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Mechanical Manufacturing Processes

Mechanical Testing of Materials

Course #: 2608A-B
Duration: 20 hours
Course Prerequisites: Practical Measurements (Block X22);
What Students Learn: PART 1 (2608A). Purpose of Testing Physical Properties of Materials; Mechanical Testing Machines; Tension Test; Compression Test.
PART 2 (2608B). Transverse or Beam Test; Shear and Torsion Tests; Hardness Testing, Impact Testing; Miscellaneous Tests for Ductile Materials; Testing of Nonmetals.

Engineering Materials

Course #: 2536A-C
Duration: 30 hours
Course Prerequisites: Introduction to Algebra, Geometry, and Trigonometry (Block X02);
What Students Learn: PART 1 (2536A). Selection of Materials; Definition of Material Properties; Composition and Characteristics of Ferrous and Nonferrous Metals and Alloys.
PART 2 (2536B). Composition and Characteristics of Ceramics, Concrete, Glass, Graphite, Mica, Asbestos, Plastics, Elastomers, and Plastic.
PART 3 (2536C). Structure and Properties of Woods, Paper, Textiles, and Coatings.

Manufacturing Processes

Course #: 2520A-D
Duration: 40 hours
What Students Learn: PART 1 (2520A). Cutting Tools; Efficient Machining; Workpiece Holding Devices; Machine Tool; Machine Tool Controls.
PART 2 (2520B). Powder Metallurgy; Casting Process; Plastics and Rubber; Hot Working of Metals; Cold Working of Metals.
PART 3 (2520C). Heat Treatment; Welding Techniques; Magneforming; Electrical and Chemical Machining; Ultrasonics; Surface Protection.
PART 4 (2520D). Metrology Caliper; Micrometer; Gage Blocks; Optical Flat; Sine Plate; Automatic Assembly.

Numerical Control for Machining

Course #: 5041
Duration: 10 hours
Course Prerequisites: Basic Machining Skills (Block X08);
What Students Learn: Introduction to Numerical Control (NC) and its Applications in Machining Operations; Advantages and Disadvantages of NC; Basics of NC - The Coordinate System; Types of Control Systems; Input Data Requirements; Components of NC Systems; The Machine Tool, Control System, Tooling, and Personnel; Steps in Performing an NC Job; Role of the Machine Operator.

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

Transfer Devices for Machine Tools

Course #: 6569A-B
Duration: 20 hours
Course Prerequisites: Practical Measurements (Block X22);
What Students Learn: PART 1 (6569A). The History and Development of Transfer Devices; Manual and Power-Operated Devices; Indexing; Cam and Roller Drives.
PART 2 (6569B). Devices Used for Linear Transfer; Chain Transfer Devices; Linkages; Trolleys; Bar Systems; Walking Beams; Compound Motion Transfer Devices.

Pumps, Part 1

Course #: 286001
Duration: 10 hours
Course Prerequisites: Hydraulic Components: Actuators, Pumps, and Motors (286061);
What Students Learn: Modern Centrifugal Pumps; Operating Principles of Pumps; Classifications and Types of Pumps; Fundamental Pump Terms: pressure, vapor pressure, head, losses, cavitation, net positive suction head, specific speed, viscosity; Centrifugal Pump Performance Curves; Types of Pumping System Curves.

Special Notes:

  • This updated course replaces course 2530A.
  • The entire course consists of study units 286001, 286002, and 286003.

    • Pumps, Part 2

    Course #: 286002
    Duration: 10 hours
    Course Prerequisites: Hydraulic Components: Actuators, Pumps, and Motors (286061);
    What Students Learn: Construction details of Centrifugal Pumps; Applications of Centrifugal Pumps; Installation and Maintenance of Centrifugal Pumps; Troubleshooting problems associated with Centrifugal Pump Operation.

    Special Notes:

  • This updated course replaces course 2530A.
  • The entire course consists of study units 286001, 286002, and 286003.

