ChabotCollege

Course Outline for Machine Tool Technology 66, Page 1

Fall 2010

ChabotCollegeFall 2010

Course Outline for Machine Tool Technology 66

BASIC TOOLMAKING

Catalog Description:

66 – Basic Toolmaking4 units

(May be repeated 3 times)

Toolroom grinding, precision measurement, precision boring, steels and heat treating, carbide cutting tools, job estimating, and basic die-making theory. Prerequisite: Machine Tool Technology 65 (completed with a grade of “C” or higher). 2 hours lecture, 6 hours laboratory.
[Typical contact hours: lecture 35, laboratory 105]

Prerequisite Skills:

Before entering the course, the student should be able to:

  1. design basic production tools;
  2. fabricate basic production tools;
  3. select and correctly apply standard jig and fixture components;
  4. apply mathematical formulae to solve tooling-related problems;
  5. set up production tools on standard and numerically controlled machine tools for production machining operations;
  6. select proper measuring tools for inspecting production workpieces;
  7. operate and program procedures and events for the Prototrak dual mode lathe;
  8. perform setups and inspections using the video measuring machine;
  9. select the proper speeds and feeds for use with carbide and carbide insert tooling;
  10. align parts using a four jaw adjustable chuck in a lathe;
  11. tram the milling machine head with a trammel gauge to .001” TIR;
  12. setup and grind workpieces flat and parallel within .001" with a vertical spindle grinder;
  13. operate and program procedures for the Makino dual mode milling machine;
  14. properly disassemble and assemble production jigs and fixtures from engineering drawings.

Expected Outcome for Students:

Upon completion of the course, the student should be able to:

  1. set up and execute basic surface and cylindrical grinding operations;
  2. properly select and perform precision part measurement;
  3. set up and perform precision boring operations;
  4. identify and heat treat basic steels and tool steels;
  5. select carbide cutting tools and calculate correct cutting speeds and feeds;
  6. identify die parts and apply basic die formulae;
  7. calculate cutter locations;
  8. calculate rectangular coordinate positions;
  9. solve simple trigonometry problems;
  10. inspect fabricated parts on a video / coordinate measuring machine;
  11. write a “first article” inspection report for each assigned project;
  12. calculate bolt circle coordinates converting them to polar coordinates;
  13. setup and machine compound angles and use tooling balls to locate features along compound angle axis;
  14. evaluate process plans and precision jig and fixture applications;
  15. inspect manufactured parts, fixtures, jigs and components necessary to fabricate tooling and workpieces.

Course Content (Lecture):

  1. Introduction to tool steel selection
  2. Fixture component location calculations
  3. Cartesian coordinates
  4. Tool and fixture types and similarities
  5. Specialized insert cutters including insert codings TiCN, TiN, and TiAlN
  6. What is tool and die?
  7. Rapid Prototyping types and applications
  8. Laser Interferometry
  9. Metrology (precision inspection)
  10. Micro machining (how small can we go?)
  11. Chemical Machining
  12. Welding as a machining tool
  13. Sheet metal machining
  14. Free state machining (machining without clamps) using vacuum chucks
  15. Advanced inspection techniques

Course Content (Laboratory):

  1. Techniques
  2. Setting tools for specialized materials
  3. Roughing in a precision setting
  4. Edge finding angled surfaces
  5. Advanced jigs and fixtures
  6. Inspection in the metric work environment from engineering drawings
  7. Optical Flats and inspecting gage blocks
  8. Inspection by air gauges (pressure and vacuum)
  9. Fits, press and running
  10. Temperature controls and material expansion and contraction
  11. Lubrication, oils and maintenance of machines, tooling and equipment
  12. Bearings and gears, seals and o rings
  13. Woodruf keys and pens
  14. Pull-out dowel pins and designs for 1part or 1,000 parts
  1. Safety
  2. Safe operation of the hydraulic press
  3. Safe MSDS procedures
  4. OSHA and the manufacturing work environment

Methods of Presentation:

  1. Lecture, informal with student questions encouraged
  2. PowerPoint presentations, videos, industry relevant movies, and model examples of large and specialized tooling and machines
  3. Hands-on demonstrations

Assignments and Methods of Evaluating Student Progress:

  1. Typical Assignments
  2. Homework: 1-2 worksheets each week on the material covered in the textbook, lecture and laboratory Example: Sketch the hole layout of the Vice Jaw Angle Plate Project, draw in the tool locations, diameters and calculate the Cartesian coordinates from datum locators. Write a program for the Makino mill to machine all holes to the specifications required for the Vice Jaw Angle Plate Project.
  3. Laboratory assignment: Setup the horizontal mill table for production of ten base pieces for the Surface Gage Project.Use fixtures to mill the bottom radius with a Shell Millcutter with the desired radius. Setup and machine using fixtures 1, 2 and 3 as needed. Use only high speed steel milling cutters. Test run each cutting tool operation checking for accuracy and proper tool cutting rotation and feed direction. Only mill utilizing conventional milling. Inspect the part on the Video / Coordinate measuring machine and create a “first article” inspection report. Did the part pass inspection? If not, why? What remediation would correct the problem, if any?
  1. Methods of Evaluating Student Progress
  2. Homework
  3. Quizzes
  4. Written laboratory inspection report on each part project
  5. Fabricated parts checked for accurate size and shape
  6. Midterm, manipulative and written examinations
  7. Final, manipulative and written examinations

Textbook(s) (Typical):

Jigs and Fixture Design, Edward G. Hoffman, Delmar Publishing, 2003*

*Rationale: Jigs and Fixtures theory and techniques have not changed much for many years. This book, from the Society ofMechanical Engineers, is still a good and current resource.

Special Student Materials:

Machine shop approved safety goggles

Sharp EL-531W scientific calculator

USB drive – 1gb minimum

Combination or keyed padlock

Proper laboratory attire

Revised: 9/27/09

Ashley Long/Mike Absher