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Optional: Tool and Die Maker Skills

Mechanics of Materials

Course #: 5282A-C
Duration: 30 hours (includes 3 tests)
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.

Heat Treatment

Course #: 3541A-D
Duration: 40 hours (includes 4 tests)
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.

Dies and Die Making

Course #: 5101A-B
Duration: 20 hours (includes 2 tests)
Prerequisites:

  • Basic Machining Skills (Block X08)

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 Templates; 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.

Special Notes:
  • A new addition to this course, Dies and Die Making, Part 3 (386048) focuses on modern die making practices.

Dies and Diemaking, Part 3

Course #: 386048
Duration: 10 hours (includes 1 test)
Prerequisites:

  • Dies and Diemaking, Parts 1-2 (5101A-B)

Course Objectives:
  • Explain modern-day improvements in presses and related equipment.
  • Recognize the proper use of modern tool materials and coatings.
  • Make informed choices about when to use a particular die material.
  • Explain how to build a die in a way that works well with the chosen tooling material.
  • Identify commercially available components and how they can be used in modern die designs.
  • Describe how modern machining practices are considered when designing and building dies.
  • Understand modern requirements of high-speed light-gauge stamping processes.

Forging Dies

Course #: 3199
Duration: 10 hours (includes 1 test)
Prerequisites:

  • Dies and Die Making (5101A-B)

Course Objectives:
  • Construction and Use of Drop-Forging Dies
  • Nature and Construction of Press-Forging Dies
  • Bending Dies

Making Forging Dies

Course #: 3197
Duration: 10 hours (includes 1 test)
Prerequisites:

  • Dies and Die Making (5101A-B)

Course Objectives:
  • 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

Toolmaking

Course #: 2540A-C
Duration: 30 hours (includes 3 tests)
Prerequisites:

  • Basic Machining Skills (Block X08)

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.

Special Notes:
  • A new addition to this course, Toolmaking, Part 4 (386047) focuses on modern toolmaking practices.

Toolmaking, Part 4

Course #: 386047
Duration: 10 hours (includes 1 test)
Prerequisites:

  • Toolmaking, Parts 1-3 (2540A-C)

Course Objectives:
  • Select modern tool materials to suit a particular application.
  • Explain how various tool coatings improve tool performance.
  • Identify and select standard tool inserts and tool holders for a specific application.
  • Explain the benefits of using inserted tools for drilling, milling, and turning operations.
  • Describe the benefits of and proper use of roll-forming and thread- forming taps.
  • Troubleshoot tool life and wear problems, and suggest corrective actions.
  • Describe instances in which modern machining processes such as WEDM and EDM are superior.

Gage Making

Course #: 5098
Duration: 10 hours (includes 1 test)
Prerequisites:

  • Basic Machining Skills (Block X08)

Course Objectives:
  • 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, Templates, and Template Making

Jigs and Fixtures

Course #: 5099
Duration: 10 hours (includes 1 test)
Prerequisites:

  • Basic Machining Skills (Block X08)

Course Objectives:
  • 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

Jig and Fixture Making

Course #: 5100
Duration: 10 hours (includes 1 test)
Prerequisites:

  • Basic Machining Skills (Block X08)

Course Objectives:
  • 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
Special Notes:
  • A new addition to this course, Jigs and Fixture Making, Part 2 (386049) focuses on modern jig and fixture making practices.

Jig and Fixture Making, Part 2

Course #: 386049
Duration: 10 hours (includes 1 test)
Prerequisites:

  • Jig and Fixture Making (5100)

Course Objectives:
  • Explain the required characteristics of jigs and fixtures used in modern automated assembly and CNC machining.
  • Describe a range of up-to-date machining practices used in building jigs and fixtures.
  • List and describe the uses of commercially available components that can be incorporated into jig and fixture designs.
  • Understand how to design and build jigs and fixtures to compensate for normal product variations such as flash, parting lines, burrs, and casting irregularities

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