1 DOCUMENT RESUME ED 220 638 CE 033 535 Kelly, Michael G .

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1 DOCUMENT RESUMECE 033 535ED 220 638AUTHORTITLEINSTITUTIONSPONS AGENCY-PUB DATECONTRACTNOTEKelly, Michael G.; And.OthersMachine Shop Fundamentals: Part I.waubonsee Community Coll., Sugar Grove, Ill.Illinois State Board of Education, *Springfield. Del5t.ofAdult, Vocational and-Technical Education.Feb 82R-31-21-J-2106-407; R-32-32-J-2106-407261p.,EDRS PRICE'DESCRIPTORSIDENTIFIERSMili1/PC11 Plus Postage.Behavioral Objectives; Competence; Competency BasedEducation; Lesson Plans; *Limited English Speaking;*Machine Tool Operators; Machine Tools; Machinists;Manufacturing Industry; Postsecondary Education;Secondary Education; *Units of Study*Vocatfonal English as a gecond Language; WaubonseeCommunity College ILABSTRACTThese instructional materials weie devkloped anddesigned for secondary and adult limited English proficient studentsenrolled in machine tool technology courses. Part 1 includes 24lessons covering introduction, safety and shop rules, basic machinetools, basic machine operationS, measurement, basic blueprintreading, layout, and bench tools. Each lesson contains studentperfomance objectives, procedures for the students to follow inprogressing through the le'sson, infotmation sheets illustrated woithline drawings, and references and lesson summaries as needed. Thesecompetency-based lessons may be used as a main text, as supplementsto other textbooks, or as.the basis for a prevocational course inmanufacturing trades. (A corresponding student workbook and-instructor's manuals are available.) (KC)*Reproductions suiPlied by EDRS are the best that can be madefrom the,original **.**************,***********A*****if,4,1

Machine. Shop'Fundamentals:Part IIllinois' State Board ofEducation'Edward d G. GillState Superintendentof EducationDebartment ofAdult,Mocational andTechnical iducation.Research andDevelopment SectionFebruary, 1982Projdct StaffAdministrative:Kenneth ShjbataExecUtive Vice-PrestdentLeland ThompsonDean'of Social/EconomjcSciences and Technologies-Dan Griffin,Director of Planningand%ResearchDevelopers:Michael G. KellyProject Director.Patricia A. MengesCurriculum DeveloperKebir Marti-LambertInformation and ReferralPerson/Counselor.Mary DiazSecretaryAlfredo J. RodriguezTechnical Graphic ArtistCarolyn M. CarterTechnical Graphic Artist.U S. DEPASTMENT OFEPUCATIONNATIONAL INSTITUTE OF EDUCATION"PERMISSION TO REPRODUCE TH1SMATERIAL HAS BEEN GRANTED BYUCATIONAL RESOURCES INFORMATIONCENTER (ERIC)This documereceived fromungrating ithas been' reproduced asperson or organization',.- Minor changes have been made to.,ImproveroproduCtion QuafitYPoints of vievtor (worts slated in ItI'Vocu!Mill do not necessarily reptilian( cavaftilEposition or poticv(")4TO "'HE EDUCATIONAL RESOURCESINFORMATION CENTER (ERIC)."

IllinoisState Board ofEducation.-. TOO North First StreetSpringfield, Illinois 62777Edward CopelandChairman,tcpDonald G. GillState Superintendentof Education.).4,1.,,0The Illinois State Board of Educ tionand the Waubonsee Community College LimitedEnglish Proficiency Project gra efully acknowledge the assistance Of the CaterpillarTractor Company, East P-vi ia Flant, Illinois, and of Casting Specialties Corporation,Cedarburg, Wisconsin, for perm ssion to use various,technical illustrations.v4,0

f4FOREWORD.Machine Shop Fundamentals; Part I was developed and designed for secondaryapd adult limited English proflciency students enrolled in Machine ToolTechnology'courses. Part I includes an Introduction, Safety and Shop Rules,Basic Machine Tools, Basic Machine Operations; Measurement, Basic BlueprintReading, Layout, ind Bench Tools. These twenty-four Competency basedlessons may be used as,a:main text, as supplements to other textbooks, .or asthe basis for a pre-vocational course in,manufacturing trades.The Illin s State Board of Education,is committed to assisting local educational a ncies in the development of high Ruality instructional programs forlimited english proficiency and handicapped/disadvantaged students.The pr ject develeped Machine Shop Fundamentals:Part I during twosemes ers orfield-testink with limited English proficiency adults enrolledin Ma hine Tool Laboratory I.Sincere appreciation is extended to the stu-,dents ictors, and consultants who assisted in the development of thseinstrional matls.Donald G. GillSta4e Superintendent of Educationa