    • Pumps, Part 3

    Course #: 286003
    Duration: 10 hours
    Course Prerequisites: Hydraulic Components: Actuators, Pumps, and Motors (286061);
    What Students Learn: Rotary Pumps: classifications, installation and operating principles; Reciprocating Pumps: classifications, installation and operating principles; Power Pumps; Applications of Rotary and Reciprocating Pumps; Troubleshooting Rotary and Reciprocating Pumps.

    Special Notes:

  • This updated course replaces course 2530B.
  • The entire course consists of study units 286001, 286002, and 286003.

    • Introduction to Fluid Power

    Course #: Block Y01
    Duration: 32 hours
    What Students Learn: The objective of this block is to provide the trainee with an introduction to the concepts, applications, and maintenance of fluid power systems. The course covers the common terms and the diagrams and schematics used in the fluid power systems found in a typical manufacturing facility. The physical concepts relating to energy transmission are described. Operation of the primary fluid power components are discussed in detail  pumps, compressors, accumulators, pressure valves, and receivers. An overall systems integration and performance approach is used to assist the trainee in understanding key points. This course can be beneficial to an apprentice, at the entry or skilled worker level, and the mechanical maintenance staff. It will fit well in a mechanical cross training program developed for electrical or multi-craft workers.
    Components: The Components of Fluid Power, Part 3 (Y0107); A Summary of Fluid Power (Y0108); Introduction to Fluid Power (Y0101); The Physics of Fluid Power (Y0102); Transmission and Storage of Energy by Fluid Power, Part 1 (Y0103); Transmission and Storage of Energy by Fluid Power, Part 2 (Y0104); The Components of Fluid Power, Part 1 (Y0105); The Components of Fluid Power, Part 2 (Y0106); Progress Examination (Y0121); Progress Examination (Y0122); Progress Examination (Y0123); Progress Examination (Y0124); Progress Examination (Y0125); Progress Examination (Y0126); Progress Examination (Y0127); Progress Examination (Y0128);

    Introduction to Fluid Power

    Course #: Y0101
    Duration: 4 hours
    What Students Learn:

  • Introduce the basic principles of fluid power and describe their practical application in the generation, transmission, control, and distribution of energy.
  • Establish a basic vocabulary of the terms used within fluid power.
  • Build an awareness of the size, shape, and function of generic fluid power systems and their components.
  • Recognize the graphic symbols used to represent primary system components.
  • Use three conventional systems that graphically portray fluid power systems.
  • Identify five of the physical properties of fluid power, and discuss their impact.
  • Describe the process of energy generation, transmission, storage, control, and delivery by means of a fluid power system.
  • Describe the application of system components and discuss their behavior in relation to overall system performance.

    • The Physics of Fluid Power

    Course #: Y0102
    Duration: 4 hours
    What Students Learn:

  • Describe the physical concepts of force, torque, energy, work, and power as they relate to fluid power system output, and describe their relationships.
  • Apply physical principles, such as the Law of Conservation of Energy and Pascal's Law, to fluid power systems.
  • Identify the components of fluid systems that generate force and torque.
  • Describe the roles and relationships of pressure, resistance, and inefficiency, and discuss their effect on fluid system performance.
  • Explain the features and benefits of energy transmission and control by means of fluid power.

    • Transmission and Storage of Energy by Fluid Power, Part 1

    Course #: Y0103
    Duration: 4 hours
    What Students Learn:

  • Describe how a maintenance technician must analyze and repair an overall fluid power system by diagnosis of the individual component parts.
  • Define the characteristics of fluids.
  • Describe the differences between liquid and gas system behavior as it relates to power level, speed, cost, efficiency, and maintenance.
  • Discuss the selection criteria for commonly used fluids, and describe current equipment trends that have been effected by fluid considerations.
  • Identify fluid system connectors and conductors, and discuss their selection and maintenance.
  • Describe the two major categories of output actuators, and the service and maintenance requirements for the devices most commonly applied.
  • Discuss the performance characteristics and pressure ratings for each category of device and the recommended service and maintenance.

