Mill Motions;

Boring Operations.

6118 Planers


Course Prerequisites: Shapers, Slotters, and Keyseaters (2222)

What Students Learn: Planer Cutting Action; Bed and Table Construction; Drive and

Lubrication Systems; Column, Crossrail, and Toolhead

Construction; Counterbalancing and Power Swiveling System;

Automatic Feed and Rapid-Power Traverse Systems;

Elevating and Clamping Mechanisms; Pendant Stations;

Cutters; Feeds and Speeds; Work-Setting Equipment; Planer

Practice.

6091 Broaching


What Students Learn: Broaching Principle; Broaching Tools; Internal Broaching;

Pull and Push Broaches; Chip Breakers; Burnishers; Manual

and Automatic Broach Pullers; Surface Broaches; Broaching

Machines; Broaching Press; Broaching Fixtures; Broaching

Practice; Cutting Speeds; Cutting Oils; Chip Disposal;

Dislodging a Stuck Broach.

2222 Shapers, Slotters, and Keyseaters


What Students Learn: Horizontal Reciprocating Equipment; Crank-Driven Shapers;

Stroke Length; Ram Quick-Return Motions; Stroke Area;

Rapid-Power Traverse; Universal Shaper; Hydraulic Shaper;

Draw-Cut Shaper; Work-Holding Devices; Automatic Tool

Lifter; Index Centers; Cutting Tools; Setting Length and

Position of Stroke; Overtravel and Machine Time; Speeds and

Feeds; Horizontal, Vertical, and Angular Shaping;

Duplicating; Slotters and Slotter Practice; Keyseaters;

Keyseater Bars and Cutters.

386029 Nontraditional Machining Technologies


Course Prerequisites: Toolmaking (2540A-C)



25

Think of the types of energy used in most manufacturing

processes. A lathe employs mechanical energy to remove

material from the work piece. The tool makes contact with the

work piece and the resulting shear causes the material to flow

over the tool. All traditional forms of metal cutting use shear

as the primary method of material removal. The primary

source of energy in traditional manufacturing is mechanical.

However, there are other sources of energy at work. Chemical

energy has a significant effect on every turning operation.

Think of the effect that different kinds of coolants have on the

cutting action of a tool. Some amount of chemical energy is

being used in most metal cutting operations. All forms of

manufacturing use more than one type of energy.

Nontraditional machining can be thought of as operations that

do not use shear as their primary source of energy. For

example, abrasive water jet operations use mechanical energy,

but material is removed by erosion. In this study unit, students

will learn more about nontraditional machining technologies.


able to:

• Explain how electrical discharge machining (EDM)

works.

• Describe the difference between wire and ram EDM.

• Explain how laser light is produced and how lasers are

used in industrial settings.

• Explain why a plasma cutting torch is so much hotter

than other types of cutting torches.

• Describe the difference between chemical and electro-

chemical machining.

• Explain how water can be made to cut steel.

• Describe the common manufacturing methods of rapid

prototyping.

Contents

Introduction to Machining Technologies; Electrical

Discharge Machining; Plasma Arc Cutting; Laser

Machining; Water Jet Machining; Chemical Machining;

Ultrasonic, Abrasive Flow, and Thermal Deburring;

Rapid Prototyping and Manufacturing.

3195 Hardening and Tempering



Methods of Heat Treatment; Gas-Fired and Electric Furnaces;

Controlled Atmospheres; Heating Baths; Crucible Furnace;

Oil and Air Tempering Furnaces; Quenching Baths;

Quenching Tanks; Heat-Treating Operations; Composition,

Properties, and Uses of Carbon Tool Steel; Heating and

Cooling for Annealing; Heating for Hardening; Oil-Hardening

Steels; Air-Hardening Steels; High-Carbon, High-Chromium

Tool Steels; Chisel Steels; Hardening and Tempering Taps

and Reamers; Twist Drills; High-Speed Steel Saws; Springs

and Chromium-Steel Rolls; Heat Treatment of Dies, Forged

Chisels, and Rock Drills; Structures of Alloy Steels; High-

Frequency Hardening; Dielectric Heating.