Illinois State Board of Educations1)Department of Adur Vocational and Technical EdticationResearch and Development SectionProduct AbstractPart I'Machine Shop Fundamentals:1. Title of materialtoi42. Date rnatenal was.ompletedFebruary*, 1982X3. Please check one: -New material4. Originating agencyRevised materialWaubonsee Community College.Route 47 at Harter Aoad, Sugar Grove, ILAddressZip Code 60554.5. Name(s) of developer(s), Michael G. Kelly, Patricia Mendes,.Kebir Marti-LambertWaubonsee Community College (Same is above) )Zip Code 60554AddressDeveloPed pursuant to Contract Number- R-31-21-J-2106-407 and R32-32-3-2106-4077. Subject Matter- (Check only one according to USOE Code):USOE Collet10 Indubtrial Art Education16,Technical Education17 Trade and Industrial fducation' 22 Cooperative EducationCareer EducationOther (Specify)01 Agricultural Education03 Business And Office Education04 Distributive Education07 Health Occupations Education09 Home Economics Education8. Education Level:xPre-K Tlyu 6XPost-SecondaryAdministrator (Pre-Service)x9-10Teacher (Pre-service)Other (Specify)AdultX. 11-129. Intended for Use BY:XStudentClassroom TeacherGuidance StaffTeacher EducatorOther (Specify)Local AdministratorState Personnel10. Student Type:RegularXXDisadvantagedLimited English ProficiencyX. HandicappedOther (Specify)11. Medium and Format of Materials:VIDEdTAPEX,1-1ARDCOPYNo. of pages142MinutesB&WColorPaper boundYes XDiagrams:. Yes XPhotos:Hard lormmB&WColor',

SLIDESAUDIO. FILM STFIIPS,Automatic synChAudioNo. of framesNo. of framesB & W .,B &W,ColorColorAudioCarousel providedOther packaging usedOTHER.Specify:,HzManual cueReel#(Specify)CassetteCartridge12. Availability:In ERIC system (No.Illinois State Board of Education1DAVTENameContact.For sale @ . :. per dopy& . One coby freeAddress*WO North First Street, Springfield, ILIllot availableLoan copy availablePhone al 7) 7112 4.62.0Zikode6277713. Cbpyright Restrictions:'Contact.NameIllinois State Board of Education/DAVTEAddress 100 North First Street. Sprinofield. IL14. Is Training Required for Optimum Use of These Materials?15. Ate Consultive/Training Services Available?Contact:JYes:. XPhone(217)Zip Code782-462062777Yes.2L.NoS.Illinois State Board of EducationDepartment of Adult. Vocational and Technical Education1. Research and Development Section. E-4261 op North First Street .Springfield. IL 62777(217) 782-4620 16. General Description (State the general objective and suggested method of use. Summarize the content and tell how It ,q,organized. Continue on back of dm sheet or on another sheet. if necessary.):a(See attached General Description on the next page.).17. Person Completmg this Abstract.Michael G. KellyFull Address:Waubonsee Community CollegeRoute 47 at HaRter.RoadSugar Grove, ILAZip605.54

