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Tool and Die Making

Fundamentals of Metal Cutting

Course #: 386030
Duration: 10 hours (includes 1 test)
Course Objectives:

  • Introduction to Metal Cutting
  • Fundamentals, Feed, Speed, Depth of Cut
  • Requirements for Cutting Tool Materials
  • Tool Materials
  • Carbon Tool Steels, High-Speed Steels, Carbides, Cast Alloys, Ceramics, Boron Nitride, Diamond, Abrasives
  • Principles of Single-Point Cutting
  • The Turning Tool, Tool Wear, Modern Turning Tools, and Practices
  • Other Single-Point Tools
  • Milling Cutters
  • Drills
  • Tapping, Threading, and Reaming Tools
  • Miscellaneous Multiple-Point Cutting Tools
  • Cutting Fluids
Special Notes:
  • Covers subject at an advanced, in-depth level.
  • This new course replaces courses 5021A and 386015.

Drilling, Part 1

Course #: 386050
Duration: 10 hours (includes 1 test)
Course Objectives:

  • 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.
Special Notes:
  • This course replaces 3521-A.

Drilling, Part 2

Course #: 386051
Duration: 10 hours (includes 1 test)
Course Objectives:

  • 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 Notes:
  • This course replaces 3521-B.

Metal Processing

Course #: 186087
Course Objectives:

  • 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.

Ferrous Metals

Course #: 186088
Course Objectives:

  • 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.

Nonferrous Metals

Course #: 186089
Course Objectives:

  • 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.

Identification of Metals

Course #: 186090
Course Objectives:

  • 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.

Lubrication, Part 1

Course #: 286091
Duration: 10 hours (includes 1 test)
Course Objectives:

  • 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.
Special Notes:
  • This updated course replaces course 2531A.
  • The entire course consists of study units 286091 and 286092.

Lubrication, Part 2

Course #: 286092
Duration: 10 hours (includes 1 test)
Course Objectives:

  • 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.
Special Notes:
  • This updated course replaces course 2531B.
  • The entire course consists of study units 286091 and 286092.

Applied Geometry

Course #: 186085
Duration: 5 hours (includes 1 test)
Course Objectives:

  • Recognize characteristics of angles and closed plane figures
  • Distinguish between common geometric solids
  • Apply basic geometric construction techniques
  • Calculate perimeters and areas of a polygon, circle, and ellipse
  • Apply the formula for area and volume of geometric solids
Special Notes:
  • This course replaces course X0211.

Practical Trigonometry

Course #: 186086
Duration: 5 hours (includes 1 test)
Course Objectives:

  • Define trigonometric functions and use a calculator to perform them
  • Use trigonometric tables and apply interpolation
  • Solve right triangles for angular and side dimensions
  • Apply the laws of sines and cosines in solving oblique triangles
Special Notes:
  • This course replaces course X0212.

Layout

Course #: 3501
Duration: 10 hours (includes 1 test)
Course Objectives:

  • 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.

Milling Machine Fundamentals

Course #: 386031
Duration: 10 hours (includes 1 test)
Prerequisites:

  • Basic Machining Skills (Block X08)

Course Objectives:
  • Milling Process
  • General Construction of Milling Machine
  • General-Purpose Milling Machines
  • Milling Machine Attachments and Accessories
Special Notes:
  • This new course replaces courses 3522A and 386006.

Milling Machine Cutting Tools

Course #: 386032
Duration: 10 hours (includes 1 test)
Prerequisites:

  • Milling Machine Fundamentals (386031)

Course Objectives:
  • Milling Cutter Materials
  • Milling Cutter Design
  • Milling Cutters
  • Carbide Inserts
  • Milling Techniques
  • Care and Reconditioning of Cutters
Special Notes:
  • This new course replaces courses 3522C and 386008.

Milling Machine Practice and Operation, Part 1

Course #: 386033
Duration: 10 hours (includes 1 test)
Prerequisites:

  • Milling Machine Fundamentals (386031)

Course Objectives:
  • Kinds of Work Done on the Milling Machine
  • Cutting Speeds and Feeds
  • Preparation of Stock
  • Setting Machine
  • Setting and Holding Work on Table, in Vise, on Faceplate, in Fixtures and Chucks, and between Centers
  • Taking Cuts
  • Milling-Machine Troubles
Special Notes:
  • This new course replaces courses 2217 and 386009.

