1st edition 2014, approx. 240 pages
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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Digital slides on a CD
- Production process
- File
- Sawing
- Chiseling
- Marking, punching, labelling
- Drilling, countersinking, reaming
- Thread production
- Check: Measuring and Gauging
Text volumes
- Production process
- File
- Sawing
- Chiseling
- Marking, punching, labelling
- Drilling, countersinking, reaming
- Thread production
- Check: Measuring and Gauging
Trainer
- Trainer's Guide
- Hints and solutions
Trainee
- Course materials (exercises 1 to 26)
- Learning objective tests part 1, part 2 and part 3
- The skill: explain filing, scribing, graining, sawing, chiseling, flat, angled, parallel files
- Explain the structure and function of the file
- Select files according to the work to be done
- Describe the structure and function of the parallel vice
- Explain safety and accident prevention regulations and environmental protection measures
- File the flange surfaces of a U-steel in double support flat
- Perform direct and indirect measurements with an accuracy of ± 0.5 mm
- Handling the steel rule and scriber
- Explain the structure and handling of the grain
- Explain the construction and handling of the dividers
- Detecting and correcting grain defects
- Transfer dimensions by drawing marking lines
- Describe the individual parts of the hacksaw
- Explaining the structure of saw blades
- Distinguishing, selecting and clamping saw blades
- Describe the sawing process
- Make straight and even saw cuts
- Describe the structure of the flat chisel and cross-cut chisel
- Naming the angle on the cutting edge
- Explain the process of chiselling surfaces
- Make grooves with the cross-cut chisel and surfaces with the flat chisel
- File flat surfaces at an angle non-parallel to each other
- Name and describe basic terms for tolerances
- Describe the structure of the height ruler
- Describe working technique "Marking with the height gauge
- Mark the U-piece with the height marker with a dimensional accuracy of ±0.2mm
- Describe the structure of technical drawings
- Explain the principles of dimensional registration
- File workpieces with required dimensional accuracy of ±0.2mm and surface quality of Rz 25
- Determine the work stages for manufacturing the gauge in a logical manner
- Selecting the work equipment, machines and operating facilities for production
- Check and evaluate the finished workpiece using the "control and evaluation sheet
- Document the decisions for work planning as well as the data for checking and evaluating the gauge
- Describe the design of the twist drills and
- Professional clamping of drilling tools and workpieces
- List the features of various drilling machines
- Describe the structure of countersinks and specify selection criteria
- Determine and set the rotational frequency for drilling or countersinking
- Describe the design of the hand and machine reamer
- Designate thread types and thread profiles
- Determine the center of round workpieces with the centering angle
- Determine the drilling depth for thread cutting in blind holes
- Cutting threads in blind holes
- Distinguish and describe connection types
- Distinguishing and naming screw types
- Insert assembly according to drawing
- Align and clamp workpieces in the machine vice for drilling
- Describe the work process for filing a square on a round bar