Department of Aviation and
Technology
Course Syllabus
Semester and Year: Fall, 2009
Course Section:
1 & 11
Class days & Times: M 3:00 pm. – 4:45 pm; W
3:00 pm.-5:45 pm.
Class Locations:
IS 121 & 122
Office Room:
IS 105
Office Hours:
R:
12:00-5:00
pm.
Office Phone:
(408) 924-3218
Office FAX:
(408) 924-3198
E-mail
Address:
sobi@email.sjsu.edu
Web Address:
www.engr.sjsu.edu/sobi/
Course Catalog
Description
Current numerically-controlled (CNC) and manual machining processes
including turning, milling, drilling, grinding, and sawing machines. Manual and
computer-aided part programming. Management of machining environment including
processes, tooling, instruments, equipment, personnel, safety. (Lecture 2 hours,
lab 3 hours) 3 units.
Prerequisite
Tech 20 or equivalent
Purpose of
Course
The purpose of this course is to develop fundamental skills needed for
advanced study in manufacturing technology machine tool processes and
management. To this end, areas of study will include: measurement, layout and
inspection, bench work, metal-cutting saws and processes, drilling machines and
processes, turning machines and processes, milling machines and processes,
abrasive machining safety, computer-numerical control, and related
management. There are five areas of
investigation in this course, and each has its own specific objectives. Each area has related reading
assignments and handbook tables designed to augment all laboratory
activities. Students should read
these reading assignments and refer to relative handbook tables in order to
successfully fulfill the objectives of this course.
Required Textbooks &
Materials
1) Kibbe, R. R., Neely, J. E., Meyer, R. O., & White, W. T. (2010).
Machine tool practices, (9th ed.) Prentice Hall: NJ.
2) Valentino, J. V. &
Goldenberg, J. (2008). Introduction to Computer Numerical Control (CNC) (4th.
Edition). Prentice Hall: NJ.
3) Safety Glasses
4) Appropriate
data storage devices
5) Hand calculator with trig and square root
functions
6) One set of precision dial calipers
7) Two shop rags
References
DeGarmo, E. Paul, Black, J.
Temple & Kohser, Ronald A. (latest edition). Materials and Processes in
Manufacturing.
Groover, M. P. (2002).
Fundamentals of Modern Manufacturing: Materials, Processes and Systems. John
Wiley & Sons,
Machinery Handbook & Current journal and magazine technical
articles.
Tlusty, G. (2000). Manufacturing
Processes and Equipment. Prentice Hall,
Outline of Course Content and
Unit Objectives
Part I: Measurement, Inspection & General Shop
Management
Reading Assignment: Kibbe et al pp. 87-191; V & G Chapter 5 &
9.
Handbook Tables: Kibbe et al
Tables 1-6 (pages 752-760).
Objectives:
a) Discuss and
demonstrate an understanding of the concepts of dimensions, units of measure,
blueprint reading, measurement systems, and measurement
terms.
b) Develop an
understanding of, and demonstrate the proper use of, semiprecision
line-graduated measuring instruments and related transfer measuring
tools.
c) Develop an
understanding of, and demonstrate the proper use of, the following precision
measuring instruments; micrometers, vernier calipers, depth gages, height gages,
bevel protractor, indicators, and gage blocks.
d) Discuss and
develop an understanding of advanced precision measurement equipment including
CMM, surface finish indicators, optical flats, microscopes, amplification
comparators, optical comparators, pneumatic gaging, and fixed
gages.
e) Develop an understanding of surface texture characteristics and
measurement.
f) Develop an understanding of, and demonstrate the proper knowledge and
management of shop facilities and equipment.
Part II: Bench Work, Shop
Safety, Layout and Tool Management
Reading Assignment: Kibbe et al pp. 6-85; 235-262. V & G chapters 1,
8 & Appendix A. Kibbe et al Handbook Table: Table 8 (page
763).
Objectives:
a) Develop an understanding of precision surface plates, angle plates,
and accessories.
b) Demonstrate the proper use of a sine bar, and develop an understanding
of a sine plate, sine block, and compound sine plate.
c) Develop techniques for checking parallelism, squareness, roundness,
and concentricity.
d) Develop an understanding of non-cutting hand processes such as
hammering, fastening, and clamping.
e) Develop an understanding of proper hand sawing processes including
blade selection.
f) Develop an understanding of chiseling, punching, and driving tools and
processes.
g) Develop an understanding of hand file characteristics and file
processes.
h) Develop an understanding of hand reamers and reaming
processes.
i) Develop an understanding of, and demonstrate proper hand tapping
processes and external threading using dies.
j) Describe and practice general
machine shop safety rules.
k) Determine proper safe working
habits in a machine shop environment.
l) Describe a computer
numerically controlled machine tool and its components.
m) Perform the Word Address
programming format.
n) Describe tool inventory
control system and how to manage it.
