Embed Size (px)
Citation preview
DOCUMENT RESUME
ED 261 234 CE 042 461
TITLE Precision Sheet Metal. Progress Record and TheoryOutline.
INSTITUTION Connecticut State Dept. of Education, Hartford. Div.of Vocational-Technical Schools.
PUB DATE 84NOTE 67p.PUB TYPE Guides Classroom Use - Guides (Fo.t Teachers) (052)
EDRS PRICE MF01/PC03 Plus Postage.DESCRIPTORS Academic Achievement; Behavioral Objectives;
Blueprints; Check Lists; Competency Based Education;Course Descriptions; *Design; EmploymentOpportunities; *Equipment Utilization; *Finishing;Guidelines; Hand Tools; Job Skills; Machine Tools;Measurement Techniques; *Metal Working; OrthographicProjection; Plastics; Recordkeeping; Safety;Secondary Education; *Sheet Metal Work; ShopCurriculum; Student Records; *Trade and IndustrialEducation; Welding
IDENTIFIERS Customer Relations
ABSTRACTThis combination progress record and course outline
is designed for use by individuals teaching a course in precisionsheet metal. Included among the topics addressed in the course arethe following: employment opportunities in metalworking, measurementand layout, orthographic projection, precision sheet metal drafting,simple layout, hand tools, bench tools, power machines and equipment,materials, procedures for reading blueprints, layout and development,radial line development, triangulation, fabrication, welding, metalfinishing, plastics, safety, customer relations, and businesspractices. In addition to the theory outline, which includes spacefor recording information concerning the scheduling and presentationof the lesson material, this record book also contains a list ofcourse objectives for grades 10, 11, and 12 and a grid for use inrecording the individual student's mastery of each specific skilltaught in the course. (MN)
f
************************************************************************ Reproductions supplied by EDRS are the best that can be made ** from the original document. ******P*****************************************************************
A
BEST COPY AVAILABLE
PROGRESS RECORD
AND
THEORY OUTLINE
PRECISION SHEET METAL
DIVISION OF VOCATIONAL-TECHNICAL SCHOOLS
CONNECTICUT DEPARTMENT OF EDUCATION
1983-1984
U.S. DEPARTMENT OF EDUCATIONNATIONAL INSTITUTE OF EDUCATIONpE DCATIONAL RESOURCES
INFORMATION
1cENTEn tom
rem document has been reproduced asreceived from the rt,SCO Of otisenusuonceveabng ohimce changes hare been made to urestuult'etWOduct Dually
pc.ms41 wee.,of *velem& stated on Ms docu
morli do not neseSSente rePteSent ObtolniEsosoesn ox Doke
"PERMISSION TO REPRODUCE THISMATERIAL HAS BEEN GRANTED BY
TO THE EDUCATIONAL RESOURCESINFORMATION CENTER (ERICI"
GENERAL OBJECTIVE
Stude,. will be able to:
Use their knowledge and skills to
satisfactorily perform in the
Precision Sheet Metal Trade, as
advanced apprentices.
1
3
COURSE OBJECTIVES
Grade 10
:. Learn how to read and interpret simpleprecision sheet metal blueprints.
2. Become proficient in the use and careof measuring tools, hand tools, benchcools.
3. Fabricate projects using standard shoptools and equipment.
4. Determine the gauge, blank size andequality of metals used in precisionsheet metal.
5. Do basic Oxy-Acetylene brazing. Knowoperational features of equipment, pro-cedures and safety practices. Dobrazing with gas eqipment.
6. Recognize safety hazards and practiceall safety precautions.
Grade 11
1. Work with cold rolled steel, stainlesssteel, aluminum and other metals usedin precision sheet metal work.
2. Read blueprints and know symbols andabbreviations.
3. Understand development by using radialline development for tapered parts.
4. Use power equipment, know the parts,proper maintenance and safety features.
5, Practice Electric Arc Welding. Under-stand the use of various types of arcwelding equipment and supplies.