    • Transmission and Storage of Energy by Fluid Power, Part 2

    Course #: Y0104
    Duration: 4 hours
    What Students Learn:

  • Discuss the devices used for energy transmission and storage - accumulators, receivers, pressure vessels, pumps, and compressors.
  • Describe how fluid power amplifiers - boosters and intensifiers - operate.
  • Describe how control and interface systems are designed and how they manage the transmission of energy by means of fluid power.
  • Identify directional controls, pressure controls, flow controls, special flow control systems and proportional controls, and how these systems work.
  • Understand the principles of viscosity, lubricity, friction, inertia, and heat as related to fluid power systems.

    • The Components of Fluid Power, Part 1

    Course #: Y0105
    Duration: 4 hours
    What Students Learn:

  • Discuss the characteristics of fluids (gases and liquids) and their impact on system performance.
  • Describe the critical influence of connectors and conductors, and relate the most common variables to system performance.
  • Explain the differences between linear and rotary actuator systems, and discuss common and differing influences of fluid compatibilities, construction, performance characteristics, ratings, and service recommendations.
  • Understand how pneumatic receivers and pneumatic pressure vessels operate.
  • Understand how hydraulic accumulators and hydraulic receivers operate and are maintained.

    • The Components of Fluid Power, Part 2

    Course #: Y0106
    Duration: 4 hours
    What Students Learn:

  • Discuss typical industrial pumps and compressors and explain basic designs and service considerations, such as fluid compatibility, displacement, compression ratio, heat of compression, and suction pressure.
  • Explain the theory of pressure intensification and discuss the designs of boosters and intensifiers that are applied to achieve the objectives of amplified pressures.
  • Discuss the critical design considerations that identify the devices specific to directional, pressure, and flow control.
  • Describe the relationship of each device category to the objectives of integration and overall system parameters.

    • The Components of Fluid Power, Part 3

    Course #: Y0107
    Duration: 4 hours
    What Students Learn:

  • Discuss the critical design considerations that are relevant to proportional and servo control systems and the specific devices that enable their performance.
  • Describe fluid conditioning and storage devices, and discuss their function and contribution to successful fluid system performance.
  • Explain the theory of operation and use of heat exchangers in hydraulics, and discuss their limited use in pneumatic systems.
  • Discuss the design and application considerations relative to pressure gauges, flow monitoring devices, pulsation dampers, shock absorbers, gauge snubbers, air-bleed vents, and other common performance enhancements.
  • Describe the relationship of each category of devices to the total system, with regard to the objectives of integration and overall system parameters.

    • A Summary of Fluid Power

    Course #: Y0108
    Duration: 4 hours
    What Students Learn:

  • Develop a workable understanding of overall fluid power systems design and performance applications.
  • Discuss fluid power as a means of controlling and powering motion and process.
  • Describe energy transfer by means of fluid power systems.
  • Describe typical problems, identify the most common causes, and prescribe initial steps to analyze and correct these problems.
  • Work comfortably and safely in the industrial environment with a demonstrated awareness of fluid systems, common devices, and the potential hazards of incorrect maintenance practices.
  • Focus on product applications and problem solving within the following devices:
    - Pneumatic lubrication circuits
    - Hydraulic filtration circuits
    - Hydraulic pump control circuits
    - Automated process control circuits
    - Using pneumatically timed sequential control
    - Using pneumatic moving part logic
    - Hydraulic pump assist circuits
    - Special purpose I/O interfaces

    • Fluid Power

    Course #: VB24XX
    Duration: 1.47 hours
    What Students Learn: This program is the ideal way to introduce first year students and entry level trainees to the basic concepts and principles of fluid power. Vivid computer graphics, along with real actuators and valves which have been cut open to reveal internal operations, help drive the very concepts that need to be remembered.
    Components: Principles and Fluids (VB2401); Actuators (VB2402); Controls (VB2403); Pumps and Power Units (VB2404);

    Hydraulic Power Basics

    Course #: 286060
    Duration: 10 hours
    Course Prerequisites: Introduction to Algebra, Geometry, and Trigonometry (Block X02); Introduction to Fluid Power (Block Y01);
    What Students Learn: Introduction to Hydraulic Power; Physical Principles of Hydraulic Power and Energy; Pascal's Law; Bernoulli's Principle; Work and Power; Horsepower and Loss; Hydraulic Power Systems; Basic Components of Hydraulic Systems; Basic Hydraulic System Accessories; Fittings and Couplings; Characteristics of Hydraulic Systems; Comparing Power Systems; Requirements for Hydraulic Systems; Properties of Hydraulic Fluid; Fluid Storage, Handling, and Maintenance; Filters and Strainers; Heat Exchangers; Eliminating Air; Examples of Hydraulic Systems; Proportional Displacement; Hydraulic System Operation; Working Safely with Hydraulic Systems.