386017 Tool Grinding



What Students Learn: Wheel Selection and Shapes; Oilstones; Honing Cutting

Tools; Grinding Single-Point Tools; Angle Calculations;

Universal Grinder; Drill Grinding; Testing Drill Points;

Grinding Milling Cutters; Clearance Grinding; Tooth Rest;

Grinding Side, Shank Angular, Inserted-Blade, and Helical

Cutters; Grinding Circular Saws, Formed Cutters, Gear

Cutters, Hobs, Reamers, Taps, Radial, and Tangential

Chasers; Grinding Carbide Tools; Grinding Internal and Slab

Broaches.

Special Notes: This updated course replaces course 5349.

3194 Tool Dressing


What Students Learn: Inspection of Steels; Cutting and Heating Tool Steel; Forging

Tools; Tipping Forged Tools; Annealing, Hardening, and

Tempering; Colors Corresponding to Hardening

Temperatures; Heating Furnaces; Heating Baths; Tempering

Furnace; Quenching Baths; Annealing, Hardening, and

Tempering High-Speed Steel.

2243 Gear Calculations



26

What Students Learn: Kinds of Gears; Spur Gears; Spur-Gear Calculations in

Circular-Pitch System and in Diametral-Pitch System;

Involute System; Form of Helical Gear; Helical-Gear

Calculations; Bevel Gears; Laying Out Bevel Gears; Spiral-

Bevel Gears; Worms and Worm Gears; Worm-Gear and

Worm Calculations; Spiral Gears; Spiral-Gear Calculations.

5532A-B Gear Making


Course Prerequisites: Practical Measurements (Block X22)

Plane Trigonometry (2309A-B)


Milling Machine Indexing and Spiral Work (426035)

Gear Calculations (2243)




What Students Learn: PART 1 (5532A). Processes; Cutters; Tooth Dimensions;

Milling Spur Gear; Helical Gears; Bevel Gears; Worm Gears;

Internal Gears; Planning; Generating; Herringbone Gears.

PART 2 (5532B). Hobbing; Spiral Bevels; Hypoids; Gear

Finishing; Rack Shaving; Rotary Shaving; Curve Shaving;

Burnishing; Lapping; Grinding; Gear Inspection; Gear

Materials; Heat Treatment; Flame Hardening.

186075 Manufacturing Processes, Part 1



• Relate historical trends in manufacturing to

modern ones

• Describe the development and importance of

modern quality systems

• Explain how available material types shape

manufacturing processes

• Describe early factory systems and their impact

on modern systems

• Classify modern manufacturing systems by type

and abilities This course replaces 2520A


Duration: 10 hours (includes 1 test) \


• Explain the relationship between atomic

structure and material properties

• Classify materials used in manufacturing based on physical and mechanical

properties

• Identify benefits and drawbacks of

specific materials for a given application

• Interpret the classifications of various

metallic materials

• Compare properties of various metallic

materials

• Identify properties of and applications for

various nonmetallic materials

NOTE: This course replaces 2520B




• Describe common methods and applications for

casting metals and plastics

• Describe and contrast various forming processes

including forging, drawing, and others

• Differentiate between the benefits and costs of

casting and forming processes

• Explain how the various conventional metal-


27

removal technologies are used in

manufacturing

• Identify the benefits of and range of applications

for robotics and CNC systems in

manufacturing

• Describe the benefits and costs of non-contact

metal removal and shaping processes

NOTE: This course replaces 2520C




• Relate the factors of production to how a given

manufacturing organization is structured

• List the types of manufacturing production

systems

• Suggest modifications of equipment layout to

improve productivity

• Evaluating automation strategies and problems

• Benefits of quality management methods

• Describe their role in JIT, Lean, and e

Manufacturing systems

NOTE: This course replaces 2520D

086E06 CNC Technology and Programming




• Introduction to Computer Numerical Control: History

of Numerical Control; Types of Numerical Control

Machines; Point-to-Point vs. Continuous Path; Machine

Tool Axes; Components of CNC Machines; Why

CNC?; Axes and Coordinate Systems; Absolute and

Incremental Programming.

• Fundamentals of Programming: Word Address

Programming; Part Programming; Programming

Procedures; Incremental Positioning; Circular

Interpolation; Tool Length Offset; Tool Diameter

Offsets.

• Basic Trigonometry: Pythagorean Theorem; Sine,

Cosine, and Tangent.

