Abrasives in Manufacturing
Flexible Manufacturing
Lesson Plan
Performance Objectives
After completing this lesson, the students will be able to explain the different types and grits of abrasives used
in flexible manufacturing to the satisfaction of the teacher.
Specific Objectives
 Identify file parts
 Identify types and uses of files
 Identify grits of sandpaper
 Demonstrate how to use three methods for filing metal smooth (filing, draw filing, and lathe filing)
 Demonstrate how to use sandpaper to smooth metal
Terms
 Abrasives- any material or substance used for grinding or polishing (i.e., emery, pumice, or sandpaper)
 File- a tool, usually of hardened steel, with cutting ridges for forming or smoothing surfaces, especially
metal
 Grit- the size of abrasive particles usually expressed as their mesh size; the number of openings per
inch of mesh
 Sandpaper- strong paper coated with a layer of sand or other abrasive, used for smoothing or polishing
Time
This lesson should take approximately 55-65 minutes to teach and 55-65 minutes for one lab session.
Preparation
TEKS Correlations
This lesson, as published, correlates to the following TEKS. Any changes/alterations to the activities may result
in the elimination of any or all of the TEKS listed.
Flexible Manufacturing
 130.327 (c)
o (4) The student differentiates the technical concepts that form the knowledge and skills of
metal trades. The student is expected to:
(D) examine the use of abrasives.
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Interdisciplinary Correlations
Chemistry
 112.35 (c)
o (1) Scientific processes. The student, for at least 40% of instructional time, conducts laboratory
and field investigations using safe, environmentally appropriate, and ethical practices. The
student is expected to:
(A) demonstrate safe practices during laboratory and field investigations, including the
appropriate use of safety showers, eyewash fountains, safety goggles, and fire
extinguishers;
(B) know specific hazards of chemical substances such as flammability, corrosiveness,
and radioactivity as summarized on the Material Safety Data Sheets (MSDS); and
(C) demonstrate an understanding of the use and conservation of resources and the
proper disposal or recycling of materials.

112.35 (c)
o (4) Science concepts. The student knows the characteristics of matter and can analyze the
relationships between chemical and physical changes and properties. The student is
expected to:
(A) differentiate between physical and chemical changes and properties;
(B) identify extensive and intensive properties; and
(C) compare solids, liquids, and gases in terms of compressibility, structure, shape, and
volume.
Occupational Correlation (O*Net – www.onetonline.org/)
Job Title: Tool Grinders, Filers, and Sharpeners
O*Net Number: 51-4194.00
Reported Job Titles: Grinder, Tool Grinder, Finisher, Saw Filer, Tool and Cutter Grinder, CNC Operator
(Computer Numerically Controlled Operator), Cutter Grinder, Polisher, Crankshaft Grinder, Cutter Grind Tool
Technician
Tasks
 Inspect, feel, and measure work pieces to ensure that surfaces and dimensions meet specifications.
 Set up and operate grinding or polishing machines to grind metal workpieces such as dies, parts, and
tools.
 Remove finished work pieces from machines and place them in boxes or on racks; set aside pieces that
are defective.
 File or finish surfaces of work pieces, using prescribed hand tools.
 Select and mount grinding wheels on machines, according to specifications, using hand tools and
applying knowledge of abrasives and grinding procedures.
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Soft Skills
 Operation and Control
 Quality Control Analysis
 Reading Comprehension
 Critical Thinking
Accommodations for Learning Differences
It is important that lessons accommodate the needs of every learner. These lessons may be modified to
accommodate your students with learning differences by referring to the files found on the Special
Populations page of this website.
Preparation
 Review and become familiar with the terminology, website links, and the slide presentation.
 Have materials, slide presentation, and websites ready prior to the start of the lesson.
References
 Wright, R. T. (2004). Manufacturing and automation technology. Finishing Processes (15, pp. 227 and
230). Tinley Park, IL: Goodheart-Wilcox.
 Occupational Safety and Health Standards, Machinery and Machine Guarding (1910.215), Abrasive
wheel machinery
http://www.osha.gov/pls/oshaweb/owadisp.show_document?p_table=STANDARDS&p_id=9839
 http://www.merriam-webster.com/dictionary/file
 http://dictionary.reference.com
 Webster's Seventh New Collegiate Dictionary G. & C. Merriam Company Publishers Springfield,
Massachusetts 1967
Instructional Aids
 Abrasives in Manufacturing slide presentation and notes
 Abrasives in Manufacturing Files Quiz for each student
 Abrasives in Manufacturing Files Quiz Answer Key
Introduction
The main purpose of this lesson is to help students:
 understand the different types of abrasives; and
 examine the processes using abrasives to cut, grind, and polish materials.

Ask
o Have you ever thought about the importance of abrasives?
o Have you ever sanded the scratches out of a piece of material?

Say
o We will look at the correct ways of using abrasives to smooth a project.
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Outline
MI
NOTES TO TEACHER
OUTLINE
I.
Introduce and start lesson
II.
Overview safety and operations
A. Abrasives
B. Files
C. Grit
D. Sandpaper
III.
Identify types of files and grits of
sandpaper
IV.
Demonstrate the safe use of files
V.
Administer quiz at end of lesson
Test Grades Table
Number Missed
Grade
0
100
1
94
2
88
3
81
4
75
5
69
6
63
7
56
8
50
9
44
10
38
11
31
12
25
13
19
14
13
15
6
16
0
Begin the Abrasives in
Manufacturing slide
presentation.
Review the title, terms, and
definitions (slides 1-5).
Distribute the Abrasives in
Manufacturing File Quiz.
Explain how to file
(slides 6-18).
Explain sandpaper grit and
how to sand (slides 19-23).
Use the Quiz Key to grade
the quiz and the Test Grades
Table to assign the grade.
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4
Multiple Intelligences Guide
Existentialist
Interpersonal
Intrapersonal
Kinesthetic/
Bodily
Logical/
Mathematical
Musical/Rhythmic
Naturalist
Verbal/Linguistic
Visual/Spatial
Application
Guided Practice
The teacher will demonstrate the three methods of using a file (filing, draw filing, and lathe filing).
Independent Practice
The student will file and sand a piece of metal smooth.
Summary
Review
The student will be able to answer questions over the slide presentation.
Evaluation
Informal Assessment
Teacher will assess students while filing and sanding a piece of metal.
Formal Assessment
Teacher will administer the Files Quiz on identification of file parts and types of files and uses.
Enrichment
Extension
Students will research other types of abrasive materials on the Internet.
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5
Name _________________________________________________
Date _____________ Period ______
Files Quiz
Identification of File Parts
Types of Files and Uses
Name
Shape
File
Use
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Name _________KEY________________________________________ Date _____________ Period ______
Files Quiz
Identification of File Parts
Edge
Toe
Heel
Face
Tang
Length
Types of Files and Uses
Name
Shape
File
Use
Flat
Flat Surface
Half Round or
Cabinet
Curved or Flat
Surfaces
Three Square
Inside Angles
Round
Inside Holes
Inside Small Holes
Rat Tail
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