6. Use plane figures for development andgeometric construction.
7. Recognize safety hazards and practiceall safety precautions.
- 2
I
. Grade 12
1. Practice Mig Welding. Know how touse and set up mig welding equipmentand supplies.
2. Practice Tig Welding. Set up andoperate heli-arc ecuipment.
3. Interpret advanced blueprints forprecision sheet met, parts.
4. Become proficient in the use of allprecision sheet metal equipmentavailable.
5. Know the application and use ofplastics in precision sheet metal.
6. Draw and develop patterns usingTriangulation.
7. Use precision power equipment, knowparts, proper maintenance, safetyfeatures, and set up same.
8. Know degreasing and painting pro-cedures.
9. Recognize safety hazards and practiceall safety precautions.
3
5
4
Read Scale(64ths, 32nds)
Read Protractor
Interpret GeometriConstruction Probs.
Read 1000's Scale
Compute Bend Allow-ances
.P-
7
Read Three-ViewDrawings
Read SectionalViewsRead AuxiliaryViewIdentify Line,DimensionsDraw ThreeView Drawings
Draw SectionalViewsDraw AuxiliaryViews
LA
Draw Cone andPyramidIdentify Relation-ship of positionsLayout GeometricConstruction
9
01-3=00Pt=H
Pt740Liti1-3H0z
4
Draw PrecisionTitle Block ,,,J
PJtioHWHozmXcy
P4-3
Drawing Number
Reference Number
Dash Number
DevelopApecifications
----ilemiaism---61-4Make changes and
Draw Precision Part
0.
11i0
4
Set.up Draftequipment
Bisect Angles
Divide Lines intoEqual PartsDivide Circles intoEqual Parts
Compute Sq/Rect.S.O.'s
Compute CircularStretchouts
SiCalculate Shear
..,1 Layout a Precision
Calaculate Seamar.44114-43.8
1 213
Z
-4
Scribe Metal useSteel Rule
Scribe Rt. Anglewith Steel SquareScribe V/N/ linesuse Comb. Square 0
Center Punch aPoint
Prick Punch aPointSwing Arc withDividersCut Steel usingHacksaw..J
File Metal Edgesco
SmoothPop Rivet aSeam
Measure withHeight QaugfMeasure withMicrometerCheck Blank Size/Vernier Caliper__Measure withDiameter Tape
Rivet Seams
ran Holes with I
Power Drill
14 15
Cut with Unishear
Tap Holes
Check Part withSurface Plate
1
fD
f
Cut usingSquaring Shear
Cut, Use Front-Side-Back GageUse StandardHand Brake
Locate Bend Lines
Bend Metal
S&--1tUlus Allow-ance Bend Metal
16 .17
zUH00t-'cn
tjzCI=H00rU)
Tighten Bend &Clamp Tension
Change Bendingi
IC-;
Adjust/Set Finger/ iPan BrakeBend Sides of a
1
BoxI
Set Stops onNotcher
Install Punch & pit!with Foot Press 1
. I
Install Punch & Diewi M- . ' eAlign Punches, useNibblinp: Machine--.oShear, Slit, Notchwith Comb. Noter.Coper Shear
__
1°
GageThickness
Identify Types- I
Tap Flat Stock
Install HaspStaple & Catches
Install Hinges
Install Fasteners
21.
r4
Read Drawingsw
Interpret
tC
PrinciplesIdentify Features IH z.11
65,MbaLS11Visualize a Metal
Part PJ
Read Unit Assembly t:>iDrawings H---Estimate Weight/ F)
Sheet Stock
rIv
1
0 ,
22 23
Layout Frustrumof Cone
Sweep a Toper
Roll Cone UseSlip Rolls
Layout TaperedJoint
Use Dia Tape
1
1
1
Divide Arcs,cire1ps
Layout Cone Cut- L.: -1
rw
Construct, identifyparts of triangle
Layout trz sidesTaperinLayout withcarpenter square
Roll use brake
Dev. vert. taperedsquare to round
Layout square tornnn.d
Triangulate a cone
I
213 27
Use Power Shear
Use Power Brake
Clean/ChangeElectrodesSet Machine forvar. Gage Material
Spot Weld SeveralGages Together
[ Test Weld Strengthby Bending
Check WeldPenetration
LPrepare Metal forSpot Welder
Repair Bad SpotsWelds
Set Drill Speeds
Burr Holes
Counter Drill
Grind Punches
Sharpen Drills
Dress Wheels
28#29
Install Blades.,
c
Saw Flat Stock 1
r
Set Upper andLower Die
C
Bend Metal 30 ° -90°
Flatten StampIS __Cy1 L$.. Z. I
Punch Louvers
Make Radius Bendsr-,
cl, Install Punch & Die
Make and MountStriD.ers
Punch Holes, AllSizes
Sear Metal Using
Setup/Use Power Rol
Punch Round SquareHoles
Use PortablePrinder
31
Seui-metOxynt -acetyleneE
I-.
