Russell W. Wood, Department Shop Supervisor
Room 0125, Physics
Phone: 301-405-2272
Office Hours: Monday-Friday 10:00a.m.-5:00p.m., except class times
Prerequisites: None
Texts: Modern Metalworking
The Goodheart-Willcox Co. ISBN 1-56637-710-2
by John R. Walker
Plus hand-outs
of selected and prepared materials.
Course Description
Students will learn the proper use of machine tools to manufacture
parts from metal alloys, and the importance and proper use of engineering
documentation in the development process. Aluminum, primarily due to its
ease of machining, will be used to learn basic procedures. Steel will be
introduced to illustrate the variation of properties of materials. Students
will set up and operate lathes for the first half of the semester and then
move on to milling machines for the second half. They will be required
to manufacture, from drawings, parts to tolerances as close as .003
inch. The instructor will ensure the students' safety and ability to accomplish
these tasks throughout the course. This course will be invaluable to engineering
students, graduate students in all research laboratories, and anyone planning
to become involved in a manufacturing environment.
Reading
Handouts will be presented in the context of the topic/s at hand.
The student is expected to read and thoroughly understand the supplementary
material as quickly as possible after it is handed out.
Likewise, reading assignments in the text will be aligned with the weekly
class activity. It is expected that the student will attempt to understand
the next week's class excercise ahead of time to maximize the learning
experience in class.
Course Calendar
Class 1 Principles of mechanical
drawing and engineering documentation.
Principles of metalworking: Tools and Materials
Introduction to Machine Tools
Class 2 Basic and precision measurement:
Methods and Tools
Sawing; Setting up lathe and rough turning to length.
Class 3 Turning with feed.
Drilling, Hand Tapping in lathe.
Class 4 Taper turning. Parting
off. Uses of the file on the lathe.
Class 5 Hand threading with a die.
Grinder safety; discussion of tool grinding.
Thread specifications and measurement.
Class 6 Finishing to size. Threading
in the lathe (chasing thread)
Class 7 Thread chasing continued.
Boring. Discussion of Knurling, and other secondary
operations, if time permits.
Class 8 Tour of Instrument
Shop. Discussion of Milling Applications & RotatingTooling
Demonstration of Milling Machine functions. Demonstration of
machine adjustments. Saw blanks and begin squaring of part per drawing.
Class 9 Complete milling
blocks square and to size; Filing and
De-burring; Milling grooves and shoulders.
Class 10 Deep Drilling; Drilling, Counterboring
and Tapping.
Class 11 Slotting operations with slitting
saw.
Class 12 Indexing operations. Mixed Lathe
and Mill Operations.
Class 13 Broaching. Review.
**please note: Course calendar may vary depending on speed class schedule
Grading
Course Policies
Attendance and punctuality are of utmost importance due to the nature
of this class. It is
an ongoing learning process where one operation leads to another so
if you miss or come
late often you will fall too far behind to progress. Make-up classes
may be possible, depending on instructor's work load.
Students are responsible for making sure
I have their correct email address and checking their email daily. Important
messages will sometimes be sent to the class by email.
Safety is a top priority for yourself and those around you. Accidents can
happen in a split
second, if you are not alert and concentrating. Most students receive
good grades providing they are punctual, make an effort to understand the
principles, follow direction and obey safety rules.
Support Services
The instructor is present all week to answer any questions you may
have or any guidance
you may need to excel in this course.