• Carbide Fundamentals: Fundamentals of Carbide

Tooling; Insert Selection; Insert Selection Practice; Tool

Holder Style and Identification; Chip Control;

Troubleshooting.

• Machining Centers: Types of Machining Centers; Parts

of the Machining Center; Axes of Motion; Work

Holding Devices; Tools and Tool Holders; Tools for

Milling; Climb and Conventional Milling; Cutting

Speed, Feed, and Depth of Cut; Machining Center

Operation; Safety; Machine Control Features;

Workpiece Coordinate Setting; Other Control Features;

Conversational Programming.

• Programming Machining Centers: Planning the

Program; Canned Cycles for Machining Centers.

• CNC Turning Machines: Introduction to Turning

Centers; Types; Components of CNC Lathes; Turning

Machine Axes Identification; Work Holding; Cutting

Tools; Presetting Tools; Offsets; Material Handling;

Machine Control Operation; Manual Control; Program

Editing; Diagnostics; Conversational Programming.

• Programming CNC Turning Machines: Review of

Turning Centers; Planning the Program; Quick Review

of Programming; Circular Interpolation; Canned Cycles

for Turning Centers.

• Electrical Discharge Machining (EDM): Introduction to

EDM; Cutting With EDM; Types of Wire EDM

Machines; Parts of the Wire-Feed EDM; Machine

Setup; Programming.

• Fundamentals of Communications: Introduction;

Levels of Plant Communication; Local Area Networks

(LANs); CNC Communications; Cabling

Configurations; A Simple Communication Network.

• Fundamentals of Statistical Process Control:

Introduction to Statistical Process Control; Types of

Data; Coding Data; Graphic Representation of Data;

Basics of Variation; Chance and Assignable Variation;

Average (mean); Measures of Variation; Normal

Distribution.

• Statistical Process Control: Process Capability; Benefits

of Charting; Charting Processes; Analyzing the Chart.

• Introduction to ISO 9000: Introduction to ISO 9000

Basics; The ISO 9000 Standards; Levels of

Documentation; Benefits of a Quality System; ISO

Elements; ISO Implementation; Certification; QS 9000.


28

• Fundamentals of CAD/CAM: Introduction to

CAD/CAM; Design; Computer-Aided Design (CAD);

Use of CAD; Advantages of CAD; Computer-Aided

Part Programming (CAPP); Post-Processors;

Simulation; Downloading CNC Programs; The Future

of Design.

386028 Toolholding Systems


Course Prerequisites: Toolmaking (2540A-C)


Trainees have studied the process of machining and the

various types of machine tools that are used in manufacturing.

In this study unit, they will take a closer look at the interface

between the machine tools and the work piece, the toolholder.

In today's modern manufacturing environment, many

sophisticated machine tools are available, including standard

types and CNC machines with special accessories to aid high-

speed machining. Many of these new machine tools are very

expensive and have the ability to machine quickly and

precisely. However, if a careless decision is made regarding a

cutting tool and its toolholder, a poor product quality will

result, no matter how sophisticated the machine. In this study

unit, trainees will learn some of the fundamental

characteristics that most toolholders have in common, and

what information is needed to select the proper toolholder.

Objectives


able to:

• Understand the fundamental characteristics of

toolholders required for various machine tools.

• Understand and describe how the toolholder affects the

quality of the machining operation.

• Interpret national standards for tool and toolholder

identification systems.

• Recognize the differences in toolholder tapers and the

proper applications for each type of taper.

• Explain the effects of toolholder concentricity and

imbalance.

• Find additional information from manufacturers

concerning toolholder selection.

Contents

Overview of Machine Tools; Toolholders for Conventional

Machine Tools; Toolholders for Computerized

Numerical Control (CNC) Applications; Safety with

Toolholders and Cutting Tools.

386041 CNC Turning



CNC Technology and Programming (066903)


This study unit is designed to provide the trainee with an

advanced discussion on CNC turning. This unit may be used

as an advanced supplement to a basic introduction to CNC

turning. Apprentices, machine shop personnel, and students

with basic CNC turning experience can use this unit. The

information in this unit will briefly review the basics, and then

continue with more in-depth discussions of advanced CNC

topics.

