Course Description
This course provides practical experience in the use of machine tools. Emphasis is on shop safety, use of measuring instruments, hand tools, horizontal band saw, drill press, screw cutting lathe, electric arc welding, oxyfuel welding, and oxyfuel cutting. The lab also consists of a half semester of “hands-on” introduction to electric arc welding and machine tool operation, including safety. [Lab time required]
This course consists of one hour a week of instruction for a semester, twelve 3-hour labs with practical assessments, and completion of a final project.
Entrance requirements
- Identify basic hand tools
- Operate small hand power tools
- Differentiate between different metals
- Make rough measurements
STCW Objectives
Demonstrate knowledge and understanding of the following STCW elements:
- OICEW-C1.2 Characteristics and limitations of processes used for fabrication and repair
- OICEW-C1.3 Properties and parameters considered in the fabrication and repair of systems and components
- OICEW-C1.5 Safety measures for using hand tools
- OICEW-C1.5 Safety measures for using machine tools
- OICEW-C1.5 Safety measures for using measuring instruments
- OICEW-C1.6 Use of machine tools
- OICEW-C2.4 The use of measuring instruments
- ABE-B1.6 Knowledge of the application, maintenance and use of hand tools
- ABE-B1.6 Knowledge of the application, maintenance and use of machine tools
- ABE-B1.6 Knowledge of the application, maintenance and use of measuring instruments
- ABE-B1.6 Knowledge of the application, maintenance and use of power tools
- ABE-B1.7 Knowledge of metalwork
Demonstrate proficiency in the following skills:
- OICEW-1-1A Cut a circular hole using oxyacetylene process
- OICEW-1-1B Form two steel plates using brazing process
- OICEW-1-1C Form two steel plates using electric arc welding process
- OICEW-1-1F Visual test of welded joint
- OICEW-1-1G Dye-penetrant test
- OICEW-8-1A Lathe project
Topics
- Hazards in lathe operations and welding safety
- Toolholders and cutting tools: identification, design and procedure for making single point cutting tool used for threading and turning
- Oxy-fuel cutting: set-up and operation
- Basic engine lathe design
- Lathe spindle tooling: chucks, faceplates, operation and maintenance
- Lathe controls: spindle speeds, feeds, operations, direction, threading
- Facing and center drilling in the lathe
- Base metal prep: cleaning, joint design, and joint prep
- Work between lathe centers: difference between chuck and center work
- Alignment of lathe centers: different methods
- Weld quality
- Other lathe operations: drilling, boring reaming, parting, knurling
- SMAW equip and setup
- Threading calculations: depth, fit, infeeds
- Cutting Unified and American National Std threads
- SMAW electrodes and selection
- Benchwork and hand tools: hacksaws, files, reamers, taps, dies
- SMAW beads and fillet welds
- Measurement: steel rules, vernier calipers, dial calipers, micrometers
- Groove welds
- Cutting tapers: methods, calculations, set-up
- Joint fit-up
- Using Steady and Follower Rests
- Open V groove welds
- Using cutoff machines: reciprocating and horizontal band
- Preparation and usage of vertical band machines
- SMAW pipe welds
- Drilling machine types and usage
- Drilling tools and operations
- NDT: methods, identification of discontinuities
Other objectives
- Set-up and dress the wheels on the bench grinder
- Off-hand grind a 60 degree thread form and radius thread form on a high speed steel tool blank
- Set-up and operate the lathe and tooling for facing, centerdrilling, turning and threading a test coupon to blueprint specifications
- Correctly align tool and test coupon and chase an existing thread
- Operate the horizontal band saw, vertical band saw, drill press, hydraulic press and hand tools
- Use precision measuring instruments
- Set up and use an oxy-fuel cutting torch
- Set-up and adjust SMAW equipment and weld a T-Joint
- Set-up and adjust oxyfuel equipment and weld a lap joint
- Identify welding defects using dye penetrant testing