DOCUMENT RESUME ED 261 259 CE 042 506 · Unit VI Metallurgy and Heat Treating. 37. Unit VII Casting...

DOCUMENT RESUME

ED 261 259 CE 042 506

TITLE Advanced Metals (Industrial Arts) Curriculum Guide.Bulletin 1750.

INSTITUTION Louisiana State Dept. of Education, Baton Rouge. Div.of Vocational Education.

PUB DATE 85NOTE 212p.PUB TYPE Guides - Classroom Use GUides (For Teachers) 052)

EDRS PRICEDESCRIPTORS

MFO1 /PC09 Plus Postage.Behavioral Objectives; Careers; Course Descriptions;Course Objectives; Finishing; High Schools;*Industrial Arts; Learning Activities; *MachineTools; *Machinists; *Metallurgy; *Metals; *MetalWorking; Safety; Sheet Metal Work; State CurriculumGuides; Transparencies; Welding

ABSTRACTThis curriculum guide contains materials for a

13-unit course in advanced metals, the second metals course in theindustrial arts curriculum for grades 10-12. It is intended for useby industrial arts teachers, supervisors, counselors, administrators,and teacher educators. A two-page course overview provides a briefcourse description; indicates target grade level, prerequisites,course goals, and course objectives; presents an introduction to thecourse; and suggests a time frame. The detailed, 21-page courseoutline follows. A unit teaching guide in a column format relatesobjectives to topics, student activities., teacher activities, andresources. The 1:1 units cover these topics: general safety, careers,planning, advanced metal working tools, sheet metal work and layout,metallurgy and heat treating, casting, welding, machinery, materialstesting, finishing, automation technology, and safety review.Extensive appendixes include sample materials, forms, and informationrelated to classroom management; crossword and wordfind puzzles withsolutions; safety and machine handouts/transparency masters;suggested project listings (project and sources); and lists of thesetypes of resources: films, computer periodicals, and periodicals formetals instructors. A bibliography is provided. (YLB)

***********************************************************************Reproductions supplied by EDRS are the best that can be made

from the original document.***********************************************************************

aBEST COPY AVAILABLE

1985

ADVANCED METALS(InduArial Arts)

CURRICULUM GUIDE

U.S. DEPARTMENT OF EDUCATIONNATIONAL INSTITUTE OF EDUCATION

EDUCATIONALCATIONAL RESOURCES INFORMATIONCENTER IERICI

Ths document has been reproduCed asreceived from the person Of orgenimOonOriginating it,

( I ?Ames changes have been made to Improvereproduction oualdy,

Pants of vanw or opirvorn stated in this document do not necessarily represent off culINIEpout ion or policy.

Office of Vocational Education

LOUISIANA DEPARTMENT OF EDUCATION

THOMAS 0. CLAUSEN, Ph.D.

State Superintendent2

"PERMISSION TO REPRODUCE THIS

MATERIAL. HAS BEEN GRANTED BY

TO THE EDUCATIONAL RESOURCES

INFORMATION CENTER (ERIC)."

STATE BOARD OF ELEMENTARY AND SECONDARY EDUCATION

Member Congressional District

Mr. Jesse H. Bankston 6th

Dr. John A. Bertrand 7th

Bro. Felician Fourrier, S.C., Vice-President At-large

Mr. Milton Hamel 4th

Mrs. Gloria J. Harrison At-la,Nge

Mrs. Martha Scott Henry At-large

Dr. Claire R. Landry, President 1st

Mr. Jack Pellegrin 3rd

Mr. A. J. "Sookie" Roy, Jr. Bth

Mr. Keith Johnson 2nd

Mrs. Marie Louise Snellings, Secretary-Treasurer 5th

EQUAL OPPORTUNITY STATEMENT

In compliance with Title VI, Title IX and Section 504 of the Rehabilitation

Act of 1973, this Educational Agency upholds the following policy: THIS IS AN

EQUAL OPPORTUNITY INSTITUTION AND IS DEDICATED TO A POLICY OF

NONDISCRIMINATION IN EMPLOYMENT OR TRAINING. QUALIFIED STUDENTS, APPLICANTS

OR EMPLOYEES WILL NOT BE FXCLUDED FROM ANY COURSE OR ACTIVITY BECAUSE OF AGE,

RACE, CREED, COLOR, SEX, RELIGION, NATIONAL ORIGIN, OR QUALIFIED HANDICAP.

ALL STUDENTS HAVE EQUAL RIGHTS TO COUNSELING AND TRAINING.

This public document was published at a total cost of $2,625; 700 copies of

this public document were published in this 1st printing at a cost of $3.75

each. The total cost of all printings of this document, including reprints

is $2,625. This document was published by Louisiana Department of Educa-

tion, Office of Vocational Education, Post Office Box 94064, Baton Rouge,

Louisiana 70804 for the dissemination of vocational education curriculum

materials for new and changing occupational fields under authority of Public

Law 94-482. This material was printed in accordance with the standards for

printing by state agencies established pursuant to R.S. 43:31.

3

STATE OF LOUISIANA

DEPARTMENT OF EDUCATION

BULLETIN 1750

ADVANCED METALS(Industrial Arts)

1985

Office of Vocational Education

Elaine Webb, Ed.D.Assistant Superintendent

Thomas G. Clausen, Ph.D.State Superintendent

4

?ABLE OF CONTENTS

ForewordAcknowledgements ii

Course Flow Chart 1

Course Description 2

Target Grade Levels 2

Prerequieite 2

Coals and Objectives 2

Introduction 3

Suggested Time Allotment 3

Course Outline 4

Unit Teaching GuideUnit I General Safety 27

Unit Il Careers 28

Unit III Planning 29

Unit IV Advanced Metalworking Tools 31

Unit V Sheet Metalwork and Layout 33

Unit VI Metallurgy and Heat Treating 37

Unit VII Casting 40

Unit VIII Welding 42

Unit IX Machinery 52

Unit X Materials Testing 59

Unit XI Finishing 60

Unit XII Automation Technology 61

Unit XIII Safety Review 62

Appendix 1 Classroom Management 63

Appendix 2 Crossword and Wordfind Puzzles 79

Appendix 3 Safety and Machine Pictures 120

Appendix 4 Suggested Project Listings 152

Appendix 5 Resources 157

Bibliography 166

5

FOREWORD

This publication is a guide for the improvement of instruction

in Industrial Arts Education for the State of Louisiana. It should

be of benefit to industrial arts teachers, supervisors, counselors,

and administrators. These operational guidelines will help local

administrators, teacher educators, and industrial arts teachers to

determine the extent to which their programs are meeting the needs

of our youth. Industrial Arts Education Programs must be organized

to meet the needs cf all students.

A constant concern of educator: is the construction and revision

of curriculum. Industry and technology are the core of industrial

arts instruction. Both are constantly changing; therefore, curriculum

and instruction must change in order to provide students a realistic

and accurate understanding of industry and its function in our

complex technological society.

4 /1.7141"

THOMAS G. CLAUSEN, Ph.D.STATE SUPERINTENDENT OF EDUCATION

6

ACKNOWLEDGEMENTS

This publication represents the cooperative efforts of personnel

in the Louisiana Industrial Arts Association and the Industrial Arts

Section in the Office of Vocational Education, Louisiana State

Department of Education. Special recognition goes to Project Director,

Dr. Thomas L. Eppler, Northwestern State University, who was instrumental

in the development of the guide. Special commendation goes also to the

following wLiting team members who worked diligently to produce this guide:

William Bostick, Michael Gassen, Charles Johnson, and Jeff Laughlin.

Elaine Webb, Ed.D.Assistant SuperintendentOffice of Vocational Education

ii7

ADVANCED METALS

GENERAL SAFETY

CAREERS

PLANNING ------I

i

ADVANCED METALWORKINGTOOLS

I

SHEET METALWORKAND LAYOUT

I

METALLURGY ANDHEAT TREATING

1

CASTING

WELDING

1

MACHINERY

1

MATERIALS TESTING

LFINISHING

AUTOMATION TECHNOLOGY

SAFETY REVIEW

ADVANCED PROJECTS

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Title:

Advanced Metals

Course Description:

Advanced Metals, the second metals course in the Industrial Artscurriculum, is designed for the student with a continuing interestin Metalworking and involves the exploration of the areas of Sheet

metal, Metallurgy, Casting, Welding, Machining, Materials Testing,Finishing, Safety, and the use of tools, machines, and materials

to plan, design, and construct metal products In the above areas.

Target Grade Levels:

Grades 10 - 12

Prerequisite:

Basic Metals

Course Goals:

In Advanced Metals the student will become acquainted with career

opportunities available in the fields of Sheet metal. Metallurgy,Casting, Welding, Machining, Testing, and Finishing and will be exposed

to the importance each field has on life. Also, laboratory experiences

will be provided to give a variety of advanced "hands-on" working

knowledge of tools, machines, and equipment to develop an understand-

ing of the Metals Industries.

Course Objectives:

To develop an awareness of the impact of metalworking on society.

To provide experiences in several metalworking areas so as to develop

an understanding of the technology in the metal industries.

To devellp an awareness of the impact of metalworking on society.

To provide experiences in several metalworking areas so as to

develop an understanding of the technology in the metal industries.

To develop safe work habits.

To increase understanding of the occupational requirements and

opportunities in the metal fields.

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To teach the necessary related information and develop theessential skills needed in the design, fabrication, heat treating,welding, machining, and finishing of industrial products for pre-vocational and avocational pursuits.

Introduction

This is an age of metal. In almost every activity of our lives weuse metal articles which, in turn, were made by metal machines. Themetalworking industries in the United States employ more workers thanany other industries. Highly specialized metal trades and industriesoffer many worthwhile careers. By studying and participating in thevarious Advanced Metal areas as outlined in this course, students willhave the opportunity to advance their knowledge and further developthe manipulative skills used in the metalworking industries.

Advanced Metals is designed as the second phase for a student who isentering the highly skilled field of metals. The course is brokendown into six major fields: Advanced Metalworking Tools, SheetMetalwork and Layout, Metallurgy and Heat Treating, Casting, Welding,and Machining.

The student will be re-exposed to the fundamental practices of thesefields, but will study more technical knowledge in these fields andreceive valuable "hands-on" experience through the construction ofindividual projects. Also the students will be instructed in theplanning and finishing of their project. In addition to these areas,safe use of all and power tools, equipment, and material handlingwill be taught in the course.

Suggested Time Allotment

The suggested time frame for Advanced Metals is 174 days. The re-maining six days are to be used as necessary for the opening andclosing of the metals laboratory, school functions, and in unitsfor which the instructor feels additional time is needed.

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ADVANCED METALS

1. GENERAL SAFETY

A. General Safety

1. Course syllabus2. Classroom rules and regulations3. General safety

II. CAREERS IN METALWORKING

A. Levels of Skills

1. Semi-skilled2. Skilled3. Technicians4. Professions

B. Occupations

1. Steelworker (structural)2. Welder3. Tool and die maker4. Sheet metal technician5. Machinist6. Machine operator7. Boiler maker8. Molder9. Pipe fitter

10. Plumber11. Millwright12. Pattern maker13. Metallurgical engineer14. Aerospace engineer15. Instrument technician16. Industrial technologist17. Computer programmer18. Industrial engineer19. Set-up worker20. Helpers

C. Methods of Training

1. High school2. Vo-Tech school3. College4. Apprenticeship5. On-the-job training

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C. Marking Tools

1. Srrface gauge2. ' rnier height gauge3. , Iel4. Dividers5. Scriber (scratch awl)

V. SHEET METALWORK AND LAYOUT

A. Pattern Making

1. Parallel line developmenta. prismsb. cylindersc. truncated objects

2. Radial line developmenta. conesb. funnelsc. pyramids

3. Triangulationa. offsetsb. transitionalsc. tapers

B. Hand Tools

1. Hand snipsa. straightb. circularc. double-cuttingd. hawk-bille. aviation

(1) straight(2) left cut(3) right cut

f. compound lever slittingg. bench shears

2. Nibblers3. Punches

a. solidb. hollowc. hand-leverd. chassis

4. Sheet metal gaugesa. U.S. Standard (ferrous)b. English Standard Wire (non-ferrous)

5. Hammersa. rivetb. settingc. raisingd. ball-peen

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e. mallets(1) rubber(2) leather(3) plastic(4) wood(5) brass(6) lead

f. planishingg. formingh. cross-peeni. straight-peen

6. Hand seamer7. Hand groover8. Soldering ccpLer

9. Safety

C. Machines and Equipment

1. Machinesa. squaring shearb. bar folderc. box and pan braked. slip roll forming machinee. combination rotary machine

(1) burring(2) wiring

(3) crimping(4) setting down(5) double seaming

f. tab notcherg. bench nibblerh. turret punchi. ring and circle shearj. portable power shearsk. cornice brake1. press brakem. power slitting shearn. grooving machineo. Pittsburgh lock forming machinep. bench shearq. throatless bench lever shearsr. coper

2. Equipmenta universal stake holderb. stakes

c. bench places

3. Safety

D. Bending and Shaping Operations

1. Hemsa. singleb. double

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2. Edgesa. wiredb. burredc. crimped

3. Seamsa. lap

b. flat-lock groovec. double seamd. corner seame. Pittsburgh lockf. double bottomg. lap strip

4. Safety

E. Sheet Metal Fastening

1. Rivetinga. solid rivets

(1) tinners

(2) flathead(3) roundhead(4) countersunk

b. popc. explosive rivetd. rivet set

2. Screwing3. Soldering

a. fluxb. solder

4. Spot welding5. MIG welding6. TIG welding7. Safety

VI. METALLURGY AND HEAT TREATING

A. Mechanical Properties

1. Hardness2. Toughness3. Brittleness4. Elasticity5. Tensile strength6. Malleability7. Compression strength8. Ductility9. Machinability

10. fusibility11. rigidity

B. Physical Properties

1. Melting point

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2. Specific gravity3. Thermal expansion4. Thermal conductivity5. Electrical conductivity6. ,Corrosion resistance7. Weight8. Color9. Density

C. Classifications

1. Ferrousa. iron

(1) iron ore(2) pig iron

(3) cast iron(4) wrought iron(5) steel

b. steel

(1) carbon

(a) mild(b) medium(c) high

(2) alloy

(a) high speed(b) special

(3) ways to make steel

(a) Bessemer converter(b) open hearth(c) electric furnace(d) basic oxygen process(e) crucible furnace

2. Non-ferrousa. aluminumb. tinc. zincd. coppere. leadf. silverg. others - see appendix

3. Alloysa. stainless steel

(1) molybdenum steel(2) titanium steel(3) vanadium steel(4) tantalum steel(5) chromium steel

b. nickel steel(1) monel(2) inconel(3) hasteolly

c. magnesium steel

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D. Identification

1. Surface appearance2. Sound3. Spark test

a. colorb. lengthc. shaped. number

4. Melting point5. Grain structure

a. pearliteb. ferrite

6. Color coding7. Chip test8. Magnetic test9. Fracture test

10. Density or specific gravity11. Chemical12. Flame

13. Number systema. S.A.E.

b. A.I.S.I.

E. Heat Treating

1. Typesa. annealingb. normalizingc. temperingd. hardeninge. case hardening

(1) cyaniding(2) carburizing(3) nitriding(4) flame hardening(5) induction(6) laser(7) electron beam

f. spheroidizIngg. stress relieving

VII. CASTING

..,

A. Sand Casting

1. Patternsa. simple (one piece)b. split

(1) positive draft

(2) negative draft

A

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2. Toolsa. flaskb. sprue and riserc. ramd. bottom boarde. fiddlef. strike off barg. lifter, slick, and oval

3. Molding sanda. tempering sand

4. Furnace equipmenta. crucible furnaceb. tongsc. crucible

5. Safety

B. Shell-Mold Casting

1. Resin-coated sand2. Heated pattern3. Smoother finish4. Thin shelled5. Half molds

C. Die Casting

1. Air injected2. Hot chamber (plunger)3. Cold chamber

D. Permanent-Mold Casting

1. Accurate (± 0.010")2. Gravity3. Reusable mold

a. graphiteb. metal

4. Release agent5. Not suitable for thin walls

E. Investment Casting (Lost Wax Process)

1. Shell molding2. Flask molding3. Patterns

a. waxb. plasticc. frozen mercury

F. Plaster Mold Casting

1. Reusable pattern (few times)2. Cast metals with low mating

points (400° - 1700° F.)