-4 Braze Light Gage
I
Prepare Metal To
Set WeldingE i m
Braze PartsForm Metal UsingTorch
Set TorchCarbonizeNeutralize/OxidizeFlames
32 33
. .
Set up Equipment
Select Electrodes
Strike an Arc
Run Flat Beads
i--.
co Run Butt Welds
Run Fillet Welds
Weaving/WhipMotion
Run Vertical Beads
Identify Metal
Control Distortion
Read Symbols
Test and Inspect
Set up Equipment
Set Voltage
1--a
1/4.0
Set Slope
Select Wire
Set Wire Feed
Set Gas Regulator
Run Welds
36 37
Hri4-)
ZmroH%
Set up Welder
Set Amperage
Set Water/Cooling_aed
Set Gas Regulator
r%3 Weld Steel
Weld StainlessSteel
Weld Alunimun
.....
39
Identify typesof Plastics
Weld Plastics :
(quip_ permit-ring)Fasten Plasticby Cement/Rivets
1
131-1
A Prepare Metal forPaint
Mix Primer & Paint
Adjust Air Pressure
Set up Spray Gunfor Painting.
Spray Paint Parts
Clean Spray Gun
10 41
TRADE THEORY OUTLINE
I. TRADE INTRODUCTION AND OPPORTUNITIES
II. MEASUREMENT AND LAYOUT
III. ORTHOGRAPHIC PROJECTION
IV. PRECISION SHEET METAL DRAFTING
V. SIMPLE LAYOUT
VI. HAND TOOLS - LAYOUT TOOLS
VII. BENCH TOOLS
VIII. MACHINES AND EQUIPMENT: BENCH AND FLOOR PRECISION EQUIPMENT
IX. MATERIALS: STEEL AND STEEL STOCK, ALLOYS
X. MATERIALS: FASTENERS, ALUMINUM, STAINLESS STEEL
XI. BLUEPRINT READING SYMBOLS
XII. LAYOUT AND DEVELOPMENT
XIII. RADIAL LINE DEVELOPMENT
XIV. TRIANGULATION
XV. MACHINES AND EQUIPMENT: POUR DQUIPMENT
XVI. FABRICATION: CONE, SQUARE TO ROUNDS, ROUND TO ROUND
XVII. WELDING: OXYACETYLENE
XVIII. WELDING; ELECTRIC ARC
XIX. WELDING; MIG
XX. WELDING: TIG
XXI. METAL FINISHING
XXII. MATERIALS: PLASTICS
XXIII. SAFETY
XXIV. CUSTOMER RELATION AND BUSINESS PRACTICES
42- 22-
I. TRADE INTRODUCTION AND OPPORTUNITIES
A. History of the Trade
1. Guilds2. Apprenticeship3. Management
B. Scope of Trade
1. Job shops2. Manufacturing companies3. Shipbuilding4. Aircraft5. Defense6. Communications7. Welding8. Others
C. Trade Opportunities
1. Machine operators2. Metal finishers3. Fabricators4. Assembly5. Se: up6. Inspectors7. Model makers
D. Qualifications
1. High level of mechanical ability,dexterity
2. Resourcefulness in solving problems3. Blueprint reading ability4. Pride in workmanship
II. MEASUREMENT AND LAYOUT
A.
B.
