Improve Workforce Efficiency

Course #: 5282A-C
Duration: 30 hours (includes 3 tests)
Prerequisites:

• Introduction to Algebra, Geometry, and Trigonometry (Block X02)

Part 1 (5282A). Comparison of Materials; Simple Stresses; Reactions; Deformation; Elastic Properties of Materials; Allowable Unit Stresses; Factor of Safety; Investigation and Design of Simple Tension and Compression Members; Members Subjected to Shear; Hollow Thin Cylinders; Temperature Stresses; Riveted Joints; Welded Joints; Bolted Connections in Steel Fastenings for Timber.

Part 2 (5282B). Fixed and Moving Loads on Beams; Reactions at Beam Supports; Cantilever; Simple and Overhanging Beams; Continuous Beams and Beams with Fixed Ends; Points of Inflection; Maximum Shear and Bending Moment in Beams; Shear and Bending Moment Diagrams.

Part 3 (5282C). Flexural Stresses in Beams; Moment of Inertia and Section Modulus; Shearing Stresses in Beams; Stresses Due to Torsion; Torsion and Bending in Circular Shafts; Deflections of Beams; Investigation and Design of Beams; Theory of Column Design Radius of Gyration; Investigation and Design of Columns.

Course #: 3541A-D
Duration: 40 hours (includes 4 tests)
Prerequisites:

• Practical Measurements (Block X22)
• Elements of Chemistry (5011)

Part 1 (3541A). Steel Ingots; Hot Working of Steel; Effects of Hot Working on Microstructure; Cold Working of Steel; Heat-Treating Equipment; Cooling Mediums and Devices; Temperature Measurement and Control; Miscellaneous Equipment; Metric System Conversion Information.

Part 2 (3541B). Composition of Carbon Steels; Heat-Treating Processes; Heat-Treating Equipment.

Part 3 (3541C). Composition of Alloy Steels; Heat Treatment of Alloy Steels; Properties of Low-Alloy Steels; Special Steels; Case Hardening; Furnace Atmospheres.

Part 4 (3541D). Classification and Description of Tool Materials; Inspection, Test, and General Heat-Treating Processes; Heat-Treating Equipment; Typical Procedures of Heat-Treating Tool Steels.

Course #: 5101A-B
Duration: 20 hours (includes 2 tests)
Prerequisites:

• Basic Machining Skills (Block X08)

Part 1 (5101A). Dies for Sheet-Metal Work; Cutting Dies; Punch Presses; Speeds of Punch Presses; Attaching Dies to Presses; Examples of Die Work; Machine Tool Equipment for Die Making; Making Cutting Dies; Selecting Materials for Dies; Preparation of Die Blanks; Layout of Die; Making Templates; Machining of Die Blank; Making Stripper and Punch Plate; Forms of Cutting Dies; Shear of Dies; Making Progressive Cutting Dies; Making Subpress Cutting Dies.

Part 2 (5101B). Making Shaping Dies; Drawing Dies; Size of Blanks; Deep Cylindrical and Non-Cylindrical Cups; Redrawing Dies; Making Dies for Curling, Wiring, Seaming, Coining, Extruding, and Embossing; Making Combination Dies; Cutting, Drawing, and Embossing Combination Dies; Combination Forming and Swaging Dies; Combination Blanking, Piercing, and Swaging Dies; Progressive Combination Dies; Hardening and Tempering of Dies; Prevention of Cracks; Die Setting Estimating Capacity of Press; Lubrication of Dies; Mechanical Feeds for Punch Presses.

• A new addition to this course, Dies and Die Making, Part 3 (386048) focuses on modern die making practices.

Course #: 386048
Duration: 10 hours (includes 1 test)
Prerequisites:

• Dies and Diemaking, Parts 1-2 (5101A-B)

• Explain modern-day improvements in presses and related equipment.
• Recognize the proper use of modern tool materials and coatings.
• Make informed choices about when to use a particular die material.
• Explain how to build a die in a way that works well with the chosen tooling material.
• Identify commercially available components and how they can be used in modern die designs.
• Describe how modern machining practices are considered when designing and building dies.
• Understand modern requirements of high-speed light-gauge stamping processes.

