BENSON POLYTECHNIC HIGH SCHOOL

COURSE OUTLINE

COURSE NUMBER 16240C MANUFACTURING III – SHEETMETAL LAYOUT/DEVELOPMENT and TECHNICAL WELDING PROCESSES

CREDIT: .50 REVISED DATE: AUGUST, 2010

RECOMMENDED GRADE LEVEL: 11

LENGTH OF COURSE: ONE QUARTER / 1 BLOCK PERIOD PER DAY

REQUIRED X

PREREQUISITES: “C” or better in Manufacturing level I or II

COURSE DESCRIPTION

Manufacturing III Sheet metal Layout/Development and Technical Welding Processes is designed for juniors interested in sheet metal forming and development, welding and related industrial trades. The course will begin with the personal safety procedures and the environmental awareness required for performing in this hands-on industrial lab. Students will be given introduction to the sheet metal tools, materials and processes followed by instruction on industrial tool application. Assigned projects and activities requiring students to operate and apply sheet metal shaping and forming procedures. Students will use hand tools, machine tools, and industrial machine power tools to do metal forming. Additional design and layout will be required with the application of Mastercam for pattern cutouts with CNC plasma cutter. In addition to metal forming the student will begin the technical training for joining ferrous and nonferrous metals in the fusion process. Students will have the opportunity to experience one or all of the following welding processes oxy-acetylene, shield metal arc, gas metal arc, gas tungsten arc, brazing, oxy-acetylene cutting, plasma cutting and CNC Plasma cutting. Students may earn dual college credit through PAVTEC.

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COURSE GOALS

This course is based on performance outcomes. The following performance outcomes are based upon established industry standards and the Portland Community College courses MCH 123 Sheet Metal Fabrication. The student will demonstrate knowledge and understanding by completing PCC course activities designed to emphasize the development of skills and knowledge outcomes prescribed by established industry standards. Upon completion of this course, the student will be able to layout/develop and setup sheet metal patterns by hand. The student will perform operations with sheet metal hand tools, sheet metal machinery, and sheet metal machine power tools. Sections may be independent or dependent on other sections. Given the necessary tools indicated by the operations on a print, the student will produce a work piece to print specifications.

Inaddition to the the performance outcomes structured around the sheet metal industry, students will also begin the introduction to a variety of welding and cutting methods and procedures related to industry standards and Portland Community College WLD 271 Oxy- acetylene Welding. The student will setup and safely operate oxy-acetylene and cutting, shielded metal arc welding, plasma cutting, and CNC plasma machine cutting.

1. Understand the importance of safe work habits and conditions related to industry standards. 2. Gain basic knowledge of metal working processes used in industry to form, join and finish products in a sheet metal and welding environment. 3. Understand and develop sheet metal mathematics in a variety of applications. 4. Understand and apply the simple layout, computation, and problem solving skills for sheet metal application. 5. Identify basic hand tools and machine tools for the sheet metal industry. 6. Develop basic skills required for the operation of hand tools, machine tools and machine power tools. 7. Learn concepts and techniques associated with Mastercam CAD/CAM software to design parts 8. Learn electronic design in surfaces of 2-D geometry construction using Mastercam computer assisted machining software. 9. Learn techniques of modifying existing geometry using Mastercam computer assisted machining software . 10. Understand layout for flat patterns, radial development and triangulation. 11. Understand the proper safety procedures for oxy-acetylene welding. 12. Understand the proper safety procedures for shielded metal arc welding. 13. Perform correct welding procedures for various oxy-acetylene positions. 14. Perform correct welding procedures for various shielded metal arc welding positions. 15. Understand the proper safety procedures and operation for plasma cutting. 16. Create, design, and translate Mastercam geometry to be imported to CNC Plasma Machine. 17. Understand the importance of craftsmanship. 18. Evaluate his/hers aptitudes, interests, and abilities in exploring career opportunities. 19. Know there are training and employment opportunities for cultural/ethnic groups in precision metalworking. 20. Students must complete all assigned assignments and course projects. 2 COURSE OUTLINE

Unit 1 Orientation Oregon Skill Sets a. Safety Procedures MNZ06.02 b. Demonstrate proper work ethic MNZ08.01 c. New Processes and Methods MNZ02.03 / MNZ04.01 d. Measuring and Precision Measuring e. Proper use of vocabulary and MNZ02.01 documents f. Use systematic theory MNZ05.01 g. Develop a career plan MNZ09.02 / MNZ09.03

Unit 2 Hand Tools 1. Identification 2. Care 3. Use and Safety

Unit 3 CAD/CAM Designing 2D 1. Software Introduction 2. CAD Geometry 3. CAD Drawings

Unit 4 Machine Tools 1. Identification and application 2. Care 3. Use and Safety 4. Brake, Shear, Knotcher, Barfolder, Turret Punch, English Wheel, Slip Roll

Unit 5 Machine Power Tools 1. Identification and application 2. Care 3. Use and Safety 4. Hydraulic Shear, Hydraulic Press Brake, Hydraulic Piranha, Hammer Smith

Unit 6 Materials 1. Ferrous/Nonferrous 2. Sheet stock 3. Plate stock 4. Bar stock

Unit 7 Layout 1. Sheet metal math 2. Flat Pattern Development 3. Radial Development 3 Unit 8 Forming 1. Hems and Tabs 2. Cutting and Shearing 3. Bending order 4. Joining i.e. seams, solder, rivet, Pittsburgh lock

Unit 9 Oxy-acetylene Welding 1. Set-up and Safety 2. Application 3. Weld Positions

Unit 10 Oxy-acetylene Cutting 1. Set-up and Safety 2. Applications 3. Cutting Procedures

Unit 11 Plasma Cutting and CNC Plasma Machine 1. Set-up and Safety 2. Identification and Applications 3. Care 4. Use

Unit 12 Welding Symbols 1. Groove Welds 2. Fillet Welds

Unit 13 Shielded Metal Arc Welding (7024) 1. Set-up and Safety 2. Applications 3. Flat positions Welds

Alignment with Oregon high-skill and high-wage occupations: SOC Codes: 47-2221, 51-2011, 51-2041, 51-4121, 51-4192 and 51-4199

TEXT “Precision Sheet Metal” Shop Theory by Richard S. Budzik “Precision Sheet Metal” Mathaematics by Richard S. Budzik “Welding Technology Fundamentals” by William A. Bowditch & Kevin E. Bowditch

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