Linear Measurement
1. Units; foot, inch2. Fraction and decimal divisions3. Rules, steel scale4. Dia tape
Scale Measurement
1. Graduations of scales2. Measure lines3. 1000's scale, decimals
- 23 -
43
C. Angular Measurement
1. Terminology2. Units: degrees, minutes, seconds3. Symbols4. Protractor5. Measuring angles
D. Geometric Constructions
1. Terminology2. Bisecting lines, angles3. Polygons within a circle4. Triangles5. Tangents
E. Precision Sheet Metal Math
III. ORTHOGRAPHIC PROJECTION
A. Terms, Definitions
B. Views
]. Plan, front, end2. Glass cage relationships3. Three view drawing4. Orthographic vs pictorial5. Sectional views, auxiliary views
C. Lines, Identifications
1. Solid, heavy outlines (primary lines)2. Light lines, projection lines
(secondary lines)3. Dashes, center lines, break lines4. ASA line conventiors
D. Planes, Theory of Projection
1. Viewing positions (eye level)2. Imaginary, horizontal lines3. Cutting planes
E. True Lengths of Lines
1. Foreshortened views
z
zOa)cnrza 0Z AV A
IV. PRECISION SHEET METAL DRAFTING
A. Title Block and Title Strip
1. Name and address of company2. Name of part3. Serial prefix4. Scale
B. Drawing a Metal Part
1. Three views
C. Develop Specifications
D. Make Changes and Revisions
V SIMPLE LAYOUT .JORK, INCLUDING PRECISION TEMPLAT.S
A. Introduction
1. Layout work
B. Types of Layout: and Development
1. Simple layout2. Radial line development3. Triangulation
C. Mechanical Drawing Equipment
1. Drawing board, T-square, angles2. Scale rule (1000's)3. Pencils (H) compass4. Protractor5. Etc.
D. Using Drawing Equipment
1. Position drawing board2. Tape corners3. Pull tight, straighten4. Placement and movement of T-square5. Types, use of triangles6. Tilt pencil in, sharpening pencils7. Use of bow compass3. Scale rule9. Protractor
45- 25 -
E. Development of Patterns
1. Computation of stretchout
a. Views required for square,rectangular jobs
b. Rules for developmentc. Formulasd. Stretchoutse. Seamsf. Bend radius allowance
2. Stretchout of a box
a. Viewsb. Formulac. Ruled. Stretchoute. Bend allowancef. Notches
3. Stretchout of circular jobs
a. Viewsb. Rulec. Formulad. Pie. Stretchout
F. Fabrication of Patterns
1. Layout tools
2. Bend and assemble
G. Computing Sizes of Materials
1. Find size of materials needed forprecision parts
H. Precision Template Work
1. Proper lengths2. Blank sizes3. Define parts4. Series of bends
4 6- 26-
VI. HAND TOOLS - LAYOUT TOOLS
A. Description and Use of Layout Tools
1. Scratch awl2. Prick punch3. Straight edge4. Flat steel square5. Combination square6. Center punch7. Dividers3. Trammel points9. Height gage
10. Micrometer11. Vernier caliper12. Diameter tape13. Dial indicators14. Others
B. Using Layout Tools
1. Scribing a line on metal2. Laying out right angles with a steel
square3. Scribing vertical line with combination
square4. Scribing horizontal edgelines with
combintaion square5. Marking with prick punch and center
punch6. Setting and using dividers, trammel
points7. Measure blank size with vernier calipers8. Check dia with dia tape
VII. BE CH TOOLS
A. Hammers
1. Safety2. Uses3. Ball peen, mallets
3. Vises, Clamps
1. Safety2. Removable jaws, use of vises3. C-clamps, parallel clamps
C.
Hand
Hacksaw
1.
Safety2. Use,
blades,
teeth3.
Angle
of cut
D.
Small
Tools
1.
Safety2.
All
small
hand
tools
such
as
screw-
drivers,
wrenches,
files,
pliers,vice
grips,
pop-rivet
gun,
tappingsets,
etc.
E.
Surface
Plate
1. Use
to
check
flat2. Use
with
dial
indicator3. Us'
with
height
gage
F. Power
Tools
1.
Safety2.
Drills;
uses,
parts,
drill
bits,
sizes3. U
nishears:
uses,
parts,
adjust
blades,maintenance4. P
ortable
grinder
VIII.
MACHINES
AND
EQUIPMENT
-
BENCH,
FLOOR,
PRECISION
A.
Standard
Hand
Brake
1.
Safety2. Use,
tynes,
gauge,
capacity,
adjustments,
parts3.
Set
for
radius
bends4.
Change
blades
B.
Pan
and
Box
Brake
1.
Safety2.
Advantages
C.
Squaring
Shear
1.
Safety2 T
ypes,
gauges,
use,
parts3.
Blades
adjustment,
maintenamv4 C
orrect
user
stance,
operation5.