Part III: Turning Machines, Processes and
Management
Reading Assignment: Kibbe et al pp. 383-513. V & G chapters 17 &
19.
Kibbe et al Handbook Tables:
Tables 10, 10A, 10B & 5B.
Objectives:
a) Identify and
be able to explain the purpose of the major features of engine and CNC lathes
including lathe accessories, and attachments.
b) Describe the characteristics and specifications of basic lathe cutting
tool bits and inserts.
c) Develop an understanding of cutting tool
materials.
d) Program and calculate correct speeds and feeds for traditional and CNC
lathes.
e) Grind a
turning tool bit and a threading tool bit using a high speed steel tool
blank.
f) Select the
correct center drill, drill the centers in a workpiece and turn (machine) the
workpiece on the machine.
g) Correctly setup a machine to perform facing and straight turning
operations.
h) Correctly
setup a machine to perform shoulder turning, chamfering and rounding a
corner.
i) Develop an understanding of form tool grinding and cutting and
knurling.
j) Develop an understanding of tapers, taper turning, and taper
measurement.
k) Develop an understanding of different types of
chucks.
l) Develop an understanding of boring bars and holders, and machining
using mandrels.
m) Machine a 60o form external thread to correct
specifications.
n) Develop an
understanding of production thread making processes including casting, rolling,
milling, grinding, and broaching.
o) Develop an understanding of square threads, 29o threads,
and multiple-start threads.
p) Develop an
understanding of production turning machines including turret lathes and
automatic screw machines.
q) Employ proper safe working and housekeeping habits in working with
turning machines.
Part IV: Milling Machines,
Processes and Management
Reading Assignment: Kibbe et
al pp. 511-584. V & G chapters 2, 3, 4 & 10; Appendices B &
C.
Kibbe et al Handbook Tables:
Tables 10A, 10B.
Objectives:
a) Develop an understanding of knee-and-column type milling
machines.
b) Identify the major components of a horizontal milling
machine.
c) Develop an understanding of milling tool and work holding
devices.
d) Develop an understanding of milling cutting tools, speeds, feeds, and
cutting fluids.
e) Program and machine a workpiece using CNC milling
machine.
f) Identify major components and attachments of traditional and CNC
milling machines.
g) Develop an understanding of cutting tools and basic processes for
vertical milling operations.
h) Employ proper safe working and housekeeping habits in working with
milling machines.
Part V: Other Machines:
Metal-Cutting Saws, Drilling Machines, Grinding and Abrasive Machines, Processes
and Management
Reading Assignment: Kibbe et al pp. 301-412 & pp.
585-658.
Objectives:
a) Develop an
understanding of, and demonstrate the use of, power hacksaws, horizontal band
machines, and vertical band machines.
b) Make proper blade selection.
c) Determine the
appropriate feed, coolant, blade pitch, and velocity, using the Job
Selector.
d) Butt weld a saw blade correctly.
e) Develop an
understanding of friction sawing, diamond-edge band sawing, band filing, and
knife-edge band sawing.
f) Describe the operations of abrasive and cold saw
machines.
g) Employ proper safe working and housekeeping habits in working with
metal-cutting saws.
h) Develop an
understanding of, and be able to describe the characteristics of, different
drilling machines.
i) Explain and demonstrate the correct use of work holding
devices.
j) Identify common materials used in the manufacture of
drills.
k) Identify and explain the use of, different types of twist
drills.
l) Develop an
understanding of the main features of a twist drill including the shape and
angles of the drill points.
m) Develop an understanding of the standard designations of drill
sizes.
n) Be able to
calculate the correct RPM and determine the correct feed rate for drilling
operations.
o) Identify and explain the use of common machine
reamers.
p) Determine the correct RPM and feed rate for
reamers.
q) Develop an understanding of machine threading on a drill
press.
r) Develop an
understanding of, and demonstrate the use of countersinks, counterbors,
spotfacers, and boring tools.
s) Employ proper safe working and housekeeping habits in working with
drilling machines.
t) Develop an understanding of abrasive machines and machining processes
including surface, centerless, and cylindrical grinding.
u) Develop an understanding of grinding wheel characteristics and
standards, and be able to make an appropriate wheel selection for the required
operation.
v) Describe how to identify unsafe wheels, how to properly dress grinding
wheels, and the tools and techniques employed in wheel
dressing.
w) Employ proper safe working and housekeeping habits in abrasive
machining.