Milling Machine Practice and Operation, Part 2

Course #: 386034
Duration: 10 hours (includes 1 test)
Prerequisites:

  • Milling Machine Fundamentals (386031)

Course Objectives:
  • Kinds of Work Done on the Milling Machine
  • Cutting Speeds and Feeds
  • Preparation of Stock
  • Setting Machine
  • Setting and Holding Work on Table, in Vise, on Faceplate, in Fixtures and Chucks, and between Centers
  • Taking Cuts
  • Milling-Machine Troubles
Special Notes:
  • This new course replaces courses 2217 and 386009.

Milling Machine Indexing and Spiral Work

Course #: 386035
Duration: 10 hours (includes 1 test)
Prerequisites:

  • Milling Machines Fundamentals (386031)
  • Milling Machine Practice and Operation, Parts 1-2 (386033-386034)

Course Objectives:
  • Indexing
  • Direct Indexing
  • Indirect Indexing
  • Compound Indexing
  • Differential Indexing
  • Linear Indexing
  • Spiral Work
  • Generation of Helix
  • Calculation of Spiral-Head Change Gears
  • Cutting Helixes
  • Milling Cams
  • Tables
  • Simple and Differential Indexing
  • Compound Indexing
  • Bevel-Gear Dividing Head
  • Angular Indexing
  • Power Drive for Helical Milling
  • The Use of CNC in Modern Indexing and Spiral Work
Special Notes:
  • This new course replaces courses 2218 and 386014.

Lathes, Part 1

Course #: 386036
Duration: 10 hours (includes 1 test)
Course Objectives:

  • Types of Lathes
  • Principal Parts of a Lathe
  • Speed Controls
  • Feed Controls for Tools
  • Basic Work-Holding Devices
Special Notes:
  • This new course replaces courses 3520A and 386001.

Lathes, Part 2

Course #: 386037
Duration: 10 hours (includes 1 test)
Course Objectives:

  • Auxiliary Work-Holding Devices
  • Preparation for Machining
  • External Machining
Special Notes:
  • This new course replaces courses 3520B and 386002.

Lathes, Part 3

Course #: 386038
Duration: 10 hours (includes 1 test)
Course Objectives:

  • Internal Machining
  • Special Lathe Operations
  • Tailstock Operations
  • Offset Turning
Special Notes:
  • This new course replaces courses 3520C and 386003.

Lathes, Part 4

Course #: 386039
Duration: 10 hours (includes 1 test)
Course Objectives:

  • Types of Tapers
  • Taper Turning
Special Notes:
  • This new course replaces courses 3520D and 386004.

Lathes, Part 5

Course #: 386040
Duration: 10 hours (includes 1 test)
Course Objectives:

  • Threading
  • Thread Standards and Chasing Setup: Thread Chasing and Standard Threads. Specialty Threads
Special Notes:
  • This new course replaces courses 3520E and 386005.

Fundamentals of Grinding

Course #: 386016
Duration: 10 hours (includes 1 test)
Prerequisites:

  • Basic Machining Skills (Block X08)

Course Objectives:
  • 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.

Cylindrical Grinding, Part 1

Course #: 386010
Duration: 10 hours (includes 1 test)
Prerequisites:

  • Basic Machining Skills (Block X08)

Course Objectives:
  • 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 386010-386011.

Cylindrical Grinding, Part 2

Course #: 386011
Duration: 10 hours (includes 1 test)
Prerequisites:

  • Basic Machining Skills (Block X08)

Course Objectives:
  • General Safety Information
  • Machine Setup Procedure
  • Production Grinding
  • Roll Grinding
  • Grinding Applications
  • Troubleshooting in Cylindrical Grinding
Special Notes:
  • This updated course replaces course 3560B.
  • The entire course consists of study units 386010-386011.

Surface Grinding, Part 1

Course #: 386012
Duration: 10 hours (includes 1 test)
Prerequisites:

  • Fundamentals of Grinding (386016)

Course Objectives:
  • Introduction to Surface Grinding
  • Types of Surface-Grinding Machines
  • Components of Surface-Grinding Machines
Special Notes:
  • This updated course replaces course 5024A.
  • The entire course consists of study units 386012-386013.

Surface Grinding, Part 2

Course #: 386013
Duration: 10 hours (includes 1 test)
Prerequisites:

  • Fundamentals of Grinding (386016)

Course Objectives:
  • Preparing the Abrasive Wheel for Surface Grinding
  • Surface Grinder Operations
  • Surface Finish and Measurement
Special Notes:
  • This updated course replaces course 5024B.
  • The entire course consists of study units 386012-386013.