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G. Centrigugal Casting (Rotated onLongitudinal Axis)

H. Centrifugal Casting (Central Sprue)

I. Slush Casting (Hollow Casting)

1. Slip molding2. Dipping

J. Silicone Rugger Molding

1. Used for prototypes2. Good surface finish3. Cast metals of low melting points

VIII. WELDING

A. Safety

1. Oxyacetylene welding safety2. Cylinder handling safety3. Arc welding safety4. Basic electrical safety5. Fire prevention safety

6. General precautions

B. General Welding Shop Tools and Equipment

1. Cylindersa. oxygenb. airc. fuelsd. inert gases

2. Regulators .

a. single-stageb. double-stagec. flow meters

3. Hosesa. colorsb. size

c. coupling4. Proper clothing

a. gloves(1) leather(2) cotton

(3) asbestos

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b. eye protection(1) safety glasses(2) goggles

(3) face shields(4) hoods

c. footweard. shirtse. pantsf. bib, jackets, or aprons

5. Welding machinesa. transforms" - A.C.b. motor - generator - D.C.c. rectifier - A.C. and D.C.

6. Chipping hammers7. Tip cleaners8. Strikers (flint lighter)9. Tongs

10. Brushesa. stainless steelb. carbon steel

11. Grindersa. benchb. sidec. die

12. Oxy-acetylene tipsa. heatingb. weldingc. cutting

C. Oxy-Fuel Welding and Cutting and Brazing

1. Fuel gasesa. acetyleneb. mapp (methylacetylene propadiene)c. propaned. natural gase. hydrogenf. others

2. Characteristics of a good welda. consistent widthb. straightnessc. slightly crownedd. fused to base metale. clean appearance

3. Weld quality factorsa. proper flame adjustmentb. angle of tipc. distance from workd. speed of travele. movement of tlp

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4. Means of selecting tip sizea. metal thicknessb. size of welding rod

5. Means of selecting rod sizea. properties of base metalb. thickness og metal

6. Flame typesa. neutralb. oxydizingc. carburizing

7. Causes of backfiresa. dirty tipb. loose tipc. bad 0-rings in torchd. improper pressuree. hot tipf. tip too close to metalg. kink in hoseh. leak in hose

8. Results of flashbacks9. Steps to follow in case of flashback

a. close oxygen torch valveb. close acetylene torch valvec. release oxygen regulator screwd. release acetylene regulator screwe. inspect equipment

10. Differences between fusion welding and brazinga. the temperature of the processb. the principle of the joint

11. Composition of brassa. copperb. zinc

12. Three proper methods of physically cleaningmetal for brazinga. fileb. sandc. grind

13. Factors relating to joint strengtha. clean metalb. correct heatc. joint structured. proper amount filler rod

14. Characteristics of a good oxy-acetylene cuta. no slagb. square facec. straight pathd. sharp edgese. properly shaped drag lines

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15. Pressure control mechanisms forcutting torchesa. pre-heat oxygen valveb. torch body oxygen valvec. torch body acetylene valved. oxygen high pressure cutting lever

16. Cutting tipsa. several sizesb. various shapesc. pre-heat orifice

(1) several(2) smaller(3) heats metal to kindling

point (1600° F.)d. cutting orifice

(1) larger(2) high pressure pure oxygen

17. Reasons for poor cutsa. preheat flames too smallb. cutting speed too slowc. preheat flames too longd. cutting oxygen pressure too lowe. cutting oxygen pressure too highf. cutting speed too fastg. motion of travel unsteadyh. cut lost and not carefully restarted

D. Shielded Metal Arc Welding

1. Types of electrodesa. non-consumable (refractory)

(1) tungsten - 6100° F. melting point(2) carbon - 6512° F. melting point

b. consumables (filler metal)2. Currents

a. alternating (AC)b. Direct (DC)

(1) negative polarity electrode(straight)

(2) positive polarity electrode(reverse)

3. Factors to consider when setting amperagea. thickness of metalb. size of metalc. type of jointd. size of electrodee. type of electrodef. length of cable

4. Duty cycle5. Electrode angles6. Arc lengths

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7. Reasons for poor weldsa. current too lowb. current too highc. arc length too longd. arc length too shorte. speed too slowf. speed too fastg. improper angleh. improper electrode typei. improper electrode sizej. improper base metal preparation

8. Arc welding joints and weldsa. buttb. filletc. edged. flangee. lap

f. beadg. tackh. corneri. weavej. pad

k. nultipass1. plug

9. Welding positionsa. flat

b. verticalc. horizontald. overhead

10. Electrode selectiona. comparison of bare electrodes

to covered electrodesb. filler rod composition

(1) mild(2) stainless(3) cast iron(4) non-ferrous

(5) low hydrogenc. coverings

(1) function(2) composition

d. size11. Methods of striking arc

a. tappingb. scratching

12. Lens shade selection13. Electrode identificatiod

a. number - AWSb. Color marking - NEMA

(1) end

(2) spot(3) group

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14. Arc cutting

E. Tungsten'Inert Gas Welding - GTAW - TIG

1. Shielding gasesa. argonb. heliumc. COI

2. Current usages3. Advantages4. Power supply controls5. Torches6. Nozzle types7. Electrodes8. Fillers9. Characteristics of good welds

10. Reasons for poor welds

F. Metal Inert Gas Welding - GMAW - MIG

1. Major parts2. Advantages3. Applications4. Characteristics of good welds5. Effects of wire stickout6. Causes of poor welds

7. Types of wires8. Factors in selection of filler wire9. Major parts of equipment

10. Shielding gases

G. Resistance Welding

1. Spot welding2. Seam welding3. Flash-butt welding4. Projection welding5. Percussion welding6. Upset welding

H. Other Welding Processes

1. Ultrasonic welding2. Friction welding3. Forge welding4. Explosion welding5. Diffusion welding6. Cold welding7. Electron beam welding8. Electroslag welding9. Induction welding

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10. Laser-beam welding11. Thermit welding12. Submerged-arc welding13. Plasma-arc welding

I. Welding Print Reading

J. Principal Weld Defects

1. Incomplete fusion2. Lack of fusion3. Undercutting4. Slag inclusions5. Porosity6. Cracking7. Dimensional defects8. Brittleness

IX. MACHINING

A. Power Sawing

1. Power hacksawa. dry cuttingb. wet cuttingc. cutting speedd. blades

(1) length(2) tooth pitch

e. safety

2. Horizontal band saws

a. advantages over power hacksaw(1) smaller kerf(2) increased cutting speed(3) feed and speed control

b. safety3. Abrasive cutoff saws

a. fixed headb. oscillating headC. sized. safety

4. Vertical band sawsa. types of cutting

(1) straight-line cuts(2) angular cute(3) curved-line cuts(4) internal-contour cutting

b. band filingc. band polishing

(1) abrasive belt(1) special guide for saw

d. safety

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B. Drilling Machines

1. Handfed drill pressa. step pulleyb. variable speed pulley

2. Back-geared upright drill3. Gang drill4. Multiple-spindle drill

a. multiple drill bitsb. same time drilling

5. Radial drill press6. Turret drill press7. Twist drills

a. straight-shank drill(1) four flute(2) three flute(3) two flute(4) oil hole

(5) subland drillb. taper shank drillsc. center drilld. counter sinks

8. Drilling operationsa. countersinkingb. reamingc. counterboringd. spotfacinge. boringf. tapping

C. Lathes and Lathe Operations

1. Kinds of lathesa. manually operated latheb. screw machinesc. turret lathesd. tracer lathee. numerically controlled lathesf. CNC

2. Lathe operationsa. facingb. counter boringc. threading

(1) inside(2) outside

d. taperinge. turning between centersf. knurling

(1) straight(2) diamond

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g. drillingh. reaming

3. Parts of lathesa. headstockb. tailstockc. gear boxd. aprone. waysf. lead screwg. compound resth. power-feed clutchi. see Appendix for pictures

and complete nomenclature4. Mounting tools and fixtures

a. three-jaw chuckb. four-jaw chuck

(1) universal(2) independent

c. face platesd. lathe dogs

(1) bent-tail lathe dog(2) clamp type

e. collet(1) round

(2) square

(3) hexagonf. centers

(1) live(2) dead

g. spindle chuckh. thread gauge

i. dial-indicator gaugej. steady restk. following rest

5. Cutting toolsa. materials

(1) high-speed steel(2) cast alloys(3) cemented carbide(4) ceramics(5) diamond

b. types of cutting tools andtool holders(1) left-hand(2) right-hand(3) round-note(4) left-hand facing(5) right-hand faOng(6) cut-off tool(7) threading(8) boring tool(9) inside threading

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c. cutting-tool terms

(1) cutting edge(a) side

(b) end

(2) face(3) flank(4) nose(5) relief

(a) side

(b) end

(6) rake(a) side

(a) end

D. Milling Machines and Milling Operations

1. Types of machines

a. column and knee

b. bed

Z. Kinds of machinesa. vertical millb. horizontal millc. combination horizontal,

vertical

3. Types of milling cuttersa. plain-milling cutters

b. side-milling cuttersc. angular-milling cuttersd. end millse. formed cutters

f. face-milling cuttersg. special cutters

4. Cutter holding devicesa. nolletsh. arbors

5. Machine adjustments and controlsa. knee elevationsb. table movements

(1) cross-feed handwheel(2) longitudinal-feed control

c. spindle speed adjustmentd. feed adjustment

e. feed direction

6. Milling operationsa. cutting keyways

b. slottingc. facing

d. milling groovese. indexing or dividing

(1) sides(2) holes

f. straddle milling

g. cutting gears

h. up millingi. down milling 27

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E. Shapers and Shaping

1. Kinds of shapersa. horizontal shapers

b. vertical shapers2. Parts of shaper

a. baseb. table

c. ramd. tool head assembly

3. Machine adjustmentsa. tool slide positionb. horizontal table movementc. table elevationd. length of strokee. position of stroke

f. cutting speed selection

g. feed adjustment4. Special forged tools

a. round-nose toolb. side-cutting tool

c. gooseneck tool (flat cuts)

5. Shaper cutsa. vertical cutb. angular cut

c. horizontal cutd. angular dovecail cut

F. Ultra Modern Machining Processes

1, Electrical discharge machining (EDM)

2. Electrochemical machining (ECM)

3. Electron beam machining (EBM)

4. Laser beam machining (LBM)

5. Ultrasonic machining (USM)

6. Chemical machining (CHM)

G, Numerical Control and Automation

1. Lathes2. Milling machines

3. Drilling machines

4. Combination machines

X. MATERIAL TESTING

A. Nondestructive

1. Magnetic particle

2. Radiographica. x-rayb. gamma ray

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28BEST COPY AVAILABLE

3. Penetrant4. Ultrasonic5, Eddy current6. Leak test7. Hardness

a. Brinellb. Rockwellc. Vickersd. Shore Scleroscope

8. Thermal and infrared9. Microwave10. Strain sensing

a. brittle coatingsb. photo-elastic coatingsc. resistance strain gauges

11. Visual

B. Destructive Testing

1. Free-bend test2. Root-, face-, and side-bend test3. Fatigue test4. Longitudinal- and transverse -shear test

5. Guided-bend test6. Fillet-weld break test7. Etching8. Impact test

a. Izod

b. charpyc. Nick-break test

XI. FINISHING

A. Kinds of Finishing

1. Grinding2. Polishing3. Brushing4. Sanding5. Buffing6. Burning7. Electroplating

B. Application Techniques

1. Brushing2. Spraying

a. pressure feedb. suction feedc. electrostaticd. aerosole. flame

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3. Powder fusion coating4. Dip or flow coating5. Roller coating6. Tumbling

C. Protective Metal Finishes

1. Primers2. Metal enamels3. Lacquers4. Galvanizing5. Tin coating6. Parkerizing

XII. AUTOMATION TECHNOLOGY

A. Robotics

1. Welding2. Parts manipulation3. Finishing4. Hazardous material handling5. Quality control

B. Computers

1. Computer numerical control (CNC)2. Computer aided design (CAD)3. Computer aided manufacture (CAM)

XIII. SAFETY REVIEW

A. General Shop and Lab Safety

B. Personal Safety

C. Tool and Equipment Safety

D. Housekeeping Practices

E. Sheetmetal Safety

F. Heat Treating Safety

G. Casting Safety

H. Oxy-Fuel Processes Safety

I. Arc Welding Safety

25

30

J. TIG and MIG Safety

K. Electrical Safety

L. General Machine Shop Safety

M. Machine Operation Safety

1. Buffers2. Drill presses3. Grinders4. Milling machines5. Shapers6. Lathes

N. Fire Safety

26 31

UNIT I: GENERAL SAFETY 3 Hours

OBJECTIVES TOPICS STUDENT ACTIVITIES TEACHER ACTIVITIE

Thy student should be able to: A. General Safety Students will make themselves Construct and pass oul1. Course syllabus knowledgeable of all classroom syllabus, and discuss

demonstrate knowledge of tours,requirements, class rules and

2. Classroom rules andregulations

3. General safety

rules and regulations and generalsafety.

Students will be required to take

and regulations.

See Appendices 1 and :regulations, and generaland pass the rule and safety test classroom rules and b:safety as it applies to the

classroom and basic labors-tory experiences.

at a percentage set by the in-structor.

safety rules.

See Appendix 2 for Wol

b4

Test No. 1 - Unit 1 Puzzle on General Safi

....3


S RflSOURCPS

tours Sec Appendixrules Book 2, pp. 3-7

Book 4, Unit 2

Book 7, Unit 3Book 70, Unit V

for p. 25sic

d Find

ty.

33

UNIT II: CAREERS IN METALWORKING 3 Hours

nAJFCTTVFA_____ TOPICS STIINNT ACTIVITTFS TFACIIFR ACTIVITTFS

The student should be able to: A. Levels of Skills1. Semi-skilled2. Skilled3. Technicians4. Professionsidentify the various levels

of skill within the metal-working industries.

list some occupations inmetalworking.

34

B. Occupations1. Steelworker (structural)2. Welder3. Tool and die maker4. Sheet metal technicianS. Machinist

6. Machine operator7. Boiler maker8. Molder9. Pipe fitter10. Plumber11. Millwright12. Pattern maker13. Metallurgical engineer14. Aerospace engieer1S. Instrument technician16. Industrial technologist17. Computer programmer18. Industrial engineer19. Set-up worker20. Helpers

Students should list all jobs withmetal interaction they can thinkof.

Students should identify the skilllevel of the occupation given.

Have students research and writea paper on the occupation of theirchoice including:

Job requirementsEducational requirementsWorking hours and conditionsJob payTraining requirements

Invite job consultant tospeak on different jobsrelated to metalworking.

Lord a discussion on variousme.,F',Jorking occupations.

Grade research papers.

Rrsoart:s

Book 1

Book 2, p. 4Book 3, Unit IIBook 4, Unit 1Book 7, Unit A-1

Book 1, p. 29Book 2, pp. 7-10Book 3, pp. 64-73Book 4Book 6, p. 187

Book 1Book 2, p.Book 3, pp. 64-73Book 4Book 7, p. A-1

35

T III: DRAWING AND

AOOBJECTIVES TOPICS STUDENT ACTIVITTFS TFACHPR ACTIVITIFS

,The student should he able to: A. Review of Working Drawing Show the differences of the Book 11. Assembly drawing types of drawings. Book :2 Detail drawing

Book :

a. dimensionsb. views

Book 4

3. Isometric

apply the principles of de- D. Basic Principles of Design Have students design (draw) a Book 1sign in the project drawing. and Construction small project, then as a group look :

1. Alphabet of lines refine their product. See Appendix 1 for ruler Book :2. Proportion test. Book 43. Balance4. Emphasis5. Texture6. Color7. Function

read a rule to 1/32". C. Review of Measurement and Students should draw a ruler in Draw an enlarged ruler on Book INI Shop Mathematics their notebook to study and the board. Call on students look :y0 1. Reading a rule (review)

a. 6" rule to 1/32"b. Metrit: 1 meter to

identify readings. to identify parts. Booklook I

1 millimeter2. Shop math review

a. linear foot problemsb. square foot problemsc. calculating total

cost from unit cost

Give quiz on reading a rule.q

make a working drawing of D. Individual Project Drawing Have students gather project Show pictures of past pro- Book 1his project from a picture or 1. Selection of project pictures, e.g. catalogs, mesa- jects (slide show). Book 2replica. 2. Rough sketch tines, newspaper. Book ]

3. Teacher's evaluation ofsketch

Book 4

4. Final drawing (working)

36

liFSOURCES

p. 123

Pp. 61-66p. 22p. 50

p. 124pp. 8-11p. 22p. 50

, pp. 123 & 365

pp. 75-78, p. 50

p. 57

p. 67p. 13

, p. 66

37

UNIT III: DRAWING AND PLANNING (Continued)

OBJECTIVES TOPICS STUDENT ACTIVIT FS TEArHER ACTIVITMS

set up and fill out a billof material when planning aproject.

list the steps of procedurein building a project.

O

38

E. Bill Materials1. Part number2. Number of pieces

(quantity)

3. Part name4. Material5. Size: thickness, width,

length6. Unit cost7. Total cost

F. Plan of Procedure1. Operations (list)2. Tools (list)

3. Equipment (list)

Have students fill out a bill ofmaterials and figure total costfor project.

Sec Appendix for sample fora.

Complete bill of material byadding the plan of procedure fordesigned project.

Draw a bill of material onthe board or make a handoutsheet to give to students.

See Appendix 1 for bill ofmaterial form.

Develop handout sheet to showyour format.

141%01BR:1:S

Book I

Book 2, P. 71Book 1, pp. 43-47Book 4

look 1look 2, p. 69Book 3, pp. 43,425Book 4

39

UNIT IV: AUVANCED_,METALWORK NC 0. ':IQ =

ORZICTIVES TOPICS STUDENT ACTIVITIFS TFACHM ACTIVIICs

The studott should be able to: A. Precision Measurement Tools Demonstrate the proper1. Micrometers Have students measure different technique for holding End

a. depthb. threadc. outsided. insidec. vernier

items in the lab. reading the outside micro-meter.

identify the different calf- 2. CalipersShow different uses forpers. a. vernier

b. hermaphroditec. outsided. insidee. vernier bevel pro-

tractor

calipers.

3. Rules and scalesa. machinistb. engineers

4. Dial-indicatorLa-L

5. Gaugesa, go-nogob. ringc. plugd. feeler gaugese. drill and wire gauge

identify the different parts 6. 'Combination set Mark different angles and find Demonstrate marking uses withof the combination sets. a. center headb. protractor headc. square head

center of round stock with comb!-nation set.

combination set.

E. Clamps, Jigs, and Fixtures Identify the clamps and jigs by Show transparencies ofrecognize the different tools 1. V-block name in your shop. different clamps and fix-by sight. 2. Parallel tures.

3. Locking pliers4. 5tep block5. Drill press clamps

Call on student to identifyclamps or fixtures in shop.

l

.

6. Drill press vise7. Strap clamps

'

See Appendix 3 for handtoolsafety.

RhSOURCES

Book 1, pp.

Book 2, pp.365. 378100-104

Book 3, pp. 54, 89,323

Book 4, p. 306

Book 1, pp. 67, 75

Book 2, pp. 83-85Book 3, p. 58Book 4, pp. 61, 306

Book 2, pp. 543-550

Book 1, p. 365

Book 2, p. 81

Book 3, p. 52Book 4, p. 62

Book 1. p. 365Book 2, pp. 88, 362Book 3, p. 82Book 4, pp. 62, 386

41

UNIT IV: ADVANCED METALWORKING TOOLS (Continued)

OBJECTIVES TOPICS STUDENT ACTIVITIFS lvArak ACTIVY

a. u-clampsb. plain clampsc. gooseneckd. fingere. screw heelf. double finger

8. C-clamps9. Bar clamps

10. Pipe clamps11. Chucks12. Machine vises

Select and use the correct C. Marking Tools Point out the diffemarking tool for their job. 1. Surface gauge

2. Verniec height gaugecapabilities and fuof each marking too

3. Trammel4. Dividers

W 5. Scriber (scratch awl)

NTest No. 2, Units 3 and 4

42

tentnctions1.

winultrFC

Book 1, p. 367Book 2, pp. 87, 92Book 3, p. 49Book 4, p. 60

43

UNIT V: SHEET METALWORK AND LAYOUT 10 Hours

.

