Cutting Metal
Flexible Manufacturing
Lesson Plan
Performance Objective
At the end of the lesson, students will demonstrate how to measure, lay out, and cut sheet metal into a style
of letter using either Oxy-fuel or Plasma cutting methods, matching the criteria in the Letter Cutting
Assignment Rubric.
Specific Objectives
 Describe the different types of metal cutting
 Design a metal letter using a plasma cutter machine
 Operate a CNC plasma cutter machine
 Cut a project with a plasma cutting system
 Design a metal letter using a oxy-fuel system
 Cut a project with an oxy-fuel system
 Demonstrate safe practices during laboratory work
Terms
 Oxygen Acetylene Cutting (oxy-fuel cutting)- the use of a torch fueled with oxygen and acetylene to
heat the metal and blow the molten metal from the cut
 Plasma Cutting- the use of a blast of air or some other gas to super heat the metal and force the metal
from the cut
 Controller- the computer-type machine that drives the axis of a CNC machine
 CNC- Computer Numeric Control is the ability to control a machine using a code of numbers
 Gantry- a framework used to carry the cutting head in the different axis of movement
Time
It should take approximately three to four classes (55-65 minutes each) to teach the lesson.
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 (7) The student applies the technical concepts and skills of the welding industry to simulated
and actual work situations. The student is expected to:
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(A) examine the cutting processes such as oxy-fuel and plasma.
o (10) The student understands the function and application of the tools, equipment,
technologies, and materials used in sheet metal manufacturing. The student is expected to:
(A) safely use equipment.
Interdisciplinary Correlations
Chemistry
 112.35 (c)
o 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: Cutting, Punching, and Press Machine Setters, Operators, and Tenders, Metal and Plastic
O*Net Number: 51-4031.00
Reported Job Titles: Machine Operator, Press Operator, Set-Up Operator, Saw Operator, Slitter Operator,
Punch Press Operator, Die Setter, Adjuster, Die Cutter, Machine Setter
Tasks




Measure completed work pieces to verify conformance to specifications, using micrometers, gauges,
calipers, templates, or rulers.
Examine completed work pieces for defects, such as chipped edges or marred surfaces and sort
defective pieces according to types of flaws.
Read work orders or production schedules to determine specifications, such as materials to be used,
locations of cutting lines, or dimensions and tolerances.
Load work pieces, plastic material, or chemical solutions into machines.
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





Set up, operate, or tend machines to saw, cut, shear, slit, punch, crimp, notch, bend, or straighten
metal or plastic material.
Start machines, monitor their operations, and record operational data.
Test and adjust machine speeds or actions, according to product specifications, using gauges and hand
tools.
Install, align, and lock specified punches, dies, cutting blades, or other fixtures in rams or beds of
machines, using gauges, templates, feelers, shims, and hand tools.
Clean and lubricate machines.
Position, align, and secure work pieces against fixtures or stops on machine beds or on dies.
Soft Skills
 Operation Monitoring
 Active Listening
 Operation and Control
 Quality Control Analysis
 Monitoring
 Reading Comprehension
 Critical Thinking
 Speaking
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
 Have materials and equipment ready for students to make the assigned project.
 Have examples of the different types of cut letters and projects.
References
 Webster’s new compact office dictionary (2003). New York, NY: Houghton Mifflin Harcourt Publishing
Co.
Instructional Aids
 Cutting Metals slide presentation
 Letter Assignment Instructions
 Letter Assignment Worksheet
 Letter Cutting Assignment Rubric
Introduction
The purpose of this lesson is to help students understand the terminology of CNC Plasma Cutting and to know
how to use oxy-fuel and plasma methods of cutting.
 Show
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o These projects have been made by cutting them out of metal sheets.

Ask
o Can you think of a project that you could cut out of a piece of sheet metal?

Ask
o You have cut with the oxy-fuel and plasma cutters, would you like to cut your name out?