    Special Notes: The entire course consists of study units 286060, 286061, 286062, 286063, 286064 and 286065.

    Hydraulic Components: Actuators, Pumps, and Motors

    Course #: 286061
    Duration: 10 hours
    Course Prerequisites: Introduction to Algebra, Geometry, and Trigonometry (Block X02); Introduction to Fluid Power (Block Y01);
    What Students Learn: Actuator Design, Detail, and Operation; Linear Actuators; Hydraulic Actuator Components; Rotary Actuators; Pumping Principles; Slippage; Pump Classifications; Gear Pumps; Vane Pumps; Double Pumps; Gear and Vane Pump Lubrication and Capabilities; Piston Pumps; Screw-type Pumps; Supercharging Pumps; Variable-displacement Pump Control Fundamentals; Hydraulic Motors; Comparing Pumps and Motors; Gear Motors; Screw Motors; Vane Motors; Piston Motors; Abutment-type Motors; Losses through Fluid Motors; Deceleration and Braking.

    Special Notes: The entire course consists of study units 286060, 286061, 286062, 286063, 286064 and 286065.

    Hydraulic Components: Conductors, Conditioners, and Fluids

    Course #: 286062
    Duration: 10 hours
    Course Prerequisites: Introduction to Algebra, Geometry, and Trigonometry (Block X02); Introduction to Fluid Power (Block Y01);
    What Students Learn: Reservoirs and System Components; Types of Reservoirs; Reservoir Volume; Reservoir Components; Reservoir Interior Care and Auxiliary Tanks; Reservoir in Use; Practical Tips for Reservoir Selection and Maintenance; Conductors, Fittings, and Seals; Maintenance Tips for Conductors, Fittings, and Seals; Choice of Conductor Size and Materials; Types of Heat Exchangers; Automatic Temperature Control; Effective System Cooling Tips; Accumulators; Circuits Using Accumulators; Accumulator Safety; Hydraulic Fluids; Petroleum-based Fluids; Viscosity; Demulsibility; Oxidation Stability; Lubricating Value; Corrosion and Rust Prevention; Fire-resistant Fluids.

    Special Notes: The entire course consists of study units 286060, 286061, 286062, 286063, 286064 and 286065.

    Hydraulic Power System Control

    Course #: 286063
    Duration: 10 hours
    Course Prerequisites: Introduction to Algebra, Geometry, and Trigonometry (Block X02); Introduction to Fluid Power (Block Y01);
    What Students Learn: Explain the Function of Control Components in a Typical Hydraulic System; Identify Control Valves by Pressure, Flow, or Directional Type; Explain the Operating Principles and Typical Internal Parts of Pressure, Flow, and Directional Valves; Interpret Schematic Symbols which represent Control Valve Configurations.

    Special Notes: The entire course consists of study units 286060, 286061, 286062, 286063, 286064 and 286065.

    Interpreting Hydraulic System Schematics

    Course #: 286064
    Duration: 10 hours
    Course Prerequisites: Introduction to Algebra, Geometry, and Trigonometry (Block X02); Introduction to Fluid Power (Block Y01);
    What Students Learn: Typical Schematic Layout; Recognizing Standard Schematic Symbols; Interpreting Control Configuration from Schematic Symbols; Evaluating System Operating Characteristics from Schematics.

    Special Notes: The entire course consists of study units 286060, 286061, 286062, 286063, 286064 and 286065.

