ME41 Machine = Shop Safety and Fundamentals

Semester:

Fall 2009

Credit Units:

1 unit, Lab

Class Hours & Catalog=20 Details:

Section

Day

Time

ME Code

ISE Code

Location

Instructor

1200-1445

27785

48996

IS = 119/122

Obi

Description:

Prerequisites:

Introduction to basic machine shop safety and = skills.=20 Fabrication of mechanical components and assemblies from = engineering=20 drawings, performing tolerance inspection and developing = fabrication=20 process plans.

ME 20, Tech 20, CE 20 (or equivalent)

Instructor:

Prof. Samuel Obi | IS = 105 =20 | 408-924-3218 | sobi@email.sjsu.edu

Office Hours tentatively Thursday = 12:00-5:00 PM.

http://www.engr.sjsu.edu/sobi/=20

Course Website:

General Information: http://www.engr.sjsu.edu/sobi/

Required = Textbook

& Other = Materials:

1) Kibbe, R. R., Neely, J. 1. Kibbe, R. R., = Neely, J.=20 E., Meyer, R. O., &

White, W. T. (2010). Machine tool = practices, (9th ed.) Prentice Hall: NJ.

2.=20 Scientific hand calculator with trig and square root = functions

3. Safety goggles

4. Digital calipers

5. Rags

6. Flash drive

Course=20 Goals =

1. =20 To develop keen awareness of hazards, risks, and = safe=20 practices in a machine shop environment.

2. =20 To acquire hands on experience with fabrication = of=20 mechanical components and assemblies.

3. =20 To achieve reasonable proficiency with basic = operations=20 using common Machine tools.

4. =20 To enhance knowledge about the interdependence = among=20 design manufacturing, and inspection.

Student=20 Learning Objectives

Students who complete this course successfully will = be able=20 to:

1. =20 Identify hazards associated with specific = machine tools=20 and processes, and ways of preventing risk of injury.

2. =20 Independently and safely operate common sheet = metal=20 tools including a shear, press brake, punch, notcher, and spot = welder.

3. =20 Select appropriate tooling, fixturing, and = operating=20 parameters for common machining operations including sawing, drilling, = turning,=20 and milling.

4. =20 Independently and safely operate common = machining tools=20 including a band saw, drill press, lathe, and vertical mill.

5. =20 Explain and describe engineering fabrication = drawings=20 and perform appropriate inspection =20 with common metrology tools including calipers, micrometers, dial = indicators, and other gages.

Graded=20 Work

Prior to working in = the course,=20 each student is required to take a general laboratory safety test and = pass it at=20 the 80% performance level.* =

The student will = undertake a=20 series of laboratory projects which will be evaluated for their course=20 evaluation. These = projects include=20 a sheet metal project and a machining project. For each project, rough = sketches,=20 detailed CAD drawings for fabrication, and process planning details will = be=20 submitted. Projects will = be=20 evaluated for accuracy and detail of planning, and for the quality of=20 execution.

Lab performance will = be based on=20 laboratory habits: = neatness,=20 maintenance of a clean workstation, and conduct of lab maintenance tasks = assigned by the instructor. = Grading=20 is done as follows:

=DE = 10% for performance on the lab safety and = metrology quizzes

=DE = 20% for sheet metal project

=DE = 20% for machining project

=DE = 10% for lab participation and = contributions

=DE = 20% for detailed fabrication drawings of = elective=20 project

=DE = 20% for detailed process plan of elective = project=20

*Students will not = receive credit=20 for course unless the general lab safety quiz is passed within two tries = or=20 less.

Credit in the class is earned by earning an average = score of=20 70% on all assignments.

POLICIES

Academic=20 Integrity Standards and Policies

Academic honesty is expected without question in = this course.=20 Students who are found to have submitted materials that do not adhere to = SJSU=20 standards of academic integrity will suffer the following two = consequences:

a. = A grade of zero [0] will be given for the = assignment in=20 question; and

b. = A=20 report of the incident will be filed with the university. This report = may stay=20 on your permanent collegiate record.

c. = You may also be subject to further disciplinary = action=20 being taken by the university.

