Improve Workforce Efficiency

Course #: 386030
Duration: 10 hours (includes 1 test)
Course Objectives:

• Introduction to Metal Cutting
• Fundamentals, Feed, Speed, Depth of Cut
• Requirements for Cutting Tool Materials
• Tool Materials
• Carbon Tool Steels, High-Speed Steels, Carbides, Cast Alloys, Ceramics, Boron Nitride, Diamond, Abrasives
• Principles of Single-Point Cutting
• The Turning Tool, Tool Wear, Modern Turning Tools, and Practices
• Other Single-Point Tools
• Milling Cutters
• Drills
• Tapping, Threading, and Reaming Tools
• Miscellaneous Multiple-Point Cutting Tools
• Cutting Fluids

Special Notes:

• Covers subject at an advanced, in-depth level.
• This new course replaces courses 5021A and 386015.

Course #: 386050
Duration: 10 hours (includes 1 test)
Course Objectives:

• Identify the parts of and explain how to use basic drill presses.
• Identify and use various types of drill tools for counterboring, countersinking, spot facing, reaming, tapping, and hole sawing.
• Explain how to set up various workpieces on a drill press.
• Selecting and using tool holders and workholding devices.
• Understand how to recondition drilling tools and maintain equipment.

Special Notes:

• This course replaces 3521-A.

Course #: 386051
Duration: 10 hours (includes 1 test)
Course Objectives:

• Explain how to set up more complex drilling equipment included automated and CNC equipment.
• Select and use various types of auxiliary tools with drill equipment.
• Set up more advanced work on a drill press.
• Select and modify drills for different materials and cutting conditions.
• Determine the correct speeds, feeds, and coolant for a given operation.
• Diagnose quality, tolerance, and tool-life problems, and find solutions for them.

Special Notes:

• This course replaces 3521-B.

Course #: 186087
Course Objectives:

• Identify industrial metals by their names and chemical symbols.
• Define in basic terms the characteristics and properties of metals.
• Explain the various metal-processing methods used in producing industrial metals.
• Explain how metals are extracted from their ores found in the earth and then refined.

Course #: 186088
Course Objectives:

• Identify the features of a blast furnace.
• Recognize cast irons by their fractures and other properties.
• Describe the major steelmaking processes.
• Discuss the hot-working and cold-working methods used to shape steel.
• Classify the types of steel, according to both processing method and carbon content.
• Relate certain grade numbers to the types of steel they identify.

Course #: 186089
Course Objectives:

• Explain how the various metals are extracted from their ores.
• Describe how the addition of certain elements affects the physical properties of the base metals.
• Select the metal alloy most suitable for a given job.
• Recognize whether a copper alloy is a brass or a bronze.

Course #: 186090
Course Objectives:

• Identify a metal by making a file, test magnetic test, temperature test, chip test, or spark test.
• Find the hardness of a metal by using a Brinell-Rockwell Monotron, a Vickers-Herbert Pendulum, or a scieroscope hardness testing machine.

Course #: 286091
Duration: 10 hours (includes 1 test)
Course Objectives:

• Describe the various types of friction.
• Discuss how materials wear.
• List the various functions lubricants perform in industry.
• Explain how lubricants reduce friction.
• Classify lubricants depending upon their composition, properties, and additives.
• Understand why certain lubricants are chosen for certain tasks.
• Explain how to safely handle and store lubricants.

Special Notes:

• This updated course replaces course 2531A.
• The entire course consists of study units 286091 and 286092.

Course #: 286092
Duration: 10 hours (includes 1 test)
Course Objectives:

• Explain how to manually apply various types of lubricants in an industrial environment.
• Describe total-loss lubrication.
• Identify a nonloss lubrication system’s components and describe their operation.
• Explain how to maintain a nonloss lubrication system.
• Identify the proper lubrication procedures to use for special industrial applications including sealed bearings, oil-impregnated bearings and food-processing plants.
• Explain how lubricant-conditioning systems work and how to maintain them.
• Describe how automatic lubrication systems work and how to maintain them.
• List the tasks involved in preventive and predictive lubrication maintenance.

Special Notes:

• This updated course replaces course 2531B.
• The entire course consists of study units 286091 and 286092.

Course #: 186085
Duration: 5 hours (includes 1 test)
Course Objectives:

• Recognize characteristics of angles and closed plane figures
• Distinguish between common geometric solids
• Apply basic geometric construction techniques
• Calculate perimeters and areas of a polygon, circle, and ellipse
• Apply the formula for area and volume of geometric solids

Special Notes:

• This course replaces course X0211.

