Chabot College
Fall 2010
Course Outline for Machine Tool Technology 65
PRODUCTION PRACTICES
Catalog Description:
65 – Production Practices
(May be repeated 3 times)
4 units
Introduction to design and fabrication of production-type tooling such as jigs, fixtures, and gauges as
applied in industry. Emphasis on tool design practices, fabrication techniques, set-up procedures,
and inspection of production parts. Prerequisite: Machine Tool Technology 60B (completed with a
grade of “C” or higher). 2 hours lecture, 6 hours laboratory.
[Typical contact hours: lecture 35, laboratory 105]
Prerequisite Skills:
Before entering the course, the student should be able to:
1. properly use precision measuring tools, such as the Bore Micrometers, Large Vernier
calipers, dial height gauge, .0001” dial test indicator, and various types of micrometers, also
optical / video measuring machines;
2. perform advanced bench operations, such as draw filing, contour sawing and geometric die
head threading;
3. set up and perform advanced drill press, lathe and vertical milling machine operations;
4. machine to a precision layout on the surface grinders using precision tools, such as the
vernier protractor, parallels, and Angle and Gage Blocks;
5. apply intermediate mathematical formulas for calculating correct pitch, leads, and gearcutting data required for precision part manufacture;
6. evaluate a blueprint to make a manufacturing plan to produce the desired machine part;
7. safely setup and operate a Hardinge lathe to make a 60 Degree threaded shaft with no
thread relief;
8. safely setup and operate a manual milling machine to make a prismatic part (like the 1-2-3
Block Set) manufactured within the part drawing tolerances and geometrically shaped part;
9. heat Treat the 1-2-3 Blocks and Precision Grind all external surfaces to within the +/- .0002”
Tolerance Zone per ANSI Y14.5M;
10. offhand grind a High Speed Steel Roughing and Threading Toolbit to a tolerance of +/- 1/2
degree for each of the tool’s six major cutting or clearance angles as described in the
Machine Tool Laboratory Manual;
11. measure the Gears manufactured and evaluate whether the gear is acceptable to the print
tolerances published, all geometries and published Gear Machining Standards like ANSI
Y14.5M.
Expected Outcome for Students:
Upon completion of the course, the student should be able to:
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design basic production tools;
fabricate basic production tools;
select and correctly apply standard jig and fixture components;
apply mathematical formulae to solve tooling-related problems;
set up production tools on standard and numerically controlled machine tools for production
machining operations;
select proper measuring tools for inspecting production workpieces;
operate and program procedures and events for the Prototrak dual mode lathe;
perform setups and inspections using the video measuring machine;
select the proper speeds and feeds for use with carbide and carbide insert tooling;
align parts using a four jaw adjustable chuck in a lathe;
tram the milling machine head with a trammel gauge to .001” TIR;
Chabot College
Course Outline for Machine Tool Technology 65, Page 2
Fall 2010
12. setup and grind workpieces flat and parallel within .001" with a vertical spindle grinder;
13. operate and program procedures for the Makino dual mode milling machine;
14. properly disassemble and assemble production jigs and fixtures from engineering drawings.
Course Content (Lecture):
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Design requirements for production tooling
Types of production tooling
Standard tooling components
Setting up production tooling
Inspection of production parts
Drill bushings, types and styles and installation
Tooling components list, pricing and cost analysis
Sine bar setup and evaluation
Angular interpolation
Process planning for production
Production cost analysis and unit cost determination of time lines
Selection of fixture plate materials and heat treatment / preparation
Beginning tooling ball setup and calculation
Course Content (Laboratory):
1. Techniques
a. Set tool lengths
b. Set fixture offsets
c. Edge finding and indicating part center lines for fixtures
d. Create program / procedures from engineering drawings for the Makino dual mode CNC
mill
e. Proof program using precision measuring accessories on the machine tool
f. Generating large radii using the head tilt method
g. Trammel Gauge usage demonstration
h. High speed steel production roughing tool demonstration and application of the “5 minute
tool”
i. Contour lathe programming with the Prototrak lathe
j. Extracting production data from Solidworks files
k. Precision grinding of production tooling and components
l. Using the sine bar on the lathe to set accurate compound rest angles “short taper”
applications
m. Acme thread example and multiple start thread applications of the “higby cut”
n. Universal horizontal milling machine indicating, setup, production fixtures
2. Safety
a. Safe operation of the Dual Mode CNC machining centers
b. Safe production practices in the team working environment
Methods of Presentation:
1. Lecture, informal with student questions encouraged
2. PowerPoint presentations, videos, industry relevant movies, and model examples of large
and specialized tooling and machines
3. Hands-on demonstrations
Chabot College
Course Outline for Machine Tool Technology 65, Page 3
Fall 2010
Assignments and Methods of Evaluating Student Progress:
1. Typical Assignments
a. Homework: 1-2 worksheets each week on the material covered in the text, in lecture and
laboratory Example: Sketch the outer contour of the Trammel Gauge Project, draw in
the tool tangency locations, radii and calculate their Cartesian coordinate positions from
datum locators. Write a program using the Makino mill to machine all radii for the
Trammel Gauge Project.
b. Laboratory assignment: Setup the mill table stop base for production of ten base pieces to
mill the .750” radius with a .75” 4 flute high speed steel end mill. Use the milling machine
and rotary table and fixture. Test run each tool operation checking for accuracy and
proper tool cutting rotation and feed direction. Only mill utilizing conventional milling.
Inspect the part on the Video / Coordinate measuring machine and create a “first article”
inspection report. Did the part pass inspection? If not, why? What remediation would
correct the problem, if any?
2. Methods of Evaluating Student Progress
a. Homework
b. Quizzes
c. Written laboratory inspection report on each part project
d. Fabricated parts checked to be accurate size and shape
e. Midterm manipulative and written examinations
f. Final examination, written and manipulative
Textbook(s) (Typical):
Fundamentals of Tool Design, Society of Manufacturing Engineers, 2003*
*Rationale: Tool design theory and techniques have not changed much in the past 10 years.
This book, from the Society of Mechanical Engineers, is still the best resource on the market to
date.
Special Student Materials:
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Machine shop approved safety goggles
Sharp EL-531W scientific calculator
USB drive – 1gb minimum
Combination or keyed padlock
Appropriate laboratory attire
Revised: 9/28/09
Ashley Long / Mike Absher