Nontraditional Machining Technologies

Course #: 386029
Duration: 10 hours (includes 1 test)
Prerequisites:

  • Fundamentals of Metal Cutting (386030)

Course Objectives:
  • 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

Hardening and Tempering

Course #: 3195
Duration: 10 hours (includes 1 test)
Course Objectives:

  • 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

Tool Grinding

Course #: 386017
Duration: 10 hours (includes 1 test)
Prerequisites:

  • Fundamentals of Grinding (386016)

Course Objectives:
  • 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.

Geometric Dimensioning and Tolerancing

Course #: 386E01
Duration: 20 hours (includes 4 tests)
Prerequisites:

  • Basic Industrial Math (Block X21)
  • Reading Shop Prints (386043 and 386044)

What Students Learn:

Lesson 1 - Introduction to GD&T Systems, Datum and Feature Control Frames · Defining Tolerance Control Systems; Reasons for Using Geometrics; GD&T Symbols; Datum; Interpreting Feature Control Frames; Scanning Prints.

Lesson 2 - Geometric Tolerance Zones: Controlling Form, Profile and Orientation. · Entities Found in the Tolerance Zone; Form and Profile Controls: Straightness, Flatness, Roundness, Cylindricity, Lines and Surfaces; Orientation Controls: Parallelism, Angularity, and Perpendicularity.

Lesson 3 - Material Modifiers, Location & Runout Characteristics and the GD&T System: · Least and Maximum Material Conditions; Runout; Inspecting Geometric Position; Finding Earned Tolerance; System Notes; "The 13 Characteristics".

Lesson 4 - Practical Application of GD&T Skills for Manufacturing · Single Axis Feature Inspection and Rework; Inspecting and Reworking Two Axis Features; Computing Geometric Tolerances for Designs; Complex Tolerances.

Special Notes:
  • This course consists of a textbook and supplemental study guide.

Quality Concepts: Tools and Applications

Course #: 186036
Duration: 5 hours (includes 1 test)
Course Objectives:

  • 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.

Quality Control for the Technician

Course #: 386E02
Duration: 70 hours (includes 7 tests)
Prerequisites:

  • Basic Industrial Math (Block X21)

What Students Learn:

Part 1 (386026). 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 (386027). 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: · 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.

CNC Technology and Programming

Course #: 066903
Duration: 45 hours (includes 3 tests)
Prerequisites:

  • Basic Machining Skills (Block X08)

Course Objectives:
  • Numerical Control Basics; The History of Numerical Control; The Computer; Input Media; How Numerical Control Operates; Machine Tools.
  • CNC System Programming; Programming Data; Simple Programming; Angular and Contour Programming; Miscellaneous Numerical Control Functions.
  • Types of CNC Equipment; Machining Centers; Chucking and Turning Centers; Electrical Discharge Machining; Numerical Control and the Future.

CNC Turning

Course #: 386041
Duration: 10 hours (includes 1 test)
Prerequisites:

  • CNC Technology and Programming (066903)

Course Objectives:
  • Apply of canned cycles, subroutines, and loops in real-world programming applications.
  • Modify and adapt basic programs and commands to develop advanced turning 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.

CNC Milling

Course #: 386042
Duration: 10 hours (includes 1 test)
Prerequisites:

  • CNC Technology and Programming (066903)

Course Objectives:
  • 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.

Toolholding Systems

Course #: 386028
Duration: 10 hours (includes 1 test)
Prerequisites:

  • Fundamentals of Metal Cutting (386030)

Course Objectives:
  • 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.
  • Understand the differences in toolholder tapers and the proper applications for each type of taper.
  • Understand and describe the effects of toolholder concentricity and imbalance

Machine Sketching

Course #: 5807
Duration: 10 hours (includes 1 test)
Course Objectives:

  • Sketches of Machine Details
  • Drawing Straight and Curved Lines
  • Finish Marks
  • Surface Roughness
  • Arrangement of Dimensions
  • Partial Section
  • Conventional Sections
  • Shaft Coupling
  • Spur Gear
  • Bevel Gear
  • Pieces Requiring More Than Two Views
  • Foreshortening
  • Measurements
  • Curved Outlines and Fillets
  • Pictorial Sketching
  • Isometric Drawing
  • Oblique Drawing
  • Conventional Symbols
  • Piping Diagrams

