Projects

Tenth Grade

• Sketching Basics and drawing, communication of ideas,
• Selling ideas to a group,
• Simple harmonic motion and basic sound wave science,
• Safety and Use of metal cutting hand tools,
• Safety and Use of hammers, pliers, hand drills and small pneumatic tools,
• Simple fasteners and rivets,
• Review CNC engraving,
• Basic linear measurement.

• Safety and use of vertical band saw,
• Basic measurement and material layout & planning,
• Working as a production crew with division of tasks for a common goal,
• Detailed sketching and Blueprint formats,
• C.A.D. drawing for common idea distribution,
• Conversion of CAD drawings to CAM software,
• Using C.A.M. software to generate CNC code and transfer to machine tools,
• Set-up and run CNC production runs,
• Safety and operation of machine lathes,
• Basic turning & threading operations,
• Fixture building and bending fixture work,
• Polishing and hand finishing work,
• Assembly operations and working fits.

• Market analysis and design for retail sales.
• Basic operation and Safety of vertical milling machines,
• Squaring material in a milling vice with milling cutters,
• Basic precision measurement and material location,
• Manual programming of CNC mill equipment,
• Precision holding techniques and precision production tolerances,
• Inspection for process control and quality assurance,

• Safety and use of pedestal grinder,
• Inspecting work with hand gages,
• How properly / improperly sharpened cutting tools can effect work.

• Hand grinding HSS [high speed steel] and carbide cutters,
• Rake, clearance and other angles.

• Learn the parts of the lathe and their functions. Lathe safety practices.
• Practice lathe setups and related tool usage. Measuring on the lathe.
• Selection and maintenance of tool bits. Safety and use of pedestal grinder.
• Turning, facing, center drilling, on a practice piece in a universal chuck.
• Start plumb bob. Turing and knurling between centers.
• Holding work in a lathe collet.
• Turning chamfers and angles with compound rest.
    - Altering commercial screws and fitting small assemblies.

• Milling machine nomenclature and function.
• Milling machine safety and care.
• Practice milling machine setups and learn related tooling.
• "Trammel" or "square" machine head and work vise.
• Learn to use surface mill while squaring and sizing a steel block.
• Select and saw cut rough material for 1-2-3 blocks, (review saw safety)
• Surface mill blocks to size, leaving extra for finishing grinding. (Measuring)
• Learn how to locate, spot, center drill, tap drill, ream, counter-sink, counter-bore, pilot drill, and tap on a vertical mill.
• Learn procedure and safety on how heat-treat tool steel to desired hardness.
• Harden blocks and measure hardness for accuracy.
• Learn surface grinder nomenclature and safety.
• Precision grind and practice piece while learning related tools and technique.
• Grind blocks to finish size and squareness accurate to +/- .0002" using precision tools and technique.
• Bench marking for part identification.

• Usage and Safety of surface grinders,
• Care and storage of grinding wheels,
• Mounting, Truing and Dressing grinding wheels,
• Acquire quality surface finishes and accurate sizes,
• Practice work holding solutions for ferrous and non-ferrous materials,
• Maintaining proper cutting conditions.

• Start-up and shut-down sequences,
• Use of machine controls and programming modes,
• Enter and Edit a working program,
• Graphic simulator functions,
• Work-shift and Cutter Compensation Off-sets,
• Properly install tool holding and work holding equipment,
• Run and measure a finished machined work piece,
• Import and Edit a Posted program from a CAM software source.

• Safety and operation of metal heat treatment furnace,
• Oil hardening tool steel, Air hardening tool steel,
• Annealing and Tempering, Tempering Colors,
• Use and care of a Rockwell Hardness tester.

• Turning, facing, knurling and necking. (tool steel)
• Counter boring to protect center holes.
• Heat treating for material hardness review.
• Safety, setup and operations of a outside diameter grind.
• Truing or aligning machine centers.
• Grinding and measuring diameters to within .0002" of size and straightness.

• Holding and centering square work pieces in a lathe.
• Working with interrupted cuts.
• Cutting and measuring threads.
• Planning for secondary operations.
• Holding round work on a milling machine.
• Set up and use spacer heads and collet blocks.

• The importance of machining surfaces, holes and other features with accurate size and location repeatability.
• Maintaining matting parts fit and interchange ability.
• Hog milling, side milling, deep drilling, reaming, and boring of holes.
• Hand tapping, power tapping, and automatic tapping heads.
• Machining and measuring dovetails.
• Holding and machining small parts on a lathe.
• The fine art of finish file work and deburring.

• Control size and squareness with in .0002" accuracy.

• Precision layout of small sheet metal part,
• Angled cuts to layout lines,
• ProtoTRAK programming of simple profile,
• Precision milling of graduation lines,
• Metal stamping letters and numbers,
• Draw filing and painting engraved/stamped characters.