OBJECTIVES TOPICS STUDENT ACTIVIT Fs TrArau AcTivr

The student should be able to:

develop each kina of pattern.'

,..

identify by sight the differentnames of the snips and punches.

tratra

safely use all hand toolswhile performing op rations.

A. Pattern Making1. Parallel line development

a. prismsb. cylindersc. truncated objects

2. Radial line developmenta. cones

b. funnelsc. pyramids

3. Triangulationa. offsetsb. transitionalsc. tapers

B. Hand Tools1. Hand snips

a. straightb. circularc. double-cuttingd. hawk-bille. aviation

(1) stcalght(2) left cut(3) right cut

f. compound lever slit-ting

g. bench shears2. Nibblers3. Punches

a. solidb. hollowc. hand-leverd. chassis

Lay out line developments un paperfor notebook.

List and describe each tool andits function in notebook.

Point out different hand toolson tool rack.

Discuss hand tool safety.

Lecture discussionprocedures Inr linewent

Filmstrips if availyour area

Lecture - demonstrahand tool safety aeach tool.

See Appendix 2 forpuzzles on sheetmet

on

develop-

able in

to propernd use for

ordfind

al.

Book 1, p. 123Book 2, pp. 228-232

Book 3, p. 1SSBook 4, pp.173-178

Book 1, pp. 133-169Book 2, p. 238Book 3, p. 162Book 4, pp. 180-202

Book 1, p. 142Book 2, p. 236Book 3, p. 129Book 4, p. 181

RESOURCES

45

OBJECTIVES TOPICS STUDENT ACTIVITIES TEACHER ACTIVITIES

measure different thicknesses 4. Sheet metal gauges List and describe each tool and Cut up different sheet metalsof metal with sheet gauges. a. U. S. Standard its function in notebook. for students to measure.

(ferrous)

b. English Standard Wire(nonferrous)

name and identify each type 5. Hammers Identify hammers on tool rack.of hand tool. a. rivet

b. settingc. raisingd. ball-peene. mallets

Describe individual uses.

(1) rubber(2) leather(3) plastic(4) wood

(5) brass

(6) leadf. planishingg. formingh. cross-peenI. straight-peen

6. Hand seamier

7. Hand grooverDemonstrate the proper use ofsummer and groover.

identify and describe the use

8. Soldering copper9. Safety

C. Machines and Equipment

Show proper soldering tech-nique.

of machines and equipment. 1. Machines List and describe each machine and Lecture-explain use and

a. squaring shear its use in student notebook. function of machines and

safely perform all requiredoperations on machines.

b. bar folderc. box and pan braked. slip roll forming

machine

equipment.

46

RESOURCES


Book 1, p. 152Book 2, p. 235Book 3, pp. 58. 222Book 4, p. 74

look 2, p. 261

took 1, p. 152gook 2, p. 237

Book 3. P. 158took 15, pp. 195. 185

ook 1. pp. 134-183ook 2, pp. 241-248ook 3, pp. 162-187ook 4, pp. 180-202

47

UNIT V: SHEET METALWORK AND TOOLS (Continued

OBJECTIVES TOPICS Sruni:NT ACTIVIT FS TPACHR ACTIVIIIN

e. combination rotary Perform operations on practice See Appendix 3 for sheetmachine sheets. metal safety.(1) burring(2) wiring(3) crimping(4) setting down(5) double seaming

safely perform all required f. tab notcher List and describe each machine and Lectureoperations on machines. g. bench nibbler

h. turret punchits use in student notebook. function of machines and

equipment.I. ring and circle shear1. portable power shearsk. cornice brake

Loto

1. press brakem. power slitting shearn. grooving machineo. Pittsburgh lock form-

ing machinep. bench shearq. chroatless bench

lever shearsr. coper

identify (name) and describe 2. Equipment Draw picture of stakes in notebook. Demonstrate the use of thethe use of each stake. a. universal stake holder

b. stakesc. bench plates

sore common stakes.

3. Safety

safely perform all bending D. Bending and Shaping Opera- Practice bending operations during Lecture-list, define bandsoperations demonstrating tions lab exercises. and operations.proper sheet metal safety. 1. Hems

a. singleb. double

Demonstrate bending opera -tions.

2. edgesa. wired

b. burredc. crimped

RPSWIRCFR

Book 1, pp. 134-183Book 2, p. 239

Book 3, pp. 162, 187Book 4, pp. 180-202


Book 1, pp. 165-169Book 2, p. 232Book 3, pp. 168-193Book 4, pp. 188, 191-

196

49

UNIT V: SHEET METALWORK AND TOOLS (Continued)

OBJECTIVES TOPICS srunFm. Arrivrn PS TVAVIWR ArTIVITIFS

set and form solid rivets.

identify the different typesof solid rivets.

operate the spot welder ondifferent thicknesses ofsheet metal.

50

3. seamsa. lapb. flat-lock groovec. double seamd. corner seemc. Pittsburgh lockf. Double bottomg. Lap strip

4. Safety

E. Sheet Metal Fastening1. Riveting

a. solid rivets(1) tinners(2) flathead(3) roundhead(4) countersunk

b. pop

c. explosive rivetd. rivet set

2. Screwing3. Soldering

a. fluxb. solder

4. Spot welding5. NIG welding6. TIC welding7. Safety

List rivets and describe thesetting operations in notebook.

Spot weld practice sheets togetherto eliminate burn through.

Tets No. 3, Unit V

Lecture -- Identify and define

fa'tening devices.

Demonstrate setting solidrivets.

Demonstrate proper spotwelding techniques.

See Appendix 4 for suggestedsheet metal projects.

gFCCKII:CIS

Book 1, p. 175Rook 2, p. 184-188Book 3. pp. 169-189Book 4. p. 200

Book 1, pp. 170-174Book 2. pp. 190 -193

Book 3. p. :95look 4. pp. 45-212

51

UNIT VI: METALLURGY AND HEAT TREATING 10 Hours

OBJECTIVES

The student ihould be able to:

list and define six of theeleven properties of octal.

list and define five of thenine physical properties ofmetal.

list the three classificationsof metals.

list different metals in eachclassification.

tell the different kinds ofsteel.

52

A. Mechanical PropertiesI. Hardness2. Toughness3. Brittleness4. ElasticityS. Tensile strength6. Malleability

7. Compression strengthB. Ductility9. Hachinability

10. Fusibility11. Rigidity

B. Physical Properties1. Melting point2. Specific gravity3. Thermal expansion4. Thermal conductivityS. Electrical conductivity6. Corrosion resistance

7. Weight8. Color9. Density

C. Classifications1. Ferrous

a. iron

(1) iron ore(2) pig iron(3) cast iron(4) wrought iron

(5) steel

b. steel

(1) carbon

(a) mild(b) medium

(c) high(2) alloy

(a) high speed(b) special

STUDENT ACTIVITIES-----

List and define each property instudent notebook.

TEACHER AFTIVI11hi

Fxplain properties involved when:1. stretching a piece of copper2. hitting different metals with

A barmaer

3. breaking a piece of cast iron

Weigh diffe. !nt kinds of metal thatare in the classroom.

Have students identify metals bycolor.

Lecture, notes

Look up and tell the differencesin the kinds of steel.

Lecture, discussion,demonstration of someproperties

See Appendix 1 for list ofmetals.

Lecture. discussion

Show the different kinds ofmetals that are easily ob-tainable and that are in yourlab.

hot rolled steel, coldrolled steel, aluminum,brass. cooper

MOIMCES

Book 1. pp.18. 21Book 2, p. 19

Book 3. pp. 30. 367,374

Book 4, p. 42

Book 1, pp. 3. 8-27

Book 2. pp. 30-34Book 3. p. 30

Book 4. pp. 32-36

Book 4

Book 4. p. 41

53

UNIT VI: METALLURGY AND MEAT EATING (Continued)

OBJECTIVES TOPICS

list the ways to make steeland explain one.

list three of the five stain-less steels given.

identify metals by one ormore of the identificationprocesses.

list some identificationprocesses.

54

STUDENT ACTIVITIES

(3) ways to make steel List and explain in notebook the(a) Bessemer con- ways to make steel.

verter(b) open hearth

(c) electricfurnace

(d) basic oxygenprocess

(e) crucible fur-nace

2. Non-ferrous List or telling of other non-a. aluminum ferrous metals.b. tinc. zincd. coppere. leadf. silverg. others--see appendix

3. Alloys Lecture, notesa. stainless steel

(11 molybdenum steel(2) titanium steel(3) vanadium steel(4) tantalum steel(5) chromium steel

b. nickel steel See appendix for list of metals.(1) monel

(2) inconel

(3) hasteollyc. magnesium steel

D. Identification1. Surface appearance2. Sound3. Spark test

a. colorb. lengthc. shaped. number

4. Melting point

TFACMER ACTTVII1ES

Ask for other nonferrousmetals.

See Appendix 1 for metalsdefinitions.

Lecture discussion

After lecture and notes have stu- Show the students the sparkdents identify different metals test.by one of the identificationprocesses.

Show the different shapes ofmetal in lab.

ee Appendix 2 for puzzle oneat treating.

RESOIIRCIS

./11.*

Book 1, pp. 4-14Book 2, pp. 34, 41Rook 3, p. 32Book 4, p. 36

Book 1, pp. 17-18Book 2, pl. 46-53Book 3, pp. 39-43Book 4, pp. 45-50

Book 1

Book 2, pp. 44-45Book 3, p. 40Book 4

Book 1, n. 14

Book 1

Book 2, pp. 56-59Book 3Book 4, pp. 42-44Book 16, pp. 607-616

UNIT VI: METALLURGY AND HEAT TREATING (Continued)

OBJECTIVES TOPICS

tell what S.A.E. and A.I.S.I.mean.

list and explain five of thetypes of heat treating.

5. Grain structurea. pearliteb. ferrite

6. Color coding7. Chip testB. Magnetic test9. Fracture test

10. Density or specificgravity

11. Chemical12. Flame13. Number system

a. S.A.E.

B. A.I.S.I. 414 shape

E. Heat Treating1. Types

a. annealingb. normalizingc. temperingd. hardeninge. case hardening

(1) cyaniding

(2) carburizing(3) nitriding(4) flame hardening(5) induction(6) laser

(7) electron beamf. spheroidizing

g. stress relieving

STUDENT ACTIVITLES

In the student notebook, list and

define the types of heat treating.

FEACHIR ACTIVITIES

Lecture, discussion

Demonstrate safe furnaceprocedures.

RESOURCES

Book 1

Book 2, p. 56Book 3Book 4

Book 1, p. 23Book 2, pp. 313-322Book 3, p. 367Book 4, p. 301

57

UNIT VII: CASTING S Hours

OBJECTIVES TOPICS STUDENT ACTIVITIES


list and explain the differentypes of patterns

Identify tools used infoundry area.

A. Sand CastingI. Patterns

a. simple (one piece)b. split

t (I) positive draft(2) negative draft

correctly temper molding sand.

list and describe five of theten types of casting.

58

2. Toolsa. flask

b. sprue and riserC. ram

d. bottom boarde. fiddle

f. strike off barg. lifter, slick, and

oval3. Holding sand4. Furnace equipment

a. crucible furnaceb. tongs

c. crucibleS. Safety

B. Shell-Mold Casting

1. Resin-coated sand2. Heated pattern3. Smoother finish4. Thin shelledS. Half molds

C. Die CastingI. Air injected2. Hot chamber (plunge03. Cold chamher

Have students design and make aone-piece and two-piece pattern(possible group work).

Show how to temper molding sand.

Light and turn off furnace usingproper safety guidelines.

Lecture, notes

ThACHER ACTIVITIES

Lecture, discussion

Show the difference between

positive and negative draft.

Demonstrate the procedures(step by step) of sandcasting.

Pour hot metal on a piece ofclothing and shoe anddemonstrate need for protec-tive clothing.

See Appendix 3 for castingsafety.

Lecture, discussion on eachtype of casting

See Appendix 2 for puzzleson casting.

RESOIIRCES

Book I, p. 199-206Rook 2, pp. 266-275"Jok 3, p. 291Book 4, p. 233

Book I, p. 230Book 2, pp. 277-278Book 3, p. 306Book 4, p. 258

Rook I, p. 228Book 2, p. 282Book 3, p. 304Book 4, p. 258

59

UNIT Vii: CASTING (Continued)

OBJECTIVES TOPICS STUDENT ACTIVITIFs

60

D. Permanent-Mold Casting1. Accurate (4. 0.010")2. Gravity3. Reusable mold

a. graphiteb. metal

4. Release agentS. Not suitable for thin

walls

E. Investment Casting (Lost WaxProcess)1. Shell molding2. Flask molding3. Patterns

a. waxb. plasticc. frozen mercury

F. Plaster Mold Casting1. Reusable pattern (few

times)2. Cast metals with log

melting points (4000 -17000 F.)

G. Centrifugal Casting (rotatedon longitudinal axis)

H. Centrifuge Casting (centralspree)

I. Slush Casting (hollow casting)1. Slip molding2. Dipping

J. Silicone Rugger MoldingI. Used for protypes2. Good surface finish3. Cast metals of low melt-

ing points

Have students design an investment-type of casting and cast out oflead.

Lecture, notes '

Test No. 4, units 6 and 7

MUM: ACTIVITIES

Demonstrate a form of invest-ment casting.'

Lecture, discussion on eachtype of casting

Show film on casting if avail-able in your area.

Sec Appendix 4 for suggestedprojects on casting.

RESOURCFs

Book 1, p. 227Rook 3, p. 305Rook 4, p. 256

Book 1, p. 231Book 2, pp. 279-280Book 3, p. 307Book 4, p. 259


Book 1, p. 229

Book 2, p. 287

61.

UNIT VIII: WELDING 20 Hours

OBJECTIVESTOPICS sTuniiNT ACTIVIT TEACIIhk ACTIVIT1hS


pass a test on the materialto the satisfaction of theteacher.

explain the makeup and fabri-cation of the various cylin-ders.

recognize the types of regu-4 lators for various needs.

match the hose with the use.

discuss the need for and kindsof clothing needed forvarious operations.

62

A. SafetyI. Oxyacetylene welding

safety2. Cylinder handling safety3. Arc welding safety4. Basic electrical safetyS. Fire prevention safety6. General precautions

B. General Welding Shop Toolsand Equipment

1. Cylindersa. oxygenb. airc. fuelsd. inert gases

2. Regulatorsa. single-stageb. double-stagec. flow meters

3. Hosesa. colorsb. sizec. coupling

4. Proper clothinga. gloves

(1) leather(2) cotton(3) asbestos

b. eye protection(1) safety glasses(2) goggles

(3) face shields(4) hoods

Study units.Take test.

Construct a model.

Use in practice.

Demonstrate explosive powerof oxyacetylene gases withballoons (color codeballoons).

1st balloon 6" dia.-oxygen2nd balloon 5" dia. -acetylene

3rd balloon 3" dia. -1/2 mixture

Ignite them in order.

Lecture, discussion

See Appendix 3 for all weld-ing safety.

Show film, if available inyour area, on gas and arcwelding.

Lecture, discussionSet good example.

la:SOUK:LS

Book 1, pp. 249-255Book 2

Book 3, pp. 384, 386Boa 4, pp. 268, 279Book 36, p. 23Book 72, allBook 74, pp. 1A-25A

Book 1, pp. 249-284Book 2, p. 199

Book 3, pp. 383 -394Book 4, p. 269

Book 2, p. 201

63

UNIT VIII: WELDING (Continued

OBJECTIVES TOPICS TOIDEIR_ACTIVITIFS Treurk ACTIVIT1Fti

understand the need for theseitems.

c. footweard. shirtse. pantsf. bib, jackets, or

apronsdifferentiate between the 5. Welding machines List examples of use on tests. Bevarious types of machines and a. transformer - A.C.

gctheir uses. b. Motor - Generator-D.C.

c. Rectifier - A.C. andBc

Bc

know when to use each of thetools.

D.C.6. Chipping hammers7. Tip cleaners8. Strikers (flint lighter)9. Tongs Use in practice.

10. Brushesa. stainless steelb. carbon steel

See Appendix 2 for weldingpuzzles and wordfind.

be

4LW

recognize and use the varioustips, as well as describe theparts and adjustments.

11. Grindersa. benchb. sidec. die

12. Oxyacetylenea. heatingb. weldingc. cutting

C. Oxy-Fuel Welding and Cuttingand Brazing

Student notebook Lecture, discussion

name several examples of fuel 1. Fuel gasesBogases and their specific a. acetylene See safety experiment. Bo

characteristics. b. Mapp.(methylacetylenepropadiene)

c. propaned. natural gase. hydrogenf. others

BoBo

I o

..

,

64

I.

RESOURCES

ok 1, p. 266ok 2, pp. 206-207ok 3, pp. 382-389ok 4, p. 269

ok 4, p. 279

ow 1, pp. 256-296ok 2, pp. 195-206ok 3, pp. 383-393ok 4, p. 269ok 16, pp. 81-174k 19, pp. 3-5k 74, pp, 1D-90Dk 36, pp. 135-214

VII WELDING (Continued

OBJECTIVES TOPICS STUNNT ACTIVIT FS TEACHFR ACTIVITIrs RFil

list several characteristicsof a good weld.

2. Characteristics of agood weld

a. consistent widthb. straightnessc. slightly crownedd. fused to base metale. clean appearance

Show examples. '

demonstrate knowledge of 3. Weld quality factors Use in practice. Demonstrate using properfactors and acquired manipu-lative skills.

.

a. proper flame adjust-meat

b. angle of tipc. distance from workd. speed of travele. movement of tip

safety to show by example.

4. Means of selecting tipsizea. metal thicknessb. size of welding rod

'

it5. ?leans of selecting rod

size

a. properties of basemetal

b. thickness of metal

Student notebook Lecture. discussion,demonstration

demonstrate an understanding 6. Flame types Set torch for each type and use Demonstrate or show pictorial look 1, p. 2of when each flame type is used a. neutral each when necessary. examples. look 2, p. 2as well as identify by sight. b. oxydizing

c. carburizinglook 3, p.Book 4, p. 2

7. Causes of backfiresa. dirty tipb. loose tip

Book 16, p.Book 32, pp.

list several examples of the c. bad 0-rings in torch See Appendix 3 for weldingcauses and corrective pro-cedures.

d. improper pressuree. hot tipf. tip too close to metalg. kink in hoseh. leak in hose

chart.