    Hydraulic Power System Troubleshooting

    Course #: 286065
    Duration: 10 hours
    Course Prerequisites: Introduction to Algebra, Geometry, and Trigonometry (Block X02); Introduction to Fluid Power (Block Y01);
    What Students Learn: Sizing Components to meet Requirements; Measuring and Evaluating System Operation; Assessing Motor and Pump Capacity and Performance; Special System Control including Servos and Pressure, Temperature, and Limit Switches; Performing Periodic Maintenance and Analyzing Inspection Information; Troubleshooting System Faults; Typical Hydraulic System Faults and Failures.

    Special Notes: The entire course consists of study units 286060, 286061, 286062, 286063, 286064 and 286065.

    Hydraulic Power Systems and Troubleshooting

    Course #: VS64XX
    Duration: 0.73 hours
    What Students Learn: This course is ideal for students employed as engineers and others who require an advanced understanding of hydraulic systems operation and maintenance. From examining basic to complex circuitry, students will learn to troubleshoot and repair hydraulic systems.
    Components: Hydraulic Power Systems and Troubleshooting, Volume 1 (VS6401); Hydraulic Power Systems and Troubleshooting, Volume 2 (VS6402);

    Pneumatics

    Course #: 6623
    Duration: 10 hours
    What Students Learn: Atmospheric Pressure; Barometers; Properties of Gases; Relative Unit Pressure; Laws Relating to Change of State; Boyle's Law; Gay-Lussac's Laws; Combination of Boyle's and Gay-Lussac's Laws; Mixtures of Gases; Pneumatic Machines and Devices; The Air Pump; Apparatus Showing Weight and Pressure of Atmosphere; Siphon; Air Compressors.

    Air Compressors, Part 1

    Course #: 286013
    Duration: 10 hours
    Course Prerequisites: Metric System (186011);
    What Students Learn: Types of Compressors; Types of Comparison; Centrifugal Compressors; Axial-Flow Compressors; Construction Details of Centrifugal and Axial-Flow Compressors; Performance Curves; Installation and Performance Tests.

    Special Notes:

  • This updated course replaces course 2626A.
  • The entire course consists of study units 286013-286014.

    • Air Compressors, Part 2

    Course #: 286014
    Duration: 10 hours
    Course Prerequisites: Metric System (186011);
    What Students Learn: Reciprocating Compressors; Cylinder and Piston Arrangements; Construction Details of Various Types; Selection, Installation, and Operation of Reciprocating Compressors; Rotary Compressors; Construction Details; Lobe Compressors; Screw Compressors; Troubleshooting Rotary Compressors.

    Special Notes:

  • This updated course replaces course 2626B.
  • The entire course consists of study units 286013-286014.

    • Pneumatics

    Course #: VS21XX
    Duration: 2.87 hours
    What Students Learn: This series is designed for skilled maintenance workers who have some knowledge of pneumatics. All of the terms used in the series are explained and defined in the workbook. Fundamental topics included in the series are compressed air power, circuitry, air processing, valves, safety, maintenance, and troubleshooting.
    Each course is introduced by identifying the specific competencies expected of the pneumatics maintenance worker. Then it explains the techniques that will result in his or her improved instruction. The emphasis is to teach the specific skills required to understand pneumatics. This series is intended to be used as an enhancement to your pneumatics curriculum.
    Components: The Power of Compressed Air (VS2101); The Pneumatic Circuit (VS2102); Processing Air (VS2103); Using Compressed Air (VS2104); Pneumatic Control Valves (VS2105); Working Safely with Pneumatic Systems (VS2106); Pneumatic Systems Maintenance (VS2107); Troubleshooting Pneumatic Systems (VS2108);

    Robotics Explained

    Course #: VB05XX
    Duration: 0.33 hours
    What Students Learn: Understand how robots work and how to work safely beside them. Students will learn about the parts of the robot and the many applications they can be programmed to perform.
    Components: Robotics Explained (VB0501);

    Predictive Maintenance

    Course #: 286087
    Duration: 5 hours
    Course Prerequisites: Trades Safety: Getting Started (186001); Basic Industrial Math (Block X21); Practical Measurements (Block X22);
    What Students Learn: Preview
    Predictive technologies measure one or more characteristics of machine operation, calculate the expected life of the monitored system, and then estimate the condition of equipment and, therefore, the need for maintenance on that equipment. With this information passed along to a good preventive maintenance program, the preventive maintenance team can make informed decisions on task scheduling and make the most of its maintenance and inspection tasks.