Say
o The slide presentation will show you how to cut the different projects.
Outline
MI
OUTLINE
I.
Cutting Metal
A. Oxy-fuel cutting
B. Plasma cutting
II.
Terminology
A. Controller- the computer-type machine that
drives the axis of a CNC machine.
B. CNC- Computer Numeric Control is the ability
to control a machine using a code of numbers.
C. Gantry- a framework used to carry the cutting
head in the different axis of movement.
III.
Oxy-fuel Cutting
A. Explanation of when to use oxy-fuel cutting
B. How to cut a letter
IV.
Plasma Cutter
A. Explanation of when to use a plasma cutter
B. Hand-held plasma cutter
C. CNC plasma cutting system
i.
Terms
ii.
How to use a CNC plasma cutter
V.
CNC Plasma Cutter Projects
VI.
Assessment
A. The Lettering Assignment Worksheet will be
graded for completion
B. The Letter will be graded by the rubric
Multiple Intelligences Guide
NOTES TO TEACHER
Have different projects
for the students to
examine. Begin the
Cutting Metals slide
presentation.
After the presentation,
hand out the Letter
Assignment Instructions
and the Letter
Assignment Worksheet.
The students will use
these to develop their
letter to be cut out of a
1/8” metal sheet. The
student will make the
pattern on the
computer, or draw it.
The letter will be cut
out using one of the
methods described in
the presentation.
When the letter is
finished, it will be
graded by using the
Letter Cutting
Assignment Rubric. The
Lettering Assignment
Worksheet will be
graded with the project.
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Existentialist
Interpersonal
Intrapersonal
Kinesthetic/
Bodily
Logical/
Mathematical
Musical/Rhythmic
Naturalist
Verbal/Linguistic
Visual/Spatial
Application
Guided Practice
The teacher will guide the students as they begin to cut their letter.
Independent Practice
The students complete the assignment by cutting the letter out, grinding and filing the edges, and applying a
finish.
Summary
Review
The students will be able to describe the different types of metal cutting.
Evaluation
Informal Assessment
The students will be evaluated by teacher observation as they work in the lab.
Formal Assessment
The students’ Letter Assignment will be graded with the Letter Cutting Assignment Rubric.
Enrichment
Extension
The students could cut different design and letters.
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Name _________________________________________
Date _____________ Period ______
Letter Assignment Instructions
1.
2.
3.
4.
Open a word processing document and select a word art application.
Select a solid letter, the best option for this project.
Notice the difference between the various font themes.
Notice the difference between the font size 36 and the font size 320 in letter “C” below.
Word Art Styles
5. When the letter is the font theme and size that you want, print it out on heavy paper stock.
6. After printing the letter, cut it out for a pattern to draw on the 1/8” metal sheet.
7. Draw the letter on the sheet metal using a soapstone.
8. Cut the letter out using either Oxy-fuel or Plasma methods of cutting.
9. The project may have more than one letter.
10. Print all letters as stated above and lay them out on the metal touching each other.
11. The letters can be welded together or have a support to make the letter stand up.
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Name _________________________________________
Date _____________ Period ______
Letter Assignment Worksheet
Use the graph below to sketch your letter or letters.
Method of metal cutting used:
Oxy-fuel
Hand Held Plasma
CNC Plasma Cutter
Explain the processes for making the letter:
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Name _________________________________________
Date _____________ Period ______
Letter Cutting Assignment Rubric
Task Statement: Students will lay out and cut a letter or letters.
Task Assignment: Students will work as individuals to measure, lay out, and cut a letter or a group of letters.
Criteria Concepts/Skills to
be Assessed
Basic shape
Criteria Categories
(Novice to Exemplary)
Novice
Developing
1
2
Accomplished
3
Exemplary
4
The letter is
misshaped
The letter has four
or more gouges on
the edges
The letter has
one to three
gouges on the
edges
The letter has no
gouges on the
edges
(0-8 points)
(9-17 points)
(18-26 points)
(27-33 points)
The edges are
rough from
cutting; no
grinding or filing
has been done
The edges are
rough from
grinding; no filing
has been done
The edges are
rough from filing
The edges are
smooth and even
(Possible 33
points)
(0-8 points)
(9-17 points)
(18-26 points)
(27-33 points)
Overall
appearance
The letter is not
sanded; no finish
The letter is
sanded; no finish
The letter has a
rough finish
The letter is
smooth and has a
good finish
(Possible 33
points)
(0-8 points)
(9-17 points)
(18-26 points)
(27-33 points)
(Possible 33
points)
Edge finish
A = 79-100 points; B = 52-78 points; C = 25-51 points; D = 0-24 points
Points
Earned
Total Points: ___________
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