This unit uses both the English and Metric standards. Program

examples will be provided for both standards without

conversions between the two. Generally, programs are written

in either standard, depending on the requirements of the

particular job. If a Metric print is provided, then the program

is usually written in Metric format, without conversion. The

same is true for a print provided in English dimensions.

Objectives


able to:

• Apply basic concepts to advanced turning programs.

• Understand the application of canned cycles,

subroutines, loops, and other advanced concepts.

• Understand how special codes are used to automate

complete jobs, including dual turret turning centers.

• Understand how speeds and feeds are affected by CNC

operations.

• Understand how to correct common problems such as

part size and

feature locations that are out of tolerance.

Contents


29

CNC Safety Procedures: Axis and Coordinate Systems:

Axis Systems and Machine Axis Orientation; Cartesian

vs. Polar Coordinates; Absolute vs. Incremental Moves;

Origins; Machine Zero; Part or Program Zero; Local

Zero; Introduction to G AND M Coded Programs: Basic

Codes and Definitions; Miscellaneous Codes and

Program Control; Speeds and Feeds: Constant RPM

versus Constant Surface Speed; Feed per Minute versus

Feed per Revolution; 2-Axis Lathe Programming: Lathe

Examples with Rotary Axis; Canned Cycles for Lathes:

Metal Removal; Threading; Advanced Lathe

Programming: Subroutines; Loops; Dual Turrets; Math,

Logic, and Variables; Reference Points, Offset and

Correcting for Common Problems: Locating Zero and

Reference Points: Shifting Reference Points: Cutter

Compensation: X and Z Offsets; Tool Nose Radius and

Tool Type; Wear Offsets; Correcting Common

Problems.

386042 CNC Milling


Course Prerequisites: CNC Technology and Programming (066903)


• Apply of canned cycles, subroutines, and loops in

real-world programming applications.

• Modify and adapt basic programs and commands to

develop advanced milling programs.

• Use special codes to automate complete jobs,

including programming for maximum production

efficiency.

• Affect of some CNC operations on cutting speeds

and feed rates.

• Correct common problems such as unacceptable part

size and out-of- tolerance feature locations.

Optional: Tool & Die Maker

Skills

5282A-C Mechanics of Materials


Course Prerequisites:

Introduction to Algebra, Geometry, and Trigonometry (Block

X02)

What Students Learn: PART 1 (5282A). Comparison of Materials; Simple Stresses;

Reactions; Deformation; Elastic Properties of Materials;

Allowable Unit Stresses; Factor of Safety; Investigation and

Design of Simple Tension and Compression Members;

Members Subjected to Shear; Hollow Thin Cylinders;

Temperature Stresses; Riveted Joints; Welded Joints; Bolted

Connections in Steel Fastenings for Timber.

PART 2 (5282B). Fixed and Moving Loads on Beams;

Reactions at Beam Supports; Cantilever; Simple and

Overhanging Beams; Continuous Beams and Beams with

Fixed Ends; Points of Inflection; Maximum Shear and

Bending Moment in Beams; Shear and Bending Moment

Diagrams.

PART 3 (5282C). Flexural Stresses in Beams; Moment of

Inertia and Section Modulus; Shearing Stresses in Beams;

Stresses Due to Torsion; Torsion and Bending in Circular

Shafts; Deflections of Beams; Investigation and Design of

Beams; Theory of Column Design Radius of Gyration;

Investigation and Design of Columns.

3541A-D Heat Treatment


Course Prerequisites: Practical Measurements (Block X22)

Elements of Chemistry (5011)

What Students Learn: PART 1 (3541A). Steel Ingots; Hot Working of Steel; Effects

of Hot Working on Microstructure; Cold Working of Steel;

Heat-Treating Equipment; Cooling Mediums and Devices;

Temperature Measurement and Control; Miscellaneous

Equipment; Metric System Conversion Information.

PART 2 (3541B). Composition of Carbon Steels; Heat-

Treating Processes; Heat-Treating Equipment.

PART 3 (3541C). Composition of Alloy Steels; Heat

Treatment of Alloy Steels; Properties of Low-Alloy Steels;

Special Steels; Case Hardening; Furnace Atmospheres.

