# Machinist Level 3 Rev. January 2001

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1 Level 3

2 C3 Trade Mathematics III Duration: 24 hours 24 hours 0 hours This unit introduces the Machinist apprentice to the principles of trade mathematics and is designed to meet the requirements of the Machinist apprentice course. It consists of a review of concepts and continues with trade trigonometry. 1. Identify computed measure and ratio and proportion. 50% a. Direct proportion b. Inverse proportion Pulley systems Gear systems c. Perimeter d. Area e. Volume f. Bend allowances 2. Trade trigonometry. 50% a. Angle measurement Degree, minute, second system Decimal degrees Conversion of DMS and DD measurements b. Rule of Pythagoras c. Right triangles Sine, cosine, tangent Inverse functions Application of trigonometry to sine bar, taper and dovetails d. Oblique triangles Law of sines Law of cosines 1

3 D3 Trade Science III Duration: 24 hours 24 hours 0 hours This course introduces the Machinist apprentice to the basic concepts of trade science. Apprentices will receive instruction in the basic concepts of gears, belts and pulleys, work and power. 1. Identify and calculates speeds of gears, belts and pulleys. 50% a. Gear speeds b. Belt speeds c. Surface speeds 2. Identify concepts of work, power and energy. 50% a. Work calculations b. Power calculations c. Efficiency d. Friction 2

4 D4 Heat Treatment of Steel Duration: 30 hours 20 hours 10 hours This unit of instruction introduces the Machinist apprentice to give apprentices an understanding of heat treatment processes and their applications. It introduces the information necessary for appropriate selection and testing of materials for the job assigned. Material covered includes: properties and heat treatment of carbon steels and materials testing. 1. Select proper metal for the intended end use. 20% a. Chemical properties b. Physical properties c. Mechanical properties and alloys 2. Select appropriate alloys for specific applications. 20% a. Water hardening b. Air hardening c. Oil hardening 3. Select appropriate materials for specific applications: a. Ferrous b. Non-ferrous 4. Describe heat treatment of carbon steels. 10% 5. Perform heat treatment of carbon steels. 10% a. Purpose and applications of materials testing: Hardness Composition Properties b. Types of material testing. Destructive Non-destructive c. Machines used in hardness testing and the principles and procedures associated with each: Rockwell Hardness Tester Brinell Hardness Tester 3

5 Scleroscope d. The test and procedures used for: Tensile strength Impact Spark File f. Procedure for inspection and testing of metals for faults using: Magnaflux X-ray Ultrasound 4

6 E3 Comparison Measurement Duration: 7 hours 3 hours 4 hours This unit of instruction is designed to provide the Machinist apprentice with a variety of methods of precision measurement. The unit also covers areas of jig boring and fixture design that are not included in the National Occupational Analysis. Material covered includes: comparaters, coordinate measuring system and coordinate locating system. 1. Describe comparaters, their applications, accuracy and procedures. 30% 2. Use comparaters. 30% a. Dial indicators, their applications, accuracy and procedures b. Mechanical and electronic comparaters, their applications, advantages and procedures for use c. Optical comparaters, their applications, advantages and procedures for use d. Mechanical-optical comparaters, their applications, advantages and procedures for use e. Pneumatic comparaters, their applications, advantages and procedures for use f. Air gauges, their applications, advantages and procedures for use g. Comparaters, their characteristics and applications 3. Describe Coordinate Locating System. 40% a. Coordinates use b. Purpose, advantages and procedure for prefiguring coordinates c. Proper method for setup of the machine and location of the work piece d. Procedures for boring holes e. Procedure for measurement of holes f. Procedure for inspection of holes 5

7 H4 Lathe Operations III Duration: 40 hours 10 hours 30 hours This unit of instruction builds on the knowledge of lathe machines and their operation gained in previous units. It introduces the procedures used to cut threads. Material covered includes: thread characteristics, operating procedures, alignment of workpieces and potential problems. 1. Identify thread characteristics. 20% 2. Identify operating procedures. 20% 3. Identify alignment of workpieces. 20% 4. Identify potential problems. 20% 5. Troubleshoot potential problems. 20% 6

8 I3 Milling Operations III Duration: 75 hours 10 hours 65 hours This unit of instruction is designed to develop practical skills in application and procedures to set up and operate boring mills. 1. Identify horizontal and vertical boring mills, their components. 10% 2. Demonstrate horizontal and vertical boring mills, their components and applications. 10% 3. Use various types of tooling and accessories for boring mills. 10% 4. Sets up horizontal and vertical boring mills. 10% 5. Perform procedures for speed and feed calculations. 10% 6. Perform procedures for boring holes. 10% 7. Perform procedures to do advanced indexing. 20% 8 Perform procedures for rotary tables and processes. 20% 7

9 I4 Gears and Gear Cutting Duration: 30 hours 15 hours 10 hours This unit of instruction is designed to provide the Machinist apprentice with an understanding of gear types, parts, milling procedures and setups, methods of manufacturing gears and calculation and measurement of gears. Material covered includes: introduction to gears, gear tooth measurement, gear cutting, calculations and milling procedures. 1. Identify gears. 20% a. Principles, purpose and operation of gears b. Different types of gears and their applications: Spur gears Internal gears Rack gears Helical gears - Helical terms - Elements of helical gearing - Applications, advantages and disadvantages of helical gears - Procedure for milling helical gears using indexing heads - Procedure used to calculate and mill helical contours - Procedure for cutting a helix - Process for determining the helix angle - Procedure to determine the direction to swing the table - Procedure to calculate the change gears to produce the required lead o Inch calculation o Metric calculations - Direction of spindle rotation - Process for cutting short lead helices Pinion gears Hypoid Herringbone gears Bevel gears Miter gears Angular bevel gears Worm and worm gears c. Gear terminology: 8

