1st edition 2014, approx. 240 pages in folder
The training course "Manual Material Processing" deals with manual metal-cutting manufacturing processes in accordance with the training framework for metalworking professions (current no. 11 "Manual Metal-Cutting"). The skills of filing, sawing, drilling, countersinking, reaming, chiselling, thread production, marking and punching are taught in detail.
A further focus is on the training contents (Volume No. 9 of the training regulations "Testing, marking and labelling"). The following sections are devoted to materials science, occupational safety and environmental protection. In the 26 practical exercises, each with work information, parts lists and work planning forms as well as control and evaluation sheets, various project tasks are dealt with. The exercises are structured according to the lead text method and follow the model of the complete action. Thus they are particularly conducive to action and social competence. The exercises can be worked on both individually and in groups. The complete training course consists of the Trainer's Guide, the training course for the trainee, the sample solutions, the slides and the text volumes.
Time required to complete the course: Approx. 14 weeks
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- The skills: Explain filing, scribing, punching, sawing, chiselling, flat filing, angled filing and parallel filing
- Describe the components of the file and how it works
- Select the appropriate files for the work to be carried out
- Describe the components and function of the parallel vice
- Explain the safety provision and accident prevention regulations, as well as measures for environmental protection
- Dual-file the flange surfaces of a U-steel evenly
- Take direct and indirect measurements with an accuracy of ±0.5 mm
- Use a steel ruler and a scriber
- Describe the components of the punch and how to use it
- Describe the components of the dividers and how to use them
- Identify and correct punching errors
- Transfer dimensions by drawing scribing lines
- Describe the individual parts of the hand hacksaw
- Describe the components of saw blades
- Identify, select and clamp types of saw blade
- Explain the process of sawing
- Create straight and uniform cuts with the saw
- Describe the components of the flat chisel and the cross-cut chisel
- Identify the angle at the chisel cutting edge
- Describe the process for chiselling surfaces
- Create grooves with the cross-cut chisel and surfaces with the flat chisel
- File even surfaces at an angle and in parallel
- Identify and describe basic terminology relating to tolerances
- Describe the components of the vernier height gauge
- Describe the work techniques of "scribing with the vernier height gauge"
- Scribe a U-section with the vernier height gauge with a measuring accuracy of ± 0.2mm
- Describe the layout of technical drawings
- Explain the fundamentals of entering dimensions in drawings
- File workpieces with the required measuring accuracy of ± 0.2 mm and surface finish of Rz 25
- List the work stages necessary to produce the gauge in the correct order
- Select the tools, machines and equipment necessary for the productions of the gauge
- Use the "Inspection and evaluation sheet" to inspect and evaluate the finished workpiece
- Record the decisions made in the context of work planning along with the data for inspecting and evaluating the gauge
- Describe the components of the twist drill
- Tension drilling tools and tools correctly
- List the properties of various drilling machines
- Describe the components of countersinks and list selection criteria
- Calculate and set the rotational frequency for drilling or countersinking
- Describe the components of the hand reamer and the machine reamer
- List types of thread and thread profiles
- Use the centre square to determine the centre point of circular workpieces
- Determine the drill depth for thread cutting in blind holes
- Cut threads in blind holes
- Differentiate between and describe types of connection
- Differentiate between and identify types of screw
- Join the assembly as shown on the drawing
- Align and tension workpieces in the machine vice for drilling
- Describe the procedure involved in filing a square on a round steel