• Job planning and layout
• Fixture building and clamping set-ups
• Radius blending
• Finishing square inside corners

• Enter and edit a layered multi-tool path program
• Set-up tool magazine to match program requirements
• Set-up holding device for production run
• Be sure work shift and graphics are accurate to real machine space

• Access and run existing Computerized Numerical Control (CNC) programs.
• Learn basic C.N.C. code language.
• Create a DXF. File from and AutoCAD drawing.
• Create tool path from a DXF file.
• Learn basic Master CAM operations.
• Learn basic set ups and commands of the EMCO PC turn 50 C.N.C. lathe.

• Setup auto tool change magazine and program cutter compensations.
• Editing programs, working with different materials, and work off sets.
• Extensive integrated use of AutoCAD, Master CAM, and Emco software.
• Working knowledge of C.N.C. codes and their lathe application.
• Should be familiar with 2-axis programming.

• Learning the basics of the Anilam 1400 controller.
• More C.N.C. code programming and editing.
• More use of C.A.M. (computer automated machining)
• Learning to use "Conversational Programming"
• Living in a "3-D" world.
• Cutter compensation and/or controlling depth.
• Finding the best feed and speed rates for the material being cut and operation being performed.
• How to hold work on a C.N.C. mill and how to pre-set quick change cutters.

• Design production product for sale
• Calculate cost of production run (material, time, tooling, etc.)
• Design manufacturing process (clamping, tooling, operations)
• Write and trouble shoot automated programming
• Execute trial runs to verify cost and time predictions
• Create quality controls to asses level of success
• Sell product in retail setting

• Review surface grinding protocols
• Grind blocks as matched set
• Surface finish measuring

Eleventh Grade

• Time management skills
• Technical reading comprehension
• Detailed documentation of progress
• Research and problem solving skills
• 2D and 3D printing techniques

• Turning long diameters and maintaining concentricity.
• Precision measuring thread pitches diameters.
• Turning tapers with taper attachment and offset tail stock methods.
• Truing work in an independent chuck.
• Cutting internal threads.
• Machining curves, radii, and crowns on both manual and C.N.C. lathes.
• Using taper pins and taper reamers.
• The difference between counter bores and spot faces.
• Finish filing to "Blend" and finish polishing for maximum effect.

• Mandrel use, press fits and arbor press.
• Horizontal miller functions, tools, arbors, and attachments.
• Set up of universal indexing head and foot stock on a horizontal mill.
• Proper selection and use of spur gear cutters.
• Methods of centering milling cutters.
• Application of simple indexing * (must complete related class lessons first)
• Precision measurement of external spur gears.
• Keyway broaching and pin file use.

• Design unique shape with in specific envelope of space
• Use standard clamping devices to hold new contour shapes
• Access and execute CNC cycle tools (like "mirror" and "repeat")
• Control production to achieve balanced product performance

• Making duplicate parts of sheet metal items.
• Machining oil impregnated bronze.
• Safety, set up, and execution of cutting and measuring acme threads.
• Pros and cons of pop rivets and cold rivets.

• Detailed job planning
• Making custom holding fixtures
• Making bending die sets
• Time management
• Reverse engineering

• Advanced CNC turning operations and set-ups
• Creating specialized cutting tools
• Adapting standard machine tools to unique situations
• 4 axis milling machine set-up
• 4 axis CNC mill programming
• Adding in machining lugs to create holding surfaces
• Blending odd contour merges for a smooth finished product

• can be anything from replacing a standard commercial bought machine part to making a replacement gear from scratch.

• Using reference books to become familiar with a new operation set
• Safety and usage of basic electrode welding equipment
• Apply reference text to start safe practice exercises
• Clean and prep work area and materials
• Weld samples Flat, Right angle, Fillet, Butt
• Clean finish weld and evaluate results

• simple planning and layout of bent metal parts
• safety and use of manual metal bending tools

• Layout and planning of more complex bent metal assembly
• Practical application of manual bending tools
• Assembling complex shapes from simple bent components
• Grinding, cleaning and finishing final assembly
• Painting and finishing quality display items

• Hog milling tool steel and managing friction heat and stress.
• Watching for tool deflection and cutter flaws.
• Finish grinding an assembly.
• Grinding to exact fit and measuring close tolerance roll diameter.
• Cleaning threaded hole after heat treatment.

Twelfth Grade

• Define and understand basic EDM terms, concepts, and practices.
• How E.D.M. technology is being used in the local businesses.
• Gain "hands on" experience in our shop or at a cooperating business.

• Re-enforce lessons previously learned.
• Learn how to adapt learned skills to solve new problems.
• Rotary table usage.
• Handling internal material stress.
• Observing how different materials work together in bearings and slides.
• Introduction to cam and crank shaft machining.
• Making practical use of C.A.D. / C.A.M. technologies to solve difficult machining problems.
• Learn how to make flat and coil springs.
• Working with precision fits and how to control for desired effect.
• Exploring soldering and brazing techniques.
• Assembly dimensions, jig work, and fixturing.
• Basic knowledge of how engines work.

• Indicating square work dead true on a lathe.
• Safety and operations of a tool post grinder.
• Grinding and measuring close tolerance inside diameters.
• Learning to account for wheel wear and surface finishes.
• Precision measurement of wall thickness and central locations.
• Measuring finish ground tapers.