soMachine Shop Fundamentals: Part I was designed for limited Englishproficiency students who are enrolled in Machine Tool Technologies coursesor who are preparing to enroll in Manufacturing Trades courses. Theorganization, format, and simplified language level of Machine ShopFundamentals.make it suitable Rot only for LEP students but also ftpr otherspecial needs students who,have difficulty reading traditional texkbooks.The twenty-four competencybased lessons may be used as a main textbook,as a supplementary textbook, or as the basis for.a pre-vocational training411'tcourse.The lessons LessonLesson.Lesson.a43B3C4A4B4C40Lesson -4ELesson 5AkSson 5BLesson 5CLesson 5DLesson 5ELesson 6ALesson 6BLesson 6CLesson 7ALesson 7B'lesson 7CLesson 7DLesson 7ELesson 7FMachine Tool TechnologySafety RulesBasic Machine ToolsBasic Machine OperationsRevolutions per Minute, Depth of Cut, and FeedIntroduction to MeasurementSemiprecision MeasurementPrecision Measurement with MicrometersPrecision Measurement-with Vernier Calipers and:Vernier,Height GagesPrecision Measurement with Dial IndicatorsIntroduction to Blueprint Reading.Basic Views ,Basic LinesTolerancesTitle BlocksIntroduction to LayoutSemipreciiion LayqutPrecision LayoutWrenches, Pliers, and ScrewdriversVises, Clamps, and V-BlocksHacksa sHammer , Chisels, and PunchesI4.FilesTaps and Dies.8.4Part I STUDENT WORKBOOKThe corresponding Machine Shop Fundamentals:has for each lesson a Technical Vocabulary, Study Questions, Review Questions,and Worksheets.The VOCATIONAL INSTRUCTOR'S MANUAL has specific,teaching,strategiesand notes, Self-Tests, and student native language supplements in Spanish,Lao, and Vietnamese for each lesson.The TECHNICAL ENGLIsji INSTRUCTOR'S MANUAL has-spetific,yocationalEnglish as a second langdage (VESL) teaching strategies, VESL activitiesclosely coordinated with the Machine Shop FundamentaTs lessons,'and visuals.1

III1.Machine Shop Fundamentals4.(--TABLE OF CONTENTS,Part IOrientationS\.1 Unit 1,IntroductionLesson 1Unit 2Machine Tool TechnologySafety in the Machine.ShopLesson 2 .Safqy Rules.0Unit 3Introduction to Machine Tools ahd Machine OperationsBasic Machine ToolsBasic Machine OperationsRevolutions Per Minute, Depth of Cut, and FeedLesson 3ALesson 3Besson 3C,/linit 41MeasurementLesson 4ALesson 4BLesson 4CLesson 40Lesson 4EIntroductiah to MeasurementSemiprecision MeasurementPrecision Measurementwith MicrometersPrecision Measurementwith Vernier Calipers andVernier Height GagesPrecision Measurementwith Dial Indicators4,611tt

Unit 5.Blueprint ReadingLessonLessonLessonLessonLessonsUnit 65A5B5C5D5EIntroduction to Blueprint ReadingBasic ViewsBasic LinesTolerancesTitle BlocksLayoutLesson 6ALesson 6BIntroduction to LayoutSemiprecision LayoutLesson 6C recision LayoutBenth ToolsUnit 7LessonLessonLessonLessonLessonLesson7A Wrenches, Pliers, and Screwdrivers7B Vises, Clamps, and V-Blocks7C Hacksaws7D Hammers, Chisets, and Punchesne 'Files7F Taps and Dies(9

Machine Shop FundamentalsOrientationINTROOUCTIUNA GOOD JOBJOB ADVANCEMENTMORE TECHNICAL TRAININGENGLISHEXPERIENCETECHNICAL SKILLSTo get a good job, people need technical skills, experience and English skills.Workers need to understand directions, ask questions, and talk with theirsupervisors and other workers.This is often a problem for people whose native language is not English.MACHINE TOOLLABORATORY ITECHNICALENGLISH- Theory- Practice- Technical Vocabulary- Machine Shop Math- "Shop Talk",This machine tool training program has two classes.In the Machine Tool Laboratory I classes, students learn the theory andpractice of industrial machines in the machine shop.In the Technical English classes, students learn technical vocabulary, "shopOlk," machine shop'math, and English skills necessary for Machine ToolLaboratory I and for jobs.'The machine shop teacher and the technical English teacher work together toteach-technical machine tool skills and technical English.Both classes are important for the students.1:0