Course #: 186086
Duration: 5 hours (includes 1 test)
Course Objectives:

• Define trigonometric functions and use a calculator to perform them
• Use trigonometric tables and apply interpolation
• Solve right triangles for angular and side dimensions
• Apply the laws of sines and cosines in solving oblique triangles

Special Notes:

• This course replaces course X0212.

Course #: 3501
Duration: 10 hours (includes 1 test)
Course Objectives:

• Marking Devices: Punches, Scribers, Dividers, Calipers, Gages, Beam Trammels, Combination Sets, Bevel Protractors, Keyseat Clamps
• Scribing Problems
• Use of Bench Plates, Surface Plates, Parallels, V Blocks, and Arbors
• How to Draw Horizontal, Vertical, and Inclined Lines
• How to Draw a Circle or Circular Arc
• Layout Problems: Location of Holes in a Plate
• Location of Boundaries of Flat Surfaces
• Marking of Lines on Curved Surfaces
• Locating the Center of a Circle in an Opening
• Subdividing a Circle into a Number of Equal Parts
• Determining Required Length of Stock for Forming a Bent Part
• Laying Out of Keyways, Templates, Castings, Cams, and Sprockets

Special Notes:

• Covers subject at an advanced, in-depth level.

Course #: 386031
Duration: 10 hours (includes 1 test)
Prerequisites:

• Basic Machining Skills (Block X08)

Course Objectives:

• Milling Process
• General Construction of Milling Machine
• General-Purpose Milling Machines
• Milling Machine Attachments and Accessories

Special Notes:

• This new course replaces courses 3522A and 386006.

Course #: 386032
Duration: 10 hours (includes 1 test)
Prerequisites:

• Milling Machine Fundamentals (386031)

Course Objectives:

• Milling Cutter Materials
• Milling Cutter Design
• Milling Cutters
• Carbide Inserts
• Milling Techniques
• Care and Reconditioning of Cutters

Special Notes:

• This new course replaces courses 3522C and 386008.

Course #: 386033
Duration: 10 hours (includes 1 test)
Prerequisites:

• Milling Machine Fundamentals (386031)

Course Objectives:

• Kinds of Work Done on the Milling Machine
• Cutting Speeds and Feeds
• Preparation of Stock
• Setting Machine
• Setting and Holding Work on Table, in Vise, on Faceplate, in Fixtures and Chucks, and between Centers
• Taking Cuts
• Milling-Machine Troubles

Special Notes:

• This new course replaces courses 2217 and 386009.

Course #: 386034
Duration: 10 hours (includes 1 test)
Prerequisites:

• Milling Machine Fundamentals (386031)

Course Objectives:

• Kinds of Work Done on the Milling Machine
• Cutting Speeds and Feeds
• Preparation of Stock
• Setting Machine
• Setting and Holding Work on Table, in Vise, on Faceplate, in Fixtures and Chucks, and between Centers
• Taking Cuts
• Milling-Machine Troubles

Special Notes:

• This new course replaces courses 2217 and 386009.

Course #: 386035
Duration: 10 hours (includes 1 test)
Prerequisites:

• Milling Machines Fundamentals (386031)
• Milling Machine Practice and Operation, Parts 1-2 (386033-386034)

Course Objectives:

• Indexing
• Direct Indexing
• Indirect Indexing
• Compound Indexing
• Differential Indexing
• Linear Indexing
• Spiral Work
• Generation of Helix
• Calculation of Spiral-Head Change Gears
• Cutting Helixes
• Milling Cams
• Tables
• Simple and Differential Indexing
• Compound Indexing
• Bevel-Gear Dividing Head
• Angular Indexing
• Power Drive for Helical Milling
• The Use of CNC in Modern Indexing and Spiral Work

Special Notes:

• This new course replaces courses 2218 and 386014.

Course #: 386036
Duration: 10 hours (includes 1 test)
Course Objectives:

• Types of Lathes
• Principal Parts of a Lathe
• Speed Controls
• Feed Controls for Tools
• Basic Work-Holding Devices

Special Notes:

• This new course replaces courses 3520A and 386001.

Course #: 386037
Duration: 10 hours (includes 1 test)
Course Objectives:

• Auxiliary Work-Holding Devices
• Preparation for Machining
• External Machining

Special Notes:

• This new course replaces courses 3520B and 386002.