66

INCES

7$02

73

122

192 A-B

67

UNIT VIII: WELDING (Continued)

OBJECTIVES ToPTCS STUPFNT ACTIVITIES TrArmit ACTIVITIES RESOURCES

explain flashbacks andcorrective procedures.

B. Results of flashbacks9. Steps to follow in case

of flashbacka. close oxygen torch

valveb. close acetylene torch

valvec. release oxygen regu-

lator screwd. release acetylene

Stress importance and methodsof prevention.

regulator screwc. inspect equipment

describe the difference between 10. Differences between Student notebook Lecture. discussioneach process.

46

fusion welding andbrazinga. the temperature of

the processb. the principle of the

joint

Practice each process.

IA11. Compositon of brag:

a. copperb. iinc

discuss the relationship ofeach of these'items to Jointstrength.

12. Three methods to properlyphysically clean metalfor brazinga. fileb. sandd. grind

13. Factors relating to jointstrengtha. clean metalb. correct heatc. joint structured. proper amount filler

rod

name several characteristics ofa good oxyacetylene cut.

14. Characteristics of a good

a. no slagb. square face

ractice straight line cuts andole piercing.

Show examples.

6968

OBJECTIVES TOPICS STUDENT ACTIVITIES TFACHUR ACTIVITIES RESOURCES

c. straight pathd. sharp edgese. properly shaped drag

linesidentify and explain use ofeach pressure control mecha-ism.

15. Pressure control mecha-nisms for cutting torchesa. pre-heat oxygen valveb. torch body oxygen

valve

c. torch body acetylenevalve

d. oxygen high pressurecutting lever

16. Cutting tipsa. several sizesb. various shapesc. pre-heat orifice

Student notebook Lecture, discussion,demonstration

(1) several

In(2) smaller(3) heats metal to

kindling pointShow illustrations of variousshapes of tips.

(1600 °F.)

d. cutting orifice(1) larger(2) high pressure pure

oxygenlist several of these reasonsand select examples of eachgroup.

17. Reasons for poor cutsa. preheat Mines too

smallb. cutting speed too slowc. preheat flames toolon.d. cutting oxygen pressur

too lowe. cutting oxygen

pressure too highf, cutting speed too fastg. motion of travel un-

steadyh. cut lost and not care-

fully restarted

Critique cuts to find causes ofproblem.

Show examples.

7 0

71

OBJECTIVESTOPICS STUDENT ACTIVITIES TEACHER ACTIVITIES RESOURCES

D. Shielded Metal Arc WeldingBook 1, pp. 315-3361. Types of electrodes

a. nonconsumable (re-fractory)

Show examples of electrodesand describe when used,

Book 2, pp. 206-214Book 3, pp. 394-400Book 4, pp. 279-388(1) tungsten-6100°F.Book 16, pp. 217-253(2) carbon - 6512 °F.

Book 36, pp. 319-318N.P.b. consumables (filler

metal)

Book 74, pp. 1E-123E

decide when to use thedifferent currents to bestadvantage.

2. Currents

a. alternating (AC)b. Direct (DC)

(1) negative polarityelectrode

Student notebook Lecture, discussionExplain when each currentwould be used and the dis-advantages of each and howthey function.

(straight)

(2) positive polarityelectrode(reverse)

4..4 3. Factors to consider when

setting amperagea. thickness of metalb. size of metalc. type of jointd. size of electrodee. type of electrode

f. length of cable

Experiment with different variablesto see effects.

describe effects of variousduty cycles on welding machines. 4. Duty cycle

explain the effects of anglesand arc lengths on welds.

identify the causes of welddefects by comparison withcharts.

5. Electrode angles

6. Arc lengths7. Reasons for poor welds

a. current too lowb. current too highc. arc length too longd. arc length too short

Identify reasons for poor welds.n some sample plates.

Discuss effects of anglesand arc lengths.

Show examples.

73

72

UNIT VIII: WELDING (Continued)

OBJECTIVES TOPICS STUDVT ACTIVITIES TEACHER ACTIVITIES

e. speed too slowf. speed too fastg. improper angleh. improper electrode

typei. improper electrode

sizeJ. improper base metal

preparationidentify different samples of 8. Arc welding joints and Practice making the various joints Lecture discussionweld joints and welds.

4b,co

weldsa. buttb. filletc. edged. flangee. lapf. beadg. tackh. corneri. weave

and welds. Show examples of differentwelding joints.

J. padk. multipass1. plug

9. Welding positonsa. flatb. verticalc. horizontald. overhead

':actice welds in differentpositions.

10. Electrode selection

select the proper electrodea. Comparison of bare Show examples of the different

for the job.electrodes to coveredelectrodes

types and sizes of rods.

74

RESOURCES

75

UNIT VIII. WELDING (Continued)

OBJECTIVES TOPICS STUDFNT ACTIVIT FSI

1FArNPR ACTIV11

b. filler rod composition(1) mild .

(2) stainless(3) cast iron(4) non-ferrous(5) low hydrogen

c. coverings(1) function

(2) compositond. size11. Methods of striking

arc

a. tappingb. scratching

Demonstrate methods

identify basic commonelectrodes and their char-

12. Lens shade selection

13. Electrode identifi-cation

Student notebook Discuss importance clens shade selectior

4 acteristics. a. number - AWS40 b. color marking - Create s color chart.

NEMA14. Arc cutting Demonstrate.

select the proper shieldinggas for the job.

E. Tungsten Inert Gas Welding -GTAW - TIC

Make transparencies.

1. Shielding gasesa. argonb. heliumc. CO2 Practice welding.

2. Current uses3. Advantages4. Power supply controls5. Torches6. Nozzle types

ta-1 A

7. Electrodes Show examples.

I S

f proper

RrcOUNCPS

Book 1, p. 339Book 2, p. 215Book 3. p. 401Book 4. p. 292Book 16, p. 289Book 36. pp 378-423Book 74. pp. 17-1227

77

.....1

OBJECTIVES TOPICS ST1UWNT ACTIVIT FS TFACUFR ACTIVIT

distinguish between good andbad welds.

8. Fillers9. Characteristics of good

welds

10. Reasons for poor welds Show examples of gocbad welds.

F. Metal Inert Gas Welding - Practice welding. Hake transparenciesCRAW -MIG

1. Major parts2. Advantages3. Applications4. Characteristics of good

weldsdistinguish between good and 5. Effects of wire stickout Discusi effects of cbad welds. 6. Causes of poor welds Show examples of we]

7. Types of wires Student notebook8. Factors in selection of

filler wireLecture, discussion

Ut9. Major parts of equip-

sentC2

define the various types of

10. Shielding gases

C. Resistance Weldingresistance welding. 1. Spot welding Research different areas for Discuss various typo

2. Seam welding local use. their applications.3. Flesh-butt welding4. Projection welding5. Percussion welding6. Upset welding

explain the different processes H. Other Welding Processes Research applications for Give explaination ofof welding. 1. Ultrasonic welding

2. Friction weldingindustry. processes and exampl

uses.3. Forge welding4. Explosion welding5. Diffusion welding6. Cold welding7. Electron beam welding8. Electroslag welding

78

IrS

d and

tickout.ds.

and

weldinges of

RI-SOURCFS

Book 1, p. 346Book 2, p. 216Book 3, p. 401Book 4, p. 292Book 16, p. 351Book 36, pp. 337-317Book 74, pp. 123F-

347F

Book 1, p. 353

Book 3, p. 404Book 16, p. 410look 4, pp. 289-290

Book 1, pp. 339-360look 2, p. 217Book 3, pp. 400-40BBook 4, pp. 289-294look 16, pp. 456-563Book 36, pp. 483-495

NIT VIII: WELDING (Continued

08JECTIVES TOPICS 51111117NT ACT1VIT ES 1FACHrk ACT1V1

9. Induction welding10. Laser-beam welding11. Thermit welding12. Submerged-arc welding13. Plasma-arc welding

read welding prints with theaid of a symbols chart.

I. Welding Print Reading Discuss print symbc

J. Principal Weld Defects1. Incomplete fusion2. Lack of fusion3. Undercutting

list major weld defects. 4. Slag inclusions Show examples of es5. porosity6. cracking7. dimensional defects8. brittleness See Appendix 4 for

projects.Ut).4

Test No. 5. Unit 8

An

'11:5

Is

ch.

suggested

RESOURChN

Book 74, pp. 1C-39C

81

UNIT IX: MACHINING 20 Hours

OBJECTIVES TOPICS STIMENT ACTIVITIES


identify the different kindsor power sawing.

explain the function andadvantages of each kind ofsawing.

set up and cut different shapesof metal.

change blade on all kinds ofpower saws.

82

A. Power Sawing1. Power hacksaw

a. dry cuttingb. wet cutting

c. cutting speedd. blades

(1) length(2) tooth pitch

e. safety

2. Horizontal band sawsa. Advantages over power

hacksaw(1) smaller kerf(2) increased cutting

speed

(3) feed and speedcontrol

b. safety

3. Abrasive cutoff sawa. fixed bead

b. oscillating headc. sized. safety

4. Vertical band sawsa. types of cutting

(1) straight-line cuts(2) angular cuts(3) curved-line cuts(4) internal contour

cuttingb. band filing

Lecture, writing notes in notebook

Have a student remove and replaceblade on each machine.

lEACHER ACTIVIIIES RESOURCES

Lecture, discussion,demonstration

Sec Appendix for safetychart.

Demonstrate the proper way toposition different shapes ofmetal for cutting on eachmachine.

Demonstrate the proper way toremove and replace brokenblades on each machine.

Show proper maintenanceprocedures for each saw.

Lecture, discussion

Demonstrate proper way tocut round stock.

Book 1, pp. 35-40Book 2, pp. 372-378Book 3, pp. 84 -86Book 4, p. 410

Book 1, p. 37

Book 2, P. 375Book 3, P. 85Book 4, p. 413

Book 1

Book 2, p. 376Book 3Book 4

ook 1, p. 37

.4ot ;,

pp.

pp8r9-385ok 4, p. 413

83

go

OBJECTIVES TOPICS STUDENT ACTIVITIES TEACHER ACTIVITIES.

c. band polishing(1) abrasive belt

(2) special guide forsaw

d. Safety

Identify drilling machines B. Drilling MachinesBc

In lab.1. Handfed drill press

a. step pulley Bc

Bcb. variable speed pulley Show clamping procedure for odd- Demonstrate the proper way lic

clamp up and drill holes in2. Back-geared upright drill3. Gang drill

shaped stock.to drill all shapes of stock.

any shape stock. 4. Multiple-spindle drilla. multiple drill bitsb. same time drilling

Ste Appendix 3 for drillingsafety.

5. Radial drill press6. Turret drill press

identify the different typesof twist drills.

7. Twist drillsa. straight-shank drill

List and describe the types oftwist drills in student notebook.

Lecture, discussion,demonstrationto

(1) four fluteShow the various styles of

to)

(2) three flutetwist drills.(3) two flute

(4) oil hole

(5) subland drillb. taper shank drillsc. center drilld. counter sinks

name all drilling operations 8. Drilling operations Show procedure for different Demonstrate the differentand explain what they are. a. countersinkingb. reamingc. counterboringd. spotfacinge. boringf. tapping

drilling operations.drilling operations and ex-plain speeds and lubrication.

84

RESOURCES

ok 1, pp. 399-422ok 2. pp. 386-410ok 3. pp. 86-98ok 4, pp. 381-395

85

UNIT IX: MACHINING (Continued)

OBJECTIVES TOPICS STIMENT ACTIVITIES Ti TI1lallIt ACTIVITIES

name some kinds of lathes.

list the basic latheoperations.

identify the different partsof the lathe.

86

. Lathes and Lathe OperationsI. Kinds of lathes

a. manually operatedlathe

b. screw machinesc. turret lathesd. tracer lathe

e. numerically controlledlathes

2. Lathe-operationsa. facingb. counter boringc. threading

(1) inside(2) outside

d. tapering

e. turning between centersf. knurling

(1) straight

(2) diamond8. drillingh. reaming

3. Parts of lathesa. headstockb. tailstockc. gear boxd. aprone. ways

f. lead screwg. compound resth. power-feed clutchi. see Appendix for

pictures and completenomenclature

Ir111-

List and describe lathe operationsin student notebook.

Practice different lathe operationson scrap material.

List the parts of the lathe onhandout sheet.

Define the purpose of each part.

Identify lathe parts when lookingat the lathe.

11=:=111 ..111ZIL

Show film series on lathesif available in your area.

Demonstrate and explain alllathe operations showingproper safety procedures.

See Appendix 3 for lathesafety.

Lecture, discussion, handout,demonstration

Point out the different partson lathe in lab.

See Appendix 3 for lathepictures.

RESOURCES

Book 1, pp. 426-441Book 2, pp. 413-414Book 3

Book 4, pp. 344, 347,365

Book 46, p. 200

Book 1, pp. 457-473Book 2, pp. 439-451Book 3, pp. 331-344Book 4, pp. 356-365Book 46, pp. 159-200Book 44, pp. 239-260

BookBookBook

BookBookBook

1, pp. 431-4412, pp. 415-4193, p. 3254, p. 34744, pp. 186-19546, pp. 135-143

87


OBJECTIVES TOPICS

tr4.1%

set up and use all mountingtools and fixtures availablein lab.

88

4. Mounting tools andfixturesa. three-jaw chuckb. four-jaw chuck

(1) universal(2) independent

c. face platesd. lathe dogs

(1) bent-tail lathedog

(2) clamp typee. collet

(1) round

(2) square(3) hexagon

f. centers(1) live(2) dead

g. spindle chuckh. thread gaugei. dial-indicator gauge3. steady restk. following rest

5. Cutting toolsa. materials

(I) high-speed steel(2) cast alloys

(3) cemented carbide(4) ceramics(5) diamond

b. types of cutting toolsand tool holders(1) left-hand(2) right-hand(3) round-nose(4) left-hand facing

STUDFNT

Show proper use for setting upmounting fixtures.

List, define, or describe instudent notebook.

Set up for different directioncuts.

!LACHER ACTIVITIES

Demonstrate and explain thepurpose of each mountingfixture

See Appendix 2 for puzzleson machining.

Lecture, discussion

Show the different tools andholders available for youruse.

'RESOURCES

Bonk 1, pp. 449-456Book 2, pp. 421-429Book 3, pp. 444-449Book 4, pp. 350-353Book 44, pp. 202-218Book 46, pp. 145-168

look 1, pp. 441-449Book 2, pp. 430-434Book 3, p. 326Book 4, pp. 350-353Book 44, pp. 213-219Book 46, pp. 145-152

89

. _----,

OBJECTIVES TOPICS STUONT ACTTVTTTPS TPACHA ACTIVITIFS IIPSOURCFS

(5) right-hand facing(6) cut-off cool(7) threading(8) boring tool(9) inside threading

c. cutting-tool terms Identify parts of cutting tool Make d model of each cutting(1) cutting edge model. took out of 14" x 14" pine.

(a) side (Color code parts.)(b) end

(2) face

(3) flank(4) nose(5) relief

(a) side(b) end

(6) rake

(a) side(b) end

identify the different kindsof milling machines.

D. Milling Machines and MillingOperations

List and describe the types andkinds of milling machines in

Lecture, discussion,demonstration

Book 1, pp. 487-489Book 2, pp. 453-458

us 1. Types of machines student notebook. Book 3, p. 351Ok a. column and knee

bv bedBook 4, p. 372look 44, p. 108

2. Kinds of machinesa. vertical millb, horizontal millc. combination horizontal,

vertical

Show film on milling machinesif available in your area.

Book 46. p. 229

select the proper cutter forjob.

3. Typea of milling cuttersa. plain-milling cuttersb. side-milling cuttersc. angular-milling cutters

Mix cutters available up in a box;pick one out and identify.

Discuss the different typesof cutters and their uses.

Gok 1, pp. 485, 494,499

.00k 2, pp. 468-473ook 3. pp. 352-353

d. end mills ee Appendix 3 for milling .00k 4, pp. 361-363e. formed cuttersf. face-milling cuttersg. special cutters

safety. .00k 44, p. 319ok 46, p. 235

9091


OBJECTIVES TOPICS STIMPNT ACTIVIT 1S TFACHER ACTIVIlItis RESOIIRU-S

4. Cutter holding devices Set up the cutters on thea. colletsb. arbors

different holding devices.Book 2, p. 467Book 4, p. 376adjust the milling machine 5. Machine adjustments and

Show how all the adjustments Book 44. p 313for any type of cut ±.010. controlsa. knee elevationsb. table movements

and controls are used on themachine.

Book 46, p. 252

Book 1, p. 499(1) cross-feed hand-

wheelBook 2, pp. 458-459

(2) longitudinal-feed

controlc. spindle speed adjust-

mentd. feed adjustmente. feed direction

Book 46, p. 2326. Milling operationsa. cutting keywaysb. slotting

List, describe milling operationsin student notebook.

Lecture, discussion,demonstration Book 1, pp. 500-503

Book 2, pp. 478-489(A..4

c. facing

d. milling groovesDemonstrate all operationsfor which you have facilities,Book

Book 3, P. 4534, p. 378e. indexing or dividing

Book 44, pp. 337-378(1) sidesBook 46, p. 258(2) holes

f. straddle millingg. cutting gearsh. up millingi. down milling

describe the function of a E. Shapers and Shaping In student notebook, list and Discuss the use of the Book 1, pp. 482-484shaper if one is not available. 1. Kinds of shapersa. horizontal shapersb. vertical shapers

describe the parts, adjustments,and cuts for the shaper.

shaper. Book 2, pp. 490-495

Book 3. pp. 344-350look 4, p. 3662. Parts of shaper

a. baseb. tablec. ramd. tool head assembly

Book 44, p. 273

_ _

93

INC (Continue

OBJECTIVES TOPICS STUDENT ACTIVITIES TI.ACHER ACTIVITIES Rhshow how to make all machine 3. Machine adjustments

if available, demonstrateadjustments. a. tool slide positionb. horizontal table

movement

c. table elevationd. length of strokee. posirlon of strokef. cvcting speed

selectiong. feed adjustment

the different kinds ofadjustments.