/1,-,)MACHINE SHOP FUNDAMENTALS:PART I--\The student will use the-Machine Shop Fundalfientals: Part I textbook andstudent workbook.The textbook puts the technical information into units and lessons.The student workbook helps the student study each lesson.Each lesson has:l.y.Student WorkbookTextbook.Other Materials,ObjectivesTechnical VocabularyProceduresStudy QuestionsTechnical InforMation.Review QuestionsSlide Show,Native Language SupplementsSelf-TestThe student must 'pass the Self-Test with 80% or more correct ansWers beforehe/she studies the next lesson.The lesson is the theory part of the class.In the machine shop, the student must understand the theory before he/shesets up and runs a machine tool.For the course, the student Will need:1.Safety glasses2.A 6" machinist's rule3.A-thick 3-ring notebook4.A vise (DVP #54),.SCHEDULEMACHINE TOOL LABORATORY I10 hours per weekTECHNICAL ENGLISHSTUDY TIME AT HOME,6 hours per week.TOTAL6 hours per week22 hours per week-.-P,---The student must study 6 hours per week at home.7II2Orientation

GRADESEach student will reseive a grade for the Machine Tool Laboratory I course.Average Grade Points:90 - 100A (Superior) ,80 - 89B (Good)70 - 79C (Average)60 - 69D (Poor)59 or belowF (Failure)460%-of,the grade points are from the student's work in the Machine Shop.40% of the grade points 6re from the student's examinations and tests.The student will aso receive a grade for the Technical English course.ATTENDANCEOn the job, attendance is very important.Workers must be at their jobs. everyday and must be on time.In school, attendance is also very important.If a worker'does not go to iiis/her job everyday, fie/she gets fired.If a student does not go to-school everyday, he/she'will not learri and willfatl the course.Attendance in school is like attendance on the job.Sometimes a worker cannot go to his/her job becapse of sickness or familyproblems,.Then he/she must call the company.If a student cannot go to school, he/she must call the teacher.If you cannot go to school, callE4POrientation

,MACHINE TOOL COURSES-AT WAVBONSEE COMMUNITY COLLEGE*Waubonsee Community College.has nine courses in Machine Tool Technology:.Machine Tool Laboratory IMetallurgiand Heat Treatmerif*VMachine Tool Labbratory IIStrengths of MaterialsMachine Todl LaboratOry IIIMetrologyA.Introduction to Npmerical ControlManufacturing ProCessesDie Design and Construction--All students begin wtth Machine Tool .Laboratory I (one).In Machine Tool LaboratOry I, stadents learn to use basic measuripg toolsin the machine shop and.to do basio machine tool operations with thesemachine tools:The horizontal bandsawThe vertical bandsawThe engine lathe'The'horizontal millThe vertical ellThe drill pressThe radiO drillThe surface grinder -4.Students study the theory and pradIce of machine tools in the machine shop.When a student finishes Machine Tool Laboratory I (one) he/she has basictechnical skills and experience to begin work as a machine operator,,to takea better job in the company where he/she works, or to take more advancedclasses,After Machine Tool Laboratory I (one), many students take Machine ToolLaboratory II (two).Please ask the teacher If you want more information about the program andclasses.4,3Orientation4

Machine Shop Fundamentals1UNIT 1:introductionLESSON 1:Machine Tool TeqhnológyOBJECTIVES:1.The student will write what maChine tools make.2.The student will write the reason why accurate sizesof parts-are important.3.PROCEDURES:4.The student will choose the reasons why a machinist mustknow good math.1.Read the Objectives.Read the Lesson.Watch the Slide Show.Do the Study Questions.Do the Reyiew Questions.Do the Self-Test.2.3.4.5.6.REFERENCES:,The student will choose the correci order of steps that'a machinist follows for a,machine operation.

4INTRODUCTION.q.,Everyope wants a good job.The UOted StatesThas many factories.Many people work in factories.People need techqical skilis.and experience to get good jbbs in factories.A person caA' 'get technical skills avd. experience in vocational trainingcourses and on the job!,Everyone depends on machines fe transportation, food, homes, employment,and much more.Factories build machines.Machinists are an important group of workers in factories.A machinist uses industrial machines to make the metal parts for many dthermachines.,These industrial machines are called machine tools.Machine toals make metal parts for new machines and other products.

