Metals-Manufacturing 2: Machine Tool and Advanced Welding

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View the course Handouts.

INSTRUCTOR: MR. MUNTZ
INDUSTRIAL TECHNOLOGY DEPARTMENT
dmuntz@lghs.net
408-354-2730 x220
TEXTBOOK: MODERN METAL WORKING, JOHN R. WALKER

COURSE INFORMATION

Course Content:

Verbal, auditory, written and visual learning methods will be used daily, in addition to the hands-on (kinesthetic) learning that will happen in the second half of each semester.

Topics to be covered in Metals-Manufacturing 2 are:

INSTRUCTOR INFORMATION

My Philosophy: The Instructor is here to teach and the student is here to learn.

The purpose of this class is to develop critical thinking and manipulative skills while exploring industrial processes. The main themes of this course are the practical arts of: Following Directions, Personal Organization, Time Management, and Responsibility. My personal goals as an instructor are to maintain a safe learning environment for all students, while producing productive young members of society. The best way to ensure success in this class is to be kind, courteous, observant, and thoughtful.

Office Hours

The instructor is available for tutoring or other assistance in the lab during tutorial, Monday through Friday, unless otherwise posted. Lecture material missed during an absence from school should be made up during this time.

REQUIRED MATERIALS

Materials Required:

Three Ring Binder for notes: 1"-1 " size rings, hard cover.
This class requires a three ring binder that may be stored in the students' in-class locker. This binder is to be present in class every day, and will be checked by the instructor every six weeks. See the instructor if you cannot provide a binder for this class.

Required Class Lab Fee: $10.00
This fee covers the cost of consumable materials specific to the course. The cost for all materials used to learn skills required for the course are covered by this fee. Any projects the student makes and takes home must be paid for individually. Any additional projects students complete using school-provided materials must be paid for on an individual basis. Students will be instructed in how to make a bill of materials for each project before it is completed so they may predict the cost ahead of time. Students unable to pay the Lab fee are instructed to see the instructor to make individual arrangements.

Lockers

Lockers are provided for each student to share with one other student in the classroom. They may keep their binder, safety glasses and pencils in their locker. It is recommended that students also keep a pair of shoes on hand if they plan to wear sandals to school. No open toed shoes are allowed in the lab while any of the tools are being used. If a student is wearing sandals whey will not be allowed to enter the lab and will be unable to work on their project that class day. Locks for lockers are provided by the instructor, if lost, locks cost $5.00 to replace.
NOTE: Damage to tools or shop equipment due to misuse or carelessness will be the responsibility of the student to replace or compensate.

POLICIES AND RULES

Class Rules:

  1. No Hats
  2. No Electrical Devices
  3. No Sunglasses
  4. No Swearing
  5. No Food Drink or Gum
  6. Show Respect to all
  7. Be Prepared
  8. Do Your Best
  9. The Instructor dismisses students at the end of class, not the bell.

Required Footwear

No open toed shoes allowed in the Lab at any time. If the student is not wearing appropriate footwear he/she will not be allowed to enter the lab. This is important to remember, because the student may miss important demonstrations or work time in the lab.

Grading Policy

See separate grade sheet.

Repeat work

All lab work can be redone until quality is achieved is acceptable to student and teacher.

LAB SAFETY

Lab safety and Safety Test

In this course safety is of the utmost concern. For each tool the instructor will provide appropriate instruction and demonstrations to ensure safety of all who use it. A safety test must be passed each semester before students may use any tools in the lab. This test is a Pass/Fail exam. Safety is extremely important, and many of the tools and machines used in this class are potentially harmful if used carelessly or ignorantly. It is for this reason; a passing score on a Safety test must be 100%.

ATTENDANCE AND LATENESS

Lateness

All students must be in their seat with their notebook, and pencil ready, before the bell starts ringing.

Absences

Students are responsible for material and assignments missed. The student will be allowed the same number of days to make up work missed as the length of the absence.

Late Work

Late work and repeats are only accepted during the first six weeks of the school year. The work must be turned in within five days of the original due date or as per agreement with the instructor.

HOMEWORK AND TESTS

Homework

Very rarely is homework assigned in this class. When it is assigned it is expected to be turned in on the day due, in the proper format, completed neatly and completely.

Tests

Safety Test
Quizes
Semester One Final
Semester Two Final

CITIZENSHIP AND CLASS PARTICIPATION

Citizenship: You earn 210 points every semester, 70 points every six weeks.
+10 points for no infractions
-5 points for a tardy
-5 points for an absence
-5 points for leaving the lab/classroom
-5 points for any minor safety violation
-20 points for any major safety violation

This is a hands-on, activity based class. Students must be responsible for their own assignment completion. To complete all projects within the time allotted students must be on task every day they are in the lab. Your presence in class daily is vital to your success in the course. Lateness, and absences, will adversely affect your citizenship points.

Failure to take notes or be respectful during lecture/demo portion of class may result in a loss of citizenship points. This is considered failure to participate fully in the class.

AVAILIABLE SUPPORT/REASONABLE ACCOMODATIONS

Open Lab Time

The lab is available for use on school days after school until 5:00 PM unless otherwise posted. Open Lab Time is supervised work time for students to work on their class projects. If you require additional personal instruction on a course topic please come in during tutorial.

Personalized Tutoring and Special Accommodations

See Office Hours above.

UNIT AREAS COVERED IN METALS-MANUFACTURING 2

1. Tool Bit Sharpening

Read unit 36-10 to 15. Sharpen a piece of square pine to a general purpose tool bit point, then sharpen a genuine tool bit blank the same way for a grade.

2. Drill Bit Sharpening

Read unit 34-12 to 15. Sharpen one drill bit according to the angles indicated in the handout for a grade. Drill two holes in the provided scrap plate.

3. Oxyacetylene Welding Pipe to Pipe

Read unit 30-1 to 9. Produce a pipe to pipe weld at least two inches long (two pieces of pipe end to end), and a pipe "T" weld (with a proper fish mouth).

4. Flame Cutting (Burning)

Read unit 30. The cut must be three inches long. The cut must be strait, square to the top surface and no slag clinging on the underneath side.

5. Tungsten Inert Gas (TIG) Welding

Read portions of unit 30 relevant to TIG and handout. Flat butt weld must be three inches long. Must use Aluminum.

6. TIG Corner Weld

2-3" long corner weld Aluminum

7. Metallic Inert Gas (MIG) Welding

Read portions of unit 30 relevant to MIG and handout. Produce a "T" fillet weld that is three inches long. Must use Steel.

8. MIG Weld Butt

3" long, flat

9. Pattern Making

Make a flat back or a split pattern out of wood.

10. Casting

Read unit 21 and handout from Metals 1. Make one casting using your own pattern.

11. Precision Measurement Unit

No project is required for this topic, there will be a quiz on micrometer reading.

12. Machine Tool

Read units 36,37,38, and 33 and read Conventional Lathe and Conventional Mill units in handouts. Produce the Step Cylinder (lathe sample), the Stealth Container (lathe exercise) Mill Sample (milling exercise). Following the provided blueprints and demonstrations the student will build a fully operational Steam Engine (powered by compressed air)

OTHER ASSIGNMENT

Oral Report given in class on a topic related to Manufacturing or metalworking.

Written Report One to two page typed (see above)

FINAL ASSIGNMENT

The final project, a portfolio board , including work samples mounted neatly and labeled of:

This is used to showcase your showcase your skills and knowledge from the year.

HANDOUTS

All handouts are in .pdf format.

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