Front,
back,
side
gauges
D. Slip Roll Former
1. Safety2. Use, parts3. Adjustment of rolls4. Rolling tapered fittings
E. Notcher
1. Safety: watch hands 17hile operatingmachine
2. Set stops3. Size of notch
F. Foot Press
1. Safety: coordinate foot and handmovements
2. Check stripper plates3. Tighten die shoe bolts4. Check alignments5. Check ram adjustment
G. Hand Metal Punch and Cam Press
1. Safety: keep hands away from punch2. Match punch and die sizes3. Change stripper plate with dies4. Center punch in die carefully5. Depth adjustments6. Compensate for wear by removing gib
shims
H. Nibbling Machine
1. Safety: protect eyes2. Hand cutting an edge3. 1/32 - 1/16 at bottom of stroke4. Avoid vibration, secure stock5. Starting hole for inside circles6. Outside edge cuts7. Square inside slots
I. Comb. Botcher, Coper, Shear
1. Safety: Protect eyes and hands2. Set for 0.002" clearance3. "Pierce" or "splay" cutting4. Open throat
49-29-
IX. MATERIALS: STEEL, STEEL STOCK, ALLOYS
A. Properties of Steel
1. Strength ductility, hardness, etc.2. Corrosion resistance3. Galvanizing process
B. Description: Use of Alloys
1. Gauges, sizes, weights2. U. S. Standard gage3. Trade name, manufacturers4. Gradcs, types, paintability5. Manufacturer's charts, tables
slide charts
C. Steel Stock
1. Cold rolled sheets, black iron2. Band iron, flat bar3. Wire, rod4. Angle iron, etc.
X. MATERIALS
A. Fasteners
1. Sheet metal screws2. Machine bolts and nuts3. Rivets
B. Aluminum
1. Properties2. Processes3. Uses4. Determining gage, weight, and thickness
C. Stainless Steel
1. Properties2. Processes3. Uses4. Determining gage, weight and thickness
D. Black Iron
1. Properties2. Processes3. Uses4. Determining gage, weight and thickness
50-30-
E. Galvanized Iron
1. Properties2. Processes3 Uses4. Determining gage, weight and thickness
F. Copper
1. Properties2. Processes3. Uses4. Determining gage, weight and thickness
G. Hasp, Hinges, Catches
1. Type required2. Inside, outside, piano3. With or without lock4. Number needed
XI. BLUEPRINT READING
A. Measurement
1. Inch rule and fractional decimals2. Use of rules, and square3. Angular measurement
B. Drawing
1. Orthographic projection2. Precision drawings
C. Symbols
1. Drafting symbols2. Welding symbols
D. Sheet Metal Shop Procedures
1. Material weight and thickness2. Estimating methods
- 31-
51.
041
A4141E-(X<0A cn
XII. LAYOUT MID DEVELOPMENT
A. Development Plane Figures
1. Trapezoids2. Angles3, Circles
B. Developing Transition Parts
1. Transition joint2. Transition offset
XIII. RADIAL LINE DEVELOPMENT
A. Principles
1. Determining apex and vertex2. Slant heights and true lengths3. Views needed for radial line
development
B. Need for Radial Line Development
1. Cones2. Reducers and increasers3. Hoppers
C. Methods
1. Step off methods2. Strap method
D. Conical Shaped Jobs
1. Stretchouts2. Determining radius3. Elements of a cone
E. Pyramid Shaped Jobs
1. Order of sides in stretchout2. Brake lines
F. Pieced Jobs
1. Jobs requiring two or more patterns
G. Taper on a Pitch
1. Miter lines2. Sweeping a taper
52-32-
XIV. TRIANGULATION
4. Principles of Triangulation
1. Radial line principles2. Determining the number of true lengths
required
B. Triangle Used in Triangulation
1. True length triangles2. Using the altitude, base, and hypotenuse
C. Views Used in Triangulation
1. Plan2. Elevation3. Working views4. Foreshortened views
D..Patterns
1. Transferring measurement to patterns2. One, two and four pieced patterns
E. Square to Rounds
1. Centered square to round2. Square to round on a pitch3. Square to round off center