With machine tools, a machinist makes parts to very accurate sizes.Why?Accurate sizes of parts are important because many different parts must fittogether to make a new machine.IEach part.must have accurate sizes.If the sizes of one part are not accurate, the part will not fit with theother parts.3 16dr,

110Most parts need several machineoperations.To make a finished part,usually several machinistsmust do different operations,entand py must use dimachei e ssissigiliggiaFactories want to make-accurate1,1!!!1parin the.cheapest waypossible.'The cheapest way is massproduction.In masg production, oneOperation 3machinist does the sameoperation or operations onmany of the same parts.Then, another machinist doesa different operation .on theFill.1 15: II.lieFif # Dirmm410lirmF651151. FI,I1.1.Operatico.itV.vIi"NsaarivImoII4same parts.riiiii Zia;rat31iisaarisailsZiima; ti w4,.4Oplanaton 5.4444w!---0A0/044,40*.,When these parts are finished,assembly line workers putthem together with otherfinished parts.ton 6OVso ."," ",14

"WHAT IS A MACHINIST?,4-machinist works in the machine shop of a factory.He/she uses machine tools to make metal parts for other machines.There areman, different kinds of machine tools and machine operations.Most machine tools are umplicated.A machinist must have a lot of technical skills and shop experience.A person must study machine tool, theory and math, and mutt work for severalyears to be a skilled machinist.40A skilled machiniet makes good money.In the future, employment fer skilled machinists will be very good.Factories will have more machine tools and the machine tools will be morecomplicated than now.Factories will need many skilled machinists to use the machine tools.WHAT DOES A SKILLED MACHINIST DO?A skilled machinist uses machine toolS to Make metal parts"for newmachines and other products.How does a skilled machinist make metal parts for other machines?For a machine operation, a skilled machinist usually follows these steps:fAOty RigidMATEMALC45010 Specaties ConkCoil Rolled StogiCady tiny Wls.LEAOSCREWTOLERANCES UNLESS OTHERWISE SPECIFIEDSTEP. 1.PutteeDocrnsis 't 1164 005MolesPART N 14-101130443274The machinist reads the blueprint of the finished part.The blueprint shows the shape and exact sizes of the finished part.The blueprint also gives technical information about the finishedpart and the operations.

fr.1IIILILItISTEP 2.24,111114j,The machinist lays out the part.To lay out a part, the maqinist markS the correct sizes on the part.ASTEP 3.The machinist sets up the machine tool. ,i1To set up the machine tool, the machinist gets the machine toolready for the operatiop.AcD

t,V,por,4,/,-.1i.STEP 4,The machinist runs the machine-tool to do the different operations.To rig' a machine tool means to operate it.I4)STEP 5.-::-.--The maChinist measurei the part to check the sizes of the part.He/she compares the sizes of the part to the exact sizes on theblueprint.The machinist measures the part often to check it.-,70

MACHINE SHOP MATHfMath is very important for machinists.--4)Why?1.To read the blueprints.2.TO 1;y out paTts.z.3.To measure parts and check sizes.Machinistslyst know and understand fractions and,-cimal numbers.1'MACHINE SHOP THEORYMachine shop theory is very important for machilnists.Why?1. To make cOrrect set-ups;2.To understaL the machine tooli, the cutters of the machine tools,ud the me.Ols of the parts.3. 'To run'th0 Nithine tools.4.18Rit

Machine Shop Fundamentals2UNiT 2:Safety in, the MaChine ShopLESSON 2:Safety RulesOBJECTIVES:1. The student-will Chooae the correct Safety Rulesabout clothing in the &chine shop:4'.2.The student will choose the correct Safety Rulesabout clean-up in the machine sHop.3.The student will choose,fhe .correct Safety Rulesabout accidents Wthe-Machine shop.44.The student will choose the correct Safety Rulesabout fires irj the machine shop.5. -The student will choose the correct Safety Rulesabout safe things that the machinist must do in'the machine shop.PROCEDURES:6.The'student will choose the

- Practice - Machine Shop Math, - "Shop Talk" This machine tool training program has two classes. In the Machine Tool Laboratory I classes, students learn the theory and practice of industrial machines in the machine shop. In the Technical English classes, students learn technical vocabulary, "shop Olk," machine shop'math, and English skills .

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