See Appendix 4 for suggestedmachining projects.

set up shaper for each kind ofcut.

4. Special forged toolsa. round-nose toolb. side-cutting toolc. gooseneck tool (flat

cuts)5. Shaper cuts

a. vertical cutb. angular cut

c. horizontal cut

Student notebook

.

Lecture, discussion

Cm00 d. angular dovetail cut

F. Ultra Modern MachiningProcesses look 1, P.

look 2, pp.name three of the six modern 1. Electrical discharge Research to find more about modernBook 3, pp.machining processes machining (EDM) machining processes.Book 4, p.2. Electrochemical machiningBook 44, p.(ECM)Book 46, pp3. Electron beam machining

(EBH)4. Laser beam machining (LBH)5. Ultrasonic Machining (USH)6. Chemical Machining (Cl*()

C. Numerical Control and Automa-tion look 1, p.

ook 2, pp.1. Lathes

i:

3, pp.Milling machine3. Drilling machine Il 4,

ook 44, p.4. Combination machines Test No. 6, unit 9ook 46, p.

94

SOURCES

534

514-525361-366

416466

. 421-450

525

526-540409-4104354S6

341

95

UNIT X: MATERIAL TESTING 3 Hours

OBJECTIVESTOPICS


list several processes in non-destructive testing.

explain how several of theseprocesses work and their typi-cal applications.

tr$40

list several processes indestructive testing.

explain how several of theseprocesses work and theirtypical applications.

99

A. NondestructiveI. Magnetic particle2. Radiographic

a. x-rayb. gamma ray

3. Penetrant4, Ultrasonic

5. eddy current6. leak test7. hardness

a. Brinellb. Rockwellc. Vickersd. Shore scleroscol.e

8. Thermal and infrared9. Microwave

10. Strain sensinga. brittle coatingsb. photo-elastic coatingsc. resistance strain

gauges11. visual

B. Destructive Testing1. Free-bend test2. Root-, face, and side-

bend test3. Fatigue test4. Longitudinal-and trans-

verse-shear test5. Guided-bend test6. Fillet-weld break test7. Etching8. Impact test

a. izodb. charpy

c. nick-break test

STUDENTAELLITIES l',ACHER ACTIVIllks RESOURCES

Student notebook

Do magnetic particle testing.

Do penetrant testing (diesel oil).

Do leak test (balloon).

Do visual teats.

Do free-bend test (in vise).

Do fatigue tests (bending wire).

Lecture dircussion Book 1

Book 2, pp. 557-563Show radiograph examples. Book 3

Book 4, pp. 323-333

Explain principles ofultrasonics.

Explain hardness testing.

Construct guided-bend tester.

BEST COPY Avp.:

Book 46, p. 327Book 52, whole bookBook 36, pp. 71-95

97

UNIT XI: FINISHING 3 Hours

OBJECTIVES TOWS


list and explain the differentkinds of finishing.

list and describe differentapplication techniques.

O

finish a project using techni-ques described in lecture.

98

A. Kinds of Finishing1. Grinding2. Polishing3. Brushing4. SandingS. Buffing6. Burning7. Electroplating

B. Application Techniques1. Brushing2. Spraying

a. pressure feetb. suction feedc. electrostaticd. aerosole. flame

3. Powder fusion coating4. Dip or flow coatingS. Roller coating6. Tumbling

C. Protective Metal Finishes1. Primers2. Metal enamels3. Lacquers4. GalvanizingS. Tin coating6. Parkerizing

STUDFNUOILUT FS

List and define in student notebookthe kinds of finishing and techni-ques of application.

Experiment: take some scrap steeland prepare it vitt% different

methods (see A). Then finish asmall section of each withdifferent application techniquesusing as many finishes (see C) aspossible.

TEACH( It ACTlVl1 lI S

Lecture, discussion

Discuss the differentadvantages of the applicationtechniques.

See Appendix 2 for puzzleson finishing.

RFSOIIRCES

Book 1, p. 513Book 2, pp. 347-351Book 3, pp. 234-271Book 4, p. 441

Book 46, p. 395Book 53, whole book

99

UNIT XII: AUTOHATIO4 TECHNOLOGY 8 Hours

OBJECTIVES

The student should be able tu:

demonstrate a working know-ledge of the use of robotsin industry.

1111--

demonstrate knowledge of therole of the computer in

-automation.

0

A.

B.

TOPICS

Robotics1. Welding2. Parts manipulation3. Finishing4. Hazardous material

handling5. Quality control

Computers1. Computer numerical

control (CNC)2. Computer aided design

(CAD)3. Computer aided manufac-

ture (CAN)

IN^ 111/11 .11111111

STUDIINT ACTIV IT ThS TFACIIILACL LIES

Research

Test no. 7, Units 10, 11, 12

Obtain film/filmstrip.Hake handouts from appendix.Hake transparencies fromappendix.

Obtain working robot modelfrom Radio Shack.

Demonstrate computercapabilities.

Obtain permission of localindustry for field trip.

Obtain guest speaker.

See Appendix 5 for :.;terialon robotics.

BEST COPY AVAILAbiL

10

RO.SfRIR1F.S

Book 14, p. 499Book 38, articlesAppendix

Book 2, p. 520

Book 44, p. 492

OBJECTIVES TOPICS swum. ArTIVITIV TEACHER ACTIVillbS

The student should be able to: A. General Shop and Lab Safety Read, review safety handout.Make safety handout to in-clude all safety area.,

pass all safety tests givenby teacher.

S. Personal Safety

C. Tool and Equipment Safety

D. Housekeeping Practices

E. Sheetmetal Safety

F. Heat Treating Safety

G. Casting Safety

H. Oxy-fuel Processes Safety

I. Arc Welding Safety

Bo(cr%ty)

J. TIC and MIG SafetyI

K. Electrical Safety

L. General Machine Shop SafetySee all of Appendix 3 forsafety rules.M. Machine Operation Safety

1. Buffers2. Drill presses See Appendix 2 for puzzles on

safety.3. Grinders4. Milling machines5. Shapers6. Lathes

N. Fire Safety Test - safety

RESOURCES

k 70. Safetynual

103

APPENDIX 1

CLASS MA1/AGEMENT

63

104

SAMPLEGENERAL INFORMATION

SHEET

Mr. Angle Iron METALS TECHNOLOGYBEST euiq AVAILABLE

I. Expectation:::

A. Have a notebook and pencil in class each day.B. Have this general information sheet with you each day.C. Be in your seat ready to begin class when the tardy bell rings.D. Be respectful and listen when others are speaking.E. Bring an excuse for those days absent.

II. Materials for Metals courses:A. Notebook (100 page spiral)B. Pen or pencil every dayC. Finishing materials for projects (as required by project)D. Lab fee (if required for your course)

III. Grades are determined by the following:

A. Class participationB. Toots and quizzesC. Written uorlc, notebook, and projects

D. Attitude toward work and classroom rulesE. Work eone above ind beyond the basic requirementsF. Grading scale (Type in your own grading scale.)

IV. Classroom Ruled

The following of these rules is important to you as a student. Abiding by

the general el-I-broom rules will make your classroom experience more enjoyable,safer, and more rewarding.

1. Comply with the requests of the teacher.2. Bring your notebook and pencil to class every day.3. Do not rial:c smart remarks to the teacher.

4. Talking is not allowed:when the teacher is talking.when tests are being given.when another student is talking.luring an audiovisual presentation (film, filmstrips).

5. Lou may not leave the room without permission and a hall pass.6. be in vou- seat when the tardy bell finishes ringing or you will be marked

tardy.

7. Do not leave the room after class until you are dismissed.8. You must have an excuse for being late to class.9. Do not use obs,_ene language.

10. All school rules apply in the classroom-lab as well.

11. The shop office is off limits.12. All paper, trash, etc. must be picked up before class is dismissed.13. Do not _-toad in the doorway before class.

14. Do not play in shop, this is the most dangerous place in school.

15. If for any reason you are failing or falling behind, you must be responsibleto attack this problem in a systematic way.

A. Confer with your teacher and get his recommendations.

B. Report the matter to your parents promptly.16. Aceepc helpful criticism gracefully. Remember that your behavior reflects you.

MAKEUP TESTS: (Type your rules for giving makeups.)

64

105

PARENTAL PERMISSION SLIP

Metalsville High SchoolMetals LabMr. Angle Iron

Parents:

is enrolled in our industrial arts programand will have the opportunity to use various tools and equipment such as:

1. Lincoln arc welder 9. Portable sheet metal cutter2. TIG Welder 10. Gas Furnace3. MIG Welder 11. Gas Welders4. Pedestal grinder 12. Bar folder5. Drill Press 13. Shears6. Jig saw 14. Presses7. Portable power grinder 15. Brakes8. Portable drill 16. Roll formers

Appropriate instruction in the proper use of the tools and equipment is givenand close supervision is maintained. Every precaution is takento prevent accidents. We are asking your cooperation in impressing your childwith the impurtance of being careful. It is mandatory that all students acceptthe obligation to obey the safety rules designed to protect them and others.

You are welcome to visit our industrial arts facilities. please check throughthe main office.

has our/my permission to operate the equipment(student's name)

equipment in the metals laboratory at Metalsville High School. It is understoodthat instruction in its safe operation will be given before he/she is allowedto use any piece of equipment and that he/she will be properly supervised atall times.

In the case of an accident, it is preferred that he/she be given treatment by:

Dr:

:r Dr:

Our home phone number is:Our work phone number; is:

If neithel parent/guardian can be reached at the above numbers, please notify;

(responsible person)

Date:

Address:

at

Signed:

Student's birthday:

(telephone number)

(father/guardian)

(mother/guardian)Please advise me of any physical handicaps of medical problems which need tobe brought to my attention so that measures may be taken to ensure safe workingconditions for your child.

Thank you,

65

1 o6

SHOP FEE LETTER TO PARENTS

(example)

To: All Parents of Metals Students

From: Mr. Angle Iron, Metals InstructorMetalsville High School

Subject: Shop Fees for Metals Class

As stated in the Metalsville High Handbook, students enrolled in ind-

ustrial arts are required to pay shop fees.

In the industrial arts courses, Metals I and II, students are required

to pay for materials they use on projects that they are allowed to take home.

No set Lae is required from students in this Metals course, because the

students are required to construct two projects of their choice with the

approval of the teacher. The projects must meet the requirements of the

course. However, the students are required to pay for the materials used

or wasted in the construction of the project. The cost of the projects will

vary from project to project and from student to student.

The student will know the approximate cost of the project before he or

she begins the construction.

Thank you fet your cooperation.

Sincerely,

antiA le Iron

Metals Instructor

Parent's signature:

Principal

PLEASE RETURN THIS SHEET

66

107

Date:

actiniumaluminumamericiumantimonyarsenicbariumberkeliumberylliumbismuthcadmiumtalcium

tumceriumcesiumchromiumcobaltcoppercuriumdysprosiumeinsteiniumerbiumeuropiumfermiumfranciumgadoliniumgalliumgermaniumgoldhafniumholmiumindiumiridiumironlanthanumleadlithiumluteciummagnesiummanganesemendeleviummercury

LIST OF METALS

67

108

molybdenumneodymiumneptuniumnickelniobiumnobeliumosmiumpalladiumplatinumplutoniumpoloniumpotassiumpraseodymiumpromethiumprotactiniumradiumrheniumrhodiumrubidiumrutheniumsamariumscandiumsilversodiumstrontiumtantalumtechnetiumterbiumthalliumthoriumthulitu

tin

titaniumtungstenuraniumvanadiumytterbiumyttriumzinczirconium

Name of.Project

Student's Name

Grade Level

Course

BILL OF MATERIAL

Instructor's Approval

MATERIALS LIST

Date Started

Date Completed

Project Grade

Bill of Material Grade

PARTNO.

NO. OFPIECES

SIZE NAME OFPART

TYPE OFMATERIAL

UNITCOST

TOTALCOSTT" W" L"

TOTAL

68

109

PLAN OF PROCEDURE

STUDENT'S NAME

NAME OF PROJECT

TOOLS AND MACHINES REQUIRED

6.1.

2. 7.

3. 8.

4. 9.

5. 10.

OPERATIONS PERFORMED

2.

3.

4.

5.

6.

7.

8.

9.

10.

PLAN OF PROCEDURE

1.

2.

3.

4.

5.

6.

7.

8.

9.

10.

69

110.

SHOP JOBS

1. Shop Foreman

2. Sweeper

3. Tool cabinets 1 & 2

4. i.arge tables

5. Tool cabinets 3 & 4and goggle cabinet

6. Arc welding tables & welders


8. Sweeper

9. Soldering table

10. Gas welding tables & torches


12. Machines

13. Tables

14. Pick up with dust pan

1.,. Paint cabinet

16. Sweeper

17. Housekeeper

18. Issue and receive projects& housekeeper

19. Window closer

20. Hand tool cleaner

21. Machines

22. Foreman of all tool cabinets

control panels (locks cabinetat 7th period)

23. Sweeper

24. Cleans lathe

Everyone has a secondary job:That of the person above you when that person is absent.

70

111

SAFETY INSTRUCTIONRECORD

NAME:CLASS OR PERIOD:

INSTRUCTOR.

I UNDERSTAND THE SAFETY DEMONSTRATIONS GIVEN FOR THE OPERATIONSAND EQUIPMENT LISTED BELOW. I HAVE ALSO COMPLETED THE SAFETYTESTS THAT APPLY TO THE OPERATIONS AND EQUIPMENT LISTED.

MY SIGNATURE ON EACH OF THE LISTED ITEMS MEANS THAT I UNDERSTANDHOW TO PERFORM THESE OPERATIONS SAFELY AND I UNDERSTAND HOW TOUSE THE TOOLS AND EQUIPMENT SAFELY. MY SIGNATURE ALSO MEANS THATI AGREE TO USE ALL THE SAFETY PRECAUTIONS I HAVE LEARNED; I AGREE TOREPORT ANY UNSAFE CONDITIONS TO MY INSTRUCTOR; AND I WILL DISCUSSANYTHING I AM UNSURE ABOUT WITH MY INSTRUCTOR.

DESCRIPTION OF EQUIPMENTOR OPERATION DATE STUDENTS SIGNATURE

INSTRUCTOR'SINITIALS

1

2

3

4

5

6

7

8

9

10

11

12

13

14

15

16

17

18

19

20

21

21

23

24

71.SAFETY INSTRUCTION RECORD

112

FROM:

PARENT OR GUARDIAN NOTIFICATION

INSTRUCTOR:

CLASS:

School

SUBJECT: ACCIDENT PREVENTION

DATE:

STUDENT:

PERIOD:

This notice-is to inform you that has repeatedlydemonstrated an unwillingness to cooperate with the school's efforts tomaintain a safe environment for the students and the staff of this school.Although all students are instructed in the procedures necessary to assuretheir safety and the safety of those around them,has, on numerous occasions, chosen to ignore or violate these safety procedures.

If there is no improvement in attitude and in the level of cooperation, it maybecome necessary to restrict this student from further participation in classactivities and projects. The result may be a failing grade or dismissal fromthis class. If you wish to have a conference regarding this matter, pleaseso indicate below.

Please discuss this matter with , and sign thisnotice indicating that you, the parent or guardian, have read the notice andthat you accept full responsibility and liability in the event of personalinjury or property damage resulting from your son/daughter/ward's carelessness.

Parent/Guardian's Signature:

Date:

Yes, I would like to make an appointment to discuss this matter. Imay be reached at between the hours of

phone number

I have discussed this notice with my parent or guardian, and I understandclearly what it means.

Student's Signature:

Date:

Copies of this notice have been sent to the office of the principal.

PARENT NOTIFICATION FORM 72

113

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SOME OF TODAY'S INDUSTRIAL METALS

1. Aluminum - 1/3 weight of steel - 168 lbs./cubic foot, conductive,corrosive-resistant; used in aircraft alloys, wire, foil, andcooking utensils; melts at 1720° F.

2. Cadmium - Soft, bright, corrosive-resistant; used in solder, atomic-power control, and plating; melts at 1490° F; weight/cubic foot =540 lbd.

,3. Chromium - Bright, corrosive-resistant; used in stainless steelsand plating; melts at 2940° F; weight/cubic foot = 443 lbs.

4. Cobalt - Used as alloy element in tool steels; oxidation resistantat red heat; melts at 2696° F; weight/cubic foot = 555 lbs.

5. Copper - Second in conductility; ductile; used for electrical workand as alloying agent in bronze and brass; melts at 1981° F; weight/cubic foot = 558 lbs.

6. Gold - Most ductile and malleable; used in jewelry and coinage; meltsat 1945° F; weight/cubic foot = 1206 lbs.

7. Iron Most versatile structural metal; used in steel alloys; melts atat 2795° F; weight/cubic foot = 409 lbs.

8. Lead - Soft, toxic, high corrosion resistance; used in paints, radiationshields, gasoline, and alloys of copper and tin; melts at 622° F;weight/cubic foot = 708 lbs.

9. Magnesium - 1/3 lighter than aluminum; used in aluminum, zinc, andmanganese alloys and chemicals; melts at 1204° F; weight/cubicfoot = 1091 lbs.

10. Molybdenum - Most available high-temperature metal; used in steelalloys and high temperature forgings; melts at 4750° F; weight/

cubic foot = 636 lbs.

11. Nickel - Most versatile alloy metal, corrosive-resistant; used insteel alloys and for electroplating; metals at 2646° F; weight/cubic foot = 5551bs.

12. Platinum Highest resistance to corrosion; used in jewelry, alloys,electrical contacts, chemical equipment; melts at 3190° F; weight/cubic foot - 1333 lbs.

13. Radium - Radioactive; used in luminous paints and cancer treatments;melts at 1760° F; weight/cubic foot = 312 lbs.

74

1 115

14. Silicon - Most abundant metal, brittle, heat-, corrosion-resistant;used as ferro-silicon to add elasticity to steel and as high-

temperature coating for steel and molybdenum; melts at 2590° F;

weight/cubic foot = 151 lbs.

15. Silver - Highest thermoelectric conductivity; used in coinage,jewelry, silverware, alloys, and silver plating; melts at 1761° F;

weight/cubic foot = 645 lbs.