F. Oblong Fittings
1. Determining center and flats2. Center flair3. Oblong to round4. Oblong to square
XV. POWER EqUIPMEIT
A. Spot Welder
1. Safety
a. Guardb. Glassesc. Checking leakage to ground
2. Electrode*
a. Selecting electrodesb. Cleaning and filing electrodes
- 33 - 53
Z4b-4aZ0Encn
Z41 0a
Aa.3. Settings
a. Timer settingb. Setting ampere regulatorc. Cooling pressure
4. Cycle
a. Cycle of induction weldingb. Heatc. Timed. Pressure
5. Capacities
a. Materials and gages
6. Welds and penetration
a. Types of spot weldsb. Checking penetration
7. Maintenance
B. Drill Press
1. Safety
a. Glassesb. Guards
2. Adjustments and settings
a. Cutting speedsb. Pulley adjustmentsc. Chuck and drill sizesd. Stop adjustments
3. Hold down equipment
a. Visesb. Parallel bars
4. Maintenance
a. Lubrication
C. Grinder
1. Safety
a. Glassesb. Shields
2. Grinding Wheels
a. Grainb. Structurec. Silican carbided. Aluminum oxidee. Abrasivesf. Grade and bond
54 r- '14 --
3. Mounting the ' Wheel
a. Using proper bushingb. Balancingc. Using correct wheelsd. Checking for true
4. Wheel dressers
a. Use typesb. Maintaining wheel properly
D. Bandsaw
1. Safety
a. Glassesb. Guards
2. Blades
a. Sizesb. Typesc. Gradesd. Teeth
3. Adjustments
a. Speedb. Tensionc. Feedd. Blade
4. Blade welder
a. Fitting and blade endsb. Setting blade welderc. Welding blade
5. Maintenance
a. Lubrication
E. Power Hack Saw
1. Safety
a. Glassesb. Guards
2. Adjustments
a. Bladeb. Speeds
3. Blades
a. Types and Sizes
4. Capacities
a. Stock
5. Maintenance
- 35-55
4
F. Power Press Brake
1. Safety2. Loosen and tighten set screws3. Bring ram down manually4. Bottom dies for accuracy5. Avoid off center loading6. Set multi-bend controls7. Metal thickness3. Type of material9. Angle to be bent
10. Radii needed11. Maintenance
G. Turret Pundh Press
1. Safety2. Engage guide pin3. Line up punch and die4. Maintenance
H. Power Squaring Shear
1. Safety2. Shear operation3. Set back and front gauge4. Maintenance
I. Punch Press
1. Safety2. Check punch and die alignment3. Maintenance
J. Sheet Metal Fabricator
1. Safety2. Types and uses of machines3. Maintenance
K. Duplicator
1. Safety2. Types and use of machines3. Maintenance
L. A/C Fabricator
1. Safety2 Types and use of machine3, Maintenance
- 36-
56
z< A al.4 r4 4.1a.
g z
0 .4 0cn Nrr2Q1 a)WO dww-4Z AU) AP+ A
XVI. FABRICATION
A. Cones
1. Frustrum of a cone
B. Square to rounds
1. Square to round on center2. Square to round to one side
C. Rounds to rounds
1. Round equal taper joint2. Round taper, one side straight
SVII. WELDING OXY-ACETYLENE
A. Oxy-acetylene Equipment
1. Oxygen and acetylene cylinder const.2. Pressure regulator3. Welding torch and tips4. Welding hoses5. Gloves and glasses
B. Welding Procedures and Descriptions
1. Brazing2. Resistance welding3. Induction welding4. Arc welding5. Gas welding6. Mig welding7. Tig welding
C. Hazards and Safety of Welding
1. Lighting the torch2. Turning off the torch3. Adjusting the regulators4. Back fire5. Flash back6. Clothing and glasses7. Hose contact with flame
D. Types of Welding
1. Without rod2. With rod3. Butt weld4. Fillet weld5. Fusion welding6. Lap welds
- 37- 57
11 a
A
AP
E. Welding Procedures and Variables
1. Preparation2. Tip size3. Grip4. Flame setting5. Angle and distance of torch6. Rate of travel and manipulation7. Rod size
F. Flame
1. Carburizing2. deutral3. Oxidizing
XVIII. ARC WELDING
A. History, Background
1. Early use of the arc2. Progress after WWI3. Bare electrodes
B. Equipment
1. Power supplies2. Clothing, personal eauipment3. Ventilation requirements