PART 4 (3541D). Classification and Description of Tool

Materials; Inspection, Test, and General Heat-Treating

Processes; Heat-Treating Equipment; Typical Procedures of

Heat-Treating Tool Steels.

5101A-B Dies and Die Making


Course Prerequisites:


30


What Students Learn: PART 1 (5101A). Dies for Sheet-Metal Work; Cutting Dies;

Punch Presses; Speeds of Punch Presses; Attaching Dies to

Presses; Examples of Die Work; Machine Tool Equipment for

Die Making; Making Cutting Dies; Selecting Materials for

Dies; Preparation of Die Blanks; Layout of Die; Making

Templets; Machining of Die Blank; Making Stripper and

Punch Plate; Forms of Cutting Dies; Shear of Dies; Making

Progressive Cutting Dies; Making Subpress Cutting Dies.

PART 2 (5101B). Making Shaping Dies; Drawing Dies; Size

of Blanks; Deep Cylindrical and Non-Cylindrical Cups;

Redrawing Dies; Making Dies for Curling, Wiring, Seaming,

Coining, Extruding, and Embossing; Making Combination

Dies; Cutting, Drawing, and Embossing Combination Dies;

Combination Forming and Swaging Dies; Combination

Blanking, Piercing, and Swaging Dies; Progressive

Combination Dies; Hardening and Tempering of Dies;

Prevention of Cracks; Die Setting Estimating Capacity of

Press; Lubrication of Dies; Mechanical Feeds for Punch

Presses.

3199 Forging Dies


Course Prerequisites: Dies and Die Making (5101A-B)

What Students Learn: Construction and Use of Drop-Forging Dies; Nature and

Construction of Press-Forging Dies; Bending Dies.

3197 Making Forging Dies


Course Prerequisites: Dies and Die Making (5101A-B)

What Students Learn: Kinds of Steel Used in Making Forging Dies; Annealing,

Hardening, and Tempering Treatment of Die Blocks; Machine

Tools Used in Working with Die Sinkers; Using Hand Tools

in the Diemaking Practice; Laying Out and Machining Die

Blocks; Handwork on Die Impressions; Making Breakdowns

and Trimming Dies.

2540A-C Toolmaking



What Students Learn: PART 1 (2540A). General Toolroom Work; Materials and

Equipment; Procedure and Measurements; Limitations of

Toolmaking; Examples of Toolmaking and Toolmaking

Operations.

PART 2 (2540B). Cutting Tools; Hand Taps; Machine Taps;

Taper Taps; Hobs; Dies for Thread Cutting; Die Holders;

Reamers; Theory of Cutting Tools.

PART 3 (2540C). Counterbores; Hollow Mills; Milling

Cutters; Screw Machine, Turret Lathe, and Broaching Tools.

5098 Gage Making



What Students Learn: Classification, Accuracy, and Tolerances; Materials for Gages;

Proportions of Gages; Grinding and Lapping Gages; Making

Thread Gages; Making End-Measuring Gages; Making

Caliper Gages; Limit Gages; Flat-Surface Gages; Angular

Gages; Making Straightedges; Making Taper Gages; Contour

Gages; Pin Gages; Cylindrical Square; Indicator Gages; Ball

Gages; Gaging Teeth of Spur Gears; Gaging Compound

Angles; Sine-Bar Angles for Lathe Tools, Templets, and

Templet Making.

5099 Jigs and Fixtures



What Students Learn: Types of Jigs; Examples of Jigs; Jig Parts and Accessories;

Bushings; Jig Covers and Clamps; Miscellaneous Details of

Jigs; Fixtures; Common Vise Fixture; Special Vise Fixture;

Bolted Fixture: Combination Jig and Fixture; Trunnion

Fixture; Roller Fixture; Broaching Fixture.

5100 Jig and Fixture Making


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What Students Learn: Processes in Jig and Fixture Making; Planning; Machining;

Locating and Producing Holes; Locating Centers by Buttons;

Locating by Calculation; Locating Buttons by Rings and

Disks; Micrometer Measurements with Rings; Locating Holes;

Examples of Jig Making; Making Jig Bushings; Master Plates;

Continuous Dialing; Setting Up Indexing Jigs: Making Jigs on

Drilling Machines; Checking Jigs; Making Plate Jigs; Making

Fixtures.

penn foster’s machinist apprenticeship program

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