    Vibration analysis programs are the most commonly conducted PDM efforts. By performing inspection and repairs during downtime, uptime failures of the analyzed components are all but eliminated. PDM is more than vibration analysis, however; multiple technologies, such as infrared thermography, balance, alignment, and electrical signature analysis are part of many PDM programs. Because of these technologies, plants run better and are more competitive. PDM allows maintenance departments to predict when a unit will fail and plan its maintenance during a scheduled downtime, usually when the unit is cooler, cleaner, and not needed for the manufacturing process.

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

  • Define what PDM is and how it can be used in industry.
  • Identify the various types of technologies used in PDM.
  • Explain what goals should be considered for a new and a maturing PDM program.
  • Discuss the scope of basic mechanical PDM.
  • Explain how a time waveform and a frequency spectrum can be used to identify machine faults.

    Contents
    What Is Predictive Maintenance?; Predictive Maintenance Program Goals; Basic Mechanical Predictive Maintenance; Forms Of PDM Data.

    • Predictive Maintenance: Vibration Analysis

    Course #: 286088
    Duration: 5 hours
    Course Prerequisites: Trades Safety: Getting Started (186001); Basic Industrial Math (Block X21); Practical Measurements (Block X22);
    What Students Learn: Preview
    When a company decides to begin a predictive maintenance (PDM) program, the first technology usually embraced is vibration analysis. Vibration analysis allows the technicians or other specially trained personnel to perform condition monitoring of equipment. Condition monitoring is used at first as a coarse comb to pull out those programs that will imminently cause downtime. Then the program can progress beyond condition monitoring to provide scheduling services for preventive maintenance and identification of redesigns that address repetitive faults.

    This study unit will show you the basics of vibration analysis as performed with a data collector and a computer software program. These devices will be used to collect vibration measurement data and to store and display the results.

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

  • Explain how vibration measurements are taken and the systems used to identify measurement points.
  • Identify balance, looseness, and misalignment problems.
  • Discuss the techniques used to diagnose rolling-element bearing faults.
  • Explain how journal bearing condition monitoring and fault analysis is performed.
  • Identify speed reducer faults that occur in the gear sets or the internal bearings.
  • Describe how resonance can affect the operation of equipment.

    Contents
    Vibration Measurements; Analyzing Balance And Looseness Problems; Misalignment Of Inline And Overhung Drive Systems; Analyzing Rolling-Element Bearing Systems; Condition Monitoring Of Journal Bearings; Condition Monitoring Of Speed Reducers; Resonance.

    • Predictive Maintenance: Advanced Topics

    Course #: 286089
    Duration: 5 hours
    Course Prerequisites: Trades Safety: Getting Started (186001); Basic Industrial Math (Block X21); Practical Measurements (Block X22);
    What Students Learn: Preview
    Vibration analysis alone cannot perform sufficient condition monitoring to meet the needs of today's industry. Vibration analysis cannot easily find electrical faults, air leaks, electrical discharges, metal particles or contamination and breakdown of lubricants, or other important monitoring processes. Other technologies are needed for these tasks. This study unit will introduce you to these other technologies.
    In this study unit, we will investigate many different technologies that can and should often be part of a good predictive maintenance program (PDM). This course is designed to discuss these technologies at a basic level. If you're considering working with one of these technologies, it's very important to understand how to operate the equipment involved and to gain additional equipment training from the manufacturer. These actions will provide you with a safe and profitable expanded PDM program.

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

  • Explain the steps involved in performing balance and alignment on industrial machines.
  • Discuss the use and operation of ultrasonic equipment to find problems such as electrical arcing, bearing faults, and internal and external air leaks in pneumatic systems.
  • Describe the procedures used in electrical signature analysis (ESA) and how this inspection system can find motor problems.
  • Explain how oil analysis can find lubricant problems and contamination.
  • Describe how thermography can be used in a PDM environment.

    Contents
    Modern Balance And Alignment; Ultrasonic Testing; Electrical Signature Analysis; Oil Analysis; Infrared Thermography.

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