For the SJSU policy = on Academic=20 Integrity, refer to: http://www.sjsu.edu/senate/= F06-2.pdf=20

a) Academic integrity = statement (from=20 the Office of Student Conduct and Ethical Development):

=93Your own commitment to learning, as evidenced by = your=20 enrollment at San=20 Jos=E9 State=20 University, and = the=20 University=92s Academic Integrity Policy requires you to be honest in = all your=20 academic course work. Faculty members are required to report all = infractions to=20 the Office of Student Conduct and Ethical Development. The policy on = academic=20 integrity can be found at http://sa.sjsu.edu/student_conduct.

b) Campus policy in compliance = with the=20 Americans with Disabilities Act:

=93If you need course adaptations or accommodations = because of=20 a disability, or if you need special arrangements in case the building = must be=20 evacuated, please make an appointment with me as soon as possible, or = see me=20 during office hours. Presidential Directive 97-03 requires that students = with=20 disabilities requesting accommodations must register with DRC to = establish a=20 record of their disability.=94

More about Cheating. At SJSU, = cheating=20 is the act of obtaining or attempting to obtain credit for academic work = through=20 the use of any dishonest, deceptive, or fraudulent means. Cheating at = SJSU=20 includes but is not limited to:

Copying in part or in whole, from another=92s test = or other=20 evaluation instrument; Submitting work previously graded in another = course=20 unless this has been approved by the course instructor or by = departmental=20 policy. Submitting work simultaneously presented in two courses, unless = this has=20 been approved by both course instructors or by departmental = policy. =20 Altering or interfering with grading or grading instructions; Sitting = for an=20 examination by a surrogate, or as a surrogate; any other act committed = by a=20 student in the course of his or her academic work which defrauds or=20 misrepresents, including aiding or abetting in any of the actions = defined=20 above.

More about Plagiarism. At SJSU plagiarism is the = act of=20 representing the work of another as one=92s own (without giving = appropriate=20 credit) regardless of how that work was obtained, and submitting it to = fulfill=20 academic requirements.

Plagiarism at SJSU includes but is not limited to = the act of=20 incorporating the ideas, words, sentences, paragraphs, or parts thereof, = or the=20 specific substances of another=92s work, without giving appropriate = credit, and=20 representing the product as one=92s own work; and representing = another=92s=20 artistic/scholarly works such as musical compositions, computer = programs,=20 photographs, painting, drawing, sculptures, or similar works as one=92s = own.

Students With=20 Disabilities

Campus policy. In compliance with the Americans = with=20 Disabilities Act:

=93If you = need course=20 adaptations or accommodations because of a Disability, or if you need = special=20 arrangements in case the building must be evacuated, please make an = appointment=20 with me as soon as possible, or see me during office hours. Presidential = Directive 97-03 requires that students with disabilities register with = DRC to=20 establish a record of disability.=94

Cell=20 Phones

Students will turn their cell phones off or put = them on=20 vibrate mode while in class. They will not answer their phones in class. = Students whose phones disrupt the course and do not stop when requested = by the=20 instructor will be referred to the Judicial Affairs Office of the=20 University.

Computer=20 Use

In the classroom, you may use computers only for=20 class-related activities such as taking notes on the lecture underway, = following=20 the lecture on Web-based = Power Point=20 slides that the instructor has posted, and finding Web sites to which = the=20 instructor directs students at the time of the lecture. Students who use their = computers for=20 other activities or who abuse equipment in any way, at a minimum, will = be asked=20 to leave the class and lose participation points for the day, and may be = referred to the Judicial Affairs Officer of the University for = prohibited uses=20 of campus computers (Such referral can lead to suspension from the = University).=20 Students are urged to report to their instructors computer use that they = regard=20 as inappropriate (i.e., used for activities that are offensive or not = class=20 related).

Attendance

Attendance will not be taken during class. If you = miss a=20 class you are responsible for any material discussed or assignments = given. A=20 large portion of class will be used for problem solving in small groups. = All=20 students are expected to participate in class discussions and problem = solving.=20 Students who are often absent will find themselves at a disadvantage = during the=20 tests. If you miss a lab session you will get a zero on the lab portion = of the=20 course.

Schedule=20 of Activities

(subject = to=20 change)

Topic and = Reading=20 Assignments

Assignments=20 Due

Week 1

August 24

Orientation and = shop=20 safety. (Greensheet and handouts will be = provided).