16. Sodium - Soft, highly reactive with air and water; used in aluminum-silicon alloys, liquid-metal heat exchangers in atomic power plants,and in making tetra-ethyl lead; melts at 208° F; weight/cubic foot =

61 lbs.

17. Tin - Bright, soft, corrosive-resistant; used in solders, bearings,

type metal, and plating; melts at 449* F; weight/cubic foot = 359 lbs.

18. Thorium - Radioactive, potential source of atomic energy; used to addstrength to magnesium and life to heat-resistant alloys; melts at3350° F; weight/cubic foot = 705 lbs.

19. Titanium - Lightweight, strong, corrosive-resistant; used in high-strength aluminum alloys, high temperature titanium carbides,nonstructural sheet in jet engine shells, ducting and fittings;melts at 3300° F; weight/cubic foot = 281 lbs.

20. Tungsten - Highest known melting point - 6100° F; used in steel alloys,lamp filaments, and plating; weight/cubic foot = 1204 lbs.

21. Uranium - Radioactive, fissionable, source of atomic energy; melts at

2071° F; weight/cubic foot = 1166 lbs.

22. Vanadium - Soft, corrosive-resistant; used to add toughness to tool and

die steels, shafts, springs, and bearings; melts at 3110° F, weight/

cubic foot = 372 lbs.

23. Zinc - Bluish-white, resist atmospheric corrosion; used in alloys of

aluminum, magnesium, and copper, as well as for dry batteries and gal-

vanizing; melts at 797° F; weight/cubic foot = 446 lbs.

75

116

INDUSTRIAL ARTS

i. Teacher Readiness

A successful first meeting with your students is important. The firstimpression of you as a teacher is a lingering impression. Most of thequalities that denote a good teacher will be required in handling yourfirst encounter with a new group of students.

The chief thing to be tested, however, will be your ability to foresee,and your skill to prepare for that which you have foreseen.

As a check upon your readiness to meet the class for the first time, thefollowing points may be of value:

1. Visualize the class as fully as possible, as to age, training,temperament, aptitudes, and the like. Previous records willas:qst here.

2. Be certain that equipment and tools are in perfect condition.

3. Have a definite plan for the work for the semester.

4. Have material on hand and ready for the first piece or piecesof work to be done.

S. Have a written lesson plan of procedure for the first class meeting.

6. Have the needed tools and other devices on hand for the firstlesson.

7. Be ready to assign students to working places and lockers.

8. Plan a definite method for getting acquainted with the class.

9. Prepare to be glad to see the students arrive and to let themknow it.

10. Have a definite plan for standards of order and discipline, andbe prepared to put this plan in operation from the start.

76

117

Techniques for Maintaining Interest

The following suggestions are offered for maintaining interest and

keeping it at a high pitch over a long period of time.

1. Call class together at the beginning of each period.

2. Dave a definitely planned small unit of instruction ready

for presentation for each class meeting before students go

to work.

3. Make each presentation different from that of the day before.

This can be brought about by difference in subject matter

or in manner of presentation.

4. Use a variety of teaching aids both for instruction and for

stimulating interest.

S. Draw upon popular magazines, motion pictures, newspapers,

school shop magazine, etc. for examples of application to

work which students are doing.

6. Rotate students' jobs in class maintenance at frequent

intervals.

7. Indicate or present difficult, but interesting, problems

for solutions by class, encouraging problem solving.

8. Use chalkboard sketches for stimulating interest.

9. Give recognition to students' effort. Do so often.

10. Keep a progress chart. Students like to see their degree

of progress indicated by marks.

II. Let students assist in solving problems rather than simply

telling them what to do.

12. Assign work so that each student can experience success.

13. Keep an atmosphere of joy and accomplishment in the class

at all times.

14. Make the work of the class progress as rapidly as

possible.

IS. Use questions freely to stimulate thinking and sustain

interest.

7") 118

COURSE EVALUATION

Purpose:

This evaluation is an effort by your instructor to ascertain his teachingeffectiveness and the usefulness of course materials. It is designed toprovide suggestions on how the course can b., improved and be made more relevantto students' needs. Your cooperation will be greatly appreciated.

oinstructions:

Below are a list of qualities dealing with the course and the instructor. Youare asked to evaluate these qualitites on a scale of four to one. Four is thehighest ranking, and one is the lowest ranking. Any commentsmay be included on the back of this sheet.

you

Highest

wish to

Rankings

add

Lowest

1. The class sessions and lectures were well organized. 4 3 2 1

2. The course textbook was very helpful. 4 3 2 1

4

3. The course was interesting and enjoyable. 4 3 2 1

4. The course material satisfied my educational needs. 43 2 1

S. The tests used in the course contributed to greaterlearning. 4 3 2 1

6. Material presented in the course was easy to learnand to apply. 4 3 2 1

-.. The instructor displayed a sense of professionalism

and dignity in the class. 4 3 2 1

S. The instructor seemed personable and genuinely in-terested in students. 4 3 2 1

9. The instructor has a thorough knowledge of his sub-ject matter. 4 3 2 1

10. The variety of presentation methods was good. 4 3 2 1

11. The instructor displayed a sense of humor. 4 3 2 1

12. The instructor was clear in his explanation ofcourse material and assignments. 4 3 2 1

13. The ir-tructor always seemed prepared for classmeetings. 4 3 2 1

14. The instructor was always well dressed. 4 3 2 1

15. The instructor provided for all students to parti-cipate. 4 3 2 1

16. The instructor was patient and resourceful. 4 3 2 1

78

11 9

APPENDIX 2

CROSSWORD AND WORD FIND PUZZLES

79

120

'EST COPY AVAILABLE

Crossword PuzzleMICHAEL R. KOZAK

ACROSSI Side :taunt6 Pra.r:cz! education (abbr.)

' 7 Alternating current tabbr.)9 _cal Nes

11 Nationol coarse tahhr )17:\____ss washer

Vational Inst.:ire Education (abbe16 Open- iorcichIs -- /au/:t.r Program of work (abbe )22. Wrolght23 Too'26 stockscrela28 High steelIfs Nri trille (WI )

35 Inside d.rnelee (abbe.)37 rise40 pitch gauge41 Finish a drilled hole

Notectne coating on steel and term44 3 141645 Chamfer a hole51 Go college52 Toothed wheel53 Compans tabby56 Goggles protect )our57 gauge59 Technical education (abbr.)60 Several tssist

DOWN1 Center

spanner wrench

3 ammoniac4 Indus:nal tahbr.)5 Chief ingredient in pewter6 Ball- --hammerS Oldest metal knossn to man9 All nght10 stock

14 Cast aeon abbe )15 Half, --Me17 Lasout19 chisi.121 Thin metal sheet or nb23 istahne24 Teaching assistant tahbr.)25 carbon steel27 Flat29 horstolay31 3o;ntng metals b) fusion33 Outside diameter tabbr.)34 School is36 Direct earrent (abbe.)37 gender38 Coldrolled iabhr.)39 treatment43 Wing44 Production industries (abbr.)46 Round chisel47 Natural abrasive48 High _steel49 Presents Nile) rotation50 Copperzin: alloy53 Double- __file54 Iron55 Socir.ty of Autornonse Engineers (abbe.)58 Dial indicator (abbe.)

80

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82

123

ACROSS

1. Intimate mixing ofmolten metalWeld deposit leftafter a weld pass

5. Type of inspectiondone with no equip-ment

8. Historical event thtaccelerated the develop-ment of .KG and TIG

10. Bottom of weld11. Welding nositioi*12. Type of joint13. Welding positiolt.15. Flow of electricity

through an air gap16. Depression at the toe

of a weld which is belowthe surface of the basemetal

19. Fusibility is the easewith which metal will

4.

aNERAL WELDING PUZZLE

20. Welding has two majorfunctions-fabricationand

21. To separate metal22. Type of weld used in

T-joints25. Direct current26. Used to mark layout

lines on metal27. Fuel, heat, and oxygen

produce28. Zn

30. Penetrant test (abbr.)31. Nondestructive testing

(abbr.)33. Electroslag welding (abbr.)34. Type of weld bead made with-

out transverse oscillation36. Alloy of tin and lead38. Nickel (symbol)40. Welding goggles protect these.41. Welding is a form of

resistant welding.43. Welding position45. Welding in a joint that

lacks fusion46. TIG47. Acetylene, propane and

Mapp

:48. Interchangeable heads of torchhtidlq_

49. Nonmetallic layer that forms onthe top,of a weld

51. Beveled opening provided between. two metals to be joined

12. Nonmetallic matter trapped insidethe weld

"4. Distance down from the surface ofmaptl to where fusion ceases

58. ihielded metal arc welding59. 'American Welding Society (abbr.)61. MIG62. Never used to lubricate regulators63. Used to ignite gas64. Mixture of iron and carbon

DOWN

1. Metals containing iron2. Weld that is not continuous3. Metal that does not contain iron4. A sequence of weld bead, one on top5. Welding position6. The of the tip is determined by t

diameter of the opening at the end.7. Liquid penetrant test (abbr.)8. Assembly whose parts are welded

together9. Opposition to electron flow14. Cubic feet __hour17. Not available (abbr.)18. Cross-sectional measure of rod21. Three forms of iron--steel, wrought,

and23. Cylinders are

area.

24. Depression at the end of the weld bead27. Iron (symbol)29. Where three sides of a piece of metal

meet30. Presence of voids in the metal or weld35. Act or condition of sticking together,

fusion36. Tin (symbol)37. Pieces of metal to weld together

for testing or practice39. Type of weld done in a hole40. Type of joint42. American Welding Society (abbr.)

in cross-sectiona

83 124

GENERAL WELDING PUZZLE (Continued)

DOWN

44. GTAW45. When not in use, the

cylin,!er valves.50. To soften metal53. Submerged arc welding (abbr.)54. Longitudinal progression of

a welding operation55. Type of temporary weld56. A bend is a type of

destructive testing.57. GMAW58. Stud welding (abbr.)60. Aluminum (symbol).

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2. TPF

3. Blanks, for gears are mounted on

a for turning and facing.

4. Knurling is done with a _tool.

5. The compound holds the tool post.

6. V-shaped tracks on the bed are called

7. Feeding the tool along the workpiece

is called feed.

11. Centers with bearings are called

centers.

17. The half lever is used for

thread cutting.

20. A cone pulley uses a belt.

23. The lathe is the long part

that rests on four legs.

25. Mount the tool bit with its cutting

edge line with the centers.

ACROSS

1. A taper may be used to

turn a taper.

4. A chuck tightens the

workpiece in a chuck.

8. The type of center thatdoes not turn.

9. Use a faceplate and awhen turning between centers.

10. To face-off a workpiece youfeed the tool bit.

12. The box transmits power to

the lead screw.

13. The of the lathe determines

the size.

14. Never leave the chuck in the

chuck.

15. Turning and are operations

performed on the lathe.

16. The bull-gear pulled out to

use the back gears.

18. A machine tool is used for

metal.

19. A chuck needs a draw bar.

21. Three jaw chuck.

22. The part of the lathe that has

set-over screws.

24. A tool cuts the rotating stock.

26. The apron is used for manual

movement of the carriage.

85 126

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MetalworkingWoodworkingDraftingAuto

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Power

EnergyWelding

Electronics

Electricity

AIASA

Printing

LIASA

Plumbing

Plastics

Painting

Graphics

Body

Shop

Air

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construction

CarpentryCabinetry

Aerospace

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OxidationInductionChromiumNickelVanadiumTungstenInertMolybdenumDuctilityBrittleElasticSocketDiameter

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HERE ARE THE WORDS TO LOOK FOR:

ACETYLENEBRASSCALIPERCHISELCOPPERDIEELECTRODEFORGEFREQUENCYGEARLATHE

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119

160

APPENDIX 3

SAFETY AND MACHINE PICTURES

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161

SAFETY INSTRUCTIONS COMMON TO ALL SHOP/LAB AREAS

Almost all accidents that occur in vocational education and indus-trial arts labs and shops are attributable to one of the causes listedbelow:

1. Taking unnecessary chances

2. Getting in too big a hurry

3. Showing off

4. Lack of information

5. Preoccupation

6. Distraction of attention

7. Fear

8. Experimenting

9. Failure to follow instructions

10. Poor discipline

11. Defective machinery

12. Improperly guarded machinery

13. Faulty layout

14. Faulty installation

15. Physical defects in material on machine parts

16. Excitement

17. Selfiihfless

18. Improper clothing

19. Poor health

Note that approximately 20 percent of all accidents are caused bymechanical failure (unsafe conditions), whereas approximately 80 percentof all accidents are caused by human failure (unsafe acts).

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The safety regulations that follow offer specific, tangible suggestionsfor avoiding these common pitfalls and reducing the chance of accidentand/or injury.

It is suggested that these safety instructions be used as examplesin writing instruction sheets for each school situation,or that thesesafety instruction sheets be copied directly and used in the instructionalprogram.

General Safety Instructions

I. No horseplaying or practical joking in any shop area.

2. Never take chances.

3. Observe all posted safety notices and posters.

4. Know where fire extinguishers are located and how to use them.

5. Ensure that the ventilation system is operating for your work stationor area.

6. Secure approval of your instructor on all work you plan to do. This

applies to all projects and assignments in which you use shop equip-ment and tools.

7. Report immediately to your instructor upon incurring any injury,even though slight.

8. Caution any person you see violating a safety rule.

9. Report to the instructor any equipment that does not seem to workproperly.

10. Keep tools and materials from projecting over the edge of benches,whenever possible, so someone will not walk into them and get injured.

11. Follow prescribed safety instructions in handling large, heavy, and

long pieces of material. In general, never carry material over sixfeet in length or over 50 pounds in weight without assistance.

12. Practice designated procedures to use in case of earthquake, fire,or other emergency.

13. Walk, do not run, in all shop-areas.

14. Be considerate of the safety of others.

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15. Adhere to safety rules pertinent to a specific shop.

16. Report unsafe conditions to the instructor.

17. Never throw any object in the shop; an accident or an injury may result.

18. Never use compressed air for other than specific purposes.

19. Make certain hands and tools are free of oil and grease.

20. Clean work stations avid place tools in the proper areas at the endof each class period.

21. Study fire regulations pertinent to the shop so that you can assistin closing windows, making proper exits, etc.

22. If you feel ill, do not operate a machine, Report to your instructor.

23. Use proper lifting techniques when moving heavy objects.

24. Never treat or remove particles from the eye. See your instructoror school health personnel for immediate attention.

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Safety Instructions for Personal Protection

1. Wear proper eye protection while participating in activities that

may endanger your eyes.

2. Be sure clothes are safe and suitable for shop work. Remove or fasten

any loose clothing. Roll loose sleeves above your elbows. Keep hair

away from equipment in operation. Students with long hair must

confine their hair in nets or caps when around tools and equipment.

3. Remove rings, bracelets,,watches, and other jewelry when working

in labs/shops.

4. Wear gloves when materials such as rough boards or metal which are

subject to burrs or sharp edges, glass, or other such materWs arehandled.

lk

5. Wear protective clothing and equipment for the use for which it is

intended. Avoid wearing gloves or anything else that may be pulled

into a machine.

6. Wear a respirator when harmful dust or fumes exist.

7. Use face shields during hazadous operations in cutting metal, wood,

or similar material.

8. Never use flammable liquids for cleaning purposes.

9. We rubberized protective equipment when working with electricity.

10. Wear ear protection when excessive noise is encountered.

11. Wear helmets and hand shields when performing operations that produce

intense radiant energy like arc welding and heavy gas cutting.

12. Wear canvas or heavy cotton work gloves for operations when the

main hazards are blisters caused by friction. When heat is

involved, as in foundry work, a more protective type of glove

or mitten should be worn.

13. Wear safety shoes with steel toes when lifting heavy objects or working

around them.

14. Wear shop coats, aprons, or coveralls for general body protection

against dirt and grease.

15. Remove ties when working around machine tools or rotating equipment.

16. Use soap and water frequently as a method of preventing skin disease.

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Safety Instructions for Use of Equipment and Tools

1. Use the right tool for the job.

2. Never leave a machine while it is running.

3. Observe rules governing operators' zones around tools and machines.

4. Use a brush or piece of wood to clear away dry chips from your machine

or bench. (The machine must be turned off and must have come to a complete

stop.)

5. Secure permission from your instructor for using machines and have special

set-ups approved.

6. Do not use tools or equipment until you have received instruction relativeto safe handling.

7. If you are not operating power tools or are observing the operationthereof, keep clear of operators.

8. Do not stop or start a machine for another person except in an emergency.

9. Operate machines one person at a time.

10. Do not use machines for trivial operations or when hand tools would best

accomplish the task.

11. Do not tamper with adjustments or play with machinery at any time.

Serious accidents may result.

12. Do not lean on machines. You may press a switch or throw a controlwhich, upon starting, could endanger the safety of the operator or

damage the machine.

13. Stop all power machinery to oil, adjust, or clean.

14. Allow revolving machinery to stop on its own. Resist the desire to

grab chucks, spindles, or other rotating parts with the hand.

15. Use power tools only when your instructor is present in the room.

16. Set up shields to stop flying chips, sparks, or particles.

17. Replace grinding wheels showing cracks, those out of balance, or those

worn too small to allow proper clearance (not more than 1/8") between the

tool rest and stone.

18. Keep cutting tools sharp.

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19. Never mount a grinding wheel unless the speed of the motor and thespeed of the wheel are known and the two are appropriate.

20. When starting a machine, allow it to reach its operating rpm before.using it.

21. When finished with a tool, clean and return it to its proper location.

22: Ensure that vise handles hang free when not in use.

23. Know and follow the specific requirements of the kind of machine youare operating.

24. Enclose all gears, moving belts, and other power transmission devices.or erect barricades to prevent contact.

25. Operate equipment only after passing a test for safe operation forthat machine.

26. Do not use defective tools, machines, or other equipment.

27. Do not remove guards and safety devices.

28. Observe specific safety zones designated by the instructor and becomefamiliar with color codes.

29. Do not talk with other students while operating machines.

30. Observe safety rules posted at or near potentially hazardous machines.

31. Do not operate any machine until you nave received proper instruction,and fully understand how to operate it.

32. Have your instructor check special machine setups.

33. Check machines and make all adjustments before turning on the power.

34. Make sure no one is in the way before turning on the power.

35. Be sure the guards are in place and function properly.

36. Start and stop your own machine and remain with it until it has

come to a complete stop.