Course #: 386038
Duration: 10 hours (includes 1 test)
Course Objectives:

• Internal Machining
• Special Lathe Operations
• Tailstock Operations
• Offset Turning

Special Notes:

• This new course replaces courses 3520C and 386003.

Course #: 386039
Duration: 10 hours (includes 1 test)
Course Objectives:

• Types of Tapers
• Taper Turning

Special Notes:

• This new course replaces courses 3520D and 386004.

Course #: 386040
Duration: 10 hours (includes 1 test)
Course Objectives:

• Threading
• Thread Standards and Chasing Setup: Thread Chasing and Standard Threads. Specialty Threads

Special Notes:

• This new course replaces courses 3520E and 386005.

Course #: 386016
Duration: 10 hours (includes 1 test)
Prerequisites:

• Basic Machining Skills (Block X08)

Course Objectives:

• Forms of Abrasives
• Classification of Abrasives
• Abrasive Grinding Processes and Machines
• Standard Wheel Marking System
• Abrasive Types
• Grain Size
• Wheel Grade, Wheel Structure, Wheel Bonds
• Diamond and Cubic Boron Nitride Wheels
• Wheel Grinding Machines
• Wheel Shapes
• Grinding Wheel Testing and Maintenance
• Grinding Fluids or Coolants Coated Abrasives
• Applications and Characteristics of Coated Abrasives
• Factors Affecting Stock Removal and Finish
• Safe Practices for Grinding

Special Notes:

• Covers subject at an advanced, in-depth level.
• This updated course replaces course 5023.

Course #: 386010
Duration: 10 hours (includes 1 test)
Prerequisites:

• Basic Machining Skills (Block X08)

Course Objectives:

• Types of Cylindrical Grinding Machines
• Major Units of Center-Type Grinders
• Grinding Machine Controls
• Grinding Wheels
• Coolants

Special Notes:

• This updated course replaces course 3560A.
• The entire course consists of study units 386010-386011.

Course #: 386011
Duration: 10 hours (includes 1 test)
Prerequisites:

• Basic Machining Skills (Block X08)

Course Objectives:

• General Safety Information
• Machine Setup Procedure
• Production Grinding
• Roll Grinding
• Grinding Applications
• Troubleshooting in Cylindrical Grinding

Special Notes:

• This updated course replaces course 3560B.
• The entire course consists of study units 386010-386011.

Course #: 386012
Duration: 10 hours (includes 1 test)
Prerequisites:

• Fundamentals of Grinding (386016)

Course Objectives:

• Introduction to Surface Grinding
• Types of Surface-Grinding Machines
• Components of Surface-Grinding Machines

Special Notes:

• This updated course replaces course 5024A.
• The entire course consists of study units 386012-386013.

Course #: 386013
Duration: 10 hours (includes 1 test)
Prerequisites:

• Fundamentals of Grinding (386016)

Course Objectives:

• Preparing the Abrasive Wheel for Surface Grinding
• Surface Grinder Operations
• Surface Finish and Measurement

Special Notes:

• This updated course replaces course 5024B.
• The entire course consists of study units 386012-386013.

Course #: 386029
Duration: 10 hours (includes 1 test)
Prerequisites:

• Fundamentals of Metal Cutting (386030)

Course Objectives:

• Explain how electrical discharge machining (EDM) works.
• Describe the difference between wire and ram EDM.
• Explain how laser light is produced and how lasers are used in industrial settings.
• Explain why a plasma cutting torch is so much hotter than other types of cutting torches.
• Describe the difference between chemical and electro-chemical machining.
• Explain how water can be made to cut steel.
• Describe the common manufacturing methods of rapid prototyping

Course #: 3195
Duration: 10 hours (includes 1 test)
Course Objectives:

• Methods of Heat Treatment
• Gas-Fired and Electric Furnaces
• Controlled Atmospheres
• Heating Baths
• Crucible Furnace
• Oil and Air Tempering Furnaces
• Quenching Baths
• Quenching Tanks
• Heat-Treating Operations
• Composition, Properties, and Uses of Carbon Tool Steel
• Heating and Cooling for Annealing
• Heating for Hardening
• Oil-Hardening Steels
• Air-Hardening Steels
• High-Carbon, High- Chromium Tool Steels
• Chisel Steels
• Hardening and Tempering Taps and Reamers
• Twist Drills
• High-Speed Steel Saws
• Springs and Chromium-Steel Rolls
• Heat Treatment of Dies, Forged Chisels, and Rock Drills
• Structures of Alloy Steels
• High-Frequency Hardening
• Dielectric Heating