Week 2

August 31

Shop = safety=20 practices. Review:

Introduction:=20

Unit 1 Shop = Safety

Unit 2 Mechanical=20 Hardware

SECTION B:

Unit 3 Hacksaws

Unit 5 Hand=20 Reamers

Unit 8 Thread-Cutting Dies and = Their=20 Uses

Unit 9 Off-Hand=20 Grinding

Week 3

September 7

Labor Day =96 = Campus=20 Closed

Week 4

September 14

Sheet metal basic = skills.=20 Review:

SECTION B:

Unit 1 Arbor and Shop=20 Presses;

Unit 2 Work-Holding and Hand=20 Tools

SECTION E

Layout

Unit 1 Basic Semiprecision Layout=20 Practice

Unit 2 Basic Precision Layout=20 Practice

(Handouts = will be=20 provided)

Sheet metal working = and shop=20 safety quiz

Week 5

September 21

Sheet metal = project

Week 6

September 28

Sheet metal = project

Week 7

October 5

Sawing, drilling, = tapping,=20 filing, polishing. Review:

SECTION B:

Unit 4 Files

Unit 6 Identification and Uses = of=20 Taps

Unit 7 Tapping=20 Procedures

Unit 9 Off-Hand=20 Grinding

SECTION G

Sawing = Machines

Unit 1 Using Reciprocating=20 and

=20 Horizontal =20

=20 Band Cutoff Machines

Unit 3 Preparing to Use the=20 Vertical

=20 Band Machine

Unit 4 Using the Vertical Band =

=20 Machine

SECTION H

Drilling = Machines

Unit 1 The Drill=20 Press

Unit 2 Drilling=20 Tools

Unit 3 Hand Grinding of Drills = on=20 the

=20 Pedestal

=20 Grinder

Unit 4 Operating Drilling=20 Machines

Unit 5 Countersinking and=20

=20 Counterboring

Unit 6 Reaming in the Drill=20 Press

Sheet metal project = and=20 drawings

Week 8

October 12

Introduction to = turning.=20 Review:

SECTION I

Turning = Machines

Unit 1 The Engine=20 Lathe

Unit 2 Toolholders and = Toolholding=20

=20 for the Lathe

Unit 3 Cutting Tools for the=20 Lathe

Unit 4 Lathe Spindle=20 Tooling

Unit 5 Operating the Machine=20

=20 Controls

Unit 6 Facing and Center=20 Drilling

Unit 7 Turning between=20 Centers

Unit 8 Alignment of the=20 Lathe

=20 Centers

Week 9

~~October=20 19~~

Introduction to = milling.=20 Review:

SECTION J

Vertical Milling=20 Machines

Unit 1 Vertical Spindle Milling=20

=20 Machines

Unit 2 Cutting Tools and Cutter=20

=20 Holders for the Vertical

=20 Milling Machine

Unit 3 Setups on the Vertical=20 Milling

=20 Machine

Unit 4 Vertical Milling=20 Machine

=20 Operations

Machining safety = quiz

Week 10

October 26

Metrology and = inspection.=20 Review:

SECTION C

Dimensional=20 Measurement

Unit 1 Systems of=20 Measurement

Unit 2 Using Steel=20 Rules

Unit 3 Using Vernier, Dial, = and Digital=20 Instruments for Direct

=20 Measurements

Unit 4 Using=20 Micrometer

=20 Instruments

Unit 5 Using Comparison=20 Measuring

=20 Instruments

Unit 6 Using Gage=20 Blocks

Unit 7 Using Angular=20 Measuring

=20 Instruments

Unit 8 Tolerances, Fits, = Geometric=20

&n= bsp;=20 Dimensions, and = Statistical

&n= bsp;=20 Process Control

Week 11

November 2

Machining project

Week 12

November 9

Machining = project

Metrology and = inspection=20 quiz

Week 13

November 16

Machining = project

Week 14

~~November=20 23~~

Machining = project

Week 15

November 30

Process plan = development.=20 (Handouts will be provided)

Machining project and = drawings=20

Week 16

December 7

Process plan = development and/or=20 machining project.

Process plans for = both=20 projects

Final Exam is = Tuesday, December15, 9:45 AM -12:00=20 Noon