Instructional
Methodologies
1.
Lecture-Discussion
2.
Demonstrations
3. Laboratory
activities
4. Outside reading
assignments
5. Video/film presentations
(TU0952A and others)
Required
Projects/Assignments
This course has been carefully
planned to provide the opportunity for students to develop skills in the use of
common and computer-numerical controlled machine tools, hand tools, and in
layout, planning, inspection, and developing an understanding of heat
treatment. To this end, a variety
of laboratory activities is required as well as assigned readings in the
text. All laboratory activities
must be completed in our labs (E101, I.S. 124) unless you have my permission to
use another lab. In addition,
readings of "outside" materials are required in order to expand the study of a
particular area of interest.
Lathe Project: 25 points
A drawing, a piece of cold
rolled steel (CRS), a high speed steel (HSS) tool blank, and a Quality Assurance
Traveler (QAT), will be provided for the completion of this project. The tool bit will have to be ground for
a right hand turning tool on one end, and a 60o threading tool on the
other end. A CNC program should be prepared and the workpiece will be machined
to the specifications illustrated on the drawing. Each dimension listed on the QAT must be
checked by the student and written on the QAT. Each student's workpiece and QAT will be
randomly checked by the instructor.
If a dimension is "out of print", the student may elect to loose the
points and continue to complete the project or, start
over.
Mill Project: 25 points
A drawing, aluminum and QAT will
be provided for the completion of this project. The project will require
milling, drilling and reaming. The
procedure for completion of this project follows that outlined for the lathe
project.
Final Project:
Option 1 (Sine
Bar): 100 points: The completion of this
requirement will follow the
procedures as listed above. This
project will involve milling, surface grinding,
cylindrical
grinding, drilling, layout,
tapping, heat treatment, turning, parting, chamfer turning,
and
countersinking.
Option 2: (Steel
Hammer): 100
points: Students have the option of making a steel hammer in place of the sine
bar. This option helps to direct
some students to the lathes, and reduce the number of students on the few
milling machines available. A
drawing, two pieces of cold rolled steel rods, and a quality assurance traveler
will be provided for the completion of this project. The project will require
turning, cylindrical grinding, drilling, layout, tapping, surface grinding,
knurling, parting, chamfer turning, grooving, taper turning, filing, heat
treatment and sanding.
Outside
There are three (3) out-of-class
reading assignments. The readings
are to be from a magazine or journal not more than three (3) years old. The
subjects to be read and reported must be concerned with some aspect of processes
of industry, i.e., machine processes, woodworking, laser machining, welding,
robotics, etc. The assignments must be typed in the “Outside Reading Synopsis”
format which will be provided. The
reading assignment reports will not be accepted late and are due the first class
meeting each week as indicated in the Activity Schedule. Points (from 0-15) will be assigned for
each report based upon the thoroughness of your discussion, sentence structure,
and spelling. You may use a direct
quote in your report but you must set off the statement with quotation
marks. A word processor or computer
must be used in the preparation of this assignment, handwritten reports will not
be accepted.
Take-Home
Quizzes/Assignments: 60
points
There will be four (4) take-home
assignments. Each assignment will
be worth 15 points and students are expected to complete them within the time
frame given.
Late
Assignments:
Late assignments are not
acceptable. In certain conditions, students submitting any assignment, outside
reading or take home quiz late will lose two (2) points for each day that the
assignment is late. Other projects and exams are due as
scheduled.
Exams: 150
points
Students will take two formal
exams during the semester: A
midterm test (50 points) and a Comprehensive Final (100 points). The materials to be included in these
tests will be announced by the instructor.
Both tests should be taken during the regularly scheduled periods as
shown in the university's directory of classes.
Laboratory Safety and
Clean-Up: 25
Points
Laboratory equipment should be
used in a safe manner. Every
student is expected to participate in cleaning the lab and equipment at the end
of each lab session. There will be
a comprehensive lab clean-up of about 30 minutes on the last lab day, and every
student is expected to participate.
Instructor will issue points based on his observation of how each student
participated in lab clean-up throughout the semester. Students should also
behave in an orderly manner in all class and lab
activities.
Cheating
of any kind is not acceptable, and will be reported to the campus student
affairs office. It will result in
loss of credit for the assignment, which cannot be made up, and it MAY result in
an “F” in the class or even expulsion from the
University.