Course #: 386017
Duration: 10 hours (includes 1 test)
Prerequisites:

• Fundamentals of Grinding (386016)

Course Objectives:

• Wheel Selection and Shapes
• Oilstones
• Honing Cutting Tools
• Grinding Single-Point Tools
• Angle Calculations
• Universal Grinder
• Drill Grinding
• Testing Drill Points
• Grinding Milling Cutters
• Clearance Grinding
• Tooth Rest
• Grinding Side, Shank Angular, Inserted-Blade, and Helical Cutters
• Grinding Circular Saws, Formed Cutters, Gear Cutters, Hobs, Reamers, Taps, Radial, and Tangential Chasers
• Grinding Carbide Tools
• Grinding Internal and Slab Broaches

Special Notes:

• This updated course replaces course 5349.

Course #: 386E01
Duration: 20 hours (includes 4 tests)
Prerequisites:

• Basic Industrial Math (Block X21)
• Reading Shop Prints (386043 and 386044)

What Students Learn:

Lesson 1 - Introduction to GD&T Systems, Datum and Feature Control Frames · Defining Tolerance Control Systems; Reasons for Using Geometrics; GD&T Symbols; Datum; Interpreting Feature Control Frames; Scanning Prints.

Lesson 2 - Geometric Tolerance Zones: Controlling Form, Profile and Orientation. · Entities Found in the Tolerance Zone; Form and Profile Controls: Straightness, Flatness, Roundness, Cylindricity, Lines and Surfaces; Orientation Controls: Parallelism, Angularity, and Perpendicularity.

Lesson 3 - Material Modifiers, Location & Runout Characteristics and the GD&T System: · Least and Maximum Material Conditions; Runout; Inspecting Geometric Position; Finding Earned Tolerance; System Notes; "The 13 Characteristics".

Lesson 4 - Practical Application of GD&T Skills for Manufacturing · Single Axis Feature Inspection and Rework; Inspecting and Reworking Two Axis Features; Computing Geometric Tolerances for Designs; Complex Tolerances.

Special Notes:

• This course consists of a textbook and supplemental study guide.

Course #: 186036
Duration: 5 hours (includes 1 test)
Course Objectives:

• Describe how job roles change as a company evolves in its quality consciousness.
• Explain several ways in which you can support TQM.
• Identify approaches, practices and skills associated with positive organizational change.
• Differentiate between the "change process" at the company level and the manufacturing processes that require improvement.
• Describe major causes of process variation and give examples of how they may affect you in your job.
• Explain why and how the reduction of variability is a key factor in process improvement.
• Describe why and how quality and process improvement depend on data-driven decision making.
• Identify seven quality tools and explain their uses.

Course #: 386E02
Duration: 70 hours (includes 7 tests)
Prerequisites:

• Basic Industrial Math (Block X21)

What Students Learn:

Part 1 (386026). Lesson 1 - Total Quality Management for Technicians:

Quality Systems, Communication, and Motivation; Total Quality Management (TQM) Tools, Responsibilities and Systems; Quality Costs: Identifying, Controlling, Minimizing, Reporting and Analysis; Planning and Conducting Audits; Inspection Systems and Planning.

Lesson 2 - Blueprint and GD&T System Interpretation for Inspection:

Using Engineering Prints for Inspection; Working with Geometric Dimensioning and Tolerancing Systems; Graphical Inspection Analysis Procedures and Advantages.

Part 2 (386027). Lesson 3 - Common Inspection Tools:

Measurement Tools, Accuracy and Errors; Spring Calipers; Gage Blocks; Indicators; Micrometers and Vernier Instruments; Hole, Attribute, and Radius Gages; Tapered Parallels; Measuring Threads; Calibration Techniques.

Lesson 4 - Surface Plate Inspection Methods: · Surface Plates and Gages: Care of Equipment; Measuring Various Attributes with Surface Plates.

Lesson 5 - Special Measurement Equipment and Techniques: · Digital Measuring Equipment; Using Optical Flats; Measuring Surface Finish; Pneumatic Comparators; Circularity and Cylindricity; Optical Comparators; Coordinate Measurement Machines (CMM’s); Hardness Testing.