Metallurgy of Iron

Course #: 5110
Duration: 10 hours (includes 1 test)
Prerequisites:

  • Practical Measurements (Block X22)
  • Elements of Chemistry (5011)

Course Objectives:
  • Treatment of Iron Ores
  • Blast Furnace Plant
  • Slag Blast Furnace Reactions
  • Control of Elements in Furnace Iron
  • Pig Iron
  • Cast Iron
  • Malleable Cast Iron
  • Cast-Iron Founding
  • Electric Furnace Cast Iron
  • Molding Cast Iron
  • Specifications for Iron Castings
  • Alloy Cast Irons
  • Nature of Wrought Iron

Metallurgy of Nonferrous Metals

Course #: 5337
Duration: 10 hours (includes 1 test)
Prerequisites:

  • Practical Measurements (Block X22)
  • Elements of Chemistry (5011)

Course Objectives:
  • Ores and Extraction
  • Copper and Alloys
  • Lead and Alloys
  • Zinc
  • Aluminum and Alloys
  • Tin and Alloys
  • Nickel and Alloys
  • Magnesium and Alloys
  • Gold
  • Silver
  • Antimony
  • Manganese
  • Molybdenum
  • Tungsten
  • Chromium
  • Cobalt
  • Bismuth
  • Mercury
  • Cadmium
  • Tantalum
  • Platinum Group
  • Beryllium
  • Calcium
  • Zirconium
  • Vanadium
  • Titanium
  • Columbium

Metallurgy of Steel

Course #: 5111
Duration: 10 hours (includes 1 test)
Prerequisites:

  • Practical Measurements (Block X22)
  • Elements of Chemistry (5011)
  • Metallurgy of Iron (5110)

Course Objectives:
  • Steel Production
  • Raw Materials Used in Steelmaking
  • Regenerative System of Open-Hearth Furnace
  • Basic and Acid Open-Hearth Process
  • Oxygen
  • Process
  • Bessemer Converter
  • Basic and Acid Electric Process
  • Crucible Process
  • Alloy Steels
  • Influence of Melting Practice on Physical Properties of Steel

Metallography

Course #: 5338A-B
Duration: 20 hours (includes 2 tests)
Prerequisites:

  • Practical Measurements (Block X22)
  • Elements of Chemistry (5011)
  • Metallurgy of Iron (5110)
  • Metallurgy of Steel (5111)
  • Metallurgy of Nonferrous Metals (5337)

What Students Learn:

Part 1 (5338A). Methods of Examining Metal Structures; Mounting and Polishing Specimens by Hand and Machine; Magnifiers; Optical and Electron Microscopes; Cameras; Illumination; Polarized Light Ultraviolet Light; Use of Photographic Equipment; Metallography of Nonferrous Metals; Etching and Coloring Specimens for Macroscopy and Microscopy; Photomicrographs of Copper Aluminum; Magnesium; Nickel; Zinc and Tin Alloys.

Part 2 (5338B). Importance of Carbon in Iron and Steel; Macrostructure of Steel; Developing Microstructures; Iron-Carbon Structures; Ingotism; Iron-Carbon System; Carbide or Cementite and Pearlite; Austenite, Martensite, Spherodized Structure; Structures of Heat-Treated Alloy Sheets; Decarburized Surface; Overheated Steel; Quenching Cracks; Fatigue Cracks; Macrostructure of Cast Iron; Microstructures of Cast Iron; Alloyed Gray Irons; Malleable Iron; Electrolytic and Wrought Irons.

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.

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

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.

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

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

Manufacturing Processes, Part 1

Course #: 186075
Duration: 10 hours (includes 1 test)
Course Objectives:

  • 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
Special Notes:
  • This course replaces 2520A

Manufacturing Processes, Part 2

Course #: 186076
Duration: 10 hours (includes 1 test)
Course Objectives:

  • 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
Special Notes:
  • This course replaces 2520B

Manufacturing Processes, Part 3

Course #: 186077
Duration: 10 hours (includes 1 test)
Course Objectives:

  • 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-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
Special Notes:
  • This course replaces 2520C

Manufacturing Processes, Part 4

Course #: 186078
Duration: 10 hours (includes 1 test)
Course Objectives:

  • 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
Study Units:
  • This course replaces 2520D

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