University Policy
Information
a)
Academic integrity statement (from Office of Student Conduct and Ethical
Development): “Your own commitment to learning, as evidenced by your enrollment
at
Faculty
members are required to report all infractions to the Office of Student Conduct
and Ethical Development. The policy on academic integrity can be found at
(http://ss.sjsu.edu/student_conduct).
b)
Campus policy in compliance with the Americans with Disabilities Act: “If you
need course adaptations or accommodations because of a disability, or if you
need special arrangements in case the building must be evacuated, please make an
appointment with me as soon as possible, or see me during office hours.
Presidential Directive 97-03 requires that students with disabilities requesting
accommodations must register with DRC to establish a record of their
disability.”
Grading
Points Possible
Quiz #1
15
Quiz #2
15
Quiz #3
15
Outside
Outside
Outside
Lathe Project
25
Mill Project
25
Final Project
100
Mid-Term Exam
50
Lab Clean-up/Activities
25
Final Exam (Comprehensive)
100
Total/415 = % for final
grade
90 -100% =
A
80 - 89
= B
70 - 79
= C
60 - 69
= D
Less than 60 =
F
Percentages will be adjusted to
accommodate + and – grades as follows:
93%
- 100% = A
73% - 76% = C
90% - 92%
= A- 70% -
72% = C-
87% - 89% =
B+ 67% - 69% = D+
83% - 86% = B 63% - 66% = D
80%
- 82% = B-
60% -
62% = D-
77% - 79% = C+ Below 60% =
F
|
TECH 046
SCHEDULE OF COURSE SEMESTER ACTIVITIES
DR. SAMUEL C. OBI | ||||
|
WEEK OF: |
TOPICS TO BE DISCUSSED |
ASSIGNMENTS |
LAB DUTIES |
DUE |
|
AUG. 24 |
ORIENTATION |
BUY MATERIALS |
|
|
|
AUG. 31 |
PART I
(MEASUREMENT...) |
Kibbe et al pp. 93-197; V & G Chapter 5 & 9 |
ALL |
|
|
SEP. 9 |
PART II (BENCH WORK
...) |
Kibbe et al pp. 6-91; 251- 283; V&G 1&8.
Project. 1 |
ALL |
QUIZ I |
|
SEP. 14 |
PART III (TURNING
MACHINE…) |
Kibbe et al pp. 413-547. V & G chapters
15&16 |
ALL |
|
|
SEP. 21 |
PART III (TURNING
MACHINE…) |
Kibbe et al pp. 413-547. V & G chapters 15
& 16 |
ALL |
1ST. O.R. |
|
SEP. 28 |
PART III (TURNING
MACHINE…) |
Kibbe et al pp. 413-547. V & G chapters 15
& 16 |
ALL |
|
|
OCT. 5 |
PART IV (MILLING
MACHINES…) |
Kibbe et al pp. 549-628. V & G ch. 2, 3, 4
& 18.. |
ALL |
PROJECT
1 |
|
OCT. 12 |
PART IV (MILLING
MACHINES…) |
PROJECT 2 |
ALL |
QUIZ 2 |
|
|
MID-TERM |
LAB 2 WORK |
ALL |
2ND. O.R. |
|
OCT. 26 |
PART IV (MILLING
MACHINES…) |
PROJECT 3 |
ALL |
PROJECT
2 |
|
NOV. 2 |
PART V (OTHER
MACHINES…..) |
Kibbe et al pp. 323-412; 629-712 |
ALL |
|
|
NOV. 9 – |
PART V (OTHER
MACHINES…..) |
Kibbe et al pp. 323-412; 629-712 |
ALL |
QUIZ 3 |
|
NOV. 16 |
ALL PROCESSES |
|
ALL |
|
|
|
ALL PROCESSES |
LAB 3 WORK |
ALL |
3RD. O.R. |
|
NOV. 30 |
ALL PROCESSES |
LAB 3 WORK |
ALL |
PROJECT 3 |
|
DEC.
7 |
LAST DAY OF CLASS; CLEAN
UP |
REVIEW & CLEAN UP |
ALL |
|
|
DEC.
16 |
FINAL
EXAMINATION |
WEDNESDAY, DEC. 16,
2007: 12:15-2:30 PM. | ||
|
SUBJECT TO CHANGES
DEPENDING ON CIRCUMSTANCES IN THE COURSE OF THE
SEMESTER | ||||
|
SEPTEMBER 7 IS LABOR DAY; NOVEMBER 11 IS VETERAN”S DAY. CAMPUS WILL BE CLOSED. NOVEMBER 26-27 WILL BE THANKSGIVING |
| |||