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| MFRG160 syllabus
|COURSE NUMBER: ||MFRG160|
|COURSE TITLE:||Machining I|
|IAI CODE(S):|| MTM 921|
|SEMESTER CREDIT HOURS:||3|
|STUDENT ENGAGEMENT HOURS:||135|
This course is an introduction to machine tools and processes associated with the machine trade. Students are taught the fundamentals of shop safety, the use of metal hand tool, bench and layout work and the skills needed for the preparation for metal removal processes. Machine shop measurements using precision measuring devices are stressed in the course.
STUDENT LEARNING OUTCOMES:
Upon completion of this course, students will be able to:
- Applying the Machinery’s Handbook: The machinist must be able to reference and apply information found in the handbook to solve application problems. Referencing thread percentage, finish symbols, and allowances are some of the skills required.
- Basic Mathematics: The exam will assess basic math knowledge of fraction/decimal conversion, addition and subtraction of decimals, and an understanding of percent.
Industrial Safety: The machinist must become familiar with Hazmat, MSDS, basic personal protective equipment (PPE), and machine tool safety. Student assessment includes identification of a government body that regulates industrial safety – Occupational Safety and Health Administration (OSHA).
- Maintenance: Student assessment includes elementary knowledge of referencing and researching maintenance procedures, hand tool maintenance and safety, and simple tool maintenance.
- Process Adjustment: The exam presents basic problems of machining processes such as tapping, threading, drilling, milling, reaming, and grinding in which a process adjustment functions as the corrective action. Students must identify a basic goal of process improvement.
- Quality Control Procedures: The exam will evaluate knowledge of basic concepts of SPC and sampling plans. Basic knowledge of inspection plans includes rationale, criteria for choosing the correct measuring instrument, and organization. The evaluation includes basic knowledge of inspection setups and measuring instruments.
- Drill Press Components: Proper operation of a drill press depends on
knowledge of drill press components and their functions. Identification
of the spindle, base, table, column, variable speed control and feed
handle are essential for safe and effective use of this machine tool.
Other essential components are the table lock, column lock, motor and
- Process Improvement: An important part of any process
improvement is an understanding of the symptoms and causes of
some common problems associated with drilling operations.
Understanding root causes of drill breakage, excessive wear, enlarged
diameters and excessive RPM enable the machinist to analyze the
process and make the correct improvement.
- Twist Drill Nomenclature and Sizing: Each twist drill is comprised of
many separate features. Identifying the web and understanding web
thickness enables machinist to recognize the effects of excessive web
thickness. Knowing the purpose and location of the margin facilitates
proper drill diameter measurement as well as the effect of worn margin
near the point of the drill. All general-purpose drills have the same
identical point angle. The included point angle of a drill will vary
dependent on the application and the material being machined.
- Safety Practices: Proper safety procedures insure safe and
productive machining. Safety includes safe lifting procedures, hair
containment, jewelry removal and loose clothing containment. Drill
press safety includes the proper location of the vise, storage of the
chuck key and chip removal. Safety awareness should be apparent at
all times evident through the correct application of speeds and feeds.
Countersinking, Counterboring, Spotfacing and Center Drilling:
Spotfacing, countersinking and counterboring are drilling procedures
used to seat screws and bolts with special head configurations or to
seat a fastener or washer evenly on a rough surface. Center drilling is
an important procedure for accurate hole location as well as shaft
preparation for turning between centers. The specific drilling
operations have speeds and feeds that are proportionally slower than
drilling with general-purpose twist drills.
- Layout and Inspection: Choosing the correct measuring instrument
is primarily dependent on the tolerance range of the specific
dimension. Proper setup and correct measuring procedures for each
measuring device is imperative. The machinist must also know when
and where to apply semi-precision and precision layout. Selection and
application of proper layout tools and setups is essential in any
- Tapping: The drill diameter used to create a hole for internal
threading will dictate the thread percentage or amount of engagement
between two mating threaded components. Most tap drill charts for
conventional thread forms are based on 70% – 75% engagement.
Pipe taps used for some pneumatic and fluid connects have tap drills
based on other parameters. With the proper equipment, tapping can
be performed under power if the drill press is capable of reversing the
- Work Holding: The work piece must be held securely to prevent part
pullout from the work holding device. The equipment used for work
holding parts is dependent upon the shape and size of the part being
drilled. Proper location of the vise may prevent the vise from whipping
around if the drill gets jammed in the part. Proper selection of work
holding devices is imperative for safe and accurate application of a drill
TEXTBOOK / SPECIAL MATERIALS:
- Shop Safety
- Hand Tools
- Measurement Tools
- Speeds and Feeds
6" pocket rule, safety glasses, shop towels, calculator, note pad, and pencil
Precision Machining Technology, 2nd edition (ISBN: 9781285444543)
See bookstore website for current book(s) at https://www.dacc.edu/bookstoreEVALUATION:
Student will be evaluated on the following:
Work Projects 40%
Homework & Exams 20%
Final Exam 20%
Lab Safety & Work Ethics 20%
|STUDENT CONDUCT CODE:||Membership in the DACC community brings both rights and responsibility. As a student at DACC, you are expected to exhibit conduct compatible with the educational mission of the College. Academic dishonesty, including but not limited to, cheating and plagiarism, is not tolerated. A DACC student is also required to abide by the acceptable use policies of copyright and peer-to-peer file sharing. It is the student’s responsibility to become familiar with and adhere to the Student Code of Conduct as contained in the DACC Student Handbook. The Student Handbook is available in the Information Office in Vermilion Hall and online at: https://www.dacc.edu/student-handbook|
|DISABILITY SERVICES:||Any student who feels s/he may need an accommodation based on the impact of a disability should contact the Testing & Academic Services Center at 217-443-8708 (TTY 217-443-8701) or stop by Cannon Hall Room 103. Please speak with your instructor privately to discuss your specific accommodation needs in this course.|