C. Safety Practices
1. Eye protection, first aid2. Lenses, hoods, injurious rays3. Skin protection, gloves, leggings,
shoes4. Electrical dangers, shock, burns, cables5. Safety procedures: tanker, drums, etc.6. Clean-up procedures after welding
D. Selection of Electrodes
1. Terms2. Classification, AWS, ASTM3. Markings end, spot, group4. Coating, sheilded rods5. Polarity6. Types of rods; Steel, aluminum,
stainless, etc.7. Reading electrode charts and tables
- 38- 58
E. Striking an Arc
1. Scratching method2. Correct arc length3. Correct amperage4. Maintaining the arc5. Rate of travel
F. Welding Onerations
1. Falt heads2. Weaving motion3. Butt welds4. Fillet welds
G. Corner and Edge Welds
1. Horizontal2. Vertical3. Overhead
H. Identification and Characteristics ofMetals
1. Method of identifying metals
a. Surface appearanceb. Soundc. Spark testd. Fracture
2. Melting points for metals and alloys3. Grain structures4. Manufacture and characteristics of
metal
a. Iron oreb. Gray cast ironc. White cast irond. Malleable irone. Wrought ironf. Steel
I. Controlling Distortion
1. Expansion and contraction2. Upsetting3. Shrinkage forces4. Intermittent welds5. Proper welding sequence6. Clamps jigs7. Heat
39-
ma
59
:4¢ Aa r4a azo Aowcn t-,410 K40'474 A cn
J. Symbols
1. American Welding Society
a. Basic symbols and locationsignificance
b. Supplementary symbols
X. Test and Inspection
1. Types and tests and purposes2. Methods of testing
a. Tensionb. Bendc. Sheard. Break
3. Visual inspection4. Principles defects5. Gauge testing
XIX. MIG WELDING
A. Safety
1. Eye and face protection2. Electrical safety precautions3. Protective clothing
B. Mig Power Supply
1. Set voltage2. Set slope
C. Wire Feed
1. Types of wire
D. Gas
1. Types needed
XX. TIG WELDING
A. Safety
1. Eye and face protection2. Electrical safety precautions3. Protective clothing
B. Machine Operation
1. Gas2. Water3. Amperage 60
XXI. METAL FINISHING
A. Degreasing Procedures
1. Types of coating2. Safety3. Size of part4. Procedure for loading and unloading
B. Spray Painting
1. Type of thinner2. Adjust spray gun and regulator3. Right stroke to use4. Disassemble and clean spary gun
XXII. MATERIALS: PLASTICS
A. Terms, Definition, History
B. Types
1. Thermoplastics
a. Polyvinylchloride PVCb. Polyethlenec. Acrylicd. Acroton ABS
2. Thermosetting
a. Polyesterb. Epoxiesc. Phenolic
C. Application
1. Advantages over metal.in variousindustrial uses
D. Welding Plastics
1. Hot gas method2. Preparation sheets3. Welding position and procedure4. Types of welds
E. Fastening Procedures
1. Welding2. Cementing, adhesives3. Riveting
61- 41 -
XXIII. SAFETY
A. Eye
1. Glasses2. Shields
B. Correct Dress
1. Shoes2. Hair3. Clothing
C. Handling Metal
D. Correct Use of Tools
E. Correct Use of Machines and Equipment
F. Electrical Precautions
G. Safety First and Last
XXIV. CUSTOMER RELATIONS AND BUSINESS PRACTICES
A. Dress and Appearance - First Impressions
1. Clothing
a. Neatb. Clean
2. Personal Appearance
a. Cleanlinessb. Personal hygienec. ,
t.,tann,.!rs
1. Polite2. Tactful
B. Courtesy to the Customer
1. Telephone communications
a. Courteousb. Sincerec. Listend. Never argue but stand on factse. Misunderstanding produces ill will
62-42-
2, Association in person
a, Call customer by nameb. Pronounce name correctlyc. Efficient serviced. Brief, thoroughe. Satisfy complaintsf. Enthusiasm about companyg. Enthusiasm about product
C. Customer Psychology
1. Get the customer's story2. Agreement precedes disagreement3. Knowledge of product4. Ignorance kills customer confidence5. Show initiative