Lesson 6 - Lot by Lot Acceptance: · Basic Probability; Sampling Verses 100% Inspection; Lot-by-Lot, Process Control and Random Sampling; Using Mil-Std-105E for Sampling; Dodge-Romig Tables; Mil-Std-414; Variable Sampling Tables; Operating Characteristic Curves.

Lesson 7 - Statistical Process Control in Practice: Objectives and Tools for Process Control; Computing Average, Range and Standard Deviation; Control and Specification Limits; Identifying Processes In-Control; Plotting Techniques; Control Charts and Pattern Analysis; Process Capability.

Special Notes:

• This course consists of a textbook and two supplemental study guides. We recommend the course be purchased in its entirety. However, if needed due to targeted training, study guides (Parts 1 and 2) can be purchased separately, with or without the textbook. Note that the textbook is required for the Part 1 study guide. Call Customer Service for pricing and ordering information.

Course #: 066903
Duration: 45 hours (includes 3 tests)
Prerequisites:

• Basic Machining Skills (Block X08)

Course Objectives:

• Numerical Control Basics; The History of Numerical Control; The Computer; Input Media; How Numerical Control Operates; Machine Tools.
• CNC System Programming; Programming Data; Simple Programming; Angular and Contour Programming; Miscellaneous Numerical Control Functions.
• Types of CNC Equipment; Machining Centers; Chucking and Turning Centers; Electrical Discharge Machining; Numerical Control and the Future.

Course #: 386041
Duration: 10 hours (includes 1 test)
Prerequisites:

• CNC Technology and Programming (066903)

Course Objectives:

• Apply of canned cycles, subroutines, and loops in real-world programming applications.
• Modify and adapt basic programs and commands to develop advanced turning programs.
• Use special codes to automate complete jobs, including programming for maximum production efficiency.
• Affect of some CNC operations on cutting speeds and feed rates.
• Correct common problems such as unacceptable part size and out-of- tolerance feature locations.

Course #: 386042
Duration: 10 hours (includes 1 test)
Prerequisites:

• CNC Technology and Programming (066903)

Course Objectives:

• Apply of canned cycles, subroutines, and loops in real-world programming applications.
• Modify and adapt basic programs and commands to develop advanced milling programs.
• Use special codes to automate complete jobs, including programming for maximum production efficiency.
• Affect of some CNC operations on cutting speeds and feed rates.
• Correct common problems such as unacceptable part size and out-of- tolerance feature locations.

Course #: 386028
Duration: 10 hours (includes 1 test)
Prerequisites:

• Fundamentals of Metal Cutting (386030)

Course Objectives:

• Understand the fundamental characteristics of toolholders required for various machine tools.
• Understand and describe how the toolholder affects the quality of the machining operation.
• Interpret national standards for tool and toolholder identification systems.
• Understand the differences in toolholder tapers and the proper applications for each type of taper.
• Understand and describe the effects of toolholder concentricity and imbalance

Course #: 5807
Duration: 10 hours (includes 1 test)
Course Objectives:

• Sketches of Machine Details
• Drawing Straight and Curved Lines
• Finish Marks
• Surface Roughness
• Arrangement of Dimensions
• Partial Section
• Conventional Sections
• Shaft Coupling
• Spur Gear
• Bevel Gear
• Pieces Requiring More Than Two Views
• Foreshortening
• Measurements
• Curved Outlines and Fillets
• Pictorial Sketching
• Isometric Drawing
• Oblique Drawing
• Conventional Symbols
• Piping Diagrams

Course #: 5110
Duration: 10 hours (includes 1 test)
Prerequisites:

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

Course Objectives:

• Treatment of Iron Ores
• Blast Furnace Plant
• Slag Blast Furnace Reactions
• Control of Elements in Furnace Iron
• Pig Iron
• Cast Iron
• Malleable Cast Iron
• Cast-Iron Founding
• Electric Furnace Cast Iron
• Molding Cast Iron
• Specifications for Iron Castings
• Alloy Cast Irons
• Nature of Wrought Iron

Course #: 5337
Duration: 10 hours (includes 1 test)
Prerequisites:

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

Course Objectives:

• Ores and Extraction
• Copper and Alloys
• Lead and Alloys
• Zinc
• Aluminum and Alloys
• Tin and Alloys
• Nickel and Alloys
• Magnesium and Alloys
• Gold
• Silver
• Antimony
• Manganese
• Molybdenum
• Tungsten
• Chromium
• Cobalt
• Bismuth
• Mercury
• Cadmium
• Tantalum
• Platinum Group
• Beryllium
• Calcium
• Zirconium
• Vanadium
• Titanium
• Columbium