10 Addendum Center distance Chordal addendum Chordal thickness Circular thickness Clearance Circular pitch Dedendum Diametral pitch Involute Linear pitch Module (metric gears) Outside diameter Pitch circle Pitch circumference Pitch diameter Pressure angle Root circle Root diameter Tooth thickness Whole depth Working depth d. Procedures used for rack milling 2. Describe gear tooth measurement. 10% a. Methods of gear tooth measurement and their associated procedures Micrometer and wire b. Factors affecting accurate measurement of gear teeth 3. Describe gear cutting. 20% a. Characteristics of involute gear cutters b. How the gear cutters are sized Imperial Metric c. Characteristics of a gear cutter set and the factors relating to the number of gear teeth to be cut d. Chart for involute gear cutters: Metric Imperial e. Procedures used to cut spur gears f. Procedures used to cut a rack gear 4. Describe bevel gears. 10% a. Bevel gears, their characteristics and elements b. Procedures used to set up and mill bevel gears using indexing heads c. Procedures used to calculate and mill bevel gears using indexing heads 5. Describe worm gears. 10% a. Describe worm gears: Manufacture Applications Elements b. Describe the calculations for the parts of a worm gear: 9

11 Addendum Center distance Dedendum clearance Face width Lead of worm thread Lead angle OD worm OD worm gear Pitch of worm and worm gear Pitch diameter (worm) Pitch diameter worm gear Rubbing speed (fpm) Throat diameter (worm gear) Radius of rim corner (worm gear) Ratio Throat radium (worm gear) Tooth depth Worm thread length c. To mill a worm 6. Identify cams and cam milling. 10% a. Cams used to impart motion b. Cam motion c. Radial cam terms d. Cam milling 7. Identify rack milling. 10% a. Rack indexing attachment 8. Identify clutches. 10% To machine a straight-tooth clutch having three teeth To machine a straight-tooth clutch having four teeth 10

12 K4 Surface Grinding Operations II Duration: 20 hours 0 hours 20 hours This unit of instruction is designed to provide the Machinist apprentice with the knowledge and understanding of advanced surface grinding operations. 1. Perform procedures for mounting workpieces. 20% 2. Perform safety procedures for grinder setup and operation. 20% 3. Perform procedures required to set up and perform grinding operations on a surface grinde: a. Cut off parts b. Grind surfaces and shapes 20% 4. Perform procedures for dressing a convex radius on a grinding wheel. 20% 5. Troubleshoot problems during grinding operations. 20% 11

13 K5 Cylindrical Grinders Duration: 20 hours 5 hours 15 hours This unit of instruction introduces the Machinist apprentice to cylindrical grinders, their set up and operating procedures. Material covered includes: cylindrical grinders. 1. Describe cylindrical grinders, their types, parts, characteristics and applications. 10% 2. Describe procedures used to plan the sequence for grinding operations. 10% 3. Perform procedures used to plan the sequence for grinding operations. 10% 4. Describe procedures used to align grinder heads, tables and fixtures. 10% 5. Perform procedures used to align grinder heads, tables and fixtures. 10% 6. Describe procedures used to select speeds, feeds and depth of cuts. 10% 7. Perform procedures used to select speeds, feeds and depth of cuts. 10% 8. Troubleshoot potential problems during grinding operations, their causes and remedies. 10% 9. Describe the principles and procedures used to parallel grind an internal diameter. 5% 10. Describe procedures used for toolpost grinder. 5% 11. Perform procedures used for a toolpost grinder. 5% 12

14 K6 Universal Tool and Cutter Grinder Duration: 30 hours 3 hours 7 hours This unit of instruction introduces the Machinist apprentice to the universal tool and cutter grinder, their characteristics, and set up and operating procedures. Material covered includes: parts and characteristics, set up and operation. 1. Describe tool and cutter grinders, their parts, applications and safety precautions. 5% 2. Describe tool cutter nomenclature. 5% 3. Describe tool cutter grinder accessories and their applications. 5% 4. Describe the procedures required to set up a tool and cutter grinder. 5% 5. Perform the procedures required to set up a tool and cutter grinder. 10% 6. Describe methods required for calculating, grinding and checking clearance angles. 5% 7. Perform methods required for calculating, grinding and checking clearance angles. 10% 8. Describe the procedures required to set up and sharpen a cutter using a tool and cutter grinder. 9. Perform the procedures required to set up and sharpen a cutter using a tool and cutter grinder. 5% 10% 10. Describe the procedures required to grind clearance angles. 5% 11. Perform the procedures required to grind clearance angles. 10% 12. Troubleshoot potential problems that might be encountered during operations, their causes and remedies a. Methods of gear tooth measurement and their associated procedures Micrometer and wire 13 10%

15 b. Factors affecting accurate measurement of gear teeth 13. Describe preventative maintenance procedures for tool and cutter grinders. 5% 14. Perform preventative maintenance procedures for tool and cutter grinders. 5% 15. Describe other accessories and uses of the tool and cutter grinder. 5% 14

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