37. Never leave a running machine unattended.

38.. Allow a safe distance between your hands and blades, cutters, or

moving parts. Keep your fingers in such a position that there is nodanger of their slipping into the cutter or moving parts.

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39. Keep machines clear of tools, stock, and other items.

40. Keep the floor around the tools free of liquids, scraps, tools, andother material.

41. Give the machine your undivided attention when using it. Never lookaway for any reason.

42. Notify your instructor of any breakage or malfunction.

43. Allow all machines to come to a complete stop before removing workor making a new setup.

44. Use the proper size and type of hand tool for the specific task.

45. Make sure that all cutting tools are sharp and in good condition before

using them.

46. Use the handles of edged or pointed tools, with sharp points or edgespointed away from you and others.

47. When using sharp-edged tools, be sure to direct their action away fromyourself and your classmates.

48. Clamp small work on a bench, or secure it in a vise, when using gougeor wood chisel or driving screws.

49. Control chisels, gouges, and carving tools with one hand while the other

supplies the power.

50. When chipping or cutting with a cold chisel, arrange your work so thatclassmates are protected from flying chips.

51. Pass tools to other persons with handles forward.

52. Carefully read instruction sheets before operating machines.

53. Avoid using wrenches that do not properly fit the nuts, bolts, orother objects.

54. Develop a respect for machine tools and understand their purpose.

55. Recognize the distinctive sound of a properly adjusted and smooth-running machine tool.

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Shop Housekeeping Practices

1. Keep your work station clean and orderly.

2. Keep passageways clear to allow easy movement while working and toallow for a rapid exit in case of an emergency.

3. Keep the floor clear of scraps and litter.

4. Keep bench and cabinet drawers and locker doors closed to avoidhazards while walking.

5. Wipe up any liquids spilled on the floor immediately; then applyoil-absorbing compound to the area.

6. Avoid storing or placing objects overhead, *xcept where adequate storagespace is provided.

Provide a nonskid surface for floors.

8. Sweep daily and periodically clean all shop/lab workareas.

9. Put stock away promptly after using it.

10. Ventilate shops properly. Serious disorders can be caused by uncon-trolled vapors, mists, gases, and fumes.

11. Keep shop areas neat and orderly in appearance at all times. Clutteredor dirty shops are good sites for accidents. Heat and orderly shopshelp eliminate unsafe working conditions.

12. Maintain proper light levels in shops and study areas. Sight is essen-tial for safety. Keep windows, light bulbs, reflectors, and wallsbright but without glare. Replace burned out bulbs at once.

13. 'lily remove all sawdust, shavings, metal cuttings, and other wastematerials.

14. Place 17,11 scrap stock in the designated containers.

15. Keep the classroom and.shop orderly and clean with all tools andmaterials in their proper place.

16. Do not throw anything on the floor. Put it in the trash can.

17. Keep all clean-up equipment in its proper place when not in use.

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SHEET METAL SAFETY

1. Sheet metal can cause serious cuts. Handle it with care. Wear steel re-inforced gloves when possible.

2. Treat every cut immediately, no matter how minor.3. Remove all burrs from the metal sheet before attempting further work on it.4. Use a brush to clean the work area. NEVER brush metal with your hands.5. Use tools that are sharp.6. Keep your hands clear of the blade on the squaring shears.7. A serious and painful foot injury will result if your foot is under the

foot pedal of the squaring shears when a cut is made.8. Do not run your hands over the surface of sheet metal that has just been

cut or drilled. Painful cuts can be inflicted by the burrs.9. Get help when cutting large pieces of sheet metal. Keep your helper well

clear of the shears when you are making the cut. .

10. Keep your hands and fingers clear of the rotating parts on forming machines.11. Place scrap pieces of sheet metal in the scrap box.12. Do not use tools that are not in first-class condition--hammer heds loose

on the handle, chisels with mushroomed heads, power tools with guards re-moved, etc.

13. Wear goggles when in the shop.

HEAT TREATING SAFETY

1. Heat treating involves metal heated to very high temperatures. Handle it

with the appropriate tools.2. Wear goggles and the proper protective clothing, i.e. gloves and apron, but

never an apron that is greasy or oil soaked.3. Never look at the flames in the furnace unless you are wearing tinted goggles.4. Do not try to light the furnace until you have been instructed in its operation.

If you are not sure how it should be done, ask for further instructions.5. Be sure the area is properly ventilated.6. DO NOT use potassium cyanide as a case-hardening medium.7. Do not stand over the quenching bath when immersing work.

CASTING SAFETY

1. Never pour a casting unless you are wearing protective clothing and goggles.2. Moisture and molten metal react violently. Under no condition should moist

or wet metal be added to molten metal.

3. Place hot castings where they will not cause accidental burns or fires.4. Keep the foundry area clean.

5. Be sure your safety clothing is in first-class condition.6. Do not talk with anyone while pouring a casting.7. Stand to one side of the mold as you pour, never directly in front of it.

Steam is generated during the pouring operation and may scald you. Molted

metal may spurt from the mold if it is too moist.8. Clamp or weight down molds of large castings to prevent the mold from

floating and permitting molten metal to escape from the mold at the parting

line.

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GENERAL SAFETY INSTRUCTIONS FOR OXYACETYLENE WELDING AND CUTTING

I. Operate only with your instructor's permission and after you have

received instruction.

2. Remove jewelry, eliminate loose clothing, and confine long hair.

3. Close the cylinder valve and replace the protective cover before moving

the cylinder.

4. Fasten cylinders with a chain or other suitable device as a protection

against falling or rolling.

5. Inspect all hoses before using.

6. Make sure that all hoses are properly connectrA and that all connections

are tight.

7. Report any leaking of the cylinders or the connections to the teacher

immediately.

8. Make sure that you have ample ventilation while welding.

0 Keep all flammable material away from welding area...

10. When preparing to weld, release the regulator pressure screw first;

then, open cylinder valves gradually.

11. Open the acetylene cylinder valve one and one-fourth turns or less.

Keep the wrench in place so that the valve may be shut off quickly,

if necessary.

12. Keep the acetylene pressure in the hose below 15 pounds per square inch.

13. Use a friction torch lighter to light the torch.

14. Close the acetylene valve first if the torch backfires.

15. Make certain the lighted torch always points away from yourself and

others.

16. Keep the sparks and the flame away from the cylinders.

17. Close the cylinder valves when you have finished your welding job.

18. Quenct the section of the metal that has been welded, or mark it with

chalk, or soapstone the word "hot" on the metal, if it is necessary

for you to leave your work.

19. Always use the proper eye protection, including the proper shade of

lenses when welding and cutting, or safety glasses or goggles when

chipping and grinding.

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171

20. Do not allow oil to come in contact with hoses or equipment.

21 Keep the cylinder caps on the bottles when not in use.

22 Confine all cutting and welding to the designated area in the shop.

23. Do not weld galvanized metal without the proper ventilation.

24. . Do not weld or cut on a closed container without your instructor'sapproval.

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GENERAL SAFETY INSTRUCTIONS FOR ELECTRIC ARC WELDING

1. Obtain permission from your instructor before using an electric welder.

2. Wear a hood with a proper observation window, treated gauntlet gloves,and treated leather apron. All assistants and observers must alsowear this equipment.

3. Wear rubber soled shoes, without tracks, when electric welding.

4. When operating the electric welder, allow no one to look at the arcwithout the dark shield.

5. Make sure electric welding is done only in a correctly constructedbooth or room, or behind proper screens.

6. Make sure there is ample ventilation while welding.

7. Keep all flammable material away from the work area.

8. See that the floor area is free of all obstructions.

5. Report to the instructor at once if the electrode holder, the holdercable connection, the cable terminals at the welding machine, the groundclamps, the lugs, or the cable get hot.

10. While removing the scale from the work, wear ordinary safety glassesor goggles.

11. Have a fire extinguisher handy when electric welding.

12. Hang up the electrode holder and turn off the welder when work is beingchanged or when work has been completed.

13. Keep your sleeves and pants' cuffs rolled down and your collar buttonedUp

14. Be sure that the tops of your shoes are covered while welding.

15. Keep the cable from contacting any hot metal.

16. Keep any electrode stubs off the floor. They could easily cause aslip or fall.

17. Avoid the inhalation of fumes while welding galvanized steel, phosphorbronze, and stainless steel.

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SAFETY INSTRUCTIONS FOR OPERATING THE TIG AND MIG WELDERS

I. Operate only with your instructor's permission and after you havereceived instruction.

2. Remove jewelry, eliminate loose clothing, and confine long hair.

3. Wear additional protective welding clothing, including a helmet, along-sleeved jacket, and gloves to prevent burns from ultravioletand infrared rays emitted while arc welding.

4. Ensure that the helmet used for TIG or M1G welding is equipped witha minimum number 12 density shade.

5. Be certain that the welder equipped with a high frequency stabilizingunit is installed, maintained, and used according to the recommenda-tions of both the manufacturer and the Federal Communications Commis-sion.

6. Never touch the tungsten electrode or MIG wire while the welder isturned on. It is electrically "hot" and can cause a serious shock.

7. Never use the high frequency when performing shield metal arc (stickelectrode) welding.

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136

177

Electrical Safety Instructions

1. Know where electrical circuit breakers are located for an emergencyshutoff.

2. Keep electrical boxes closed.

3. Ground all portable and stationary per tools.

4. Keep hoses and electrical corts from becoming tripping hazards.

5. Do not use electric drills or any other electrical apparatus while standingon wet floors.

6. Cords are to be disconnected when portable tools are not 111 use.

7.. Check for frayed electrical cords.

8. Disconnect electrical power equipment before oiling, cleaning, ormaking adjustnents.

9. Dc not use extension cords for permanent connections.

10. Ground all motors, fuse boxes, switch boxes, and other electricalequipment.

H. Assume that an electrical apparatus is "hot" nd treat it as such.

12. Use a test lamp or a suitable meter for testing a circuit.

13. Never turn on a switch unless you know what it operates.

14. Turn off per when replacing a fuse

15. Locate and correct the fault that caused the circuit breaker to openor the fuse to blow before turning on the power.

16. Se sure a circuit is protected against an overload by a fuse or circuitbreaker of correct circuit-carrying capacity.

17. Make changes in the wiring of a circuit only when the power is turned off.

18. Select and use wire orthe correct current-carrying capacity.

137

178

GENERAL SAFETY INSTRUCTIONS FOR THE MACHINE SHOP

1. Keep your work area free frori scraps of metal stock.

2. Keep metal cutting tools sharp.

3. Always put a handle on a file before you use it.

4. Grind mushroom heads and all burrs off cold chisels, center punches,

and other small hand tools.

5. Never try to hold a piece of metal in your hand while it is being

machined. Use a fixture or a clamp to hold the workpiece.

'. Wear appropriate gloves when handling hot metals.

7. Always wear eye protection. A sliver of metal in the eye can cause

blindness.

8. Put away tools and accessories. Clutter causes accidents.

9. Exercise caution when using portable hand tools, spot welders, electric

shears, and the like. (These tools operate on at least 110 volts of elec-

tricity. This charge can either kill or cause a serious shock or burns

under certain conditions.) Make sure that the power cords are in good

working condition and that plugs are not broken. Keep cords away

from oil and hot surfaces.

10. Be sure that your hands are dry before using an electrical power tool.

11. Never use measuring tools on metal while it is being machined.

12. Always keep machine guards iJ.place. They were put there for your

protection.

13. Operate a machine only after you have received instruction on its use.

Remember that you must know what you are doing before you start a machine.

14. Stop a machine before oiling it.

15. Never "feel" the surface of a metal while it is being machined.

16. Clean chips off with a brush, never with a rag cr your hand.

17. Never allow anyone to stand near a machine that you are operating.

18. Handle files carefully since they are brittle. They can shatter in

your hands. Always use a file with a handle.

138

19. Wear protective clothing when working with hot metals.

20. Wear a face mask when there is a danger of flying chips.

21. Wear goggles when grinding metals.

22. Do not attempt to oil, clean, adjust, or repair any machine while itis running. Stop the machine and lock the breaker box in the "off"position.

23. Get help for handling long or heavy pieces of material. Follow safelifting practices, lifting with your legs, not your back.

24. Do not talk to others when they are operating machines.

\

139

180

SAFETY INSTRUCTIONS FOR OPERATING THE DRILL PRESS

1. Wear proper eye protection.

2. Hold material securely with a vise or clamps.

3. Select a properly sharpened bit. For metal, center punch when a holeis to be drilled.

4. Adjust the table or the depth stop to avoid drilling into the table.

5. Select the correct speed, normally slower for metal faster for wood.The larger the bit, the slower the speed.

6. Be certain that the table and head of the drill press are secure.

7. Select the correct size and the kind of drill for the work. Be sureit is sharp.

8. Select the designated coolant for the drill press and apply it to thedrill point as needed. (No coolant is used when drilling wood.)

9. See that the belt guard is in place.

10. Remove the chuck key immediately after using it.

11. Keep hands away from the revolving spindle, chuck, drill, and chips.

12. Operate the feed handle so that the drill cuts evenly into the work.

13. Ease up on the feed pressure when the drill begins to break throughthe material.

14. Back the drill out as soon as the hole is drilled.

15. Allow the drill pr-ss to stop before attempting to remove the work,chips, or cuttings. Do not stop the revolving chuck with your hands.

16. Use a brush to remove the chips or the shavings.

17. Keep the floor clean around the-drill press.

18. Step away immediately if the work, comes loose and is caught in the drill.Shut off the power, if possible. Aithout endangering yourself.

140

181

lidifififigirr MOM

VARIABLE SPEED

PILOT WHEEL

SWITCH

DEPTH STOP

QUILL LOCK

QUILL

KEY CHUCK

TILTI 149 TILE

LOWER TABLE OR BASE

MOTOR

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SAFETY COLLAR

PILOT WHEEL FEED

OR FEED HiliIDLE

TILE L 0 cKinlqCLiMP

COLUMI'J

n."TILT ANGLELO di CLAMP

PRIM PZESS

141

182

SAFETY INSTRUCTIONS FOR OPERATING THE GRINDER

1. Obtain permission from the instructor before operating a grinder.

2. Wear proper clothing.

3. Wear a face shield, safety glasses, or goggles and use a glass safetyguard on a grinder.

4. See that the guard is in place.

5. Set tool rest 1/16" to 1/8" from the wheel.

6. Dress the wheel when necessary.

7. Make sure that no one except you is inside the operator's zone.

8. Adjust the grinder for your job before turning the power on.

9. Stand to one side of the wheel when turning the power on. The wheelmay be cracked, causing it to break up.

10. Turn on the power after permission is given.

11. Keep your hands away from the wheel while it is in motion.

12. Hold the work with your hands. Ask permission to grind small pieces.

13. Use only the face of the wheel.

14. Press materials against the wheel with the correct amount of pressure.

15. Keep the work in motion across the face of the wheel.

16. Do not grind on the side of the grinding wheels.

17. Stand to one side when starting the Machine.

18. Discard or report grinding wheils that are excessively small or cracked.

19. Hold small work pieces with a "vise grip" type of pliers.

20. Do not leave the machine until the grinding wheels have come to acomplete stop. .

142 183

firdiffifflille

SAFETY SHI ELO

gRUJONG WHEEL

WIER POT

MOTOR

SWITCH

PEDESTAL

orJUSTABLE SPARK

DEFLECTOR

WHEEL lUARO

ADJUSTABLE TOOL REST

OUST CHUTE

PEDESTAL fa/RIDER

143

134

SAFETY INSTRUCTIONS FOR OPERATING THE BUFFER

1. Obtain permission from your instructor before using the buffer.

2. Wear a face shield, safety glasses, or goggles.

3. Hold work with both hands.

4. Secure special instruction and permission from your instructor beforebuffing small pieces.


6. Turn on the power only after permission is given.

7. Apply the compound sparingly.

8. Keep your hands away from the wheel while it is in motion.

9. Hold the work below center (horizontal axis) as the wheel revolvestoward you.

10. Buff the flat surfaces from the center toward the lower edge. Sharpedges should point downward.

11. Press the material against the wheel with the correct amount of pressure.

12. Turn off the power after using the buffer.

13. Clean the buffer and the area with a brush.

144

185

SAFETY INSTRUCTIONS FOR OPERATING THE MILLING MACHINE

1. Obtain permission from the instructor before using the milling machine.


3. Make adjustments or set up only when the machine is at a dead stop.

4. Use correct fitting wrenches on machine parts.

5. Handle all cutters carefully.

6. Use only a soft hammer or mallet to seat work against the parallelsor the bottom of the vise.

7. Select the proper cutter. Be sure it is sharp.

8. Be sure the job is securely fastened.

9. Make certain that the work, milling machine table, and any holding devicewill clear the arbor and support during the cut.

10. Set the machine for the proper depth of cut.

11. Disengage handles when the automatic feed is to be used or the tableis to be locked.

12. Select the correct feed.


14. Stand to one side of the machine.


16. Be sure that the cutter is turning in the proper direction.

17. Feed against, or opposite co, the direction of the rotation of the cutter.

18. Use a brush to remove chips from work when the machine is at rest.

19. Keep the floor clean around the machine.

20. Turn off the power after using the milling machine and remain there untilthe machine has stopped.

21. Release all of the automatic feeds.

22. Clean the machine and the area with a brush.

145

186

23. Be sure the cutter is tightly held in the collst and the material issecurely held by a vise, clamps, or magnetic chuck.

24. Check the spindle rotation, speed, depth of cut and all power feedadjustments before starting the cut.

25. Keep your hands away from the cutter. Remove the chips with a brushafter the machine is turned off.

26. Once a cutting pass is made, do not back out or return to the startingposition without proper clearance.

27. Do not climb cut without specific permission.

28. Check the depth and the width of the cut, the cutter rotation, plusthe speed of the cutter and the power feed before starting the machine.

.29. Never clear chips away while the machine is in operation. Keep yourhands away from the chips and the point of operation.