Course #: 5111
Duration: 10 hours (includes 1 test)
Prerequisites:

• Practical Measurements (Block X22)
• Elements of Chemistry (5011)
• Metallurgy of Iron (5110)

Course Objectives:

• Steel Production
• Raw Materials Used in Steelmaking
• Regenerative System of Open-Hearth Furnace
• Basic and Acid Open-Hearth Process
• Oxygen
• Process
• Bessemer Converter
• Basic and Acid Electric Process
• Crucible Process
• Alloy Steels
• Influence of Melting Practice on Physical Properties of Steel

Course #: 5338A-B
Duration: 20 hours (includes 2 tests)
Prerequisites:

• Practical Measurements (Block X22)
• Elements of Chemistry (5011)
• Metallurgy of Iron (5110)
• Metallurgy of Steel (5111)
• Metallurgy of Nonferrous Metals (5337)

What Students Learn:

Part 1 (5338A). Methods of Examining Metal Structures; Mounting and Polishing Specimens by Hand and Machine; Magnifiers; Optical and Electron Microscopes; Cameras; Illumination; Polarized Light Ultraviolet Light; Use of Photographic Equipment; Metallography of Nonferrous Metals; Etching and Coloring Specimens for Macroscopy and Microscopy; Photomicrographs of Copper Aluminum; Magnesium; Nickel; Zinc and Tin Alloys.

Part 2 (5338B). Importance of Carbon in Iron and Steel; Macrostructure of Steel; Developing Microstructures; Iron-Carbon Structures; Ingotism; Iron-Carbon System; Carbide or Cementite and Pearlite; Austenite, Martensite, Spherodized Structure; Structures of Heat-Treated Alloy Sheets; Decarburized Surface; Overheated Steel; Quenching Cracks; Fatigue Cracks; Macrostructure of Cast Iron; Microstructures of Cast Iron; Alloyed Gray Irons; Malleable Iron; Electrolytic and Wrought Irons.

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

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

What Students Learn:

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

• Basic Machining Skills (Block X08)

What Students Learn:

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.

Special Notes:

• 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)

Course Objectives:

• 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)

Course Objectives:

• 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)

Course Objectives:

• 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)

Course Objectives:

• 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

Special Notes:

• 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)

Course Objectives:

• 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

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

• Basic Machining Skills (Block X08)

What Students Learn:

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.

Special Notes:

• 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)

Course Objectives:

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

• Dies and Die Making (5101A-B)

Course Objectives:

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

• Dies and Die Making (5101A-B)

Course Objectives:

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

Course #: 186075
Duration: 10 hours (includes 1 test)
Course Objectives:

• Relate historical trends in manufacturing to modern ones
• Describe the development and importance of modern quality systems
• Explain how available material types shape manufacturing processes
• Describe early factory systems and their impact on modern systems
• Classify modern manufacturing systems by type and abilities

Special Notes:

• This course replaces 2520A

Course #: 186076
Duration: 10 hours (includes 1 test)
Course Objectives:

• Explain the relationship between atomic structure and material properties
• Classify materials used in manufacturing based on physical and mechanical properties
• Identify benefits and drawbacks of specific materials for a given application
• Interpret the classifications of various metallic materials
• Compare properties of various metallic materials
• Identify properties of and applications for various nonmetallic materials

Special Notes:

• This course replaces 2520B

Course #: 186077
Duration: 10 hours (includes 1 test)
Course Objectives:

• Describe common methods and applications for casting metals and plastics
• Describe and contrast various forming processes including forging, drawing, and others
• Differentiate between the benefits and costs of casting and forming processes
• Explain how the various conventional metal-removal technologies are used in manufacturing
• Identify the benefits of and range of applications for robotics and CNC systems in manufacturing
• Describe the benefits and costs of non-contact metal removal and shaping processes

Special Notes:

• This course replaces 2520C

Course #: 186078
Duration: 10 hours (includes 1 test)
Course Objectives:

• Relate the factors of production to how a given manufacturing organization is structured
• List the types of manufacturing production systems
• Suggest modifications of equipment layout to improve productivity
• Evaluating automation strategies and problems
• Benefits of quality management methods
• Describe their role in JIT, Lean, and e Manufacturing systems

Study Units:

• This course replaces 2520D