Course #: 3199
Duration: 10 hours (includes 1 test)
Prerequisites:

• Dies and Die Making (5101A-B)

• Construction and Use of Drop-Forging Dies
• Nature and Construction of Press-Forging Dies
• Bending Dies

Course #: 3197
Duration: 10 hours (includes 1 test)
Prerequisites:

• Dies and Die Making (5101A-B)

• Kinds of Steel Used in Making Forging Dies
• Annealing, Hardening, and Tempering Treatment of Die Blocks
• Machine Tools Used in Working with Die Sinkers
• Using Hand Tools in the Diemaking Practice
• Laying Out and Machining Die Blocks
• Handwork on Die Impressions
• Making Breakdowns and Trimming Dies

Course #: 2540A-C
Duration: 30 hours (includes 3 tests)
Prerequisites:

• Basic Machining Skills (Block X08)

Part 1 (2540A). General Toolroom Work; Materials and Equipment; Procedure and Measurements; Limitations of Toolmaking; Examples of Toolmaking and Toolmaking Operations.

Part 2 (2540B). Cutting Tools; Hand Taps; Machine Taps; Taper Taps; Hobs; Dies for Thread Cutting; Die Holders; Reamers; Theory of Cutting Tools.

Part 3 (2540C). Counterbores; Hollow Mills; Milling Cutters; Screw-Machine, Turret-Lathe, and Broaching Tools.

• A new addition to this course, Toolmaking, Part 4 (386047) focuses on modern toolmaking practices.

Course #: 386047
Duration: 10 hours (includes 1 test)
Prerequisites:

• Toolmaking, Parts 1-3 (2540A-C)

• Select modern tool materials to suit a particular application.
• Explain how various tool coatings improve tool performance.
• Identify and select standard tool inserts and tool holders for a specific application.
• Explain the benefits of using inserted tools for drilling, milling, and turning operations.
• Describe the benefits of and proper use of roll-forming and thread- forming taps.
• Troubleshoot tool life and wear problems, and suggest corrective actions.
• Describe instances in which modern machining processes such as WEDM and EDM are superior.

Course #: 5098
Duration: 10 hours (includes 1 test)
Prerequisites:

• Basic Machining Skills (Block X08)

• Classification, Accuracy, and Tolerances
• Materials for Gages
• Proportions of Gages
• Grinding and Lapping Gages
• Making Thread Gages
• Making End-Measuring Gages
• Making Caliper Gages
• Limit Gages
• Flat-Surface Gages
• Angular Gages
• Making Straightedges
• Making Taper Gages
• Contour Gages
• Pin Gages
• Cylindrical Square
• Indicator Gages
• Ball Gages
• Gaging Teeth of Spur Gears
• Gaging Compound Angles
• Sine-Bar Angles for Lathe Tools, Templates, and Template Making

Course #: 5099
Duration: 10 hours (includes 1 test)
Prerequisites:

• Basic Machining Skills (Block X08)

• Types of Jigs
• Examples of Jigs
• Jig Parts and Accessories
• Bushings
• Jig Covers and Clamps
• Miscellaneous Details of Jigs
• Fixtures
• Common Vise Fixture
• Special Vise Fixture
• Bolted Fixture: Combination Jig and Fixture
• Trunnion Fixture
• Roller Fixture
• Broaching Fixture

Course #: 5100
Duration: 10 hours (includes 1 test)
Prerequisites:

• Basic Machining Skills (Block X08)

• Processes in Jig and Fixture Making
• Planning
• Machining
• Locating and Producing Holes
• Locating Centers by Buttons
• Locating by Calculation
• Locating Buttons by Rings and Disks
• Micrometer Measurements with Rings
• Locating Holes
• Examples of Jig Making
• Making Jig Bushings
• Master Plates
• Continuous Dialing
• Setting Up Indexing Jigs: Making Jigs on Drilling Machines
• Checking Jigs
• Making Plate Jigs
• Making Fixtures

• A new addition to this course, Jigs and Fixture Making, Part 2 (386049) focuses on modern jig and fixture making practices.

Course #: 386049
Duration: 10 hours (includes 1 test)
Prerequisites:

• Jig and Fixture Making (5100)

• Explain the required characteristics of jigs and fixtures used in modern automated assembly and CNC machining.
• Describe a range of up-to-date machining practices used in building jigs and fixtures.
• List and describe the uses of commercially available components that can be incorporated into jig and fixture designs.
• Understand how to design and build jigs and fixtures to compensate for normal product variations such as flash, parting lines, burrs, and casting irregularities