146

187

p.3,ETRAVERSE

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KAIEE ELEVIVdg SCREW

OPERATOR CONTROL Pilo

Va2711CAZ f,MINE MACHINE

BEST COPY AVAILABLE148

189

SAFETY INSTRUCTIONS FOR OPERATING A METALWORKING SHAPER

1. Obtain permission from your instructor before using the shaper.

2. Protect your eyes with a face shield, safety glasses, or goggles.

3. Be sure fences and guards are fastened tightly in place.

4. Make adjustments or set up only when the machine is at a dead stop.

5. Use a soft hammer or a mallet to set work on the parallels.

6. Secure work firmly in the machine.

7. Select the proper tool for the job.

8. Set the machine for the proper depth of cut.

9. Be sure that ram and head will clear your work and any holding device.

10. Use the proper file to remove sharp burrs and corners to prevent fingersfrom being cut.

II. Make sure that no one except you is inside the operator's zone.

12. Check to see that the 'ever is in a neutral position before startingthe motor.

13. Stand to one side of the machine.


15. Keep your hands away from the cutting tool and the line of travel ofall moving parts.

16. Turn off the power after using the shaper and stand by until the machinehas stopped.

17. Clean the machine and the area with a brush.

18. Make sure all guards are secure before starting the machine.

19. Do not lay either the tools or tooling on any part of the machine.

20. Never remove chips while the machine is in motion.

149

190

FEED SCREW

AdD CRAIIK

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TOOL LIFTER

TOCL POST

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150 BEST COPY AVAILABLE

191

SAFETY RULES TO BE OBSERVED WHILE OPERATING THE MACHINE LATHE

1. Obtain permission from the instructor before operating the lathe.

2. Wear proper clothing.


4. Clamp the tailstock and adjust the tool rest before starting the lathe.Be sure the chuck key is removed.

5. Turn the lathe by hand while putting on or removing a face plate or chuck.Power is never to be used.

6. Make any adjustment of the cutting tool or measurements on the workwhen the lathe is not running.

7. Remove chips from the work and from the machine with a brush. Fingersshould never be used.

3. Always keep your left arm and body a safe distance from the lathe dog.

9. Never reverse the lathe until it has fully stopped.

10. Remove the tool bit from the holder when taking work from the latheor changing chucks.

11. if you are in doubt about what to do, ask the instructor.

151

192

APPENDIX 4

SUGGESTED PROJECT LISTINGS

152

1.93

SHEET METAL PF1JECTS

Book Number Page NumberTHREE DRAWER TOOL BOX 64 224 - 226

CONTEMPORARY CHANDELIER 66 75

BARN SHAPED MAILBOX 66 88 - 89PORTABLE BARBECUE GRILL 66 52 - 54EARLY AMERICAN MAIL BOX 66 22

TANK WITH WIRED EDGE 12 178

RECTANGULAR DUCTELBOW 12 179

ROUND TEE 12 190

THREE-PIECE ELBOW 12 192 - 194ROUND FITTING BY TRIANGULATION 12 205 - 208PAPER PAD 3 434PATIO LAMP 68 7

HUNTER'S SEAT AND SHELLBOX 3 440BUCKET 12 265FUNNEL 12 266 - 267

WASTE BASKET 12 268 - 271TOOL BOX 12 273 - 275BOX WITH SLIDING TOP 12 279PATIO LAMP 3 437

CHARCOAL SCOOP 65 44COFFEE SERVER 65 36

PATIO DUST PAN 65 26

153

194

CASTING PROJECTS

Book Number Page Number

GOBLET 64 161 - 166DESK PEN BASE 2 580

DOOR KNOCKER 67 81 - 82CASTMASTERS . 67 65 - 68DOORKNOCKER 65 71

BOOKENDS 65 55

NAMEPLATE 65 52

154

195

WELDING PROJECTS


BAC CART 68 26 -27

PORTABLE GRILL 68 30 - 31

HOSE CART 68 20 - 21

TABLE LAMP 68 4

BASKETBALL GOAL 69 222 - 223

UTILITY TRAILER 69 234 - 235

NATURAL GAS BARBEQUE 69 106 - 107

CAS, WOOD, AND SMOKER BARBECUE 69 120 - 124

HAND TRUCK 65 38

UTILITY TRAILER 69 264 - 265

CAR RAMPS 69 200 - 201

OXYACETYLENE CUTTING AND

WELDING TABLE69 204 - 205

TWO-WHEEL UTILITY TRAILER 68 12 - 13 sec. II

WELDING TABLE 68 2 - 3 sec. II

155

196

MACHINING PROJECTS


CAMERA TRIPOD 64 211 - 213

CANDLESTICKS 64 181 - 189

HAMMER HEAD 63 10

PEEN HANDLE 63 12

PARALLEL CLAMP 63 22

TAP WRENCH 63 40 - 42

SURFACE GAUGE 63 60,- 64

DRILL PRESS VISE 65 28 - 29

CHAIN BREAKER 64 220 - 222

ADJUSTABLE SQUARE 4 283

SOLID SQUARE 4 282

SCRIBER 4 283

MEAT TENDERIZER 4 490

PHONE FINGER 65 75

CONTEMPORARY CANDLESTICKS 65 67

PUNCH HAMMER 65 63

MUG 65 59

PICTURE FRAME CLAMP 65 54

GAVEL PAPERWEIGHT 65 41

TWO PIECE VISE 65 18 - 19

BUFFING HEAD 65 12

SERVING TRAY 65 6

156 197

APPENDIX 5

RESOURCES: FILM, COMPUTERPERIODICALS, ROBOTICS

157

198

RESOURCES FOR FILMS

Modern Talking Picture Service5000 Park Street NorthSt. Petersburg, Florida 33709813/541-5763

149

RESOURCES OF MANUFACTURING

CNC - Robotics - CAD - Computers

1. Brodhead-Garrett1-800-841-4967

2. EMCO-Lux CorporationP. O. Box 078242050 Fairwood AvenueColumbus, Ohio 43207

3. Technovate, Inc.910 S. W. 12 AvenuePompano Beach, Florida

305/946-4470

4. Cincinnati MilacronIndustrial Robot Division215 S. West StreetLebanon, Ohio 45036

5. Bridge Port Machines500 Lindley StreetBridgeport, Connecticut 06606

205/367-3651

6. Paxton-Patterson5719 West 65th StreetChicago, Illinois 60638

1-800-323-8484

"92:70

COMPUTER SOFTWARE

1. AbraxasP. 0. Box 1416Eugene, Oregon 97449503/485-6747

2. MIND

Statewide Teaching AidsP. 0. Box 8241Alexandria, Louisiana 71360318/445-2572

3. Career Aids, Inc.

8959 Lurline Avenue, Dept. MChatsworth, California 91311818/341-8200

4. Goodheart-Willcox Company123 W. Taft DriveSouth Holland, Illinois 604731-800-323-0440

5. Apple-Swap607 Sycamore

Starkville, Mississippi 39759

6. MECC SoftwareState Department of EducationBaton Rouge, Louisiana

7. CENLA Professional Development CenterDr. Bob GillanPDC, TEC - Northwestern State UniversityNatchitoches, Louisiana 71497

318/357-4182

160201

COMPUTER PERIODICALS

Classroom Computer News51 Spring StreetV.tertown, MA 02172

Educational ComputerP. O. Box 535Cupertino, CA 95015

Electronic Learning902 Sylvan AvenueEnglewood Cliffs, NJ 07632

School Microware ReviewsDresden AssociatesP. O. Box 246Dresden, ME

The Computing TeacherDepartment of Computer & Information ServicesUniversity of OregonEugene, OR 97403

Electronic Educatioii

Electronic CommunicationsSuite 220, Executive Center DriveTallahassee, FL 32301

School Microware DirectoryDresden AssociatesP. O. Box 246Dresden, ME 04342

T.H.E. JournalInformation SynergyP. O. Box 992Acton, MA 01720

Robotics Age174 Concord StreetPeterborough, NH 03458603/924-7136

1612 :2

*APPLE-SWAP*

INFORMATIrM SHEET

APPLE-SWAP (Software With A Purpose) Is an international software clearinghouse foreducational programs developed on and for the Apple microcomputer The stated objectiveis to assist teachers, administrators, parents, but most importantly, students in the,advancement of facilitative learning experiences with the Apple It was founded in 1980by Dr Dan Brook. Associate Professor and Assistant Department Head of the VocationalEducation and Technology Department at MissistAppi State University, and lit LarryAlderson. former industrial arts teacher, middle school principal, and now instructor inthe VED Department with Dr Brook We hope that newly of the advantages gained as a resultof using APPLE-SWAP will be carried over into the entire school environment

The clearinghouse was originally designed for Industrial Arts teachers, but later .'asexpanded to serve all Vocational Education. However, as the requests kept coming fromother areas, we decided to make it cover all facets of education. Ve are here to serveanyone who wants help -- and at a VERY reasonable cost!!!

We have set forth some rules governing our software exchange library The first time youuse the library, you should send 2 disks and :2. One of your disks should be blank. Itwill be kept here to help the library expand. The other disk should have your contributedpublic domain programs on it If you don't have any programs to send in the first time,we will be expecting you to contribute later. We will take your programs off, place the*into the library, then copy the volumes you requested on your disks and return it to youOn the first exchange, we always send our Introductory Disk (Vol. 10) on the front side ofyour disk. but we will copy the volume of your choice on the back of the disk Ve willcopy entire disk volumes, not individual programs,

Each time after your first exchange, you will send $1 per disk side you want copied. Forexpmple. 1 side and :1, 2 sides and $2, 3 sides and $3, etc. Please remember that we willcopy two volumes per disk. so request two volumes from the library list for each disketteyou send The library list is available for a fee of $1 which covers duplication costs.Updates to the original list will be made available periodically Ve feel that it is a

good Idea to share APPLE-SWAP programs with other teachers in your locality.

Some of you have asked, "Can we request the entire library at one time?" The answer is,"Yes "

We trust that this information has been helpful in explaining our position and our workwith APPLE-SWAP If we can be of service, don't hesitate to let us know.

*APPLE -SWAP*

607 SycamoreStarkville, HS 39759

162()

Dr. Dan Brook 323-7000 (Home)

325-2281 (Work)

Mr Larry Anderson 324-0677 (Home)

325 -2281 (Work)

BEST COPY AVAILABLE

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410 MUM*sTAALVILLt. NS 37711

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(FLOPPY) ELECTRONIC MAGAZINES

The publishers of Softdisk Magazette*(Apple Format) and MAG-80 (TRS-80 III or IVFormat) have authorized me to share a single

issue of their ele^tronic magazine with our

schools. Mail 2 disks for the Softdisk orcue for the MAG-80 to the PDC for yourcopies of these outstanding educationalbuys.

Subscriber, info:Softdisk, 3811 St. Vincent, Dept. 511,

Shreveport, La. 71108 (12 issues - $55.00)MAG-80, Dept. B., P.0 Box 8470, Bossier

City, La. 71113 (12 issues - $90.00)

*********************************************

P_UBLIC DOMAIN SOFTWARE AVAILABLE

Our Apple Compatible library continues to

grow providing us with more software to share

with you. Below is a general listing of the

140+ disks available:Education - 40

Graphics - 6

Utilities - 10

Business & Stat - 16

Home & Hobby - 4

Novelties - 4

Games--Misc. - 13/Fantasy/Adv. - 21

Electronic Magazines/Club Disks - 26

We have ten TRS-80 III & IV disks and

really need contribution in this area.

Send your disks (including any public

domain programs that you have) to the PDC

and specify your interest based on the above

categories.**Commodore support is planned for spring/

swamer.*********************************************

COMPUTER lilli

"Tender Loving Computers" is a free film

for educators to use to inform teachers andparents how children are preparing to live

in a computerized world.Write: Mattel Toys.

5150 Rosecrans Ave.,Hawthorne, CA. 90250.

sorirbm-i-

the FREELOADER is published by the

Met; PRDFESSICINAL DEVELoPmEur CEMER.

Direct any inquiries to Dr. &.b Gillan,

PDC, TEC-NEU, Natchitoches, La. 71497.

318/357-4182

cuRRIcaminanNational Diffusion Network is a publica-

tion that lists 16 validated projects fromaround the country. Copies of the publica-tion may be obtained by calling or writing:

Mr. Martin McConnell, Project DirectorNDN State FacilitatorCollege of Education/BERS2046 Terrace Ave.University of TennesseeKnoxville, Tn. 37996615/974-4165

********.***********************************

RESOURCE GUIDE

A resource guide containing suggestionson hardware purchase planning, softwareselections, and a list of administrativesoftware packages is available from theFlorida Department of Education. To obtainthis guide, write or call:

Chase W. CrawfordManagement Systems & ServicesFlorida State Department of ' ducation

Tallahassee, FL. 32301904/487 -22d0

********************************************

TEACHING TIPS

J.L. Hammett Microcomputer Division has aCurriculum Idea Sheet on using particularsoftware packages in the classrooth. Copies

may be requested from:Curriculum Idea Sheet

Microcomputer DivisionJ.L. Hammett Co.Box 545Braintree,MA. 02184

*********************************************

COMPUTER CLUB KITS.

Apple Computer Kits for elementary andsecondary levels are available through re-quest of the principal on school letterhead,name of sponsor is requireo. Write to:Apple romputer Club, Box 94d, Lowell, MA.

_01b53__ _

PERIODICALS FOR METALS INSTRUCTORS

Send for your subscription to the following:

Machinery, 200 Madison Ave.; New York, NY 10016

Industrial Arts & Voc. Ed., 866 3rd Ave., New York, NY 10022

Industrial Teacher, 1201 16th North West, Washington, D.C. 20036

Industrial Design, P. 0. Box 2153, Radnor, PA 19089

Machine Tool Blue Book, Hitchcock Pub. Co., Wheaton, IL 60187

Industrial Finishing, Hitchcock Pub. Co., Wheaton, IL 60187

School Shop, B:,x 8623, Ann Arbor, MI 48107

Stabilizer, Lincoln Electric Co., 22787 St. Clair Ave., Cleveland OH 44117

The Home Shop Machinist, Vollage Press, Inc., P. 0. Box 968, Traverse City, MI49684

207165

BIBLIOGRAPHY

1. Graham, Gregory S. Metalworking: An Introduction. Boston:Breton Publishers, 1981.'

2. Repp, Victor; McCarthy, Willard J. and Aswald, A. Ludwig. MetalworkTechnology and Practice. Bloomington, Illinois: McKnight andMcKnight Publishing Company, 1982.

3b. Workbook.

4. Johnson, Harold V. Technical Metals. Peoria, Illinois: BennettPublishing Company, 1981.

4b. Workbook.

5. Feirer, Jonn L. and Lindbeck, John R. Metalwork S I Metric Edition.Peoria, Illinois: Bennett Publishing Company, 1979.

5b. Workbook.

6. Miller, Rex and Morrisey, Thomas J. Metal Technokm. Indianapolis,Indiana: Howard W. Sams and Company, 1975.

7. Walker, John R. Modern Metalworking. South Holland, Illinois: Goodheart-Willcox Company, 1981.

7b. Workbook.

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9. Traister, John E. Basic Blueprint Reading for Practical Applications:Blue Ridge Summit, Pennsylvania: TAB Books Inc., 1983.

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29. Griffin, Ivan H.; Roden, Edward M.; and Briggs, Charles W. Basic Art

Welding. Albany, New York: Delmar Publishers, 1977.

30. Sellon, William A. and Matthews, John. Arc Welding. Cleveland, Ohio:James F. Lincoln Arc Welding Foundation, 1977.

31. Griffin, Ivan H.; Roden, Dr. Edward M.; and Briggs, Charles W. Welding

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32. Carr, Richard H. and O'Con, Robert L. Welding Practices and Procedures.Englewood Cliffs, New Jersey: Prentice-Hall, Inc., 1983.

33. Giachino, J. W.; Weeks, W.; and Johnson, G. S. Welding Technology.Chicago; American Technical Society, 1973.

34. Smith, Dave. Welding Skills and Technology.. New York: McGraw-HillBook Company, 1984.

35. Sacks, Raymond J. Welding: Principles and Practices. Peoria, Illinois:Chas. A. Bennett Publishing Company, 1981.

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37. Sarapin, Marvin I. and Post, Paul E. Computer Programs for IndustrialArts and Technology Education. South Holland, Illinis: Goodheart-Willcox Company, 1984.

38. Robotics Age. Vol. 6, No. 6, Peterborough, New Hampshire, 1984.

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40. Pales, James; Sheets, EverEtt; Mervich, Gregg; and Dinan, John. Manufacturing:a Basic Text for Industrial Arts. Bloomington, Illinois: McKnightPublishing Company, 1980.


41. Wright, R. Thomas and Jensen, Thomas R. Manufacturing Material Processing,Management, Careers. South Holland, Illinois: Goodheart-WillcoxCompany, 1976.

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43. Burghardt, Henry D; Axelrod, Aaron; andOperation. New York: McGraw-Hill B

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49. Cambridge Basic Skills Company. Basic Engine Lathe. New York: A

New York Times Company, 1979.

50. Cambridge Basic Skills Company. Intermediate Engine Lathe. New York:


51. Cambridge Basic Skills Company. Milling and Tool Sharpening. New York:


52. Southwest Research Institute. Nondestructive Testing. Washington, D. C.:

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53. Soderberg, George A. Finishing Technology. Bloomington, Illinois:

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Gulf Publishing Company, 1967.

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Theodore Audel and Company, 1972.

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60. D'Arcangelo, Bartholomew; D'Arcangelo, Benedict; and Guest, J. Russell.

Mathematics for Plumbers and Pipe Fitters. Albany, New York: Delmar

Publishers, Inc., 1982.

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62. Ruley, M. J. Practical Metal Projects. Bloomington, Illinois: McKnight

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63. Knight, Roy E. Machine Sho' Pro ects for Trade, Vocational, and Hi ;h

School Shops. Bloomington, Illinois: McKnight and McKnight Publishing

Company, 1943.

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66. Fifer, Bill. Metal Projects Book 2. South Holland, Illinois: Goodheart-

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67. Daniele, Joseph William. Early American Metal Projects. Bloomington,

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170

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DOCUMENT RESUME ED 261 259 CE 042 506 · Unit VI Metallurgy and Heat Treating. 37. Unit VII Casting...

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Transcript of DOCUMENT RESUME ED 261 259 CE 042 506 · Unit VI Metallurgy and Heat Treating. 37. Unit VII Casting...