D. Business Practices
1. Maintain good records
a. Customer filesb. Service callsc. Time spentd. Parts usede. Billingf. Correspondenceg. Inventoryh. Service bulletinsi. Cost (all costs)j. Taxes (all taxes)k. Gross income1. Net profit
E. Ethics
1. Workmanship2. Parts cost3. Labor cost4. Overhead cost5. Promptness6. Contractual and implied obligations7. Customer consideration
- 43 - 63
TITLE
TEXTS AND REFERENCES
AUTHOR PUBLISHER
Precision Sheet Metal Shop Budzik Howard W. SamsPractice
Precision Sheet Metal Budzik Howard W. SamsBlueprint Readiug
Precision Sheet Metal Budzik Howard W. SamsMathematics
Precision Sheet Metal Budzik Howard W. SamsTheory
Student Work Books
Instructors' Guides
44- 64
TEXTS AND REFERENCES
Bibliography: Sheet Metal
TITLE AUTHOR PUBLISHER
Measurement & Layout DelmarHand Process DelmarMachine Process DelmarJob Series DelmarTeacher Manual Delmar
Related Information Sheet Metal 1 Johnson DelmarRelated Information Sheet Metal 2 Johnson Delmar
Related Information Sheet Metal 3 Johnson Delmar
Related Information Sheet Metal 4 Johnson DelmarInstructors' Guides 1, 2, 3, 4 DelmarQuiz & Test Packets, 1, 2, 3, 4 DelmarMathematics for Sheet MetalFabrication DelmarInstructors' Guide DelmarSheet Metal Blueprint Reading DelmarRound Layouts Kaberlein BruceTriangulation Kaberlein BruceSheet Metal Pattern Drafting Daughtery & Powell BennettSheet Metal Layout Leo A. Meyers McGraw-HillSheet Metal Simplified
Volumes I, II, III Reid EdwardsSheet Metal Shop Practice Bruce & Meyer Amer. Tech. Soc.Oxy-Acetylene Welding DelmarBasic Arc Welding DelmarGas & AC Arc Welding & Cutting Jennings McKnightArc Welding Lessons Kugler Lincoln Co.Metals & How to Weld Them Jefferson & Woods Lincoln Co.
-45-
65
CATALOGS - MANUALS - CHARTS
International Acetylene Association30 East 42nd StreetNew York, N. Y.
Safe Practices for Installation and Operation ofOxy-Acetylene Welding and Cutting Equipment
Welding Codes and Specifications
Oxy-Acetylene and Its Applications
Bronze Welding or Brazing by Oxy-Acetylene
Miscellaneous Uses of Oxy-Acetylene Flame
Ame_ican Welding Society33 West 39th StreetNew York, N. Y.
Safe Practices Welding and Cutting Containers
Factory Insurance AssociationHartford, Conn.
Preventing Cutting and Welding Fires
Linde Company300 First AvenueNeedham Heights, Boston, Mass.
Precautions and Safe Practices
TRADE JOURNALS
FMA Journal of the Fabricator7811 North Alpine RoadRockford, Illinois 61111
BIBLIOGRAPHY: Sheet Metal
VISUAL AIDSFILMS NUMBER SUPPLIER
Hot Rolling of Steel Sheets SU 980 U. S. SteelZinc Controls Corrosion 1627 Modern Talking
PicturesBuild Better with Ramset 2333 Modern Talking
PicturesScience of Making Brass Tech. Vac. -Ind.
FilmCopper S-843 Associated FilmsOblique Cones & Transition Dev. Tech. Voc-Ind.
Film
FILMSTRIPS
Oxy-Acetylene Welding Series A2 to E3 (15 in set) Jim Handy Co.
KIT NO. TITLE
A-1 An Introduction to WeldingA-2 Setting Up & Lighting the Welding TorchB-1 Welding Flat RipplesB-2 Flat Butt WeldsC-1 Fillet Welds, SteelC-2 Vertical Welds, SteelE-1 Oxy-Acetylene CuttingE-2 Brazing & Silver Soldering
McGraw-Hill No. 070805 Sheet Metal Laying Out & CuttingNavy - SN 2330p Transition Piece - Square to Round
TRANSPARENCIES
McGraw-Hill Mechanical Drawing Series Unit VII
Number Title
22264 Developing a Cone22265 Developing a Pyramid22267 Developing a Truncated Cone
(irreg. frustrum)22268 Developirg a Transition Piece
(rect. to rd.)22269 Developing Intersecting Cylinders
Sheet Metal Series - DCA Education Products
BasicsHand ToolsPattern DevelopmentS.M. Fabrication
67- 4 7 -
